AC40C 70982b Part1 - en PDF

Translation
of the Original Operating Instructions

AC40C
This document is a translation of the original operating instructions which are sent with this specific
machine and are designated as belonging to this machine. It is not intended as a basis for further
translations.
Please use only the original operating instructions as a reference. They are labelled accordingly.
40C−0000−001c_en 1/1
Index
Manufacturer’s Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Working Conditions and Computed Design of the Crane . . . . . . . . 13
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Classification of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.3 Classification of the Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.5 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.6 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3.7 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.8 Scrapping / Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.9 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 27
1.3.10 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4.2 Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4.3 Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4.4 Combination of Hazards with Combined Operation
of Two or More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4.5 Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.4.6 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.4.6.3.1 Problems and Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4.6.3.2 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.4.6.3.3 Specific Instructions for Mobile Hydraulic Cranes
with Telescopic Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4.6.3.4 Specific Instructions for Crawler−mounted Cranes
with Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4.7 Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.4.8 When Assembling and Dismantling Crane Components . . . . . . . . 87
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 97
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 99
40C−1000−982a_en 1
Index
2 Structure of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Technical Data Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Dimensions, Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Travel Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.3 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.4 Wheels/tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.5 Climatic Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.6 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Technical Data Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Crane (Components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Safety−relevant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Steps and Catwalks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.3 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Chassis and Construction Number . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Decals (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6.1 Crane identification plate / serial plate . . . . . . . . . . . . . . . . . . . . . . . 45
2.6.2 Safety Signs (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6.3 Safety Signs (Only for the USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.7 Preparation for Emergency Control, Superstructure . . . . . . . . . . . . 61
2.8 Separate Fuel Tank (”Extra Tank”) in the Chassis
for Superstructure Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . 63
Appendix to section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Crane Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Operator’s Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Entering / Leaving the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.1 Ignition−starter Switch (67) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2.2 Steering Wheel Adjustment (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2.3 Driver’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.4 Headrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.5 Safety Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.6 Opening / Closing Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2.7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
40C−1000−982a_en 2
Index
4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.1 Battery isolating switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Checks Before Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.6 Battery Charging Device (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6.1 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6.2 Temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6.3 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6.4 Charging batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6.5 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.7 Engine Quick Stop Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 25
4.8 “Quick Stop” with Air Shut−off Valve (Optional) . . . . . . . . . . . . . . . . 25
4.9 Limiting the Engine Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 29
4.10 Immobiliser (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.11 Warming up the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.2 Warming−up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.12 Diesel Particle Filter (Huss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.12.1 Intended Use − Regulated Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.12.2 Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.12.3 Control System ”Huss Control” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.12.4 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.12.5 Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.12.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 Instructions for all Types of Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Checks before Every Journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Transport safety locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.4 Axle Loads / Speeds / Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.1 Calculating Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4.2 Calculating Axle Loads in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.2.1 Calculated Basic Condition (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.2.2 Weight Table (Component Weights in kg) . . . . . . . . . . . . . . . . . . . . 17
5.4.3 Calculating Axle Loads in lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4.3.1 Calculated Basic Condition (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4.3.2 Weight Table (component weights in lbs) . . . . . . . . . . . . . . . . . . . . . 19
5.4.3.3 Example of an Axle Load Calculation . . . . . . . . . . . . . . . . . . . . . . . . 21
40C−1000−982a_en 3
Index
5.4.4 Possible axle loads / permitted speeds . . . . . . . . . . . . . . . . . . . . . . . 25

5.4.4.1 Tyres, Manufactured by Michelin (XGC) . . . . . . . . . . . . . . . . . . . . . . 25
5.4.4.2 Tyres, manufactured by Michelin (X Crane AT) . . . . . . . . . . . . . . . . 27
5.4.4.3 Tyres, manufactured by Michelin (X Crane +) . . . . . . . . . . . . . . . . . 29
5.4.4.4 Tyres, Manufactured by Michelin (XZY) . . . . . . . . . . . . . . . . . . . . . . 29
5.4.4.5 Tyres, Manufactured by Bridgestone . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4.4.6 Tyres, Manufactured by Magna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.5 Driving with Uneven Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4.6 Driving with Reduced Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.7 Driving with Axle Loads over 12 t (26.4 kip) . . . . . . . . . . . . . . . . . . . 45
5.4.7.1 Driving with Axle Loads of up to 12.5 t (27.6 kip) . . . . . . . . . . . . . . 47
5.4.7.2 Driving with Axle Loads up to 16.5 t (36.4 kip) . . . . . . . . . . . . . . . . 49
5.4.8 Shorter Maintenance Intervals for Axle Loads over
12.5 t (27.6 kip). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Driving on Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.5.1 Driving with Axle Loads of 12 t (26.4 kip) (EEC Directive) . . . . . . . 55
5.5.2 Driving in the United Kingdom (UK Approval) . . . . . . . . . . . . . . . . . 55
5.5.3 Checks before Starting Any Journey on Public Roads . . . . . . . . . . 57
5.6 Defined Driving Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6.1 Total Weight Driving Configuration 36 t (79.4 kip)
(Approval Condition in Accordance with German Authorisation) . 59
5.7 Driving downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.8 Driving over hill summits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.9 Driving a Stuck Crane Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.10 Checking the Operation Functions while Driving . . . . . . . . . . . . . . . 67
5.11 Driving on the Construction Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.11.1 Driving in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.11.2 Driving in the configured condition “Driving when rigged”
(with main boom / equipment erected) . . . . . . . . . . . . . . . . . . . . . . . 69
5.11.2.1 Instructions on ”Driving in the configured condition” . . . . . . . . . . . . 69
5.11.2.2 Driving Tables
(in SI − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
(in British / American Dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.11.3 Driving the Crane in the Operating Mode “360 Degrees”
(without Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.11.3.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.11.3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.11.4 Driving the crane with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.11.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.12 Dolly Coupling / Supply Connections (Optional) . . . . . . . . . . . . . . . 91
5.12.1 Coupling and Decoupling a Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.13 Attaching and Removing the Spare Wheel
(Spare Wheel Holder, Hoist Arrangement, Optional) . . . . . . . . . . . 97
40C−1000−982a_en 4
Index
6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1 Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.1 Description of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.2 System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1.3 Driving Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1.3.1 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1.3.2 Neutral Position “N” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1.3.3 Reverse Gear ”R” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1.3.4 Drive Position ”D” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1.3.5 Driving Range Selection ”1” to ”6” . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1.4 “Transmission Information” Display (26.1) . . . . . . . . . . . . . . . . . . . . 11
6.1.4.1 Operating Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1.5 Driving and Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.5.1 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.5.2 Driving, Driving Forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.6 Reversing / Changing the Driving Direction . . . . . . . . . . . . . . . . . . . 15
6.1.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.8 Shutting Down the Engine and Vehicle . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.9 Slow Travel of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.10 Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.12 Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.13 Rolling Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.14 Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.15 Overspeed Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.16 Roller Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 System Malfunctions / Error Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.1 Transmission oil level information . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.2 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.3 Troubleshooting with the Troubleshooting Table . . . . . . . . . . . . . . . 33
6.3 Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.1 Operating the Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Driving a Stuck Crane Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1 Emergency Pressure Supply − Braking System . . . . . . . . . . . . . . . 3
7.2 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4 Emergency Filling of the Braking System (Optional) . . . . . . . . . . . 9
7.5 Test Points of the Braking Circuits
(Optional Equipment / National Regulations) . . . . . . . . . . . . . . . . . . 9
7.6 Engine Brake (Sustained−action Brake) . . . . . . . . . . . . . . . . . . . . . . 11
7.7 Anti−Blocking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.7.1 ABS: Full Function / Off−road Mode . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.7.2 ABS Functions Check / Fault Display . . . . . . . . . . . . . . . . . . . . . . . . 13
7.7.3 Braking with ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.7.4 ABS with Dolly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
40C−1000−982a_en 5
Index
8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.1 General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.2.1 Safety Instructions for Protecting the System . . . . . . . . . . . . . . . . . 3
8.2.2 Safety Instructions for the Protection of Life and Limb
for Maintenance / Adjustment Work . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.3 Monitoring Functions for all Steering Programs . . . . . . . . . . . . . . . . 7
8.3.1 Monitoring the Steering / Emergency Steering Pump . . . . . . . . . . . 9
8.3.2 Monitoring the Electric−hydraulic Rear−axle Steering
(for Operation on the Construction Site) . . . . . . . . . . . . . . . . . . . . . . 11
8.4 Steering Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.4.1 Selection of the Steering Program “On−road Travel” or
“Construction Site Mode” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.4.2 Steering Program “On−road Travel” . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.4.3 Steering Program “Construction Site Mode” . . . . . . . . . . . . . . . . . . 17
8.4.3.1 Shared Characteristics of all Steering Programs for
“Construction Site Mode” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.4.3.2 ”Tight Cornering” (Steering Figure ”a”) . . . . . . . . . . . . . . . . . . . . . . . 21
8.4.3.3 ”Diagonal Steering” (Crab Walk; Steering Figure ”b”) . . . . . . . . . . . 23
8.4.3.4 “Rear−axle Steering” (Steering Figure “c”) . . . . . . . . . . . . . . . . . . . . 25
8.4.4 Switching off the Electric−hydraulic Rear−axle Steering /
Placing Axles 2 and 3 in Road Travel Position . . . . . . . . . . . . . . . . 27
8.5 Steering Computer / Fault Diagnosis / Fault List . . . . . . . . . . . . . . . 29
8.5.1 Operating Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.5.2 Registration of a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.5.2.1 Fault Display on Screen (A) of the Steering Computer . . . . . . . . . 33
8.5.3 Error Memory / Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.5.3.1 Activating / Reading off the Fault Memory (explained on
the CAN diagnosis display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.5.3.2 Deleting Error Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.5.4 Fault Categories / Fault Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.5.5 Fault List (Following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.6 Manual Emergency Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9 Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 Hydraulic Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 Suspension Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.2 Operating and Monitoring Equipment (Overview) . . . . . . . . . . . . . . 5
10.3 Setting the Suspension Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.3.2 Setting for Driving in the Transport Position
(”Placing the Crane in the Level Position”) . . . . . . . . . . . . . . . . . . . . 13
10.3.3 Setting for Raising Loads in the
LLD Operating Mode “on Wheels 360 Degrees” and for
“Driving the Crane with Load”
(Suspension Cylinders “Fully Retracted”) . . . . . . . . . . . . . . . . . . . . . 15
10.4 Level Check (for Driving in the Transport Position) . . . . . . . . . . . . . 17
40C−1000−982a_en 6
Index
10.5 Locking the Suspension for

“Driving in the Configured Condition” . . . . . . . . . . . . . . . . . . . . . . . . 19
10.5.1 Activating the Suspension Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.5.2 Switch−off Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.6 Pulling up and Lowering the Axles
(Crane Supported on Outriggers) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.6.1 Raising the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.6.2 Lowering the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Notes on Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.2 Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.1 Control Elements on the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.2 Control Elements in the Crane Operator’s Cab . . . . . . . . . . . . . . . . 13
11.2.3 Tilt display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11.2.4 Support Pressure Display (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.2.5 Support Base Display and Support Base Surveillance (Optional) 19
11.3 Outrigger Plate Fixing Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.4 Extension Locks of the Outrigger Struts . . . . . . . . . . . . . . . . . . . . . . 23
11.5 Support procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.5.1 Extending the Outriggers (from the Controls of the
Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.5.2 Levelling the Crane (from the Controls
of the Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.5.3 Levelling the Crane (from the Controls in the
Crane Operator’s Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.5.4 Notes on Levelling with the Counterweight . . . . . . . . . . . . . . . . . . . 41
11.5.5 Retracting the Outriggers
(for Driving the Crane in Transport Condition) . . . . . . . . . . . . . . . . . 43
11.5.6 “Lock Suspension” for
“Driving the Crane in the Configured Condition” . . . . . . . . . . . . . . . 47
11.5.7 “Suspension Fully Retracted” Driven for Raising
Loads in the LLD Operating Mode “On Wheels 360 Degrees”
and for “Driving the Crane with Load” . . . . . . . . . . . . . . . . . . . . . . . . 53
11.6 Supporting variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.6.1 Outrigger Support Area 6.30 m x 6.20 m (Normal
Outrigger Support Area)
(20 ft 10 in x 20 ft 4 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.6.2 Outrigger Support Area 6.30 m x 4.40 m
(20 ft 10 in x 14 ft 5 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
(20 ft 10 in x 7 ft 8 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.6.4 Free on Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.7 Supporting the Outrigger Plates Due to Insufficient
Load−bearing Capacity of the Ground . . . . . . . . . . . . . . . . . . . . . . . 61
11.7.1 Permitted Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.7.2 Determining the Required Support Area . . . . . . . . . . . . . . . . . . . . . . 65
11.8 Safe Distance to Slopes and Pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
40C−1000−982a_en 7
Index
12 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 . . . . in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 . . . . in the Erected State, Supported on Outriggers . . . . . . . . . . . 5
13 Towing the Crane and Towing the Crane to Start . . . . . . . . . . . 1

13.1 Towing the Crane to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.2 General Towing Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.2.1 Towing the Crane in case of Engine demage or
defective Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.2.2 Towing the Crane with Defective Distributor Gear . . . . . . . . . . . . . . 7
13.3 Towing the Crane Free on Soft Ground . . . . . . . . . . . . . . . . . . . . . . 9
14 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 Engine−independent heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
14.1.3 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.1.3.1 Setting the time and weekday for the first time . . . . . . . . . . . . . . . . 9
14.1.3.2 Adjusting the time and day of the week . . . . . . . . . . . . . . . . . . . . . . 9
14.1.4 Heating operation without pre−set times . . . . . . . . . . . . . . . . . . . . . . 11
14.1.4.1 ... with the ignition ”OFF”
......................................................... 11
14.1.4.2 ... with ignition ”ON” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14.1.5 Heating operation with preselection . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14.1.5.1 Heating start within 24 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14.1.5.2 Heating start after 24 hours (max. 7 days) . . . . . . . . . . . . . . . . . . . . 17
14.1.6 Rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
14.2 Air conditioning equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
14.3 Liquid gas heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
40C−1000−982a_en 8
Index
15 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Operating Controls and Display Elements . . . . . . . . . . . . . . . . . . . . 3
15.2 Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.2.1 Warnings / General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.2.2 Operation of Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2.2.1 System Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2.2.2 Crane Control in Driving Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2.2.3 Crane Control during Crane Operation . . . . . . . . . . . . . . . . . . . . . . . 9
15.2.2.4 Switching the System off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15.3 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.3.1 Overload Cut−off Using the Load Limit Device (LLD) . . . . . . . . . . . 13
15.3.1.1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.3.1.1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.3.1.1.2 Displays, Warnings and Interventions of the Control System . . 19
15.3.1.1.2.1Design “EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
15.3.1.1.2.2 Design ”Non−EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15.3.1.2 Bridging the Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15.3.1.2.1 Bridging with the ”Setup” Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
15.3.1.2.1.1 Displays, Warnings and Interventions of the Control System . 29
15.3.1.2.2 Bridging the Shut−down of the Movement ”Raising Luffing Gear” 31
15.3.1.2.2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15.3.1.2.2.2 Displays, Warnings and Interventions of the Control System . 33
15.3.1.2.3 Bridging the Shut−down of All Movements . . . . . . . . . . . . . . . . . . 35
15.3.1.2.3.1 Design “EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
15.3.1.2.3.2 Design ”Non−EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
15.3.2 ”Selection of Operating Mode” Screen . . . . . . . . . . . . . . . . . . . . . . . 47
15.3.2.1 Calling up the ”Selection of the Operating Mode” Screen . . . . . . . 47
15.3.2.2 Structure of the ”Selection of the Operating Mode” Screen . . . . . . 47
15.3.2.3 ”Set Date and Time” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15.3.2.4 ”Support Pressure / Support Base Area Display” Screen
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15.3.2.5 Setting the Operating Mode Parameters . . . . . . . . . . . . . . . . . . . . . 51
15.3.2.5.1 ”Support Base Area” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3.2.5.2 ”Reevings” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3.2.5.3 ”Crane Configuration” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.3.2.5.3.1 ”Operation with Main Boom” Screen . . . . . . . . . . . . . . . . . . . . . . 53
15.3.2.5.3.2 ”Operation with Boom Point” Screen (Optional) . . . . . . . . . . . . 55
15.3.2.5.3.3 ”Operation with the Main Boom Extension” (Optional) . . . . . . 55
15.3.2.5.4 ”Counterweight” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15.3.2.5.5 ”Operating Range Limits” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15.3.2.5.5.1 Slewing angle limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15.3.2.5.5.2 Head height limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15.3.2.5.5.3 Radius limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
15.3.2.5.5.4 Luffing Angle Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
15.3.2.5.5.5 Virtual Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
15.3.2.5.5.6 LIM Settings – Saving the Limit Values . . . . . . . . . . . . . . . . . . . 67
15.3.3 ”Crane Operation” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15.3.3.1 Calling up the ”Crane Operation” Screen . . . . . . . . . . . . . . . . . . . . . 69
15.3.3.2 Structure of the ”Crane Operation” Screen . . . . . . . . . . . . . . . . . . . 69
15.3.4 ”Main Menu” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15.3.4.1 Calling up the ”Main Menu” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 77
40C−1000−982a_en 9
Index
15.3.4.2 Calling up the ”Main Menu” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 77

15.3.4.3 ”Contrast” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
15.3.4.4 ”Visual Display Computer Inputs / Outputs” Screen . . . . . . . . . . . . 79
15.3.4.5 ”Fault Messages” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
15.3.4.6 Data Logger (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
15.3.4.7 ”Superstructure Inputs / Outputs” Screens . . . . . . . . . . . . . . . . . . . . 87
15.3.4.7.1 Calling up the ”Superstructure Inputs / Outputs” Screens . . . . . 87
15.3.4.7.2 Superstructure Inputs / Outputs That Can Be Viewed . . . . . . . . 87
15.3.4.8 ”Chassis Inputs / Outputs” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15.3.4.9 ”Brightness” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15.3.5 Load Monitoring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
15.3.6 Procedure in the Event of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
15.3.6.1 Fault−free Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
15.3.6.2 Operation with Fault Messages Whose Cause
Cannot be Rectified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
15.3.6.3 Emergency control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
15.3.7 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
15.4 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
15.5 Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15.6 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
15.6.1 Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
15.6.1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
15.6.1.2 Function Test of the Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . 105
15.6.1.3 Bridging the Hoist Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
15.6.2 Lower Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
15.6.2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
15.6.2.2 Bridging the Lower Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
16 Notes on Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.1 Wind Forces on the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.1.1 Measuring the Wind Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.1.2 Behaviour in Relation to the Wind Speed . . . . . . . . . . . . . . . . . . . . . 5
16.1.3 Wind Forces on the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.2 Crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.3 Operation with Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . 19
16.4 Monitoring Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16.5 Operating Instructions on Pilot Control /
Setting the Speed of the Movements . . . . . . . . . . . . . . . . . . . . . . . . 23
16.5.1 Engine−Speed−Dependent Crane Movements . . . . . . . . . . . . . . . . 23
16.5.2 Engine−Speed−Independent Crane Movements . . . . . . . . . . . . . . . 23
16.5.3 Fine Tuning of the Movement Speed / Crane Movements
Which Can be Modified Using Pushbuttons . . . . . . . . . . . . . . . . . . . 25
16.5.4 High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
16.6 Limiting the Engine Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 29
16.7 Operation Planning / Monitoring Safety Measures . . . . . . . . . . . . . 29
16.7.1 GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
16.7.2 Condition of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16.7.3 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16.8 Conversion of Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
40C−1000−982a_en 10
Index
17 Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.1 Preparations for Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.2 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
17.3 Slew Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17.4 Braking the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
18 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.1 Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.1.1 Extension Length of the Telescopic Sections . . . . . . . . . . . . . . . . . . 5
18.1.2 Control Levers for Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18.1.3 Telescopic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18.2 Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18.2.1 Telescoping without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18.2.2 Telescoping Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18.2.3 Telescoping Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19 Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19.1 Raising and Lowering the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . 3
19.2 Luffing Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20 Hoist 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1 Raising and Lowering the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.2 Hoist Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 Main Boom Extension (MBE) (Optional) . . . . . . . . . . . . . . . . . . . 1

21.1 GeneralNotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21.2.1 Transport Dimensions / Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21.3 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.4 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21.4.1 Transport Instructions for the MBE in the Transport Position . . . . 11
21.4.2 Transport Instructions for Separate Transportation . . . . . . . . . . . . . 13
21.5 Folding up and down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21.5.1 General Instructions for Folding over the Equipment . . . . . . . . . . . 15
21.5.2 Folding the 7.1 m (23.3 ft) Basic Boom out of the
Transport Position into Operating Position . . . . . . . . . . . . . . . . . . . . 19
21.5.3 Folding the 13 m (42.7 ft) Main Boom Extension from the
Transport Position into Operating Position . . . . . . . . . . . . . . . . . . . . 27
21.5.4 Folding the Main Boom Extension
(7.1 m or 13 m (23.3 ft or 42.7 ft)) from
0 Degrees to Operating Position 30 Degrees and Back . . . . . . . . . 35
21.6 Fitting and Removing for Separate Transportation . . . . . . . . . . . . . 37
40C−1000−982a_en 11
Index
22 Reevings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
22.1 Rope Equipment and Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
22.1.1 Uneven Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
22.1.2 Even Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
22.2 Load Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
22.2.1 Hoist Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
22.2.2 Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
22.2.2.4 Hook Block Types / Transport Dimensions / Weights . . . . . . . . . . . 21
22.3 Reeving the Hoist Rope on the Main Boom Head . . . . . . . . . . . . . . 23
23 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23.1 Standard Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23.1.1 Attachment Points Standard Counterweight . . . . . . . . . . . . . . . . . . 3
23.1.2 Weights and Transport Dimensions Standard Counterweight . . . . 3
23.1.3 Counterweight 5.4 t (11.9 kip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23.1.4 Counterweight 3 t (6.6 kip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23.1.5 Dismantling the 2.35 t (5.2 kip) Counterweight Section (Optional) 7
23.1.6 Removal of the Side Counterweight Blocks
(Optional: Pinned Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
23.2 Special Counterweight 5.4 t (11.9 kip) . . . . . . . . . . . . . . . . . . . . . . . . 11
23.2.1 Attachment Points Special Counterweight . . . . . . . . . . . . . . . . . . . . 11
23.2.2 Weights and Transport Dimensions Special Counterweight . . . . . 11
25 Central Lubricating System (Optional) . . . . . . . . . . . . . . . . . . . . 3

25.1 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
25.1.3 Setting the Pause and Operating Times . . . . . . . . . . . . . . . . . . . . . . 7
25.1.4 Additional Lubrication Impulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25.1.5 Manual Lubrication in the Case of an Emergency . . . . . . . . . . . . . . 11
25.1.6 Filling the Grease Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25.2 Malfunctions / Elimination of Malfunctions . . . . . . . . . . . . . . . . . . . . 13
25.3 Lubricating Points and Setting Times . . . . . . . . . . . . . . . . . . . . . . . . 17
25.3.1 Lubricating Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
25.3.2 Setting Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
26 Searcher Hook (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

26.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
26.1.1.1 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
26.2 Fitting the Searcher Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
26.3 Operating with the Searcher Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
40C−1000−982a_en 12
Index
27 Boom Point (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

27.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
27.1.1 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
27.2 Fitting the Boom Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
27.3 Setting the tension bars for Raising Loads with
Different Main Boom Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
27.3.1 Boom Point Fitted in the ”Short” Position (for a Main
Boom Angle of less than 25 Degrees) . . . . . . . . . . . . . . . . . . . . . . . 11
27.3.2 Boom Point Fitted in the ”Medium” Position (for the
Main Boom Angle of 25 − 40 Degrees) . . . . . . . . . . . . . . . . . . . . . . . 13
27.3.3 Boom Point Fitted in the ”Long” Position (for a
Main Boom Angle Larger Than 40 Degrees) . . . . . . . . . . . . . . . . . . 13
27.4 Reeving the Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
27.5 Raising Loads without the Hoist Rope (15 t / 33 kip) on
the Boom Point (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
27.5.1 Clevises / Single Hooks (15 t / 33 kip) (Optional) . . . . . . . . . . . . . . 17
27.5.2 Double Hook (15 t / 33 kip) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 21
27.6 Raising Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
27.7 Boom Point in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . 25
34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

34.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
34.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
34.3 Important Information before Using the Radio Remote Control . . 5
34.4 Radio Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
34.5 Operating Elements of the Radio Transmitter . . . . . . . . . . . . . . . . . 11
34.6 Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
34.7 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
34.8 Commissioning of the Radio Remote Control . . . . . . . . . . . . . . . . . 15
34.8.1 Automatic Shut−down of the Transmitter . . . . . . . . . . . . . . . . . . . . . 19
34.9 Crane Operation Using Radio Remote Control . . . . . . . . . . . . . . . . 21
34.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
34.11 Battery Charging Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
34.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
34.13 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
36 Emergency Activation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40C−1000−982a_en 13
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 40C
Construction number ___________________
Manufacturer Terex Cranes Germany GmbH

Dinglerstraße 24
D−66482 Zweibrücken
Phone: +49 6332 83−0
Fax: +49 6332 16715
www.terexcranes.com
40C−1001e_en 1/1
Foreword
Foreword
This document provides you
We have assembled all the information required for operation,

lubrication and maintenance in the supplied documents for
you, the owner of the crane which we have built.
This makes it easier to operate the crane and to use it as intended
and in accordance with regulations.
Among other things, these documents contain operating instruc-

tions.
It has been composed with trained personnel in mind.
The operating instructions of this crane consists of 3 parts:

Part 1 − Operating Instructions for the Crane Chassis /
Superstructure
Part 2 − Lubrication and maintenance instructions for the
Crane Chassis / Superstructur
Part 3 − Various
At least the operating instructions for the for the crane chassis /
superstructure (part 1) must always be available on location.
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 in your origi-
nal documentation.
This is especially valid for the part of the documentation that is
kept in the crane.
40C−1002g_en 1/13
2/13 40C−1002g_en
Foreword
Give these operating instructions to your crane operator and

driver as well as to the specialists concerned with maintenance,
asking them to read these instructions carefully before starting
operation for the first time and again 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 us. Our
address can be found in the section ”Manufacturer’s Specifica-
tions”.
The editors would welcome your involvement.
”Putting experience into practice”.
40C−1002g_en 3/13
4/13 40C−1002g_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
Steam spray gun
Before commissioning
You should inspect the crane thoroughly together with our service
engineer.
Spare parts
Use only original spare and wear parts authorised by the crane
manufacturer.
40C−1002g_en 5/13
6/13 40C−1002g_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.
The manufacturer’s address can be found in the section ”Manu-

facturer’s Specifications”.
Or contact your nearest TEREX partner.
Modifications to the crane
We would like to draw your attention to the fact that any changes
to the crane (for example by obtaining boom components, etc.)
render the details in these operating instructions partially invalid
or 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.
40C−1002g_en 7/13
8/13 40C−1002g_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 example, which wind speeds are permis-
sible while raising the crane and during crane operation.
WHERE do I find the information required above ?
The operating instructions of this crane consists of 3 parts:

Part 1 − Operating Instructions for the Crane Chassis /
Superstructure
Part 2 − Lubrication and maintenance instructions for the
Crane Chassis / Superstructur
Part 3 − Various
These parts are divided by index sheets.
“Wind speed” deals with matters concerning operation of the

crane, which includes the operating instruction (part 1).
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 16, Working Instructions”.
3. In this section 16 I then find ”Wind speeds” as item 16.2.

The page details on the right−hand side of the page refer to
the page number within the section.
40C−1002g_en 9/13
Z 26 350
10/13 40C−1002g_en
Foreword
HOW do I find the page in section 11 ?
1. I take the pages of part 1 and flick through the pages as

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

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

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

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

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

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

understood as looking in the direction of travel.
40C−1002g_en 13/13
Safety Instructions 1
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1 Safety Instructions
1.1 General
This section ”Safety Instructions” provides a compact and gene-

ral 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.
The safety instructions for lubrication, maintenance and service

work can be found in Lubrication and Maintenance Instructions.
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1.2 Intended Use
The crane is designed for lifting loads.
Risk to life and limb!

The mobile crane must never be used for entertainment
purposes, for example, lifting of persons for shows, bun-
gee jumping (leaping / bouncing from an elastic rope), din-
ner−in−the−sky or lifting of other structures with people on
the structure or underneath it (e.g. lifting of tents).
This is improper use of the crane and constitutes extreme
danger to life and limb!
The crane is not intended for lifting people. It is prohibited to

transport people with personnel carrying equipment!
Risk of accidents!
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.
The crane may only be used to lift people in a so−called ”person-

nel cage” and to keep them at that height as an exception in ex-
traordinary operating situations and when it is the least dange-
rous way of executing the work.
This does not apply to the working platforms fitted to the crane
boom which are intended for lifting people, as they are covered
by international standards for mobile hoist operating platforms.
Such an exceptional use is only permitted if the requirements li-

sted on the following two pages are fulfilled.
The crane operator carries the responsibility.
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General requirements
− The use of mobile cranes for lifting persons is permitted by

national law in the country of the crane’s current operation.
Specific regulations for the use of personnel cages as stipula-
ted by national law are applied.
− The use of the crane for lifting persons is reported to the natio-
nal health and safety authority if required by national law (the
use may need special approval).
− The possibility of rescuing people in the personnel cage in the
case of an emergency has been evaluated prior to the job by
means of a job−specific risk assessment. Provisions for
emergency rescues must be taken if so required by national
law.
− A pre−lift meeting has been held with all the relevant partici-
pating people.
− The provisions for working in the vicinity of power lines accor-
ding to the job−site conditions and national law / regulations
are observed.
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Requirements concerning the equipment
− With the exception of the personnel cage being the load, the
crane is used as intended and described in the respective
operating manual.
− The crane is checked and no damage / defects are found
prior to lifting persons.
− The personnel cage fulfils the requirements in accordance
with national law and / or standards and is used as intended.
− The personnel cage is thoroughly checked prior to lifting per-
sons and no defects are found.
− Any emergency rescue device as required by national law
has been checked and found to be operational.
− Hooks used must be equipped with a safety catch which pre-
vent the hook jaw from opening. It is required by national law
to either close the lock manually and to lock or to use an auto-
matically operated, spring−loaded safety catch.
Requirements concerning tests before use
− Prior to lifting persons, an overload test lift (approval test) with

an overload of 125% of the lifting capacity of the personnel
cage has been carried out. This must be done at each new
construction site and after every modification or repair to ver-
ify the safe performance of the personnel cage and the lifting
tackle (relocation of the crane to a larger construction site
does not require a new overload test).
− Prior to lifting persons, a test lift has been carried out with an
unoccupied personnel cage, which has, however, been loa-
ded with at least the anticipated lift weight (simulating a loa-
ded man basket), in order to simulate the complete planned
lifting cycle.
This trial lift must be done wherever the crane is set up on the
construction site for lifting persons.
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Requirements for use
− The rope pull is limited to 50% of the maximum line pull.

− The crane is used at 50% of the maximum capacity of the re-
levant load capacity table.
The crane is designed exclusively for assembly operation.

Any other type of use or use which goes beyond the limits speci-
fied, for example handling of general cargo or grab operation, are
not classified as intended use. The manufacturer shall not be
held liable for any damage which results. The operator carries full
responsibility for this type of use.
Risk of accidents!
It is prohibited to use the crane to pull free fixed loads!
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 spe-
cifications.
If operation of the crane for general cargo 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 Working Conditions and Computed Design of the

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

tions and the lubrication and maintenance instructions.
1.3.2 Classification of the Crane
The crane is classified according to ISO 4301 and EN 13000 as

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

factured for normal assembly operation. This assumes that crane
operations with full crane utilization, crane operations with lower
utilization and operational breaks occur in a ratio that is typical for
an assembly crane. More exacting working conditions necessa-
rily lead to a shorter life expectancy for the crane.
Working conditions or types of use other than assembly opera-

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

4301−2 and FEM 1.001. They have been calculated and desi-
gned based on specific working 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 = .......
Theoretical Service Life D = .......
The respectively applicable values can be obtained from the ta-

ble ”Monitoring the winches” in the crane log book.
The classification of the power units is the basis for their evalua-
tion during the annual inspection (see Lubrication and Mainte-
nance Instructions).
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1.3.4 Workplace Ergonomics
The noise levels listed in the following table can occur at the
crane operator’s workplace in the crane operator’s cab. To re-
duce noise during crane operation, we recommend keeping the
cab doors and windows and the cover flaps of all drive units clo-
sed.
− Engine idle (550 min−1/rpm) < 75 dB(A)
− Maximum engine speed without load (2750 < 85 dB(A)
min−1/rpm)
− Engine speed at highest engine torque wi- < 80 dB(A)
thout load (1300 min−1/rpm)
The measurements were taken at the ear position of the crane

operator using a sound level meter with a test microphone. 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 ope-
ration on construction sites using dosimeters.
Outside the crane operator’s cab and/or when the crane opera-
tor’s cab door is open, the driver of the crane and/or the auxilia-
ries will be subjected to higher levels of exposure to noise. Per-
sonnel may therefore only work there if wearing ear muffs.
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, backrest and armrests. It is therefore possible
to select the optimum operating 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.
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1.3.5 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the configu-
ration, boom length and working radius. It is specified by the
crane manufacturer in the load capacity tables.
The capacity tables supplied with the crane specify limit values
which may not be exceeded.
The limit of the winches’ load bearing capacity is basically re-

ached 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

−25°C to +40°C (−13°F to +104°F), if the maximum or minimum
temperature occurs only a few days a year.
At temperatures below −20°C (−4°F), the following rules are ap-

plicable:
− Adapt consumables
The consumables may not cover the entire temperature
range. They must therefore be replaced if necessary.
Please observe the detailed information in section 2 “Consu-
mables (and Capacities)” of the lubrication and maintenance
instructions.
− Optional equipment
The crane must be equipped with auxiliary heating and a fuel
preheater.
The corresponding consumables and optional equipment can be

supplied.
− Warm−up phase
Please observe the detailed information in the operating in-
structions, section 4 “Engine” under “Warming up the hydrau-
lic system” and in the lubrication and maintenance instruc-
tions, section 2 “Consumables” under “Notes / legend”.
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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 regu-

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

maintenance instructions.
With an oncoming wind the crane operator must follow the rules
outlined in the operating instructions. See section ”Working in-
structions”.
The ground on which the crane is supported on outriggers − or

on which it drives − must have sufficient load−bearing capacity.
Detailed information on the ground’s load−bearing capacity can
be found in the section ”Working instructions” or ”Outriggers”, de-
pending on the type of machine.
The demands on the road for the various driving configurations
are described in the ”Driving” section.
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 (ser-

vice 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 condi-
tions.
− the entire number of the crane’s load cycles in this time is less
than 32 000 (for example, 5 − 10 strokes / day on 200 days
/ year).
A ”load cycle” encompasses all processes which begin when a

load is raised and end when the crane is ready to raise the next
load.
− The type of load (the load collective) of the entire crane does
not indicate any proportions which are less favourable than
the following values:
∗ for 1/10 of the load cycles, the crane is placed under max.
load
∗ for 4/10 of the load cycles with 50% of the max. load
∗ for 5/10 of the load cycles with 33% 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 car-

ried out properly, the theoretical service life can be more than 20
years.
Harder operating conditions naturally lead to a reduction in the
service life.
However, the regulations for determining the remaining

theoretical service life in the “Inspections of the crane” sec-
tion in the lubrication and maintenance instructions must be
observed for the winches.
Some components (e.g. ropes) are not designed for the en-
tire service life of the crane, but must be replaced after a cer-
tain amount of time.
Observe the instructions in the lubrication and maintenance
instructions.
1.3.8 Scrapping / Disposal
If the crane (or components thereof) is/are scrapped, you must

ensure professional disposal.
It is particularly important that no poisonous materials (fuel, oil,
etc.) or substances which are incompatible with the environment
(for example, plastics) pollute the environment.
The relevant national regulations must be adhered to.
1.3.9 Standards and Calculation Regulations
The calculation of the crane meets the requirements of ISO 4301

and EN 13000.
For countries in which other regulations and standards apply,

special−case service life calculations can be carried out.
If required, these calculations must be specially ordered by the
crane operator. The working conditions for the crane are not alte-
red, however it may be necessary to limit the lifting capacities.
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1.3.10 Dangers to Air Traffic
As considerable heights are reached when the crane is operated,

this can lead to air traffic being endangered.
For this reason, in particular in the vicinity of airports, landing
areas and air traffic control areas (so−called protected zones),
the crane may only be operated with the permission of the autho-
rities responsible for air traffic control.
For more information regarding Germany, contact the Deutsche

Flugsicherung GmbH (DFS).
Observe respective national regulations.
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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).
The crane operators of cranes which are controlled using
radio remote control must be outside of the danger zone of
the moving crane components and the load.
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 configuration procedure is completed. During
stacking, the person attaching the equipment must remain
outside the hazardous area.
When attaching and disconnecting the load, particular care

must be taken due to hazards resulting from swinging
loads or hook blocks. The person attaching the equipment
must be proficient in handling hook blocks.
Immediately after the procedure has been completed, the
person handling the load must leave the slewing or hazar-
dous area.
The person handling the load must be easily recognisable

to the crane operator. The fitter must wear one or more
means of identification, for example, jacket, helmet, col-
lars, armbands, signalling discs.
These means of identification should be in a distinctive co-
lour and where possible of an identical design and must be
exclusive to the fitter.
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1.4.1 Organisational Measures
In addition to the operating instructions, applicable national re-

gulations 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 instruc-
tions.
Such stipulations may involve, for example, handling hazardous

substances, making available / wearing personal protective
equipment or road traffic regulations.
In addition to the operating instructions and the accident preven-

tion regulations valid in the country and on the operating site
where the crane is in use, the recognised technical regulations
pertaining to safe and correct working procedures must also be
observed.
The operating instructions should be supplemented by any other

instructions that are necessary, including supervisory and repor-
ting duties for any special operating occurrences, for example
with regard to work organisation, operating procedures, alloca-
ted personnel etc.
Keep a complete and legible set of all safety and hazard instruc-
tions on the crane at all times.
Safety guards on the crane must not be opened or removed du-

ring crane operation.
Provide instructions on the location and use of fire extinguishing

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

of the crane operator’s cab, the outriggers and the winches must
be illuminated by the spot lights, which are fitted on the crane
(rear outside lighting, front outside lighting, side outside lighting).
Other surrounding areas (load, load path, slewing range, driving
path, and similar) must be lit using suitable means, independently
of the crane. The responsibility for this lies with the crane opera-
tor.
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1.4.2 Personnel Requirements
To make optimum use of a crane, without overloading it or failing

to use it to its full potential, the crane operator and the mainte-
nance, assembly and dismantling engineers must be thoroughly
trained.
The crane operator / owner is responsible for providing this trai-
ning.
Use only reliable, trained or instructed personnel for work on and

with the crane.
Make sure that only authorised personnel are allowed to carry out
work .
Observe the minimum working age.
Personnel must be physically and mentally capable and may not

be under the influence of alcohol, drugs or medicine.
Clearly specify all areas of responsibility:

− for operation, configuration and maintenance.
− for the machine operator, also with regard to responsibility for
observing road traffic regulations. Allow him to refuse instruc-
tions from third parties which contravene safety regulations.
Personnel who are still being trained and instructed in the use of
the crane, or who are completing a general apprenticeship, may
only be allowed to work on the crane under the constant supervi-
sion of an experienced member of staff.
Personnel who are responsible for work on the crane must have
read the operating instructions before commencing work, and
in particular the section on ”safety instructions”.
It is too late to start during operation!
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 uncovered if it is long,

nor to wear loose clothing or jewellery, including rings. There is
a risk of injury, e.g. as a result of being caught or dragged by mo-
ving parts.
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1.4.3 Particular Hazards
1.4.3.1 Electric 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 and / or cordon off the danger zone.
Both measures may only be carried out by qualified electri-

cal specialists.
If these measures cannot be carried out, a sufficient safety clea-

rance must be maintained between the crane ( hoist rope, lifting
tackle, hook block, load) and current−carrying lines. Risk to life
and limb!
Keep a clearance of at least 10 m (32.8 ft). If this is not possible,
you must obtain information on required minimum safety distan-
ces 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 sa-
fety 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:
− Bring the crane out of the danger zone: drive it out, swing it,
adjust the boom system!
If this is not possible:

− do not leave the crane or the cab!
− Warn anyone in the vicinity against approaching or touching
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/da-
maged line has definitely been disconnected from the power
source.
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High−frequency radiation / operating in vicinity of transmit-

ters
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:

− Discuss the problem with the operator of the transmitter
(maybe switch off the transmitter).
− Connect the track−free mobile crane to ground.
In order to protect the rotating connection the grounding ca-
ble must be fastened directly to the superstructure of the
crane or to the main 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 electrical system
At the same time, the crane’s electrical system, especially the

load limit device, cannot be considered to be functioning safely,
depending on the strength and frequency of the transmitter.
The risk of the load limit device being influenced by high−fre-

quency radiation is minimised by state of the art technology
(shielding). However, it cannot be fully discounted, especially un-
der extreme circumstances.
This is especially valid if the crane is used in the close vici-

nity of high−frequency radiation sources (e.g. radar sta-
tions, radio transmission stations, radio and television sta-
tions).
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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.
If there is a fear that lightening has struck, the general functions

of the crane must be checked. It is especially important that the
following is checked:
− Electrics in general, in particular:
∗ Load limit device; if it is defective a fault message appears
on the display.
∗ Limit switches; to see if they are functioning.
∗ Inductive proximity switches; to see if they are functioning.
− Luffing and outrigger cylinder with a visual check for external
damage caused by voltage flashovers or fusing.
By retracting and extending the relevant cylinders several ti-
mes, check if there are suspected internal leaks due to dama-
ged seals.
− Hoists, especially for damage to ball and roller bearings.
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Z 29 802
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1.4.3.2 Gas, Dust, Steam, Smoke
Only operate combustion engines and fuel−operated heaters in

sufficiently ventilated spaces. Make sure that sufficient ventila-
tion is provided before operating in restricted spaces.
Follow the applicable regulations for the operating site.
The State of California advises that diesel engine exhaust

and some of its constituents are known to cause cancer,
birth defects, as well as harm to genetic material.
1.4.3.3 Crushing / Collision

(Z 29 800)
For the points listed below, please also refer to the detailed des-
cription in the corresponding sections of the operating instruc-
tions.
− Hook block / load when slewing the superstructure
1.4.3.4 Becoming Entangled / Dragged in

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

(Z 29 800)
tions.
− when telescoping the main boom in and out
− when lowering the main boom on the foot bearing of the su-
perstructure frame
− when slewing the superstructure
− when extending and retracting outriggers and cylinders
− when releasing the suspension lock following the outrigger
procedure in the vicinity of the wheels
− near the hook block or the load during uncontrolled move-
ments
− when stacking the counterweights
− when fitting and removing hoist 2
− when fitting and removing the main boom or the superstruc-
ture
− 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 Dangers Due to Slipping, Tripping, Falling

(Z 29 803)
Only the described catwalks and ladders may be used. There are
sufficient gripping devices there for holding on and attachment
eyelets for personal protective equipment. In addition, the cat-
walks are designed to be slip resistant (for example, sanded
areas, corrugated metal plates, or similar).
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1.4.4 Combination of Hazards with Combined Operation

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

collisions.
The operating company or its representative must:
− specify the working sequence in advance.
− make sure that there is a clear line of communication with the
crane operator!
If the crane operator does not have spoken or visual contact, sui-
table measures must be taken, e.g. use of radios, spotters/
banksmen etc.
The communication connections for communicating with the
crane drivers (e.g. walkie−talkies, etc.) must be inspected for re-
liable functioning before beginning any work on the crane.
If banksmen are used, suitable signals must be agreed between

these banksmen and the crane operators. In this regard, please
refer to section 1.5 of this section ”Safety Instructions”.
The crane operators must operate their cranes carefully and in

a restrained manner to make sure that collisions cannot occur as
a result of uncontrolled movements.
They must receive suitable training and instructions to this end.
1.4.4.2 Several Cranes Raising a Load Together
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 proce-
dure and appoint a supervisor, in whose presence the operations
are carried out.
The most important requirement for this type of operation is, ho-
wever, 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 ha-
zards 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 in-
fluences (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 ”Cranes” of the em-
ployer’s liability insurance association (BGV D6) can be
used as an aid. It contains regulations and safety instruc-
tions for operation with several cranes. It states in particu-
lar that sufficient safety reserves must be planned for each
crane and that the full load value of the capacity 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 weight and
the position of the centre of gravity of the load, the safety
reserves must be increased accordingly.
Before carrying out heavy−duty operations, the crane manufac-

turer should be consulted to see whether the crane can be fitted
with any additional safety devices (e.g. limiters) or whether the lif-
ting capacity needs to be restricted additionally for the operation
in question.
Avoid oblique pull under all circumstances!
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1.4.5 Driving Operation
1.4.5.1 Before Driving
In order to ensure the safety and operational readiness of the

crane, the checks and maintenance work must be carried out in
accordance with the lubrication and maintenance instructions.
In particular, check the effectiveness of the brakes, steering and

signal and lighting equipment daily; if the crane is used infre-
quently, check it every time before starting operation (or driving).
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
(we recommend actuating the horn before starting the engine).
If you cannot see the hazardous area, a spotter (or banksman)

must be used (see section 1.5)!
This also applies if noise levels are too high to allow normal verbal
communication.
Keep the windows clean to maintain good visibility at all times.
Make sure that all accessories are stored safely and cannot
cause an accident.
When driving on public roads, highways and precincts observe

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

the technically possible load (technical driveability) and the load
permitted in accordance with the road traffic regulations.
”Technical driveability” is only permitted on construction sites or
private roads (with the exception of countries which permit axle
loads over 12 t / 26.4 kip).
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Axle loads over 12 t (26.4 kip) are not authorised for road travel
in countries subject to EU regulations (or to reduced axle loads).
If the crane is driven on the road with axle loads above
12 t (26.4 kip), thenthe crane operator assumes sole responsibi-
lity. All components and installations are designed and calculated
for axle loads of 12 t (26.4 kip) at maximum speed.
If this 12 t (26.4 kip) axle load is exceeded, the service life of ax-
les, wheel hubs, bearings, suspension cylinders and brakes will
be reduced. In particular wear to the brake linings and the risk of
the brakes overheating and fading are increased.
The brake delay for the brakes (EEC: 50%) is reduced in propor-
tion to the increase in axle load or to the transportation weight of
the crane.
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1.4.5.2 During Travel
When driving on the road, the main boom must be lying on the
travel rest in the transport position and the telescopic sections
must be secured against undesired telescoping out.
For crane types with pinnings between the telescopic sections,
these must be pinned.
For crane types with telescoping cylinders and rope drives, the
main boom must be secured against undesired telescoping out
using a rod or a rope.
When driving on inclines, always adapt the speed of the crane to

the conditions. Never shift gear once on the slope, but change to
a lower gear before reaching the slope.
When negotiating underpasses, bridges, tunnels, overhead

power cables, etc. always make sure that there is sufficient clea-
rance.
When towing, follow the towing regulations with respect to the

prescribed transport position, permitted speed and distance tra-
velled.
Additional persons may only drive along when sitting in the pre-
scribed and regulated seats (with safety belts, etc.).
For crane types which have a chassis cab (driver’s cab) no−one
may be taken along in the crane operator’s cab.
Emergency exit from the cab:

For crane types which have a chassis cab, the passenger door
may be used as an emergency exit.
For crane types which only have a cab on the superstructure, the
front window of the cab which can be opened widely can be used
as an emergency exit.
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1.4.6 Crane Operation
1.4.6.1 Before Crane Operation
In order to ensure the safety and operational readiness of the

crane, the checks and maintenance work must be carried out in
accordance with the lubrication and maintenance instructions.
Check the load conditions again before commencing crane ope-

ration: Is the mass (the weight) of the load and the operating pro-
cedure known and is there sufficient lifting capacity, working ra-
dius and lifting height? Compare the values with the load capacity
table.
Using the crane’s display systems, check: Load status, fluid sta-
tuses, motor operation, hydraulic oil pressures and wind speeds.
Check whether outside conditions such as wind, snow, poor visi-

bility, unfavourable temperatures etc. could impair crane opera-
tion.
Make sure that the ground has sufficient load−bearing capacity

when supporting the crane on outriggers.
Maintain a safe distance between the supported crane and slo-
pes and ditches.
Depending on the machine type, there are detailed notes on both
subjects in the sections ”Working instructions” or ”Outriggers”.
Before commencing work, familiarise yourself at the operating

site with its surroundings. 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 pu-
blic traffic areas.
To operate the crane, unhindered sight of the crane, load and

load path must be ensured. If this is not ensured, banksmen must
be used.
Either signals for communication (see section 1.5, from page 93)
must be agreed between the spotter / person attaching/deta-
ching the load and the crane operator or a communication system
(for example, voice radio) must be used.
If a communication system is used, it must be provided by the
crane operator.
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Carry out the necessary measures to ensure that the crane is

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

sure that they are functioning properly.
Operate the crane only if all safety guards and equipment are fit-
ted and functional.
Check the effectiveness of brakes, signal and lighting equipment,

limit switches and overload cut−off devices daily, or in the case
of cranes which are seldom used, before the equipment is placed
in operation.
If a radio remote control is used on the crane, radio transmitters,

atmospheric interferences or other radio remote controls trans-
mitting on the same frequency can disrupt the radio transmission.
For this reason, the radio remote control and / or the radio trans-
mission must be checked for proper function before the actual
operation.
If interferences in radio transmission cannot be rectified by chan-
ging the operating frequency, the radio remote control must not
be used during the operation or interfering radio transmitters and
other radio remote controls must be switched off.
Observe the charging state of the batteries.
Before commencing work with the crane make sure that no−one
is in the hazardous area. If necessary, give a warning sign (we
recommend actuating the horn before starting the engine).
As oil can be emitted during maintenance and assembly work,

suitable collecting vessels and binding agents must be placed re-
ady.
Insofar as necessary or required by regulations, personnel must

wear protective clothing and equipment (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!
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The weight of the load must be known.
It is difficult to calculate the load weight during dismantling

work. If a load that is attached to the crane is released from
its previous connection to other parts and is too heavy, the
crane will be unavoidably destroyed or will tip over, regard-
less of the load limit device.
When dismantling hollow components (pipelines, cement si-
los 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 accor-
dance with the individual load case.
Before reeving and before starting crane work, check the status
of all accessible ropes (including the end connections), winches
and sheaves.
Select the lifting tackle in accordance with the weight of the load,
the type of attachment and the angle of inclination.
Only hook blocks supplied by the crane manufacturer may be

used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.
Pay attention to the rules and regulations for working with load
handling equipment (attachment ropes etc.) and load handling
devices (lifting beams etc.). Never use lifting tackle and load
handling devices if there is any doubt as to their lifting capacity.
Check to make sure that the lifting tackle and all load handling de-
vices are in perfect condition.
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1.4.6.2 During Operation of the Crane
When carrying out power−driven working procedures

(raise / lower load) only the crane operator is allowed on the
crane (and he must be in the crane operator’s cab). Remai-
ning personnel must remain clear of the hazardous area on
and around the crane.
For cranes which are controlled using radio remote con-
trol, the crane operator must be outside of the danger zone
of the moving crane components and the load.
The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work if people fail to leave the hazardous area in spite of
warning signals.
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.).
The crane operator may only start movements if he has good visi-
bility of the hazardous areas.
When working from the crane operator’s cab, keep the windows
clean so that good visibility is ensured.
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 is also the case if normal verbal communication or voice ra-
dio is not possible due to increased noise levels.
Depending on type, a radio remote control can be delivered so
that the crane operator can monitor danger zones with a direct
view, which otherwise could only be supervised by a banksman.
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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.
An exception is only permitted in emergencies. 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 possible
– movements that have been started should be completed
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.
During crane operation, the outrigger control box must be locked.

The chassis cab must be locked in cranes which have one.
The engine of the crane chassis must be switched off in cranes
with an engine in the crane chassis and crane superstructure.
The erected crane without load may only be left without the su-
pervision of a trained crane operator if certain conditions are met
(see operating instructions, section ”Parking”).
Conveying of persons with the load or the load lifting tackle is pro-
hibited.
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 instructions on the crane.
Avoid any type of action that could possibly impair the safety of
the crane (for example that may reduce the stability of the crane).
Never slew loads over people.
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When working from the crane operator’s cab:

Only start the crane engine from the driver’s seat. Only actuate
the control lever from the cab.
The crane operator must only initiate, execute and finish crane
movements from the designated operating position.
This is to prevent unintentional crane movements being initiated
when entering and exiting the crane cab.
The crane operator must only assume the designated operating

position if the left−hand arm console (where the left−hand control
lever is) is folded away.
The crane operator must only exit the designated operating posi-
tion if the initiated crane movement has been completed and the
left−hand arm console (where the control lever is) has also been
folded away.
If the left−hand arm console has been folded up, the left−hand
arm console is put out of function.
RISK OF ACCIDENTS!
If the arm console is folded up or down while the control le-
ver is steered, it causes abrupt
braking or initiation of the corresponding movement.
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Oblique pulling and dragging of loads is prohibited for operation

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

closed or open.
Check the crane at least once per shift for any visible signs of da-
mage and 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 malfunctions, shut down the crane immediately and se-

cure the crane. 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 out-

side 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. They are in the super-
structure on the back wall of the cab. For crane types with a dri-
ver’s cab on the crane chassis, the storage compartment is on
the inside in the driver door.
Make sure that all personnel are conversant with fire reporting
and fire fighting equipment and procedures.
Pay attention to the weight and surface area of the load exposed
to the wind.
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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.
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 sup-

ported on outriggers. Note that slewing is only permitted for cer-
tain crane configurations (e.g. with regard to outrigger support
area, counterweight etc.).
For some crane types, there are load capacity tables ”Free on
wheels”. Only then is it permitted to slew the superstructure when
not supported on outriggers.
Always observe the instructions in the load capacity tables.
Slewing of the superstructure in the overload range (load limit de-
vice has shut down) is generally prohibited.
In an emergency the wide−opening front window can be used as

an exit.
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1.4.6.3 Disruption of Crane Operation −

Parking and Leaving (Partially)
Erected Mobile Cranes Unsupervised
Manufacturers of mobile cranes and operators using mobiles

crane are aware that it might not be possible under certain condi-
tions to fully retract the boom and the crane equipment or to lower
them into the position of rest to temporarily shut down the crane
(for example, at night) when at locations with limited space op-
tions.
1.4.6.3.1 Problems and Risks
Some examples of possible events which can occur when the

crane is left unsupervised are listed below. The associated poten-
tial risks must be taken into consideration:
− The ground giving way:
− The ground could slip away due to heavy rainfall, landsli-
des or erosion
− Melting ice under the supports
− Bad weather:
− Storms and winds
− Thunderstorms
− Rain / floods
− Hydraulic cylinders of the crane:
− Slow retraction of the support cylinders, luffing cylinders
and/or telescoping cylinders when telescopic systems are
unpinned (for example, due to a change in the ambient and
oil temperature or a leak).
− Vandalism.
If a qualified crane operator acquainted with the operating site

determines that the boom of a crane cannot be lowered into the
position of rest, the additional instructions listed below must be
adhered to.
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1.4.6.3.2 General Instructions
A general rule is: If a configured crane can no longer be suffi-

ciently controlled, the boom and other equipment must be lowe-
red.
The following instructions are valid for all mobile cranes, regard-
less of type, configuration, configuration mode and ambient
conditions:
− The crane must be positioned in the smallest and most stable

permitted operative configuration which is possible in prac-
tise at the operating site. This also applies to parameters
such as the boom angle, the slewing direction and the top
section adjustment angle.
− The attached counterweight of a jib or a Superlift must be lo-

wered onto the ground.
− The engines must be switched off.
− A load may not remain attached on the hook.
− All levers must be switched in the neutral position or in a ”lok-

ked” position.
− All secondary systems, for example the heating system, the

air conditioning, etc. must be switched off.
− Close all windows.
− When the crane is left unsupervised, the energy supply and

the functional efficiency of the safety features and equipment
(for example, the aircraft warning lights, etc.) must be ensu-
red.
− All keys must be kept in a safe place to prevent unauthorised

use.
− The crane must be secured and the cab doors (of the chassis
and superstructure) must be locked to prevent unauthorised
use.
− Lock any unused control platforms.
− Depending on the crane type, the mobile control platforms

connected with the crane via cables must be removed and/or
stored in a safe location to prevent unauthorised use.
− To prevent unauthorised use, any cordless control platforms

must be stored in a safe location and it must ensured that the
batteries are charged or are being charged.
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If the crane is erected and the conditions at the operating site do

not allow for complete lowering of the boom and/or the equipment
into a position of rest, a qualified crane operator acquainted with
the situation at the operating site and with the existing conditions
and limits must decide in which the configuration the crane is to
be left unsupervised. Furthermore, the following instructions
must be observed:
− Before leaving the crane unsupervised, an emergency plan
must be determined with which the crane can be placed in a
safe position in case of emergency (for example, unforeseen
change in weather or other possible events such as the ones
described on page 75). This plan must provide sufficient
space to place the technical equipment in a safe position.
− The crane must be left without a load attached, i.e. without
the load−handling devices as well.
− The hook block must be in the uppermost position, so that no
contact is possible between the cables and the boom or other
obstacles.
− The location and configuration of the crane may not cause
any risks for the surrounding area − for example, endange-
ring road traffic or causing a risk of collision with obstacles in
the area; under certain circumstances this requires a risk as-
sessment before the crane is left unsupervised.
− It must be checked whether accidental (slow) movements are
possible, for example, due to internal or external leaks in all
load−bearing hydraulic cylinders and winches:
− support cylinders in vertical supports
− main boom luffing cylinders
− hydraulic cylinders for adjusting the equipment, if applica-
ble
− hoist winch
− derricking winch, if applicable
− etc.
Slight movements can also be caused by a change in the oil tem-

perature (for example, temperature changes due to heating up
caused by sunlight or the hydraulic oil cooling down).
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− The weather report must be obtained throughout the entire

time in which the crane is erected.
− When determining the parking location and the crane con-
figuration, changes to meteorological conditions such as
wind, ice, rain, floods and thunderstorms must be taken
into consideration before parking and leaving the crane
unsupervised.
− If, due to unforeseen weather conditions, wind speeds ex-
ceed the permitted values for an erected boom, the crane
must be secured as best as possible and everyone must
be evacuated from the affected area.
1.4.6.3.3 Specific Instructions for Mobile Hydraulic Cranes with

Telescopic Boom
− If the crane is parked and left unsupervised, the boom must

always be retracted as much as possible and must be secu-
red (for example, pinned).
− If the predicted wind speed exceeds the maximum value li-
sted in the operating instructions for the selected configura-
tion, the boom must be telescoped in and lowered before the
maximum permitted wind speed for assembly and dismant-
ling is reached.
1.4.6.3.4 Specific Instructions for Crawler−mounted Cranes

with Equipment
− If the predicted wind speed exceeds the maximum value li-

sted in the operating instructions for the selected configura-
tion, the boom must be lowered before the maximum permit-
ted wind speed for assembly and dismantling is reached.
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1.4.6.4 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 must
be put in the neutral position or in the ”Locked” position.
∗ the heating must be switched off.
∗ the parking brake of the crane chassis must be applied (if not
already occurred).
∗ the crane must be secured to prevent unauthorised use and
accidental movement.
If the crane is parked on steep ground, the travel gear must be

additionally secured with chocks, the slew brake applied and the
main boom secured.
Close all control panels that are fitted with a lock when they are
not being used.
Depending on the crane type, there are mobile control panels on
the crane which are connected with cables. Remove them when
they are no longer needed.
If your crane is equipped with a radio remote control, store it sa-

fely. Make sure that the batteries are recharged.
Even when parking the crane, pay attention to the permitted wind
speeds (also for the time when the crane is stationary). If neces-
sary telescope in and set down the main boom.
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1.4.7 Power Supply Failure
General
If the power supply fails, all movements are stopped. An uninten-

tional 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 (lo-
wering 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 rare, there is no built−in option

for lowering a load on the hook. Such cases must be reported to
Customer Service.
If hoses or pipes should burst, therefore, there will be no dange-

rous 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 rigged configuration (erect condi-

tion).
When the crane is driven in the rigged configuration, the load

rests on the suspension cylinders. These are not equipped with
pipe burst valves, in order to guarantee problem−free suspen-
sion behaviour during driving of the crane. To avoid hazardous
situations, the regulations outlined in the operating instructions
for the crane chassis, section ”Driving the Crane”, ”Driving in the
Configured Condition” must be strictly observed.
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1.4.8 When Assembling and Dismantling Crane Compo-

nents
Although all possible protective and safety measures have

been provided, there is still a risk of crushing during assem-
bly 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 stated).
Crane components may not, under any circumstances, be as-

sembled and dismantled by untrained personnel. This also ap-
plies to staff providing temporary help.
Incorrect assembly can result in danger to life and limb.
Due to danger by slipping, stumbling and falling, you may not

step on the superstructure, main boom and equipment (for exam-
ple, main boom extension).
Exceptions are only permitted if access areas are provided. Ho-
wever, this requires additional safety measures. Safe measures
for walking are then described in the corresponding section of the
All assembly work is to be carried out with the help of suitable ac-
cessories (ladders, hoist platforms, scaffolding, auxiliary crane
etc.). The assembly personnel must be sufficiently secured. Furt-
hermore access is only permitted to areas where there is no risk
of falling.
Normal assembly prescribes that all component parts which are

to be transported separately are transported near to the ground
with suitable auxiliary cranes and lifting tackle (ropes) − and are
safely connected to the basic crane.
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88/99 40C−1010−982a_en
Before assembly personnel approach suspended loads, for ex-

ample counterweights, outrigger struts, intermediate sections,
main 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, personnel must never

walk or stand in the area where there is a risk of the load
falling or directly beneath suspended loads, until the pre-
scribed procedure for securing the load has been comple-
ted.
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 fastening procedure is only completed once the hanging crane

element is firmly connected to the stable, set down crane compo-
nent, for example by knocking in a pin of an intermediate section
or by tightening all screws of a screwed connection with the pre-
scribed torque, etc.
A safe distance should be kept from unavoidable crushing ha-

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

during the assembly of fly jibs, unless the operating instructions
expressly state otherwise.
Only when all bolts of a construction element have been knocked
in is it possible to secure them with auxiliary bolts and clip pins.
40C−1010−982a_en 89/99
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90/99 40C−1010−982a_en
Connecting bolts may only be knocked out during the dismantling

of fly jib components or other parts when all individual compo-
nents are safely supported symmetrical to their centre of gravity.
After release, the responsible shift foreman must decide
whether sudden falling or folding movements are to be ex-
pected due to the releasing procedure. In case of doubt, a ser-
vice 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 of a removed bolt or pin, a re-
leased rope or other components must be planned and safeguar-
ded using suitable measures.
Make sure that no tools are forgotten following the completion of

work. Falling or flung tools can cause risk to life and limb!
Sometimes it is required to bridge limiters (for example, limit swit-

ches) when assembling and removing crane components. This
can also lead to additional hazards. The systems may therefore
only be bridged if this is required in the operating instructions for
a certain piece of work.
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92/99 40C−1010−982a_en
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 position himself in a safe location from

where he can SEE the LOAD and can BE SEEN clearly by
the CRANE OPERATOR.
The spotter must be easily recognisable for the crane ope-

rator. The spotter should wear one or more suitable means
of identification e.g. jacket, helmet, collars, armbands, si-
gnalling 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.
40C−1010−982a_en 93/99
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Z 26 024
94/99 40C−1010−982a_en
1.5.1 General Hand Signals

(Z 26 024)
1. START
Caution, note the following hand signals
Arms stretched out horizontally sideways, palms of the

hands facing forwards.
2. STOP!
Interruption, end movement
Right arm raised, palm of the right hand facing forwards.
3. END
of a movement
The hands folded at chest height.
4. DANGER!
Emergency stop
Both arms up, palms of the hand facing forwards.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
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Z 26 026
96/99 40C−1010−982a_en
1.5.2 Hand Signals for Working Movements

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

Signal with both hands. Thumbs pointing outwards.
6. TELESCOPE IN boom
Signal with both hands. Thumbs pointing inwards.
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Z 26 025
98/99 40C−1010−982a_en
1.5.3 Hand Signals for Driving Movements

(Z 26 025)
1. Drive FORWARDS
Arms angled; palms pointing inwards; underarms making
slow movements towards the body.
2. Drive BACKWARDS
Arms angled; palms facing outwards; underarms 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 direc-
tion 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 direc-
tion shown.
40C−1010−982a_en 99/99
Structure of the Crane 2
40C−1020k_en 1/65
2
A1
B1
A2
Z 115 373
2/65 40C−1020k_en
2 Structure of the Crane
2.1 Technical Data Chassis
2.1.1 Dimensions, Weights
(Z 115 373)
Total length of the crane vehicle
∗ A1 = 8.80 m (28.9 ft)

Total height of the crane vehicle
∗ with tyre size 385/95 R 25: B1 = 3450 mm (11.3 ft)
∗ with tyre size 445/80 R 25: B1 = 3434 mm (11.3 ft)
∗ with tyre size 445/65 R 22.5: B1 = 3347 mm (11.0 ft)
Width of the crane vehicle
∗ Width with tyre size 385/95 R 25 = 2.53 m (8.3 ft)
∗ Width with tyre size 445/80 R 25 = 2.55 m (8.4 ft)
∗ Width with tyre size 445/65 R 22.5 = 2.55 m (8.4 ft)
Length of the crane chassis
∗ A2 = 7.34 m (24.1 ft)
Angle of gradient
∗ front : 11° with tyre size 385/95 R 25
∗ front : 10.5° with tyre size 445/80 R 25
∗ front : 9° with tyre size 445/65 R 22.5
∗ rear : 23.5° with tyre size 385/95 R 25
∗ rear : 23° with tyre size 445/80 R 25
∗ rear : 18° with tyre size 445/65 R 22.5
Turn radius “Road travel”
∗ Interior: 5.94 m (19.5 ft)
∗ Chassis, exterior: 9.8 m (32.2 ft)
∗ Main boom head, exterior: 10.1 m (33.1 ft)
∗ with fitted main boom extension, exterior: 10.5 m (34.5 ft)
40C--1020k_en 3/65
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4/65 40C−1020k_en
Turn radius, ”with independent rear−axle steering”

∗ Interior: 5.94 m (19.5 ft)
∗ Chassis, exterior: 6.57 m (21.6 ft)
∗ Main boom head, exterior: 6.98 m (22.9 ft)
∗ with fitted main boom extension, exterior: 7.32 m (24.1 ft)
Total weight
∗ Road travel condition: 36 t (79.3 kip)
Axle loads
∗ in road travel condition: 12 t each (26.4 kip)
2.1.2 Travel Performance
Speed
∗ highest speed technically possible (due to design): 80 km/h
(50 mph)
∗ Permitted speed:
A number of different maximum speeds have been defined,
depending on axle load and tyres (see section 5 ”Driving” un-
der ”Possible axle loads, permitted speeds”.
Climbing ability
∗ 55 % during road travel
with tyre size 385/95 R 25 (14.00 R 25)
Starting on inclines:
∗ 31 % during road travel
with tyre size 385/95 R 25 (14.00 R 25)
The parking brake holds the crane on a max. incline of 23%

but not on the maximum incline on which the crane can be
driven.
40C−1020k_en 5/65
2
6/65 40C−1020k_en
2.1.3 Drive
Engine
Type OM 906 LA
6−cylinder diesel motor, water−cooled
Output: 205 kW (275 HP)
Torque: 1100 Nm (811 lbf−ft)
Certification: EUROMOT 3a, TIER 3 and CARB
Transmission
Allison MD 3060P automatic transmission with torque converter,

6 forward and 1 reverse gear;
Distributor gear
2−stage distributor gear with shiftable off−road stage and shifta-

ble longitudinal lock.
Axles
All axles have single tyres
2.1.3.1 Axles, Drive 6x4x6
∗ Axle A1: driven, steered

∗ Axle A2: not driven, steered (driven for 6 x 6,
optional)
∗ Axle A3: driven, steered
40C−1020k_en 7/65
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8/65 40C−1020k_en
2.1.4 Wheels/tyres
385/95 R 25 445/80 R 25 445/65 R 22,5

Tyres
(14.00 R 25) (17.50 R 25) (18.00 R 22,5)
Rim* 9.5 / 1.7 14.00−25/1.7 14.00−22,5
CR
Vehicle 2.53 m 2.55 m
width (8.3 ft) (8.4 ft)
Vehicle 3.45 m 3.44 m 3.35M
height (11.3 ft) (11.3 ft) (11.0 ft)
* = Only the rims which can be obtained from the crane

manufacturer may be used.
Permitted speeds: see section 6 ”Possible axle loads, permitted

speeds”
2.1.5 Climatic Operating Conditions
Instructions in part 1, section 1 of this document.
2.1.6 Optional Equipment
∗ Drive / Steering 6 x 6 x 6
40C−1020k_en 9/65
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10/65 40C−1020k_en
2.2 Technical Data Superstructure
Max. capacity See capacity tables

Max. main boom length 31.2 m (102.4 ft)
Max. system length with main
44,2 m (145.1 ft)
boom extension
Max. rope speed hoist 100 m/min (328 ft/min)
Drive motor OM 906 LA
205 kW (275 HP)
1100 Nm (811 lbf−ft)
Operating voltage 24 V
Further technical data on possible optional equipment can be

found in the section of the individual component or in the section
“Various” of this document.
The capacity tables contained in the brochure are only for infor-
mation purposes.
Only the capacity tables supplied with the crane may be

used to operate the crane.
40C−1020k_en 11/65
2
24
25
26
1 27
3
23 4
5
6
7
R 22 8
21
9
20
19 10
11
12
13
18 14
15 L
B
17
16
Z 115 374
12/65 40C−1020k_en
2.3 Crane (Components)

(Z 115 374)
The basic terms of a mobile crane are described in the following.

They are relevant for understanding the procedures which must
be carried out at the superstructure.
(1) − Main boom
(2) − Luffing cylinder
(3) − Hoist rope
(4) − Hoist
(5) − Superstructure frame
(6) − Air filter for drive motor (at rear of vehicle under co-
ver)
(7) − Counterweight
(8) − Spare wheel (optional)
(9) − Hydraulic carrier
(10) − Rear back stop
(11) − Diesel engine
(12) − Tank for cab heating (under cover)
(13) − Wheels / tyres, axles 1−3
(14) − Fire extinguisher (in the storage compartment)
(15) − Fuel tank
(16) − Front back stop
(17) − Crane operator’s cab
(18) − Hydraulic oil reservoir
(19) − Crane chassis
(20) − Roller−bearing Slewing Ring
(21) − Main electrical unit chassis / engine batteries (under
cover)
(22) − Slewing gear
40C−1020k_en 13/65
2
24
25
26
1 27
3
23 4
5
6
7
R 22 8
21
9
20
19 10
11
12
13
18 14
15 L
B
17
16
Z 115 374
14/65 40C−1020k_en
(Z 115 374)
(23) − Hook block (with sheaves)

(24) − Runner / assembly jib
(25) − Searcher hook
(26) − Hook suspension gear
(27) − Main boom extension (MBE)
Some of the listed elements can only be seen and are accessible
after opening / removing the corresponding covers.
(L) − Outrigger length

(B) − Support width
(R) − Radius between the slew ring centre to the centre of
gravity of the hook block or of the hook suspension
gear
The radius (R) can also be described as the utilization or load ra-
dius.
40C−1020k_en 15/65
2
16/65 40C−1020k_en
2.4 Safety−relevant Components
2.4.1 Steps and Catwalks

The crane is equipped with ladders, holding devices and anti−fall
guards. These must be used to access the crane and to get down
from it.
It must be ensured that:

− all corresponding safety equipment is fitted.
− all safety equipment is in the condition required for operation
(for example, hinged rails placed in the functioning position).
− all safety equipment can be accessed and used without any
restrictions (free of snow, contamination, etc.).
In addition to suitable auxiliary equipment provided, only

the ladders described may be used to get onto the super-
structure. There are sufficient gripping points to hold onto.
The catwalks are designed so that they are slip−resistant
(sand, corrugated sheet metal, or similar).
40C−1020k_en 17/65
2
91
1a
Z 104 812
18/65 40C−1020k_en
(1a) − Ladder, hinged

The vehicle houses several folding ladders, depending on the
version of the crane (1a).
Risk of accidents!
When they are not in use and for transportation, the hinged
ladders (1a) must be folded up and secured in the transport
position.
Risk of accidents! Risk of damage!

If these ladders remain folded down or are not secured in
the transport position, they can shift suddenly and could
cause damage or injury.
Operating position of the hinged ladders (1a)

(Z 104 812 schematic diagram)
Release the lock and swing the ladder (1a) out laterally by 90°.
Fold back bracket (91) downward / inward at a right angle and fold
the ladder up to the chassis so that the bracket (91) is supported
at the tyre.
This ensures a stable ladder position and a suitable angle for go-
ing up and down the ladder.
Risk of stumbling! Risk of falling!

Before getting onto the hinged ladders (1a), ensure that
support (91) is folded in properly and is supported on the
tyre. The wheel must be in the ”straight ahead position”.
There is a risk of stumbling and falling if the support re-
mains folded in or even folded outward instead of inward
when the ladder is used.
40C−1020k_en 19/65
2
4a
3a Z 115 375
2−EXPLICIT
3−EXPLICIT
Z 55 536
20/65 40C−1020k_en
(3a) − Platform at the crane operator’s cab

(Z 115 375)
To allow the platform (3a) to be used across its full width, the
door of the crane operator’s cab must be closed.
The platform (3a) may only be extended and retracted, if
no−one is on or directly in front of the platform.
(4a) − Handle outside of the crane operator’s cab
(Z 55 536)
(6) − Folding / sliding ladder
Depending on the crane’s DBM−supply, a fol-
ding / sliding ladder is delivered with it.
The supplied folding / sliding ladder can be fastened to the main

boom extension folded to the side or to the main boom for trans-
portation.
− If the folding / sliding ladder (6) is attached, the 4 locks (71,

tensioning straps) must be undamaged and hooked in place.
The ladder weighs approx. 8 kg (18 lbs).
40C−1020k_en 21/65
2
66
Z ›104 583‹ Z 65 146
Z 65 147
22/65 40C−1020k_en
Holding device for attaching the folding / sliding ladder
(Z 104 583 principle illustration, Z 65 146, Z 65 147)

Depending on the design of the crane, there are metal plates on
the crane to attach the ladders safely during the corresponding
working procedure.
Risk of accidents!
When working with ladders, always make sure they are po-
sitioned firmly and safely.
If there are holding devices for attaching the ladders, addi-
tionally secure the ladders by hanging them in the designa-
ted holding devices! Make sure that the ladder hooks lock
in correctly as shown in figure (Z 104 583)!
Attachment eyelets (66):
Depending on the design of the crane, there are attachment eye-

lets for attaching suitable personal protective equipment. In this
case, country−specific regulations on personal protective equip-
ment might have to be adhered to.
Risk of accidents!
The diameter of the attachment eyelets is 25 mm (1 in). A
suitable hook of the corresponding size must be used for
attachment (see Z 65 146).
Excessively large hooks (Z 65 147) are not permitted to be
used. There is a danger of the hook sliding out!
All attachment eyelets (66, Z 104 583) are marked with cor-
responding adhesive signs. The attachment eyelets thus
marked are not to be used except exclusively for attaching
the hook of the personal protective equipment.
Under no circumstances are they to be used to hang indivi-
dual crane component parts to an auxiliary crane.
Risk of overloading! Risk of breakage! Danger of the atta-
ched objects falling down!
Risk of falling!
When working at heights, the ladders must be attached and
you must be secured against falling using personal protec-
tive equipment during the entire assembly procedure.
40C−1020k_en 23/65
2
24/65 40C−1020k_en
2.4.2 Headlights
Spotlights are fitted on the crane chassis in accordance with road
traffic regulations.
Depending on the version, spot lights are mounted on the super-

structure:
− on the basic case of the main boom, electrically adjustable
from the cab,
− on the front of the cab,
− on the back of the cab,
− in the hoist area, manually adjustable.
2.4.3 Emergency Exit
The front window of the crane cab can be opened wide to the
front. It is therefore suitable as an emergency exit.
2.5 Chassis and Construction Number

The chassis and construction numbers are engraved in the serial
plate.
The serial plate is in the crane operator’s cab.
Additionally, the chassis number is engraved in the front bumper

brace next to the trailer coupling.
40C−1020k_en 25/65
2
26/65 40C−1020k_en
2.6 Decals (General)
Each individual sign can be clearly identified using the item num-
ber which is usually on the sign. The depiction of the individual
signs can be found in the table on the following pages.
Keep all of the signs specified below complete and make

sure they are legible.
Item Item no. Drawing Meaning

no.
529 018 40 Z 104 361 Sign: Hydraulic oil (on the hydraulic oil
tank)
HYDRAULIC OIL
Specification as per operating manual!
(Language variant, see appendix di-
rectly after this section)
529 017 40 Z 104 358 Warning sign: Slewing, telescoping
and luffing prohibited without extended
outriggers!
512 216 40 Z 104 359 Warning sign:
“Driver instructions and precise follo-
wing of the operating instructions are
required prerequisites for safe crane
operation; for this reason the operating
instructions must be read and under-
stood by the crane operator before
starting operation of the crane for the
first time!”
001 218 98 Z 104 360 Warning sign: Danger zone
Unauthorised persons are warned to
keep out of working range of crane.
529 019 40 Z 104 379 Sign: 10 bar (145 psi) for 385/95 R 25
(14 R25)
(16 R25)
(17.5 R25) or 525/80 R 25 (20.5 R25)
40C−1020k_en 27/65
2
28/65 40C−1020k_en

no.
148 956 12 Z 104 365 Sign: Connections for emergency acti-
vation
289 512 12 Z 104 368 Designation light 1.0 %
668 778 40 Z 104 382 Sign: Differential lock
529 013 40 Z 104 383 Sign: Wheel nuts
529 015 40 Z 104 384 Sign: Engine stop
224 197 40 Z 104 364 Warning sign: Caution during welding
work
The vehicle is equipped with Wabco
Tecalan plastic pipes.
Caution during welding operations!
Permissible exposure to heat of un-
pressurised lines:
Maximum 130° C and maximum 60 mi-
nutes.
WABCO.
192 264 12 Z 105 105 Crane identification plate / serial plate
569 906 12 (crane chassis)
(see section 2.6.1 on page 45)
569 907 12 Z 105 107 Crane identification plate / serial plate
(superstructure)
(see section2.6.1 on page 45)
529 011 40 Z 104 362 Sign: Diesel (on the fuel tank)
113 054 12 Z 104 363 Sign: Quick coupling
“The couplings must be applied up to
the stop.”
(depending on the crane design)
40C−1020k_en 29/65
2
30/65 40C−1020k_en

no.
Z 550 079 Warning sign for speed limit for activa-
ted construction site steering programs
Z 550 080 Warning sign for diagonal steering
(crab steering, crab walk)
Crab walk
Not allowed for road travel,note signal
lamp!
Z 171 180 Warning sign for folding / assembling
the main boom extension
The pinning on the main boom head
AND on the side centre of motion may
not be released at the same time.
183 666 12 Z 63 905 Warning sign: Risk of crushing hands
Serious injury can result from contact
with moving components.
Keep away from moving components.
183 666 12 Z 63 910 Warning sign: Risk of crushing bodies
People can be killed or severely inju-
red when they come into contact with
moving components.
Keep away from moving components.
Secure components before carrying
our work.
40C−1020k_en 31/65
2
32/65 40C−1020k_en
Item no. Drawing Meaning

no.
000 207 12 Z 104 385 Sign (design for Germany):
Operating regulations for cranes in ac-
cordance with the accident prevention
regulation ”Cranes” (BGV D6)
529 775 40 Z 104 386 Warning sign: Risk of tilting when sle-
wing and not supported on outriggers
(United Kingdom).
180 373 12 Z 104 387 Sign: GB STGO−Plate Cat C
(Design for United Kingdom, see seg-
ment “Driving in the United Kingdom”)
Z 104 395 Information sign on vehicle height (na-
tional regulations)
586 023 40 Z 104 388 Sign: Heavy transport!
(specific to country, if existing, see ap-
pendix directly after this section)
Z 104 389 Warning instructions (design for Italy)
Z 104 390 Sign: Chassis cab (length, width,
weight) (design for France)
313 082 12 Z 104 391 Sign: Speed limit 85 km/h (specific to
country)
001 546 12 Z 104 392 Sign: 70 km/h (design for Italy)
313 910 12 Z 104 393 Sign: 80 km/h (specific to country)
313 909 12 Z 104 394 Sign: 90 km/h (specific to country)
40C−1020k_en 33/65
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34/65 40C−1020k_en

no.
Z 104 367 Crane identification sign (design for
the Netherlands)
Z 64 217 Manufacturer ’s sign (design for the
USA)
Z 104 369 Warning sign, general (main boom,
left− and right−hand side) (design for
China)
275 912 12 Z 104 378 DANGER!
Risk of electrocution:
Persons can be killed or seriously inju-
red if they come into contact with high−
voltage lines.
Always consult the owner of the high−
voltage lines.
The electric current must be switched
off or the high−voltage line must be re-
moved or insulated before the machine
begins operation.
(design for Russia)
40C−1020k_en 35/65
2
Spezifikation siehe Betriebsanleitung!
HYDRAULIKÖL
Z 104 361de
O.K.
512 216 40
Z 104 358 Z 104 359
10 bar
Z 104 360de Z 104 379
9 bar 7 bar
Z 104 380 Z 104 381
Z 104 365 Z 104 368
36/65 40C−1020k_en
Z 104 382de Z 104 383de
Fahrzeug ist mit

Wabco−Tecalan−Kunststoffrohren
ausgerüstet.
Motor Stop
Vorsicht bei Schweissarbeiten!
Zulässige Hitzeeinwirkung auf drucklose
Leitungen:
max. 130°C und max. 60 min.
WABCO
Z 104 384 Z 104 364de
DIESEL
EN 590
Z 104 362de Z 104 363
40C−1020k_en 37/65
2
Hundegang
Bei Straßenfahrt nicht zulässig,
beachte die Signalleuchte!
Z 550 079 Z 550 080de
X Y
Y
X
Y
X
4−FRONT
Y
X
Z 171 180 Z 63 905
Z 63 910
38/65 40C−1020k_en
UVV
Z 104 385
STGO 1) Axle loads Speed 4) Speed 4)

category up to [kg] [mph] [mph]
Danger!
Danger
of tipping!
Z 104 386 Z 104 387
SCHWERTRANSPORT
Z 104 395 Z 104 388de
40C−1020k_en 39/65
2
Z 104 389 Z 104 390
MAX
km/h Z 104 391 Z 104 392
Z 104 393 Z 104 394
kraankenmerk
kraanken maximale max.viucht maximale kraangroep
getal last bij max. gieklengte
last
tm t m m
Z 104 367 Z 64 217
40/65 40C−1020k_en
Z 104 369
Z 104 378
40C−1020k_en 41/65
2
Z 70 543
19b.1 19b
19b.2
19b.3
19b.4
19b.5
19b.6
19b.7
Z 80 011
42/65 40C−1020k_en
For cranes delivered after January 2011:
EU−Flex
(Z 70 543)
Item Meaning
19a Information sign: EU−Flex
Details on the vehicle emissions regulations of the
engine used
Only valid for the European economic region
19a.1 Details on the running machine number
19a.2 Details of the number of the authorised engines
19a.3 Details of the engine type
19a.4 Details of the engine number
19a.5 Details of the authorisation number
USA−TPEM
(Z 80 011)
Item Meaning
19b Information sign: USA TPEM
Details on the vehicle’s emissions regulations of the
engine used. Only valid for the USA
19b.1 Description of the sign
19b.2 Company name and logo
19b.3 Year of first commissioning
19b.4 Contact address
19b.5 Declaration of conformity in accordance with U.S.

EPA Emission Standards
19b.6 Declaration of conformity in accordance with Califor-
nia Emission Standards
19b.7 TPEM serial number
40C−1020k_en 43/65
2
20
”a”
20.6
20.7
20.8
20.1 20.9
20.10
20.2 20.11
20.3 20.12
20.4
20.5
”b” ”c”
20.13
20.1
20.14
20.2
20.3
20.15
20.16
20.17
20.18
20.19
20.5
Z 105 105
44/65 40C−1020k_en
2.6.1 Crane identification plate / serial plate

(Z 105 105)
Depending on the date of manufacture, one of the variants (”a”,

”b”, ”c”) shown in the figure (Z 105 105) from the crane identifica-
tion plate / serial plate in the chassis cab is used.
If the crane identification sign / serial plate shown in
(Z 105 105 ”a”) is in the chassis cabin, crane identification sign
/ serial plate (49) is in the superstructure cab.
Item Meaning
20 Crane identification sign / serial plate (crane chassis)
20.1 Logo, company name and address
20.2 Vehicle type
20.3 Construction number
20.4 Engine output, chassis
20.5 Corrected absorption factor (exhaust emission value)
20.6 Vehicle manufacturer
20.7 Vehicle identification number
20.8 Number of the EC type approval (if existing)
20.9 Country−specific specifications
20.10 Permitted total weight of the vehicle
20.11 Permitted total weight of the towed vehicle
20.12 Permitted axle load
Only for crane identification sign / serial plate in accordance with

(Z 105 105 ”b”) or (Z 105 105 ”c”):
Item Meaning
20.13 CE conformity marking,
only for the European economic region
20.14 Type of crane
20.15 Maximum capacity in t
20.16 Year of first commissioning
20.17 Year of construction
20.18 Engine performance superstructure
20.19 Engine performance chassis
Outside of the European economic region, the variants (”b”, ”c”)
of the crane identification plate / serial plate receive no CE−mar-
king (20.13) as per (Z 105 105 )!
40C−1020k_en 45/65
2
49
49.1
49.6
49.2
49.3
49.4 49.7
49.5 49.8
Z 105 107
46/65 40C−1020k_en
(Z 105 107)
Item Meaning
49 Crane identification plate / serial plate
(superstructure)
49.1 CE conformity marking,
only for the European economic region
49.2 Type of crane
49.3 Construction number
49.4 Maximum lifting capacity
49.5 Year of construction
49.6 Logo, company name and address
49.7 Year of first commissioning
49.8 Engine performance
Outside of the European economic region the crane identification

plate / serial plate receives no CE−marking (49.1).
40C−1020k_en 47/65
2
1 12 13 4 3 7 9 4 3
10
1 7 6 5 8 1
11
4 3 2 1
1 7 6 5 1
Z 115 376
48/65 40C−1020k_en
2.6.2 Safety Signs (CE)

Item Item no. Type of risk / Meaning

1 511 675 98 Warning: Crushing / Collision
2 511 676 98 Warning: Snagging / entanglement
3 511 678 98 Warning: Risk of falling
4 511 684 98 Prohibited: Access prohibited
5 511 679 98 Warning: Fire hazard
6 511 682 98 Prohibited: Naked flame
Prohibited: Access for unauthorised per-
7 511 683 98
sons
8 511 677 98 Warning: Crushing
9 511 680 98 Warning: Suspended load
10 511 685 98 Note: Fire extinguisher
The fire extinguisher supplied is located in the cab of the crane

chassis.
11 511 686 98 Note: First aid
First aid box − and other equipment in accordance with the road
traffic licensing regulations − must be stored in the chassis cab.
12 588 863 40 Sign: CE

13 Sign: 107 dB(A); Specification of the ma-
ximum sound output level outside the cab
All safety instructions on the crane must be kept complete

and must be legible.
40C−1020k_en 49/65
2
50/65 40C−1020k_en
2.6.3 Safety Signs (Only for the USA)

Each individual sign can be clearly identified thanks to the item
number on each sign. The depiction of the individual signs can
be found in the table on the following pages.
All safety instructions on the crane must be kept complete

and must be fully legible.
Item Item no. Figure no. Type of risk / Meaning

178 722 12 Z 63 901 Danger: Voltage (high)
178 702 12 Z 63 902 Danger: Voltage
178 705 12 Z 63 904 Risk due to machines
178 706 12 Z 63 905 Risk of crushing hands
178 707 12 Z 63 906 Risk due to outriggers
178 708 12 Z 63 907 Warning before crane operation
178 709 12 Z 63 908 Warning: Lifting people
178 710 12 Z 63 909 Risk of falling
178 711 12 Z 63 910 Risk of crushing bodies
178 712 12 Z 63 911 Danger: Snagging
178 713 12 Z 63 912 Fire hazard
178 714 12 Z 63 913 Crane operation
178 715 12 Z 63 914 Risk of tilting!
178 716 12 Z 63 915 Hand signals USA
511 685 98 Z 63 916 Fire extinguisher
The fire extinguisher supplied is located in the cab of the crane

chassis.
40C−1020k_en 51/65
2
52/65 40C−1020k_en
Item Item no. Figure no. Type of risk / Meaning

178 718 12 Z 63 917 Warning: Risk of combustion
178 719 12 Z 63 918 Warning: Fan wheel
178 720 12 Z 63 919 Danger: Pressure
178 721 12 Z 63 920 Danger: Battery
178 727 12 Z 63 922 Danger: Passenger
178 728 12 Z 63 923 Welding prohibited
178 729 12 Z 63 924 Danger: Assembly work
179 564 12 Z 63 921 Danger: Oil jet
511 686 98 Z 63 925 Note: First aid
283 340 12 Z 104 646 Note: Country of origin
First aid box − and other equipment in accordance with the road
traffic licensing regulations − must be stored in the chassis cab.
40C−1020k_en 53/65
2
Z 63 901
Z 63 902
Z 63 904
54/65 40C−1020k_en
Z 63 905 Z 63 906
Z 63 907 Z 63 908
Z 63 909
40C−1020k_en 55/65
2
Z 63 910 Z 63 911
Z 63 912 Z 63 913
Z 63 914
56/65 40C−1020k_en
Z 63 915
40C−1020k_en 57/65
2
Z 63 916 Z 63 917
Z 63 918 Z 63 919
Z 63 920
58/65 40C−1020k_en
Z 63 922 Z 63 923
Z 63 924 Z 63 925
Z 63 921 Z 104 646
40C−1020k_en 59/65
2
1 2 3
Z 115 365
60/65 40C−1020k_en
2.7 Preparation for Emergency Control, Superstructure
(Z 115 365)
There are 3 hydraulic connections on the chassis on the right−

hand side (between axles 1 and 2):
1 connection PUW (pressure oil)
2 connection LUW (leakage)
3 connection TUW (tank)
If the superstructure power units break down, a hydraulic trans-

former can be connected at these points, which enables limited
superstructure functions.
For exact details, see the operating manual of the superstructure,
section 36.
The hydraulic connections 1 − 3 may only be used with a hy-

draulic transformer.
A direct connection to the superstructure hydraulic system
is not permitted as there is no capacity for this in the oil tank.
40C−1020k_en 61/65
2
5
3
3
4
6
5
6
7
2
1
Z 115 239
76 0
1
2
3
4
77
Z 115 240
62/65 40C−1020k_en
2.8 Separate Fuel Tank (”Extra Tank”) in the Chassis for

Superstructure Operation (Optional)
(Z 115 239, Z 115 240)
Depending on the individual country, the fuel supply of the engine

for superstructure operation is permitted from a separate fuel
tank (extra tank 3 l). It is directly connected to the standard fuel
tank (1).
The extra tank (3) is in the rear of the chassis on the left−hand
side. It is filled by its own filler neck (4) on the top of the tank, inde-
pendent of the standard fuel tank (= main tank) (1).
In order to switch from the main tank (1) and the extra tank (3) or
vice versa, there is a button (77) and a lamp (76) in the cab’s in-
strument panel.
As a prerequisite for switching the fuel supply to the separate fuel
tank (3), the drive motor must be running and the hand brake ap-
plied.
In order to switch between the main tank (1) and the extra tank
(3), or vice versa, button (77) must be activated. During the
switch−over procedure the lamp (76) flashes slowly. If fuel supply
is switched to the extra tank (3), the lamp (76) is illuminated con-
stantly. A system malfunction is indicated by rapid flashing of the
lamp (76).
When switching back form the separate fuel tank (3) to the main
tank (1), a rinsing procedure for the fuel leads is started at the
same time.
During this rinsing procedure, fuel is taken from the main tank (1)
and then flushed into the extra tank (3).
40C−1020k_en 63/65
2
5
3
3
4
6
5
6
7
2
1
Z 115 239
76 0
1
2
3
4
77
Z 115 240
64/65 40C−1020k_en
Nominally, an approx. filling quantity of 60 litres (15.9 gal) fit into

the extra tank (3). There is an inspection glass (5) in the extra
tank’s (3) side panel for checking the filling level. If the extra tank
(3) is completely filled, it can spill over after a rinsing procedure.
This is why the extra tank (3) may not be filled above the marker
(6) on the inspection glass (5). Then there is still reserve volume
in the extra tank (3) in order to carry out several rinsing procedu-
res.
In order to prevent the tank from spilling over after a rinsing

procedure, the extra tank (3) may only be filled approx. 3/4
full!
If the level goes below the reserve volume (lower end of the in-
spection glass, at the height of the level sensor (7), the fuel sup-
ply is automatically redirected to the main tank (1) and the rinsing
procedure is initiated.
40C−1020k_en 65/65
Appendix to section 2
Specification as per operating manual! Unauthorised persons are

warned to keep out of
Hydraulic Oil working range of crane.
Z 104 361en Z 104 360en
Differential locks
Should only be used when the crane is statio-

Wheel Nuts
nary, if required care must be taken to get
smooth slow movement by careful use of the Check with torque wrench as per opera-
clutch and accelerator! ting manual and re−check after
50 km!
The locks must only be used for short duration
to improve traction in poor ground conditions,
and should not be used with locked suspen-
sion, or when turning!
Z 104 382en Z 104 383en
This vehicle is equipped with

Wabco Tecalan nylon pipes.
Caution during welding operations!
Permissible exposure to heat of unpressurised lines:
Not more than 130 °C for 60 minutes.
DIESEL
WABCO EN 590
Z 104 364en Z 104 362en
40C−1021_en 1/2
2
Crab steering
Not allowed for road travel,
note signal lamp!
Z 550 080en
2/2 40C−1021_en
Crane Operator’s Cab 3
40C−1030−872e_en 1/43
3
117
118
119 25
116
115
11
28
29
18
38
17 39
14
13
12
10
9
172
1
Z 115 398
2/43 40C−1030−872e_en
3 Crane Cab
3.1 Operator’s Platform
(Z 115 398)
No. Element Designation Function

1 Pedal Speed adjustment
9 Thermostat Thermostat for engine−indepen-
dent heater
10 Pedal Foot brake
11 Control lever, left Telescopic sections / slew gear
12 Foot−operated Engine brake / with crane opera-
switch ting horn
13 Pedal Slew gear brake
14 Toggle Steering wheel adjustment
17 Combination lever Turn signal indicator, full
beam,horn, windshield wiper/was-
her
18 Steering wheel
25 Control lever right− Luffing gear / hoist
hand side
28 A 5320 EU tachograph 1) Tachograph
Basic display with time, speed, mi-
leage. (Observe the operating in-
structions of the manufacturer.)
1) Due to manufacturing, there can be deviations between the
display of the tachograph (28) and the display of the speedo-
meter (100). The data on the tachograph (28) has priority.
40C−1030−872e_en 3/43
3
117
118
119 25
116
115
11
28
29
18
38
17 39
14
13
12
10
9
172
1
Z 115 398
4/43 40C−1030−872e_en
(Z 115 398)

29 S 710 Enable emergency control
Warning light:
− green Display of the state of the load limit
38 − yellow device and of the load utilisation of
− red the crane
(see section ”Safety equipment”)
39 Key switch Bridging the load limit device (func-
tion only for control software in ac-
cordance with EN 13000) 2),
movement authorisation for emer-
gency control system
115 Button Switch to precision control crane
movement hoist up/down
116 Self−return rocker Precision control for crane move-
switch ments Slew gear left/right, hoist up/
down
117 Self−return rocker Fine adjustment for crane move-
switch ment, luffing gear down
118 Knob Hoist rotation indicator
119 Button High speed hoist up/down, luffing

gear up
172 left−hand arm con- rotate away to the side:
sole, − to enter the cab
can be rotated
− in driving mode
rotate forward:
− during crane operation
2) = You can check whether the crane is equipped with control
software in accordance with EN 13000 by selecting the “Informa-
tion” screen in crane control. In this case, a corresponding note
can be found there.
40C−1030−872e_en 5/43
3
2
1 3
0 4
106 107 111 109
110 65 89
88
108 114
Z 115 390
6/43 40C−1030−872e_en
(Z 115 390)

65 S 327 electric adjustment of mirror
88 Warning buzzer Alarm diesel particle filter 3)
894) Warning light Alarm diesel particle filter 3)
106 S 301.1 Switch, lockable Superstructure / chassis in ope-

ration
107 Rocker switch Hoist function on/off (when ope-
rating with options cross beam
and hook for boom point)
108 4) S 115 Switch Hazard light 3)
109 S 328 Switch Adjustment of 1st spotlight on the
basic boom section of the main
boom (item 111) 3)
110 S 14 Rocker switch Slew gear parking brake
111 Lighting equipment operating
range, can be adjusted electri-
cally; fitted on the basic boom
section, left−hand side 3)
114 S 356 Self−return rocker Rear−axle steering
switch
3) = optional
4)= Alternatively, switch (108) for the hazard light (optional) or
warning buzzer (88) for the diesel particle filter (optional) can
be assigned at this point.
40C−1030−872e_en 7/43
3
2
1 3
0 4
76 78 40 41 42 43 51
69
68
77 79 46 47 48 49 50
64 52 53 54 55 56 57
101
58 59 60 61 62 63
Z 115 245
8/43 40C−1030−872e_en
(Z 115 245)

40 S 303 Switch Dipped beam, parking lights
41 S 304 Switch Fog tail light
42 S 307 Switch Rotaflare light
43 S 311 Switch Fog lamps 3)or
S 311 Switch Spotlight ”Support” 3)
46 S 352.2 Switch, lockable off−road gear

47 S 314.1 Switch, lockable Transverse differential lock axle 1
48 S 314.2 Switch, lockable Transverse differential lock axle 2
and 3
49 S 313 Switch, lockable Longitudinal differential lock
50 S 357 Switch, lockable Activate electric−hydraulic rear
axle steering
51 S 131 Switch Wiper, roof window (2 steps)
52 S 802 Double key Enable left outriggers
53 S 803 Double key Enable right outriggers
54 S 804 Button Enable all outriggers
55 S 805 Double key Retract/extend horizontal outrig-
gers
56 S 801 Double key Retract/extend vertical outriggers
57 S 386 Switch Switch ABS in towing vehicle
over to off−road mode
(indicator light 138)
3) = optional
Check the wiper blades regularly for dirt and damage.
40C−1030−872e_en 9/43
3
2
1 3
0 4
76 78 40 41 42 43 51
69
68
77 79 46 47 48 49 50
64 52 53 54 55 56 57
101
58 59 60 61 62 63
Z 115 245
10/43 40C−1030−872e_en
(Z 115 245)

58 S 363.1 Double key ”Raise”/”lower” suspension front
left−hand side
right−hand side
60 S 361.1 Double key ”Raise”/”lower” suspension rear
left−hand side
right−hand side
62 S 370.1 Double key ”Raise”/”lower” together
63 S 360 Switch, lockable Enable Pull up axles
64 S 100 Luminous touch Quick stop of the engine
contact
68 Rotary switch Thermostat
69 Rotary switch Fan
76 Lamp Switch−over main tank / extra
tank 3)
− flashes slowly duringswitch−
over procedure
− is constantly illuminated when
switched over to extra tank
− flashes rapidly if thereis a
malfunction
77 Button Switch−over main tank / extra
tank 3)
78 Switch Circulation on/off
79 Switch Air conditioning equipment on/off
101 Pressure gauge Brake system pressure
3) = optional
40C−1030−872e_en 11/43
3
2
1 3
0 4
120
121 122
123 124
125 126
127 128
129 130
132 133
134 135
136 137
138 139
140 141
131
Z 115 246
12/43 40C−1030−872e_en
(Z 115 246)

120 P 200 Indicator light module 1
121 H 323 Indicator light Air filter clogged
122 H 324 Indicator light Hydraulic oil filter clogged
123 H 322.1 Indicator light Steering circuit I ”no flow”
124 H 322.2 Indicator light Steering circuit II ”no flow”
125 H 310 Indicator light Parking brake applied
126 H 310.6 Indicator light Warning light braking pressure
below 5 bar (72.5 psi)
127 Indicator light not assigned
128 H 301 Indicator light Charge control light
129 H 440 Indicator light Do not change gear
130 H 399 Indicator light Converter operation
131 P 201 Indicator light module 2
132 H 308.7 Indicator light Direction indicator
133 H 308.8 Indicator light Direction indicator dolly 3)
134 H 305.3 Indicator light Upper beam switched on

135 H 430 Indicator light Flame starting system
136 H 352.2 Indicator light All−terrain transmission switched
on
137 H 352.1 Indicator light Road travel transmission swit-
ched on
138 H 386 Indicator light ABS monitor, crane
− lights up in case of fault
− flashes when ABS is swit-
chedto off−road mode using-
button 57
139 H 387.2 Indicator light ABS control, trailer (or fault)
140 H 388 Indicator light Retarder
141 H 300 Indicator light Fault engine
3) = optional
40C−1030−872e_en 13/43
3
2
1 3
0 4
100
100.1
44
100.3 100.2
45 67
Z 115 247
14/43 40C−1030−872e_en
(Z 115 247)

44 S 326 Switch Mirror heater
45 S 308 Switch Hazard flashers
67 S 302 Ignition switch (see 3.2.1)
100 P 301 Speedometer Speed display,
route counter, partial route coun-
ter
100.1 LCD 2−digit display: entire mileage /
(Display for partial mileage / time
Ignition on)
100.2 Reset button Press button briefly:
switch−over partial mileage /
time.
Press button > 2 seconds:
Reset partial mileage.
100.3 Indicator light Function check (no diagram disc
/ chip card) applied; general fault
display speedometer
40C−1030−872e_en 15/43
3
2
1 3
0 4
160
162 163
161 164
165 168
166 167
Z 115 248
16/43 40C−1030−872e_en
(Z 115 248)
160 P 100 MFA 10 display unit

1st warning signal 2nd warning signal
161 Fuel supply 10 % 5%

162 Engine oil pressure  
163 Coolant temperature > 103 °C / 217 °F > 110 °C / 230 °F
164 Transmission oil temp. > 120 °C / 248 °F > 130 °C / 266 °F
165 Engine speed  
166 Daily operating hours
167 Charge control < 20 V < 16 V
168 wind speeds 18 km/h / 11 mph 45 km/h / 28 mph
The various points of information (161 − 167) can be called up on the MFA
10 display unit (160) at the press of a button. The relevant LED comes
on.The assigned light−emitting diode (LED) comes on.
When the ignition is switched off, the display shows the time (above) and
the total operating hours (below). If no information is called up when the
ignition is on,
(all light−emitting diodes (LED) are off), this information is likewise dis-
played.
To reset the daily operating hours, button (166) must be held down for three
seconds.
If transmission oil or coolant temperature are too high or if voltage supply
or engine oil pressure are too low, this information flashes on the display,
even if it has not just been selected. At the same time, the assigned light−
emitting diode (LED) flashes and a warning signal sounds. These warning
signals can be acknowledged by actuating the particular button (3 se-
conds).
Setting the time:
− simultaneously press keys (166) and (167) for five seconds
− time flashes on the display
− press keys (165), (166) and (167) or (168) until the correct time is set
− the corresponding time unit jumps by one digit value
Saving the time:
− simultaneously press keys (166) and (167) until the time stops blinking
Indicator lights in your crane may not be located at the same points shown
here. The symbol on the actual switch indicates its full function.
40C−1030−872e_en 17/43
3
2
1 3
0 4
95 96 97 98 99
90 91 92 93 94
66
Z 115 249
18/43 40C−1030−872e_en
(Z 115 249)

66 A 190 Heating clock
90 H 371 Indicator light Suspension circuit to the rear and left
not level
91 H 374 Indicator light Suspension circuit to the rear and right
not level
92 H 373 Indicator light Suspension circuit to the front and left
not level
93 H 372 Indicator light Suspension circuit to the front and right
not level
94 H 326 Indicator light Hydraulic oil temperature too high
95 H 319 Indicator light Longitudinal differential locked
96 H 314 Indicator light Transverse differential locked
97 H 392 Indicator light Crane operation
98 H 356.1 Indicator light Steering not locked (axles 2 + 3) (road
travel prohibited)
99 H 356.2 Indicator light Steering unlocked (for “independent
rear axle steering”)
40C−1030−872e_en 19/43
3
2
1 3
0 4
75
102 103 104 105
70 71 72 73 74
Z 115 250
20/43 40C−1030−872e_en
(Z 115 250)

70 S 160 Telescoping operation
71 S 700 Key switch Activate the setup button (func-
tion only for control software in
accordance with EN 13000, 2);
otherwise:
Load limit device bridged (in-
stead of item 39)
72 S 701 Key switch Bridging “hoist limit switch”
73 S 705 Key switch Bridging “raise luffing gear”
74 Key switch Release radio remote control 3)
75 Operator−interface computer of
the crane control system
102 H 700 Indicator light State of the key−operated push-
button item 71
103 H 701 Indicator light Hoist limit switch bridged
104 H 705 Indicator light “Raise luffing gear” bridged
105 H 710 Indicator light Emergency control: crane move-
ments are possible
2) = You can check whether the crane is equipped with control
software in accordance with EN 13000 by selecting the “Informa-
tion” screen in crane control. In this case, a corresponding note
can be found there.
3) = optional
40C−1030−872e_en 21/43
3
2
1 3
0 4
26
R Mode
N
171
170
19
D
20
21
27
Z 115 399
22/43 40C−1030−872e_en
(Z 115 399)

19 Socket
20 Box level Straight level display
21 Cigarette lighter
26 Switch panel Driving range selection
27 Lever Parking brake
170 electronic key Immobiliser (Optional)
(see section 4)
171 Light diode Check immobiliser system
40C−1030−872e_en 23/43
3
5
30
6
23
8
7
Z 115 401
24/43 40C−1030−872e_en
3.2 Entering / Leaving the Cab

(Z 115 401)
Risk of falling!
− Use handles and ladder assembly / steps to enter and
exit.
Do not jump out of the crane operator’s cab.
− Safety is diminished on the steps and at the entry areas
due to dirt and mud. This means you can slip on the
steps.
Keep steps, entry areas and shoes clean of contamina-
tion (for example:mud, clay, snow and ice).
No. Designation Function

5 Handle for entry / exit
6 Handle for entry / exit
7 Lever Door catch
8 Lever Retract/extend platform
23 Step Cab entry / exit
30 Door handle / Unlock / lock the cab door Slide
hand grip the cab door open / closed
40C−1030−872e_en 25/43
3
5
30
6
23
8
7
Z 115 401
26/43 40C−1030−872e_en
(Z 115 401)
Access to the cab

Depending on the position of the cab to the crane chassis, the
cab is accessed using one of the hinged ladders or the hanging
ladders, which can be fitted at various places of the crane chassis
(see in section 2, segment “Ladders, fixtures and anti−fall
guards”).
To enter / leave the cab, the platform (23) should be completely
extended. Press the lever (8) in the crane operator’s cab to slide
the platform in or out.
Opening the cab door from the outside

1. Unlocking the door:
Unlock the cab door using the ignition key in the door lock
(30).
2. Slide cab door open using handle (30).
Entering / exiting the cab

− Use handles (5, 6) to enter and exit safely.
− The cab door is automatically locked when completely open
to prevent accidental closing.
− It might be necessary to rotate the left−hand arm console
back to enter and exit more comfortably.
40C−1030−872e_en 27/43
3
5
30
6
23
8
7
Z 115 401
28/43 40C−1030−872e_en
(Z 115 401)
Closing the Cab Door

Risk of crushing!
There is a risk of crushing between the door and the cab
frame when closing the cab door.
For that reason, use the hand grips provided to ensure that
one’s hands are not in an area of danger!
1. If the cab door is locked while completely open:

Press lever (7) and release door lock.
2. Closing the door:
− from the outside: using handle (30)
Opening the cab door from the inside

1. Unlocking the door:
Press lever (7) and release door lock.
Exiting the cab in an emergency

Use the front window as an emergency exit (for opening the front
window, see 3.2.6.2).
Locking the cab door (from the outside)

Lock the cab door using the door lock (30).
40C−1030−872e_en 29/43
3
2
1 3
0 4
67
Z 115 242
30/43 40C−1030−872e_en
3.2.1 Ignition−starter Switch (67)
(Z 115 242)
Position ”1”: Position for exiting the crane with hazard
warning lights and / or lighting switched
on.
In this position crane control is switched
on and uses power from the vehicle bat-
teries.
Depending on the version, the key can
be removed.
Position ”2”: All users are disconnected from the bat-
tery, except: tachograph.
Removable key.
Position ”3”: Driving position
The ignition is switched off; Blower can
be switched on.
Position ”4”: Start position
The engine switches on.
The radio can always be switched on regardless of the position

of the ignition switch.
− Only remove the key when the vehicle is stationary.
− Even if you are leaving the vehicle for a short time re-
move the key to prevent unauthorised persons starting
the vehicle.
− Only remove the key in position ”2” when shutting down

and parking the vehicle without lighting, etc.
40C−1030−872e_en 31/43
3
14
Z 115 254
32/43 40C−1030−872e_en
3.2.2 Steering Wheel Adjustment (14)
(Z 115 254)
Both the height and tilt of the steering wheel can be adjusted. The
steering wheel is pneumatically unlocked (or locked according to
the setting).
Steering wheel is set as follows:

− Stop the vehicle and engage the parking brake.
− Hold the steering wheel and unlock the lever (14).
− Adjust the steering wheel.
− After adjusting the steering wheel, secure lever in place (14).
Only set when the vehicle is standing still and theparking

brake is set.
Crane operation
Set the steering wheel to the highest position so that you have
sufficient space while operating the crane.
40C−1030−872e_en 33/43
3
9
8
7 4
6
Z 30 100
34/43 40C−1030−872e_en
3.2.3 Driver’s Seat
(Z 30 100)
The crane operator is protected against mechanical vibrations by

means of a dampened seat. The seat height is automatically set
pneumatically.
The seat offers infinite adjustment options for the seat tilt, back-
rests and armrests. This enables the seat to be set to the opti-
mum operating position for every operator.
The seat can be adjusted infinitely variably using the following

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

(3) − Control element for adjusting the backrest
(4) − Bar for horizontal adjustment of the seat (without con-
sole)
(6) − Bar for horizontal adjustment of the seat (with console)
(7) − 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 seat tilt (at rear seat
edge)
(9) − Control element for adjusting the seat tilt (at front seat
edge)
40C−1030−872e_en 35/43
3
14
15
15
17
16
15 17 16
Z 30 101
36/43 40C−1030−872e_en
(Z 30 101)
3.2.4 Headrest
The headrest (14) can be adjusted for height and angle indepen-
dent of the backrest.
Set the headrest so that the rear part of the head is sup-
ported at about the height of the eyes.
3.2.5 Safety Belt
The safety belt system is fastened to the cab. No subsequent mo-

difications are allowed. If modifications are made, the operating
licence will expire.
The use of safety belts is a regulation in many countries.

In the interest of your own safety, always put on the safety belts.
Fastening the safety belt:
− Pull the belt with the latch plate (15) over your shoulder and
lap. The belt may not be twisted.
− Press the latch plate (15) into the belt buckle (16) until it locks
audibly.
− The belt must always be taut. Check for tightness regularly.

If need be, tension the lap belt by pulling the shoulder belt up-
wards.
Releasing the safety belt:
− Press the red button (17) in the belt buckle (16).
− Bring the latch plate (15) back to the initial position.
Automatic safety belt winder − operation

The automatic safety belt winder for the safety belt locks the belt
pull−out during vehicle deceleration in all directions and when
pulling on the belt quickly.
Function test
To check the locking function of the retractor, pull the belt out with
a quick jerk.
40C−1030−872e_en 37/43
3
38/43 40C−1030−872e_en
− Fasten your safety belt before driving
− All safety belts are only to be used for one person.
− Three−point belts for designed for people with a

height of at least approx. 150 cm (4.9 ft).
Smaller passengers require specially suited devices
for their protection in case of an accident (due to the
fact that safety belts cannot be fitted correctly.
− Avoid seat positions that interfere with the correct

course of the safety belt.
Set the backrest to almost 90 .
Your back should touch the backrest.
The belt must run across the middle of your shoulder.
− Safety belts that have been placed under heavy strain

during an accident must be replaced.
Have belt anchors checked by a specialist workshop.
− Replace damaged safety belts.
− Belts may not run across sharp edges.
− No changes may be made to the safety belts.
40C−1030−872e_en 39/43
3
140
141.1
141
141.2
Z 171 023
40/43 40C−1030−872e_en
3.2.6 Opening / Closing Windows
3.2.6.1 Rear Window

(Z 171 023)
The window in the back wall of the cab is a sliding window.
When closed, the catch (141) on the window element and the fi-
xed counterpiece (140) on the cab frame support are locked to-
gether.
To open the individual window press the catch on the gripping

piece together (141.2) as shown in figure (Z 171 023). The lok-
king nose (141.1) is lifted and the window element can be closed/
opened.
Risk of crushing!
When closing the window there is a risk of crushing bet-
ween the window element and the door− / cab frame. Only
use the handles provided to ensure that your hand does not
get caught!
40C−1030−872e_en 41/43
3
134
”A”
132.1
132.2
”B”
132 Z 171 024
42/43 40C−1030−872e_en
3.2.6.2 Front Window

(Z 171 024)
The front of the cab is fitted with a large front window.

When closed, the two handles (132) are in position (”A”). The cor-
responding locking nose (132.2) is then in the transverse position
behind the fixed locking plate (132.1) 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 (134).
In order to close the front window, the window element must be
pulled down using both handles (132), against the holding pres-
sure of the gas−operated positioners. Then bring both handles
(132) back to position (”A”).
RISK OF DAMAGE!
If you only pull on one side on one handle (132) to close the
window element, it causes the front window to twist. This da-
mages the window seal.
For this reason, always pull at both handles (132) to close the
window.
Risk of crushing!
When closing the window there is a risk of crushing bet-
ween the window element and the cab frame. Use the hand-
les provided to ensure that your hands are not caught in the
hazardous areas!
In case of emergency, the wide−opening front window can be

used as an emergency exit.
3.2.7 Storage
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 ope-
rating instructions)
40C−1030−872e_en 43/43
Engine 4
4 Engine
Damage−prevention measures
The following safety measures must be observed to prevent in-

jury to persons and damage to the engine, components or cable
sets.
− Only start the engine when the batteries are securely connec-
ted. Do not disconnect the batteries when the engine is run-
ning.
− In order to start the engine, the battery switch must be in the
’function position’ (for further instructions, see 4.1).
− After switching off the ignition you must wait 1 minute before
the crane’s electrical system with the battery switch can be
disconnected from the vehicle’s batteries. Risk of crane con-
trol (LLD) malfunctioning (for further instructions, see 4.1)!
− Only start the engine when the speed sensor is connected.
− Do not use a high−speed charger to start the engine.
Only jump start with separate batteries.
− For boost charging of the batteries, the battery terminals must
be disconnected. Follow the operating instructions for the
boost charger.
− The batteries must be disconnected when electric welding
work is carried out, and the two ”+” and ”−” cables must be
firmly connected to one another.
− The control unit connections may only be disconnected or
connected when the electrical system is switched off.
− Switching the poles of the supply voltage for the control units
(for example, by connecting the poles of the batteries incor-
rectly) can lead to the destruction of the control units.
− Tighten the plug connections on the injection system to the
prescribed torque.
− Remove the control devices if temperatures exceed + 80 °C
(176 °F) (dry furnace).
40C−1040−872d_en 1/55
4
2/55 40C−1040−872d_en
Engine 4
− Only use suitable test cables for measurements on plug con-

nections (Mercedes−Benz connector set).
− Telephones and radio equipment which are not connected to
an external antenna can cause malfunctions to the vehicle
electronics, endangering the operating safety of the engine.
Before commissioning, make sure that you have read the

operating instructions of the engine manufacturer. These
can be found in part 4 of these documents.
The following points are primarily limited to information
which specifically affects the crane.
40C−1040−872d_en 3/55
4
”A” ”B”
2 1 2 1
Z 57 812 Z 57 813
4/55 40C−1040−872d_en
Engine 4
4.1 Battery isolating switch (optional)
(Z 57 812, Z 57 813)
The battery is disconnected from the vehicle electronics without
delay by means of the battery isolator (interruption of the battery
plus line) or switched on again.
The battery switch consists of the actual switch (1) and the remo-
vable switch handle (2).
The battery isolating switch is located on the right side of the

chassis between axle 1 and axle 2.
Whenever the switch handle (2) is removed from the bushing of
the battery switch (1), the exposed switch bushing must be clo-
sed using the corresponding rubber cover.
Proceed as follows to switch on the battery:

− Remove the rubber cover from the switch’s (1) bushing.
− Insert switch handle (2) in the battery switch bushing and ro-
tate a quarter of a turn to the right (battery “ON”).
Switch off the battery as follows:

− Turn the switch handle (2) a quarter of a turn to the left and
remove from the switch’s (1) bushing (battery “OFF”).
− Place the rubber cover on the switch’s (1) bushing.
The switch handle (2) must be removed and kept in a safe place
so that it is not lost
(for example, keep it with the vehicle keys).
In order to start the motor, the battery isolator must be switched
on by turning in the t−handle switch (2).
40C−1040−872d_en 5/55
4
6/55 40C−1040−872d_en
Engine 4
As far the procedures and instructions described under subpoint

4.2 require an activated ignition or a running engine, it is assu-
med that, depending on the vehicle’s design, the battery switch
has connected the vehicle electrical system with the vehicle’s
batteries.
4.1.1 Instructions on Switching the Engine off
Risk of damage for electric crane components!

Risk of crane control (LLD) malfunctioning!
After switching off the ignition you must wait 1 minute before
the crane’s electrical system with the battery switch can be
disconnected from the vehicle’s batteries. Shutting down
the engine using the battery switch should only be done in
an emergency.
(For instructions on crane control malfunctioning, see sec-
tion ’Safety devices’)
4.1.1.1 Instructions on Shutting down the Engine with Hot

Water Auxiliary Heating System (Optional)
Risk of damage!
It is not permitted to terminate the lag period of the heater as-
sembly prematurely by actuating the battery isolator.
40C−1040−872d_en 7/55
4
Z 115 010
Z 155 014
Z 75 040
Z 75 039 Z 75 041
8/55 40C−1040−872d_en
Engine 4
4.2 Checks Before Starting up
Please consult the operating instructions for the diesel engine.

(Z 155 014)
Checks before starting:
− whether the parking brake (27) is applied (Z 115 010)
− if the neutral position is preselected on the display of the se-

lector keypad (26) (Z 115 010)
− the engine oil level (Z 75 039)
− the cooling water level (Z 75 040)
Only open the cover when the coolant temperature is below

90 °C (194 °F).
Initially, only turn the cap up to the first notch so that any re-
maining pressure can be relieved from the system.
− the hydraulic oil level (Z 75 041)
When the engine is started, the hydraulic pumps for super-

structure operation and steering immediately start running.
For this reason, the engine must not be started if the visco-
sity level of the hydraulic oil is above 1600 cSt (see corres-
ponding details in section 2 “fuels and lubricants” of the lu-
bricating and maintenance instructions).
− See also section 5.1 ”Checks Before Driving”.
40C−1040−872d_en 9/55
4
Z 115 011 Z 115 010
10/55 40C−1040−872d_en
Engine 4
4.3 Starting up
(Z 115 011)
This is how the engine is started:
1. Insert the ignition key in the ignition lock (67, S 302) and turn
it one position to the right.
For cranes with immobiliser system (optional):

Insert the electronic key of the immobiliser system in the dashbo-
ard (see 4.10, page 29).
2. The charge control light (128, H 310), indicator light for par-
king brake (125, H 310), the indicator light ”Do not shift” (129,
H 440) and the indicator lights for steering circuit 1 (123, H
322.1) and steering circuit 2 (124, H 322.2) and the indicator
light for the flame starting system (if the engine is cold) (135,
H 430) must come on.
3. Once indicator light (135) has gone out, turn the ignition key
as far as it will go and keep it in this position until the engine
starts (without actuating the speed control).
4. While the engine is running, the charge control light (128)

and the indicator light for steering circuit 1 (123) must go out.
Indicator light (129, H 440) also goes out.
Release the ignition key as soon as the engine starts. Under

no circumstances must the starter must be actuated with the
engine running.
Handbrake valve must be closed

Push handbrake lever back) (Z 115 010, Pos. 27)
”N” position is automatically selected (Z 115 010, Pos. 26)
In order to prevent an excessive build−up of soot, do not actuate

the speed control when starting a warm engine.
40C−1040−872d_en 11/55
4
Z 115 402
12/55 40C−1040−872d_en
Engine 4
Observe the following points if the engine fails to start up after 5

seconds (Z 115 402):
− Slowly press down the speed adjuster (1)

− Repeat the starting procedure. Do not try to start the engine
for longer than 20 seconds.
− Wait 60 seconds before attempting another start.
− If the engine fails to start on the third attempt, determine the
cause of the fault with the aid of the engine manufacturer’s
Instructions after starting
(Z 115 402)
− If no oil pressure is indicated on the multi−display (160) or

the indicator light flashes to show that engine oil pressure
is too low (162), switch off the engine immediately and de-
termine the cause.
− If indicator light air filter clogged (121, H 323) comes on,
clean or replace the air filter elements.
− If the indicator light for ”hydraulic oil filter clogged” (122, H
324) comes on when the hydraulic oil is warm, replace the
filter.
This only applies when the hydraulic oil is at operating tempera-

ture.
At low temperatures, this lamp may remain lit up for a brief period
without there being a fault.
− Avoid running a cold engine at high revs.

− Only run the engine when the battery is properly connected
as otherwise the alternator will be damaged.
− See also section 5.1 ”Checks Before Driving”.
Switch off the engine immediately in case of:
− falling or heavily fluctuating oil pressure

− ventilation is not constant
− Loss of power and engine speed without having altered
the position of the accelerator and without any change
in the operating conditions;
− heavily smoking exhaust
− coolant or oil temperature too high
− abnormal engine noises
40C−1040−872d_en 13/55
4
Z 115 403
Z 160 077
14/55 40C−1040−872d_en
Engine 4
4.4 Shutting down
(Z 115 403)
Stop the engine as follows:
1. Return the speed control pedal (1) to the idle position.
2. Apply the parking brake (27) to prevent the vehicle from rol-
ling.
3. Preselect position ”N” at the selector keypad (26).
Use chocks to secure the crane additionally on inclines

and downhill slopes. (Z 160 077)
4. Leave the engine running for approx. 2 minutes at idle

speed.
5. Turn the ignition key (67, S 302) back to the left to the ”0” po-
sition and remove
Right before switching the engine off, do not ”accelerate”.

Do not switch off the engine immediately, but leaving running wi-
thout load at idle speed for a few minutes in order to balance out
the temperature.
4.5 Jump Starting
Follow the instructions in the operating manual of the engine

manufacturer.
40C−1040−872d_en 15/55
4
Z 200 708
16/55 40C−1040−872d_en
Engine 4
4.6 Battery Charging Device (Optional)
(Z 200 708)
Depending on the design, a battery charging device, type ”MULTI

XT 14000”, is fitted in the crane.
The charging device reactivates, charges, monitors and receives

the charge of the batteries. It is an 8−stage, fully automatic char-
ging device which can remain connected for months at a time.
4.6.1 Overload protection
The charging device is equipped with an overload protection fea-

ture in order to prevent overcharging of the batteries.
The charging device is equipped with a 220V mains plug.
The use of this overcharging protection permits the charging de-
vice to be remain constantly connected to the mains network.
This is also required with parked cranes in rigged condition and
switched−on aircraft warning lights.
4.6.2 Temperature protection
The charging device is equipped with an output limitation feature

to protect it against overheating. Output power is reduced in the
presence of high ambient temperatures. The output power is also
reduced if the charging device is accidentally covered over. This
ensures secure protection of the charger. The device continues
to function, albeit with a lesser output power. If the ambient tem-
perature falls later, then the output power will automatically rise
again.
40C−1040−872d_en 17/55
4
Z 59 452
Z 59 453
18/55 40C−1040−872d_en
Engine 4
4.6.3 General description
4.6.3.1 Component parts of the display
(Z 59 452, Z 59 453)
Display Description
0 Fault: the loading procedure was interrupted.
Information concerning troubleshooting is provi-
ded further below.
1 Soft start (heavily discharged battery)
2 Charge at full load
3 Absorption charge
4 Trickle charging
5 Supply
6 Recond, reactivation of completely discharge
batteries.
A Charging without temperature compensation.
B Mains voltage connected.
C Normal
D Supply
E Recond
40C−1040−872d_en 19/55
4
Z 59 453
20/55 40C−1040−872d_en
Engine 4
4.6.3.2 Mode key
Repeated pressing of the ”Mode” key permits the selection of va-

rious programs.
Normal Normal position for open batteries.

(preset)
Supply The charging device supplies a constant
voltage in this position. It can also be
used as a power supply unit when no bat-
tery is connected.
Recond This position is intended for the reactiva-
tion of deeply discharged batteries. The
battery must be disconnected from the
vehicle for this procedure.
4.6.3.3 Malfunction
The charging device switches to ”Malfunction” if the amount of

time for a soft start has been exceeded or if the self−discharge
of the battery is too great.
4.6.4 Charging batteries
(Z 59 453)
− Connect the charging device to the mains socket. The char-
ging device shows ”Power”, the yellow display (B) is illumina-
ted.
− The display for heavily discharged batteries (1) lights up
when the voltage of the battery is less than 24 V.
− Normal charging sequences are displayed with the following
lamps:
1 Soft start, (heavily discharged battery)

2 Full charge
3 Absorption charge
4 Trickle charging
5 Recond ”Reactivation”
− If the trickle charging display (4) is illuminated, then the bat-

tery is charged. The charging sequence starts over again
when the voltage in the battery drops off. The device can re-
main connected for months at a time.
40C−1040−872d_en 21/55
4
22/55 40C−1040−872d_en
Engine 4
− The charging sequence can be interrupted at any time by pul-

ling the mains plug out of the socket.
If the display for the voltage set and the power display are still lit,
but no other display is, the battery could be defective. If the char-
ging sequence cannot be started, then this may also be caused
by the failure of the socket to provide any electricity.
Do not bend over the batteries while they are being charged!
Risk of chemical burns!
Naked flames or sparks are prohibited in the vicinity of the
battery! No smoking! Risk of explosions!
Do not place any metal objects on the batteries. Risk of short
circuiting!
Discharged batteries can freeze at about. −105 C / 145F. This
usually destroys them. Therefore always keep the batteries
well charged.
If, however, the batteries have only been frozen slightly and
you want to attempt to charge them, the batteries must be
thawed out BEFORE attempting the jump starting proce-
dure.
Check whether the charging device has switched to trickle
charging before you leave the charging device switched on
unmonitored for a long period of time. If the charging device
has not gone into trickle charging after three days, there is
an fault. The device must be switched by hand.
4.6.5 Maintenance and care
The charging device is maintenance−free. The device must not

be dismantled. The housing of the charging device can be clea-
ned with a damp cloth and a mild cleaning agent.
Before cleaning, pull the network plug out of the socket.
40C−1040−872d_en 23/55
4
64
Z 115 269
2
Z 58 667
24/55 40C−1040−872d_en
Engine 4
4.7 Engine Quick Stop Switch (Optional)
(Z 115 269, Z 58 667)
Your crane is equipped with engine cutout equipment. This inclu-

des three engine cutout switches. One switch is located in the
cab on the dashboard (item 64). Two additionalengine cutout
switches are located on the chassis frameon the right− and left−
hand side (Y and Z).
The engine cutout switch is only guaranteed to work when the

parking brake is applied in the cab and the transmission is placed
in “neutral”.
The engine/motor is switched off! The message ”Engine quick

stop button activated” appears in thecab. The engine can only be
restarted once all engine cutout switches have been unlocked
again.
4.8 “Quick Stop” with Air Shut−off Valve (Optional)
(Z 115 269, Z 58 667)
In order to operate in an atmosphere at risk of explosions (e.g.

air with easily flammable gases), your crane can be equipped
with an automatic engine stop device.
Using a trap between the air filter and engine the air flow is cut
off when the device is actuated.
For manual activation of the air shut−off flap there are engine ra-
pid stop switches on the crane.
Depending on the design, there is an additional engine rapid stop
switch in the cab over the dashboard. There are two other engine
rapid stop switches, one each on the right− and left−hand side of
the chassis frame (Y and Z).
Independent of manual activation, the rapid stop device is auto-

matically initiated when a certain limit speed is exceeded. At the
same time the fuel supply is interrupted. The engine is switched
off.
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4
64
Z 115 269
2
Z 58 667
26/55 40C−1040−872d_en
Engine 4
(Z 115 269, Z 58 667)
The function of the engine rapid stop device is only ensured when
the parking brake has been activated and the transmission is
switched to ”neutral”.
Restarting the engine
The following must be carried out before the engine can be re-
started:
When working in the engine compartment you must re-

ach past engine components which move when the en-
gine is running.
In order for the resetting procedure to be carried out wi-
thout risks, you must therefore prevent the engine from
being started up when someone is still in the engine’s
danger zone.
If required, the ignition key must be removed and the
cabs must be locked.
1. Reset the shutoff flap (1) to the original position.

To do so, the setting lever (2) of the shutoff flap (1) must be
set back to the original position.
The shut−off flap is in the suction lead between the air filter and
the engine.
2. Check that all air guiding hoses (including the aftercooler ho-
ses between the engine and the aftercooler) are fitted cor-
rectly and are fully unblocked.
Risk of damage!
When the air shut−off valve is closed, the engine cannot be
started. Repeated starting attempts lead to engine damage.
If closing of the shut−off flap has been initiated by an engine rapid

stop switch:
3. Unlock the relevant engine rapid stop switch.
Now may the engine be started.
40C−1040−872d_en 27/55
4
67
171
170
Z 115 267 Z 115 400
28/55 40C−1040−872d_en
Engine 4
4.9 Limiting the Engine Speed (Optional)
(Z 115 267)
Due to regulations in some countries (optional), the noise level

must be limited during superstructure operation.
For this reason the engine speed is always limited to a maximum

of 1200 min−1 (rpm) by activating switch (Z 115 267) ”Engine
speed limit” in the crane cab.
4.10 Immobiliser (Optional)
(Z 115 400)
Optionally, the crane can be equipped with an immobiliser.

In this case ensure that the immobiliser is switched off before
using the ignition switch (67).
4.10.1 Immobiliser System ”ON”
The immobiliser is activated automatically 30 seconds after swit-

ching off the engine.
Indicator light (171) flashes when the immobiliser is activated.
4.10.1.1 Immobiliser System ”OFF”
After the electronic key has been briefly fully inserted in the key−
operated pushbutton (170), the vehicle can be started within 30
seconds (indicator light (171) ”OFF”).
If the vehicle is not started within this time, the immobiliser is acti-
vated again (indicator light (171) flashes).
4.10.1.2 Starting Attempt with Immobiliser System ”ON”
If the ignition−starter switch (67) is turned when the immobiliser

system is switched on, the indicator light (171) is continuously lit
during this time.
40C−1040−872d_en 29/55
4
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
400
kinematische Viskosität [mm**2/s]
300
200
150
100
90
80
70
60
Tellus S3 1
50 2
40
30
25
20
18
16
14
12
10
9
8
7
5
4.5
4
Shell Tellus S3 V 32
3.5 V40: 32; V100: 6,5
3
V40: 46; V100: 8,4
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 71 387
30/55 40C−1040−872d_en
Engine 4
4.11 Warming up the hydraulic system

The hydraulic system must be warmed up only if:
− in relation to the ambient temperature, the oil viscosity is bet-
ween 1000 and 1600 cSt (for a standard hydraulic oil filling,
that means between −14°C and −18°C / +6.8F and −0.4°F,
see table)
and
− the hydraulic oil has cooled down to the ambient temperature
after a longer standstill period (about 8 to 10 hours).
4.11.1 Hydraulic oil

(Z 71 387)
Remember that a suitable hydraulic oil MUST be used, de-

pending on oil temperature and viscosity. The appropriate
oil viscosity depends on the oil used.
The relevant specifications can be found in the following ta-
ble.
Standard hydraulic oil filling for average temperatures

Oil tempe- Speed of diesel
Oil viscosity
Shell Tellus S3 V46 rature engine (min
(cSt) −1/rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idling)
min −14 / +6.8 1000
Operation (2) max
max +91 / +195.8 10
The conditions listed in the table must be complied with.

Otherwise safe operation of the crane cannot be guaranteed
and hydraulic components could be damaged.
When using other equivalent oils, make sure in particular

that they comply with the characteristics described for the
recommended oils.
40C−1040−872d_en 31/55
4
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
400
kinematische Viskosität [mm**2/s]
300
200
150
100
90
80
70
60
Tellus S3 1
50 2
40
30
25
20
18
16
14
12
10
9
8
7
5
4.5
4
3.5 V40: 32; V100: 6,5
3
V40: 46; V100: 8,4
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 71 387
32/55 40C−1040−872d_en
Engine 4
4.11.2 Warming−up procedure

(Z 71 387)
1. First use the following table to make sure that the correct hy-
draulic oil has been used, depending on the existing tempe-
ratures. The viscosity of the oil must be below 1600 cSt.
2. Start the diesel engine.
The permitted engine speeds are specified in the following table.
Standard hydraulic oil filling for average temperatures

Oil tempe- Speed of diesel
Oil viscosity
Shell Tellus S3 V46 rature engine (min
(cSt) −1/rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idling)
min −14 / +6.8 1000
Operation (2) max
max +91 / +195.8 10
As soon as the diesel engine is running − first at idle speeds − the

hydraulic pumps also run automatically. In this way, the hydraulic
oil circulates without pressure and warms up.
The hydraulic system must warm up until the viscosity of the oil
is below 1000 cSt.
With a running time of 30 minutes and approximately 1000

(min−1/rpm) the hydraulic oil is warmed by 4° to 5° C (7° to 9°F).
3. Then carefully drive all movements repeatedly for about 10

to 15 minutes without load. Warming up is then completed.
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34/55 40C−1040−872d_en
Engine 4
4.12 Diesel Particle Filter (Huss)
Risk of accidents!
Only personnel who are trained in filter regeneration and
who are acquainted with any occurring risks may fit and
operate diesel particle filters and rectify any faults therein.
It is prohibited to work on the diesel particle filter during
operation.
If any damage is recognised or there are any malfunctions,
the diesel particle filter must be shut down immediately.
It must be ensured that there are no deposits of flammable
materials in the filter area.
Risk of burning!
During regeneration, hot exhaust fumes come out of the ex-
haust outlet tube.
4.12.1 Intended Use − Regulated Use
The HUSS diesel particle filter is designed − without exception −

for exhaust filtering in operating machines with diesel engines.
No additives are required for this. The filter is burned clean during
regeneration.
40C−1040−872d_en 35/55
4
13
Z 115 391
13
Z 115 392
88 89
Z 115 393
36/55 40C−1040−872d_en
Engine 4
4.12.2 Function Description
(Z 115 391, Z 115 392, Z 115 393)
While the engine is running, the diesel engine exhaust fumes

blow through the diesel particle filter (1) (silicon carbide mono-
lith), which almost completely holds back all damaging soot parti-
cles. The longer the diesel engine runs, the higher the filling de-
gree of the diesel particle filter, which increases the exhaust co-
unterpressure. The operator can see the filling degree of the die-
sel particle filter on the display of “HUSS Control” (13) (for a detai-
led description, see pg. 39) and proceed with the regeneration at
the correct time.
When a defined maximum counterpressure or a maximum loa-
ding time has been reached, “HUSS Control” activates the alarm
”Full filter“.
The alarm “Full filter” is indicated in the crane operator’s cab by
a warning light (89) and an acoustic signal (warning buzzer: 88).
In order to burn off the soot particles collected in the filter, regene-
ration is started with ”HUSS Control” (13) with the engine swit-
ched off.
Burning the diesel particles − using an integrated fuel burner − is
done without any residue, i.e. all particles and the hydrocarbon
compounds contained therein are converted into carbon mono-
xide (CO), carbon dioxide (CO2) and water vapour. The exhaust
fumes come out of the end pipe of the filter.
No external energy sources are required.
A start−up lock is integrated in the control system for the protec-

tion of the engine and the diesel particle filter (1).
40C−1040−872d_en 37/55
4
13
Z 115 391
13.1 13 13.2 13.3
13.4
13.5
13.7 13.6
Z 115 394
38/55 40C−1040−872d_en
Engine 4
4.12.3 Control System ”Huss Control”

(Z 115 391, Z 115 394)
”Huss Control” (13) serves to control and monitor the particle fil-
ter. It is on the chassis on the right−hand side in the assembly
compartment between axle 1 and axle 2.
It only functions when the ignition is switched on.
Item Element Function

13.1 Display, top line Display of the function steps
13.7 Display, lower line Bar display for the state of
the filter (counterpressure or
length of regeneration)
13.2 Key ”C” Control
13.3 Key ”M” Mode
13.4 Key ”F” Function
13.5 LED (red)
13.6 LED (green)
”Huss Control” has a comprehensive datalogger function which

collects and records all required data of the filter system.
Using the supplied software, the data can be downloaded using
a PC or Bluetooth interface.
40C−1040−872d_en 39/55
4
13
Z 115 392
40/55 40C−1040−872d_en
Engine 4
4.12.4 Normal Operation

(Z 115 392)
Operation Display in the dis- Function LED

play
Switch on crane ignition. The buzzer Self−test green and red
signal is activated for at least 1 se- LEDs are illumi-
cond, at the same time, both LEDs nated
are illuminated.
If a message has been saved, it is Alarm / filter full red LED flashing
displayed; in addition, the red LED HHHHHHHHHHHHHHHH
is illuminated.
Saved message:
Before the last shutdown, the ex-
haust counterpressure exceeded
the top limit for at least 20 seconds
or a regeneration was stopped. The
buzzer signal is active without inter-
ruption.
Note on this message: Caution!
Start−up lock − the crane engine In a dangerous situation, the crane can
cannot be started − a regeneration be started despite the start−up lock by
is required. continuously pressing the key combina-
tion ”M” and ”F”.
However, in this instance the crane may
only be operated until the dangerous
situation has been rectified (for exam-
ple, setting down load).
Under no circumstances may operation
of the crane be continued permanently.
Risk of damage to the engine and
particle filter!
If no message has been saved, the Engine ready −−−
engine can be started.
40C−1040−872d_en 41/55
4
13
Z 115 392
42/55 40C−1040−872d_en
Engine 4
Messages during normal operation which indicate the state

of the diesel particle filter
(Z 115 392)
Display in the dis- Function LED Explanation

play
Filter state green LED flas- Normal operation possible; during
HHHHHHHH; hing engine operation, the counterpres-
the number of bars sure is monitored.
(max. 16) show the
filling degree of the
filter
Regenerate red LED is illumi- The pre−alarm pressure (130 mbar /
HHHHHHHHHHHHHHHH nated 1.9 psi) is reached; filter is loaded
approx. 90%; a regeneration must
be carried out soon.
Regenerate red LED flashing The maximum loading pressure
HHHHHHHHHHHHHHHH (150 mbar / 2.2 psi) is reached or
Alarm / filter full the loading time is exceeded; filter is
(16 bars) full; buzzer signal is active without
interruption.
The crane engine must be switched
off and the regeneration must be
carried out.
Calling the service −−− Regeneration must have taken
team / white ash place 10 times within the maximum
loading time, the customer service
team must be called.
servicing −−− Maintenance work required on the
diesel particle filter; the customer
service team must be called in.
40C−1040−872d_en 43/55
4
13
Z 115 392
44/55 40C−1040−872d_en
Engine 4
4.12.5 Regeneration
(Z 115 392)
As described under ”Normal operation”, the display of ”Huss Con-

trol” shows when a regeneration is required. At the latest, this is
after 8−10 hours. The length of the regeneration is 5 − 35 minu-
tes.
A regeneration must be carried out once a day, even if the fil-

ter is not yet fully loaded.
Operation Display in the dis- Function LED

play
Set down the crane horizontally and
shut down the engine.
Ignition ”ON”:
HUSS Control is supplied with
power.
Press key ”M” and hold down for 5 Regeneration / start green LED is illu-
seconds. The regeneration starts in 5 s minated
after 5 seconds. HHHHHHHHHHHHHHHH
Note:
The time up to the start of the rege-
neration (5 seconds) is shown in the
display, running backwards.
Letting go of the ”M” key before the
5 seconds are up lead to shutdown
− a self test follows.
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4
13
Z 115 392
46/55 40C−1040−872d_en
Engine 4
(Z 115 392)
Further displays after 5 seconds
Display in the dis- Function LED Procedure
play
Glow plug −−− The fan is switched on for precoo-
Precooling ling.
Regeneration/ −−− The glow plug is switched on.
start glow plug
Regeneration/ −−− The fuel / air mixture is ignited.
start ignite
Regeneration on −−− Regeneration of the diesel particle
filter is carried out. The remaining
running time of the regeneration is
shown in the display.
Regeneration ex- −−− Regeneration is finished. The dis-
ecuted play is shown for 3 minutes in the
display.
Interrupt regeneration Display in the dis- Function LED

play
A regeneration which has been star- Alarm / filter full red LED flashing
ted can be interrupted by shutting HHHHHHHHHHHHHHHH
off the ignition using the crane igni-
tion key or by pressing the “F“ key in
the control system.
To do so, 5 seconds are counted
down backwards in the display up to
the shutdown of the regeneration.
The buzzer signal is active without
interruption.
deactivate start−up lock Display in the dis- Function LED

play
Caution! Alarm / filter full red LED flashing
In a dangerous situation, the crane HHHHHHHHHHHHHHHH
can be started despite the start−up
lock by continuously pressing the
key combination ”M” and ”F”.
However, in this instance the crane
may only be operated until the dan-
gerous situation has been rectified
(for example, setting down load).
Under no circumstances may opera-
tion of the crane be continued per-
manently.
Risk of damage to the engine and
particle filter!
40C−1040−872d_en 47/55
4
13
Z 115 392
48/55 40C−1040−872d_en
Engine 4
(Z 115 392)
Fault displays during regeneration
During regeneration, the individual functions are checked on the

hardware and software side. Malfunctions lead to regeneration
being stopped. The malfunction is shown on the display of ”HUSS
Control”. In addition, the battery voltage is checked.
If voltage is below the minimum, regeneration is stopped.
If one of the following malfunctions is shown on the display of
”HUSS Control”, the customer service team must be called out to
rectify the fault:
− malfunction glow plug
− malfunction fuel pump
− malfunction solenoid valve
− malfunction fan
− malfunction temperature sensor
− malfunction regeneration
− regeneration interrupted
− undervoltage.
40C−1040−872d_en 49/55
4
13
Z 115 392
50/55 40C−1040−872d_en
Engine 4
4.12.6 Troubleshooting
(Z 115 392)
Display in the dis- Troubleshooting

play
no switch−over from Generator contact/oil pressure switch, check cables,
”Engine ready” to check red indicator lamps on the vehicle (loading pres-
”Filter state” sure and oil pressure)
Regeneration inter- often burner problems: Check ”clean” fine filter (fuel
ruption after half the filter) in the suction line for cleanliness and check con-
burning time nections in front of and behind the fuel filter for leak−
tightness (clamp + suction line)
Malfunction glow Remove the glow plug, check throughfeed with mouth
plug or hose, check electric lines; fit a new glow plug with
regular service, check fuses and their brackets
Malfunction solenoid Check electric lines, check function with external ca-
valve bles. If the fault should reoccur despite correct function,
check/replace Huss Control
Malfunction metering Check electric lines, check function with external ca-
pump bles, check grounding; fitting position: horizontal
Malfunction fan Check electric lines, check function with external ca-
bles, check grounding, finger test in intakes: dust=OK,
soot indicates defective or opening solenoid valve (due
to high counterpressure)= filter overloaded; fan can be-
come damaged on the inside by hot exhaust fumes.
Look out for small absorbed components, such as pa-
per or even water
Malfunction G−M− Check fuses and their brackets
D−G
White ash Blow through filter with the burner removed until grey
ash can no longer be seen. To do so, hoover up dust
directly with an industrial hoover. Instruct operators of
the machine on issues of engine oil consumption and
filter characteristics. In the menu, set back all mainte-
nance displays (fault messages, operating hours, rege-
neration, regeneration interruptions, premature regene-
ration and maintenance counters (Reset: M)).
40C−1040−872d_en 51/55
4
13
Z 115 392
52/55 40C−1040−872d_en
Engine 4
(Z 115 392)

play
Filter state only 1 block (Huss Control V202, 203, 204): display
”Pressure sensor interrupted” with simultaneous war-
ning buzzer (Huss Control V205): pressure reduction
might be clogged at the exhaust inlet: clean. Check the
counterpressure hose and clean
Confused symbols Electronic magnetic incompatibility of ”Huss Control”
with other electric components in the cab; rectified
using silent rubber or changing the location of ”Huss
Control”
Undervoltage Check resting voltage of the battery.
12−V system: total discharge 7.2 V<
undervoltage 7.2 − 10.2 V
overvoltage >16.2 V
24−V system: total discharge 19.0 V <
undervoltage 19.0 − 22.0 V
overvoltage 32 V
Undervoltage During regeneration, switch off light and other consu-
mers such as fresh air fan, radio and seat heating
Vehicle does not Existing relay for start interruption?
start Cable ”starter 1+C” okay?
Information: with relay, start shutdown is after 1−3 se-
conds if there is undervoltage, without relay a bit later;
this is also dependent on the state of the coal brushes
and the amount of coal dust deposits in the starter
Filter overloaded with Remove burner, blow through filter and hoover with in-
soot dustrial hoover, regenerate and measure counterpres-
sure. Filter overloading can be caused by a defective
or bent counterpressure hose, clogged pressure reduc-
tion or unsealed exhaust piping to the filter.
Check: does the display switch from ”Engine ready” to
”Filter state” after starting the engine?
If no, check the cable ”Generator”
40C−1040−872d_en 53/55
4
13
Z 115 392
54/55 40C−1040−872d_en
Engine 4
(Z 115 392)

play
Alarm filter full Once the soot overloading has been removed as des-
cribed above, the display ”Alarm filter full” can be dele-
ted by pressing the key combination C+F+M at the
same time: in the meantime, switch the ignition off and
on again, hold key combination until ”Self test” appears
Overloading the filter Remove the burner, blow through the filter, regenerate
with soot and diesel and measure the counterpressure; then regenerate
twice
Burner Clean with a suitable brush or brake cleaner, clean the
bypass tube with pipe cleaners using long−nosed
pliers, clean glow plug stumps with a round brush
Solenoid valve After cleaning, carry out a pressure test with a clean
tube, flow through against the direction of the arrow
Non−return valve Check the spring and the sealing cone, remove soot,
pressure test, flow through in the direction of the arrow
40C−1040−872d_en 55/55
Driving 5
5 Driving
5.1 Instructions for all Types of Driving
All the control and monitoring elements required for driving the
crane are located in the crane operator’s cab.
The freedom of movement of the pedals must not be restric-

ted in any way. Be sure that there is enough room for the pe-
dals when using foot mats and carpets. Do not store any ob-
jects in the driver’s foot area. Store or secure all loose ob-
jects (for example, tins, bottles, tools, bags, etc.) in such a
way that they cannot get into the driver’s footwell while dri-
ving. Such objects could get under the brake pedal, block it
and thereby make it impossible to brake the crane vehicle.
5.2 Checks before Every Journey
Risk of accidents! Risk of injury! Risk of damage!

The checks and tasks described in the following must be
carried out in order to prevent the corresponding risks.
The following checks must be made every time before the crane
is driven, even when only driving short stretches.
− Driving condition of the mobile crane:
Check axle loads; observe instructions (see ”Axle loads /
speeds / tyres” and ”Defined driving conditions”).
− Check the transport position of supports and outrigger plates
(see section 11)
40C−1050−891c_en 1/99
5
2
1
5 3 4
Z 115 301
14
13
12
Z 115 304
2/99 40C−1050−891c_en
Driving 5
(Z 115 301, Z 115 304)
− Main boom in “Driving position”:

− The main boom must be set down on the crane chassis.
− The main boom must be in the ”Road travel state” if speeds
are to be driven which are faster than walking speeds:
− The main boom head must be lashed to the basic boom
with the retaining rope (1).
− The main boom must be set down on the crane chassis.
− The underride guard (5) must be secured to the main boom
head.
Risk of damage.
If the 1−sheave or 3−sheave hook block is to be hung at the
front of the chassis with even reeving, the hoist rope must
be fitted to the main boom head in a special fixing point (see
arrow) (optionally available).
The side fixing point may not be used for fastening the hoist
rope end.
See also section 22 “Reeving”.
If the special fixing point (see arrow) is not on the main boom
head and if the hook block is to be hung on the chassis, the hook
block must be reeved with an uneven number.
− The mirror rod (2, Z 115 301) is in the ”Travel position” for dri-
ving (Z 115 301, Z 115 304).
− Remove cover (12) in order to fold the mirror rod (2,
Z 115 304) up into the “Travel position”. Fold the mirror rod
(2) up completely and slide in. Fasten the clamping brak-
kets (13) and the retaining hook (14).
The mirror rod is folded into the “Superstructure slewing
position” in the same way, but in the opposite sequence
(see also section 17.1).
If the mirror is not brought into the “Travel position”, a banksman

must be assigned.
− Check that all auxiliary equipment and components are cor-

rectly pinned and secured.
40C−1050−891c_en 3/99
5
123 124 99
H322.1 H322.2 H356.2
Z 115 014
4/99 40C−1050−891c_en
Driving 5
− Make certain that there are no unattached components on

the vehicle.
Check the capacities for all fuels and lubricants − see lubricating
and maintenance instructions (part 2).
− Check the engine oil level, add extra oil if required.

− Check the hydraulic oil level.
If incorrect: Determine the cause − and only then top up.
Let the engine run at middle speed till the hydraulic oil has war-
med up.
− Check the oil level in the transmission, add extra oil if requi-
red.
− Check the coolant level.
If incorrect: Determine the cause − and only then top up.
− Check the tyre condition and air pressure.
Tyre pressures have a major influence on:
− The handling of the vehicle
− The running characteristics of the tyres
Tyre damage is inevitable if the tyre pressure is too low.
For this reason, do not fail under any circumstances to use the
correct air pressure (see table in section 5.4.4 ”Possible axle
loads / permitted speeds”).
(Z 115 014)
− Check the steering.

Indicator light (123, H 322.1 − ”steering circuit 1 no flow”) must
go out shortly after the engine has started.
Since the emergency steering pump is driven by the rolling
vehicle, indicator light (124, H 322.2 − ”steering circuit 2 no
flow”) goes out only when the crane has started to move.
Driving the crane with defective steering constitutes a

major safety hazard. Faults must be rectified before the
crane is driven.
40C−1050−891c_en 5/99
5
123 124 99
H322.1 H322.2 H356.2
101
Z 115 014 Z 115 299
125 126
26 H310 H310.6
27
Z 115 282 Z 115 297
6/99 40C−1050−891c_en
Driving 5
(Z 115 014, Z 115 299, Z 115 282, Z 115 297)
− The steering must be in the ”Road travel state” if speeds are

to be driven which are faster than walking speeds,
which means that the indicator light ”Rear−axle steering not
locked” (99, H 356.2) must have gone out.
As long as indicator light (99, H 356.2) is illuminated, the stee-
ring is not yet in the ”Road travel” position, which means you
must check the switch−over from ”Electric−hydraulic rear−
axle steering” to ”Steering for road travel” (see section 8).
− Check the braking system:
− Emergency pressure supply in brake circuits 1 and 2
If the pressure supply at the pressure gauge (101) is below 7 bar

(102 psi), the air tanks of the braking system must be topped up
at middle engine speeds, until a pressure of 8 bar (116 psi) has
been achieved.
Indicator light (126, H 310.6) must be off.
− Parking brake: Indicator light (125, H 310) is illuminated if

parking brake (27) is applied.
Immediately after starting up, test the brakes on a dry, slip−

proof road surface (service brake and parking brake). When
doing so, make sure the crane brakes evenly, does not veer
to the side and that brake deceleration is faultless.
At no time must there be any oil or water on the brake linings.

If moisture has seeped through to the brake linings, apply
the service brake lightly until braking is faultless.
40C−1050−891c_en 7/99
5
90 91 92 93
H371 H374 H373 H372
Z 115 039
14
106
S301.1
Z 115 075 Z 115 020
160
P100
110
S14
161
Z 115 019 Z 115 298
8/99 40C−1050−891c_en
Driving 5
(Z 115 075, Z 115 039, Z 115 020, Z 115 019, Z 115 298)
− Bring the steering wheel into the “Travel position”:

Using toggle (14), release the steering column and bring the
steering wheel into an ergonomic position (Z 115 075 princi-
ple depiction).
An exact description of the steering wheel/driver seat setting can

be found in section 3 “Crane cab”.
− Vehicle lighting; check indicators and brake lights

− Check the suspension system.
If a suspension circuit is outside of the road travel level, the
corresponding indicator light (90), (91), (92) or (93) comes on
(see section 10).
All suspension cylinders must be in the road travel position (indi-

cator light (90), (91), (92) or (93) are not illuminated).
− The crane must be in the operating mode “Driving operation”.

Which means lock switch (106) must not be activated.
If lock switch (106) is not activated, the crane is in the operating

mode “Operation of the crane”. In this state the suspension would
be locked. Driving would only be permitted at walking speeds
(see 5.11.2 “Driving in the configured condition”, 5.11.3 “Driving
the crane in operating mode 360° (without load)“ or 5.11.4 “Dri-
ving the crane with load”).
− Apply slew gear brake (110).

− Check the fuel supply, add fuel if required.
You can see the fuel level on the store indicator (161) in the
dashboard.
Do not fill up with fuel while the engine is running.
Other important specifications are outlined in the individual sec-

tions.
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2
1
5 3 4
Z 115 301
Z 115 305
10/99 40C−1050−891c_en
Driving 5
5.3 Transport safety locks
(Z 115 301, Z 115 305)
During transportation, the transport safety locks provided must

be applied.
After driving and before the superstructure is put into operation,

the safety locks must be removed again.
The slew gear brake is only released if the operating step requi-
res it.
− The hook block (max. 3−sheave) must be set down in the

support designed for this purpose or fastened to the chassis
in fixing points (3) or (4, optional).
− When driving without the reeved hook block, the hoist rope
is fastened to fixing point (3) using the rope socket.
− The platform at the crane operator’s cab must be slid into the
transport position (lever (8) in the footwell of the crane opera-
tor’s cab; see section 3 “Crane Operator’s Cab”)
− The outrigger beams and plates must be correctly secured
(see section Outriggers, segment “Retracting the outriggers
(for driving the crane in the transport condition)).
40C−1050−891c_en 11/99
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12/99 40C−1050−891c_en
Driving 5
5.4 Axle Loads / Speeds / Tyres
The permitted driving speed depends on the axle load and tyres.
There is a direct correlation between axle load, tyre size and per-
mitted speed.
With the axle loads we differentiate between the technically
possible loads and those permitted by road traffic regula-
tions.
All chassis parts / components are designed, adjusted to each

other and approved ex works for even axle loads of 12 t (26.4 t
kip) per axle.
Axle loads above and below 12 t (26.4 kip) represent a deviation

from the documented EEC approved condition.
Uneven or excessively high axle loads affect the handling of the

crane negatively in any case. Lower axle loads also have a nega-
tive effect.
Deviation from the approved condition always means worse

handling characteristics. The greater the deviations, the
worse the driving characteristics become.
As a result, the limits that must be observed increase accor-
dingly.
Comply with the relevant instructions in the following sub-
sections.
Before driving in public traffic, the driver must familiarise

himself with the changed driving/steering/braking beha-
viour (for example, longer braking distances) of the crane −
especially where the driving condition of the crane deviates
from the standard configuration.
40C−1050−891c_en 13/99
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14/99 40C−1050−891c_en
Driving 5
5.4.1 Calculating Axle Loads
Any addition or removal of components affects the vehicle / dis-

places the axle loads.
Additional components can, depending on the centre of gravity
of the crane, cause an increase or decrease of weight on the af-
fected axles.
The axles are marked in the table with the description “A” and an
additional digit (e.g. the description ”A1” is for “Axle 1”, etc.).
In section 5.4.2 information is given on how to calculate axle

loads in kg.
In section 5.4.3 information is given on how to calculate axle
loads in lbs.
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5.4.2 Calculating Axle Loads in kg
5.4.2.1 Calculated Basic Condition (kg)
The basic condition serves as the basis for all axle load calcula-
tions. The crane then weighs 31500 kg and is equipped with the
following:
Crane with:
− drive steering design: 6 x 4 x 6
− tyres 445/65 R22.5 (18.00 R 22.5)
− main boom extension 13 m
− hook block 1−sheave
− counterweight 5.45 t
5.4.2.2 Weight Table (Component Weights in kg)
Current axle loads can be calculated for different combinations

starting with the basic condition, using the weights listed in the
following.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.
Optional equipment Total A1 A2 A3
weight (kg) (kg) (kg)
(kg)
Basis 31500 9000 11200 11300
Drive 6x6x6 300 0 300 0
tyres 385/95 R 25 (14.00 R 25) 555 185 185 185
tyres 445/80 R 25 (17.50 R 25) 675 225 225 225
Spare wheel 445/65 R 22.5 (18.00 R 22.5) 230 0 115 115
Spare wheel 385/95 R 25 (14.00 R 25) 320 0 160 160
Spare wheel 445/80 R 25 (17.50 R 25) 340 0 175 175
MBE 7.1m (reduced weight) −260 −100 −80 −80
Hook suspension gear in support 140 220 −40 −40
Hook block 3−sheave instead of hook 370 75 −20 −20
block 1−sheave
Removal CWT 2.35 t −2350 500 −1425 −1425
Runner in support 205 −140 170 170
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5.4.3 Calculating Axle Loads in lbs
5.4.3.1 Calculated Basic Condition (lbs)
The basic condition serves as the basis for all axle load calcula-
tions. The crane then weighs 69446 lbs and is equipped with the
following:
Crane with:
− drive steering design: 6 x 4 x 6
− tyres 445/65 R22.5 (18.00 R 22.5)
− main boom extension 42.7 ft
− hook block 1−sheave
− counterweight 12.0 kip
5.4.3.2 Weight Table (component weights in lbs)
Current axle loads can be calculated for different combinations

starting with the basic condition, using the weights listed in the
following.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.
Optional equipment Total A1 A2 A3
weight (lbs) (lbs) (lbs)
(lbs)
Basis 69446 19842 24692 24912
Drive 6x6x6 661 0 661 0
tyres 385/95 R 25 (14.00 R 25) 1224 408 408 408
tyres 445/80 R 25 (17.50 R 25) 1488 496 496 496
Spare wheel 445/65 R 22.5 (18.00 R 22.5) 507 0 254 254
Spare wheel 385/95 R 25 (14.00 R 25) 705 0 353 353
Spare wheel 445/80 R 25 (17.50 R 25) 750 0 386 386
MBE 23.3 ft (reduced weight) −573 −220 −176 −176
Hook suspension gear in support 309 485 −88 −88
Hook block 3−sheave instead of hook 816 165 −44 −44
block 1−sheave
Removal CWT 5.2 kip −5181 1102 −3142 −3142
Runner in support 452 −309 375 375
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5.4.3.3 Example of an Axle Load Calculation
Exceptional driving condition for reducing the axle loads to

meet respective national regulations.
Crane with:
− drive 6x6x6
− tyres 385/95 R 25 (14.00 R 25)
− Main boom in transport condition
− hook block (3sheave) on bumper
− hook suspension gear in holder
− chain box, front
Crane without:
− Main boom extension

− counterweight support
Axle load distribution:
∗ Axle 1: 10 t (22.1 kip)

∗ Axle 2: 11.5 t (25.4 kip)
∗ Axle 3: 11.5 t (25.4 kip)
Risk of accidents!
If the described driving conditions are not adhered to (spe-
cifically: 3−sheave hook block fitted to the bumper, hook
suspension gear set down in support and chain box fitted
in the front), axle 1 is relieved of load. This deteriorates the
driving characteristics of the crane.
If axle loads arise that are over 12 t (26.4 kip):
RISK OF ACCIDENTS due to overloading of tyres!

The maximum permitted speed must be observed for the
current axle load (see section 6 under ”Possible axle loads
/ permitted speeds”). The determining factor is always the
most heavily loaded axle. Failure to comply with these in-
structions can result in the tyres being overloaded and bur-
sting.
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Extreme risk of accidents due to extended braking distan-

ces!
Axle loads exceeding 12 t (26.4 kip) result in a significantly
longer braking distance and the risk of fading.
For driving on public roads, the permitted axle loads and the cor-
responding speed limits must be observed.
If axle loads arise that are less than 12 t (26.4 kip):
Risk of accidents!
For axle loads less than 12 t (26.4 kip), section 5.4.6 (page
41) ”Driving with reduced axle loads” must be observed.
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5.4.4 Possible axle loads / permitted speeds

Pay attention to the relation between the axle loads, the driving
speed and the tyres fitted − as shown in the following table.
The determining factor is the axle that is placed under the highest
load.

The maximum permitted driving speed must be observed
for the current axle load.
Failure to comply with these instructions can result in
the tyres being overloaded and bursting.
DANGER !
Risk of accident due to overloading of tyres when driving

at construction sites or off−road.
The service life of tyres is dramatically shortened when

driven off−road.After an accumulated distance of 20 km (12
mi) has been reached, the tyres must be replaced.
5.4.4.1 Tyres, Manufactured by Michelin (XGC)
Michelin tyres
Tyre size 445/80 R 25
(17.50 R 25)
Designation 170E
Tyre pressure 7.0 bar
(102 psi)
Tread XGC
Axle loads Axle loads
Maximum speed
On Road Off Road
km/h mph t kip t kip
80 50 9,8 21.6 − −
70 44 12,0 26.4 − −
60 37 13,1 28.8 − −
50 31 14,2 31.3 − −
40 25 14,9 32.8 − −
30 18 15,6 34.4 15,6 34.4
20 12 15,9 35.0 15,9 35.0
10 6 20,1 44.3 20,1 44.3
5 3 22,8 50.3 22,8 50.3
2 1 26,2 57.8 26,2 57.8
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5.4.4.2 Tyres, manufactured by Michelin (X Crane AT)
Michelin tyres
(14.00 R 25)
Designation 170F
(131 psi)
Tread X Crane AT
Maximum speed
On Road Off Road
80 50 12,0 26.4 − −
70 44 12,6 27.8 − −
60 37 13,2 29.1 − −
50 31 13,4 29.5 − −
40 25 13,8 30.4 − −
30 18 15,0 33.1 15,6 34.4
20 12 18,0 39.7 17,8 39.2
10 6 21,6 47.6 22,5 49.6
5 3 25,2 55.5 25,4 56.0
2 1 28,1 61.9 32,0 70.5
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5.4.4.3 Tyres, manufactured by Michelin (X Crane +)
Michelin tyres
(16.00 R 25)
Designation 174F
(131 psi)
Tread X Crane +
Maximum speed
On Road Off Road
80 50 13,4 29.5 − −
70 44 14,1 31.1 − −
60 37 14,7 32.4 − −
50 31 15,0 33.1 − −
40 25 15,4 33.9 − −
30 18 16,8 37.0 − −
20 12 20,1 44.3 21,1 46.5
10 6 24,1 53.1 26,8 59.1
5 3 28,1 61.9 33,4 73.6
2 1 31,4 69.2 38,0 83.8
5.4.4.4 Tyres, Manufactured by Michelin (XZY)
Michelin tyres
Tyre size 445/65 R 22,5
(18.00 R 22,5)
Designation 169K
(145 psi)
Tread XZY
Maximum speed Axle loads
km/h mph t kip
2 1 20,0 44.1
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5.4.4.5 Tyres, Manufactured by Bridgestone
Bridgestone tyres
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25
(14.00 R 25) (16.00 R 25) (14.00 R 25) (16.00 R 25)
Designation 170F 174F 170F 174F
(131 psi)
Tread VHS
Maximum speed
On Road Off Road
km/h mph t kip t kip t kip t kip
80 50 12,0 26.4 13,4 29.5 − − − −
70 44 12,6 27.8 14,0 30.9 − − − −
60 37 13,2 29.1 14,7 32.4 − − − −
50 31 13,4 29.5 15,0 33.1 − − − −
40 25 13,8 30.4 15,4 33.9 − − − −
30 18 15,0 33.1 16,7 36.8 15,0 33.1 16,7 36.8
20 12 18,0 39.7 20,1 44.3 18,0 39.7 20,1 44.3
10 6 21,6 47.6 24,1 53.1 22,0 48.5 26,8 59.1
5 3 25,2 55.5 28,1 61.9 25,4 56.0 31,0 68.3
2 1 − − − − 32,0 70.6 38,0 83.8
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Bridgestone tyres
(17.50 R 25)
Designation 170E
(102 psi)
Tread VGT
Maximum speed
On Road Off Road
80 50 9,8 21.6
70 44 12,0 26.4
60 37 13,4 29.5
50 31 14,2 31.3
40 25 14,9 32.8
30 18 15,6 34.4 15,6 34.4
20 12 15,9 35.0 17,8 39.2
10 6 20,1 44.3 22,0 48.5
5 3 23,9 52.7 25,4 55.9
2 1 − − 28,8 63.5
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5.4.4.6 Tyres, Manufactured by Magna
Magna tyres
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25
(14.00 R 25) (16.00 R 25) (14.00 R 25) (16.00 R 25)
Designation 170F 174F 170F 174F
Tyre pressure 10.0 bar 9.0 bar 10.0 bar 9.0 bar
(145 psi) (131 psi) (145 psi) (131 psi)
Tread MA03
Maximum speed
On Road Off Road
km/h mph t kip t kip t kip t kip
80 50 12,0 26.4 13,4 29.5 − − − −
70 44 12,6 27.8 14,1 31.1 − − − −
60 37 13,2 29.1 14,7 32.4 − − − −
50 31 13,4 29.5 15,0 33.1 − − − −
40 25 13,8 30.4 15,4 33.9 − − − −
30 18 15,0 33.1 16,8 37.0 18,4 40.6 18,6 41.0
20 12 18,0 39.7 20,1 44.3 20,3 44.8 20,6 45.4
10 6 21,6 47.6 24,1 53.1 24,2 53.4 28,6 63.1
5 3 25,2 55.5 28,1 61.9 27,0 59.5 33,2 73.2
2 1 28,1 61.9 31,4 69.2 30,7 67.9 36,6 80.7
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5.4.4.7 Tyres, Manufactured by Techking
TechKing
(16.00 R 25)
Designation 174F
(131 psi)
Tread ETGC
Maximum speed
On Road Off Road
80 50 13,4 29.5 − −
70 44 14,1 31.1 − −
60 37 14,7 32.4 − −
50 31 15,0 33.1 − −
40 25 15,4 33.9 − −
30 18 16,8 37.0 19,0 41.9
20 12 20,1 44.3 20,6 45.4
10 6 24,1 53.1 27,0 59.5
5 3 28,1 61.9 33,2 73.2
2 1 31,4 69.2 36,2 79.8
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5.4.5 Driving with Uneven Axle Loads
Uneven axle loads have a negative effect on the handling of the

crane.
The braking system is designed for even axle loads of 12 t

(26.4 kip) in accordance with EC guidelines and German
road traffic regulations.
Different axle loads at the front and rear represent a devia-

tion from the approved crane configuration. The vehicle
handling will deteriorate to a greater or lesser degree, de-
pending on the degree of deviation.
The larger the differences, the more serious the deteriora-
tion. Drive with appropriate caution and reduce the driving
speed; if necessary, walking speed must be maintained.
React to poor road conditions by further reducing the driving
speed.
Axle load ratios, heaviest axle : lightest axle > 2:1 are not al-
lowed as they cannot be properly handled from a driving per-
spective.
Any deviating driving states must be listed under “Defined
driving states” or require our express permission from case
to case.
In the case of uneven axle loads, the steering can be overloa-

ded at specific points. This can result in damage to the stee-
ring.
Caution when braking!

Apply force evenly when braking. Sudden and abrupt ap-
plication of the brake pedal can cause various wheels to
lock; the vehicle could skid.
Caution when steering!

When driving around corners, the vehicle drifts towards
the straight−ahead steering position.
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5.4.6 Driving with Reduced Axle Loads
Reduced axle loads have a negative effect on the handling of the

vehicle.
Brakes:
Risk of accidents!
The braking system is designed and approved for axle
loads of 12 t (26.4 kip). At lower axle loads, the crane is
overbraked.
Vehicles without ABS:

Abrupt use of the brake pedal could cause all the wheels
to lock suddenly. The lower the axle loads, the greater
the risk of the axles locking.
Use the brakes therefore with care, as appropriate to the
situation!
Vehicles with ABS:

The braking effect becomes less satisfactory.
Steering:
Risk of accidents!
The steering behaviour is changed.
The steering system is lighter and reacts more quickly
when axle loads are reduced. It becomes less smooth.
Risk of damage!
There is a risk of damage to the steering components; e.g.
as a result of external resistance at the wheels.
Suspension system:
Risk of accidents!
The standard−equipped suspension system is designed
for axle loads of 12 t (26.4 kip). The suspension becomes
”harder” with lower axle loads. When axle loads are less
than 7 t (15.4 kip), the crane behaves as though the sus-
pension were locked. The crane may begin to skid.
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There is a way to adjust the suspension system permanently to

the reduced axle loads. The charging pressure of the accumula-
tors must be adapted for this purpose. If your machine is desi-
gned for this, you will find corresponding information on the hy-
draulic circuit diagram or in the corresponding lubrication and
maintenance instructions in the ”Hydraulic system” section. If no
information concerning this is available, appropriate values can
be obtained on request.
Risk of accidents!
If the crane is to be moved again with axle loads of 12 t
(26.4 kip), then the preliminary tension of the suspension
accumulator must be modified again accordingly.
If the crane is driven alternately with 2 axle load states, the crane
can be optionally equipped so that the suspension can be swit-
ched between the 12 t (26.4 kip) axle load configuration and the
axle load configuration with reduced axle loads per switch actua-
tion.
A corresponding switch is then located in the driver’s cab.
Additional information on this topic can be found then in section
10 ”Suspension system”.
Behaviour of the driver with reduced axle loads:
Risk of accidents! Risk of skidding!

If the charging pressure of the accumulators of the suspen-
sion system is not reduced, the maximum driving speed
must be reduced. The lower the axle load, the slower the
driving speed must be. For axle loads of less than 8 t
(17.7 kip), the permitted maximum speed is still no more
than 30 km/h (18 mph). The maximum speed must be redu-
ced even further with additional axle load reduction and/or
poor road conditions.
Risk of accidents! Risk of skidding!

For vehicles without ABS:
If the charging pressure of the accumulators of the suspen-
sion system is reduced (manually or with switchover), the
maximum driving speed must be reduced to 50 km/h
(31 mph).
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5.4.7 Driving with Axle Loads over 12 t (26.4 kip)
Driving with axle loads of more than 12 t (26.4 kip) is always

an exceptional condition and is only permitted for short
stretches.
Drive extremely carefully and reduce your maximum driving
speed.
The correlation between the technically possible axle loads
and the maximum driving speed must be observed.
All chassis parts / components are designed and authorised for

axle loads of 12 t (26.4 kip).
Axle loads of 12.5 t (27.6 kip) mean that the approved crane con-
dition has already been exceeded.
Axle loads over 12 t (26.4 kip) mean:
− Increased stress
− Overloading of the tyres (for certain sizes)
− Extended braking distances / risk of fading
Increased stress
Axle loads of more than 12 t (26.4 kip) lead to increased loads on

the steering, axle suspension, axles, wheel hubs, bearings, sus-
pension system, suspension cylinders, brakes, wheels and tyres.
This means a considerable reduction in durability and service life
for the parts in question.
Wear on brake linings is particularly increased. There is a risk of
overheating (fading).
Loading / overloading of tyres
Abrupt stress (for example, driving against kerbs), bead damage

or cutting damage must be avoided under these more difficult
working conditions.
Damage to a tyre can result from the combination of overloading

and / or increased speed. Damage following a handling error
might not be immediately apparent. Damage is cumulative over
time and can eventually lead to sudden catastrophic failure follo-
wing a relatively minor incident.
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Risk of accidents as a result of tyre damage!

Tyre damage must be rectified by professionals.

Observe the maximum highest speed permitted for the ac-
tual axle load (see segment “Possible axle loads / permit-
ted speeds” in this section). Failure to comply with these
instructions can result in the tyres being overloaded and
bursting.
Extended braking distances / risk of fading
The brake system of this crane is designed in accordance with

EC directives and German road traffic regulations for an axle load
of 12 t (26.4 kip).
Extreme risk of accidents due to extended braking distan-

ces!
At axle loads above 12 t (26.4 kip) the braking deceleration
as required in accordance with EC partial operating appro-
val, can no longer be guaranteed / maintained.
The braking distances are, as a result, considerably or
even extensively extended and there is a risk of overhea-
ting (fading).
5.4.7.1 Driving with Axle Loads of up to 12.5 t (27.6 kip)

Observe the maximum highest speed permitted for the ac-
tual axle load (see segment “Possible axle loads / permit-
ted speeds” in this section). Failure to comply with these
instructions can result in the tyres being overloaded and
bursting.
Possible driving speeds are permitted only within existing tyre li-
mit values; i.e. the maximum possible speed must not be driven
if the tyres are not approved for that speed (for certain axle loads).
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5.4.7.2 Driving with Axle Loads up to 16.5 t (36.4 kip)
This technically possible driving condition does not meet the re-
gulations of the German road traffic licensing regulations or the
EEC directives.
Therefore driving in this region is only permitted on private roads
and grounds. These must have a sufficient load−bearing capa-
city and must be sufficiently level (e.g. no potholes).
If the crane is driven with axle loads above 12.5 t (27.6 kip), the
following points must be observed:
− Only short driving stretches are permitted at any time.
− Before driving, take the axle loads from the listed driving con-
dition or recalculate them based on the current configuration
using the weight table.
The determining factor is always the most heavily loaded
axle.
− The crane must not be steered on the spot or when on very
uneven ground.
− Calculate the maximum permitted speed based on the cur-
rent axle load and observe this maximum while the crane is
driven.
− The driver must acquaint himself in−depth with the changed
driving / braking behaviour (for example, longer brake paths).
− Reduce the maintenance intervals; carry out inspections
more often.
Risk of damage as a result of premature wear!
Risk of accidents as a result of worn components!
Special instructions / warnings in this respect are contained
in subsection “Shorter maintenance intervals for axle loads
above 12.5 t (27.6 kip)”.
The information given here must be complied with at all ti-
mes.
The crane manufacturer shall not be held liable for damage resul-
ting from premature wear when driving with axle loads above
12.5 t (27.6 kip).
Crane operators / crane drivers carry sole responsibility when the

crane vehicle is driven with axle loads > 12.5 t (27.6 kip).
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5.4.8 Shorter Maintenance Intervals for Axle Loads over

12.5 t (27.6 kip).
Even when observing the specified, axle−load−dependent dri-

ving speeds, driving with axle loads > 12.5 t (27.6 kip) is only per-
mitted temporarily.
Driving with axle loads of more than 12.5 t (27.6 kip) is always
an exceptional condition and is only permitted for short
stretches; even if higher values are permitted by special na-
tional regulations pertaining to axle loads.
The crane manufacturer shall not be held liable for damage resul-
ting from premature wear when driving with axle loads above
12.5 t (27.6 kip).
Risk of damage as a result of premature wear!

If the crane is driven with axle loads above 12.5 t (27.6 kip),
steering, axle suspension, axles, wheel hubs, bearings, sus-
pension system, suspension cylinders, brakes, wheels and
tyres must be checked regularly − at least once every 3
months however − for damage and wear.
This applies especially to the setting of the steering geome-
try and the brake linings!
Risk of accidents as a result of worn components!

When defects are detected, they must be dealt with immedia-
tely to prevent safety risks, further wear or irreparable da-
mage to the component.
The steering geometry and other components relevant to the

safety of the crane may only be checked and, if necessary,
repaired by our customer service technicians or a corres-
ponding specialist workshop.
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5.5 Driving on Public Roads

(Z 115 017)
Make sure that the vehicle is driven with caution and fore-
sight (avoiding regular acceleration and braking).
The technically permitted maximum speed for this vehicle is 80

km/h (50 mph).
The permitted maximum speed is dependent on the road traffic
regulations valid in the country in which the crane is driven.
When driving on public roads, the crane vehicle must be in a very

specific transport condition.
The transport condition of the mobile crane depends on the road
traffic regulations applicable in the country in which the crane is
operated.
In countries with EEC approval regulations, axle loads of

max. 12 t (26.4 kip) are permitted when driving on public
highways.
In countries with different national regulations the permitted
axle loads may actually be lower than 12 t (26.4 kip).
The crane operator / driver must ensure that the axle loads
are within the permitted limits and that they are evenly distri-
buted and that any additional restrictions are observed.
If the axle loads are exceeded or other regulations are not
followed, they carry sole responsibility.
As a rule, the specifications in the section “Axle loads /

speeds / tyres” and the corresponding subsections must be
observed exactly.
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In the interest of safety, pay special attention to the cor-

relation between technically possible maximum axle
loads and the maximum speed.
Adapt the driving speed to the actual axle loads and the
route conditions.
5.5.1 Driving with Axle Loads of 12 t (26.4 kip) (EEC Direc-

tive)
In accordance with the EEC directive and the German road

traffic licensing regulations, axle loads are permitted of up
to 12 t (26.4 kip).
5.5.2 Driving in the United Kingdom (UK Approval)
In the United Kingdom (UK) special approval regulations apply.
In the United Kingdom (UK) − as a result of a special national

regulation − other (higher) axle loads can occur.
Instructions on applying the national regulation ”Special type ge-

neral order” can be found in part 3, in the additional section 51
”Driving in the UK”.
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5.5.3 Checks before Starting Any Journey on Public Roads
Risk of accidents! Risk of injury! Risk of damage!

The checks and tasks described in the following must be
carried out in order to prevent the corresponding risks.
Before every journey on the road, always ensure that the follo-
wing is in place:
− The “Checks before starting any journey” (5.2, from page 1)
must be carried out.
When driving on public roads, main boom and steering must
be in the “Driving state” and the mirror must be in the “Travel
position”, no matter what speeds are driven.
− All transport locks must be applied (see “Transport locks“, 5.3
on page 11).
− The fork ends’ edge covering (1, Z 115 300) of the main boom
extension (optional) folded in the transport position must be
fitted (country−specific, see section 21).
− In countries in which it is a regulation to have a tachograph,
a tachograph chart or a driver’s card must be inserted.
− Emergency devices, for example, the first aid box, warning
triangle, fire extinguisher must be accessible and complete.
− The housing cover of the outrigger controls on the side of the
chassis must be closed.
− The ladder (optional) must be hung in its holding devices and
fixed with rubber catches.
Take care with the routes in regard to vehicle height and

width.
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5.6 Defined Driving Conditions
Defined driving conditions are assigned in accordance with natio-

nal regulations or other appropriate requirements.
Driving conditions beyond these can be determined on a case by
case basis using the weight table (component weights) (see un-
der “axle loads / speeds / tyres”).
5.6.1 Total Weight Driving Configuration 36 t (79.4 kip)

(Approval Condition in Accordance with German
Authorisation)
Crane with:
− drive 6x4x4
− tyres 445/65 R 22,5 (18.00 R 22,5)
− Main boom in transport condition
− main boom extension 13 m (42.7ft)
− hook block (1sheave) on bumper
− counterweight 5.45 t (12.0 kip) on the superstructure frame
Axle loads:
− axles 1 to 3: 12 t each (26.4 kip)
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5.7 Driving downhill
− Reduce speed and select a lower gear.

− Observe engine speed. Do not ”overrev” the engine.
− Use the non−wearing sustained−action brake (exhaust
brake).
− Only use the service brake briefly as an auxiliary brake.
Before downhill driving, the driving range must be selec-

ted in the drive in good time with which the crane can be
maintained at a constant speed on the downhill stretch.
The effect of the exhaust brake depends on the engine speed.

The higher the speed, the more improved the braking effect.
The service brake must only be used to brake the crane

until the speed is reached at which the transmission
shifts down to the next gear step.
The service brake must not be used for sustained pe-
riods under any circumstances. Risk of fading!
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49
95
H319
Z 115 302
62/99 40C−1050−891c_en
Driving 5
5.8 Driving over hill summits
(Z 115 302)
When driving over hill summits, it must be ensured that all axles
remain in contact with the ground.
The crane operator bears sole responsibility for any damage to
the crane chassis caused by ”exceeding the maximum suspen-
sion travel” or ”lock position of the suspension” and exceeding the
maximum axle loads when an axle lifts off the ground.
When driving over hill summits, it is prohibited:

− to lock the suspension (crane control in state (”Opera-
tion of the crane”)
− Axle loads over 14 t (30.9 kip)
Otherwise components MAY BREAK!
If, however, an axle should lift off the ground, proceed as follows:
1. Stop the crane in a straight position and actuate the longitudi-

nal differential lock. To do so, actuate switch (49); Indicator
light (95) lights up.
2. Drive over the summit at walking pace (max. 5 km/h / 3 mph).
Whilst driving over the summit:

− Avoid turning the steering
3. After driving over the hill summit, stop the crane immediately
and switch off the longitudinal differential lock again. To do so,
actuate switch (49); the indicator light (95) goes out.
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46
26.1
26 26.3
26.4
26.5
26.6
129 26.9
26.8
26.7
136 137
Z 115 266 Z 115 262
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Driving 5
5.9 Driving a Stuck Crane Free
(Z 115 266, Z 115 262)
If the crane is stuck on difficult terrain, it can driven ”free” by dri-

ving forwards and backwards.
Action steps for driving the crane free:
1. Engage off−road gear (press dual button (46)).
2. Press “D“ (26.7) on the keyboard (26).
3. Apply careful pressure to the accelerator pedal (1).

Move the vehicle as far forwards as possible.
4. Apply the service brake and stop the vehicle.

Engine idling!
5. Wait for standstill.
6. Press “R“ (26.9) on the keyboard (26).
7. Apply careful pressure to the accelerator pedal (1).

Move the vehicle as far backwards as possible.
8. Apply the service brake and stop the vehicle.

Engine idling!
9. Wait for standstill.
Repeat this procedure, as long as the crane is gaining more di-

stance at each change of direction.
If the wheels are spinning, stop the attempt; the crane will have
to be towed free.
”Towing free”: see section 13 of this operating manual.
You can only switch to a different direction of travel if the

wheels are at a standstill (engine idling).
If the vehicle is rolling, it will not shift gears; the transmis-
sion shifts into ”Neutral”.
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5.10 Checking the Operation Functions while Driving
All indicator lights / displays are in the dashboard of the crane

operator’s cab (see section 3).
While driving, the driver must constantly observe the display in-
struments and monitoring elements.
5.11 Driving on the Construction Site

Observe the maximum highest speed permitted for the
actual axle load (see segment “Possible axle loads / per-
mitted speeds” in this section). Failure to comply with
these instructions can result in the tyres being overloa-
ded and bursting.
5.11.1 Driving in the Transport Condition
Notes on ground conditions:
The ground conditions must be suitable for the individual axle

loads as well as for the total weight.
The route must be even and the ground must be able to support
the load.
When driving with the steering program “Construction site

operation”, deviating regulations apply (see section 8).
Differential locks may be engaged only for a brief period of time

in order to bypass obstacles and when driving straight ahead.
Driving speeds over 5 km/h (3 mph) overload both the tyres and
the drive.
After passing the obstacle, the differential locks must be disenga-
ged again immediately.
The crane must be stationary when switching the differential

locks on and off.
The crane must be in the “Driving operation” state. The hydraulic

suspension must be set to “level position” (see section 10).
When driving over hill summits or ramps, the same rules ap-
ply as for ”Driving over hill summits” on the road.
The instructions in that section must be followed.
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5.11.2 Driving in the configured condition “Driving when

rigged” (with main boom / equipment erected)
You may only drive with an erected main boom and possibly fit-
ted devices without load.
5.11.2.1 Instructions on ”Driving in the configured condition”
(Z 115 303)

Risk of overturning!
The overall stability of the system is determined by the
tyres during the procedure “Driving in the configured
condition”.
− The tyres may not show any signs of damage.
− Due to the high pressure, the tyres are greatly defor-
med. The elastic movements of the tyre walls lead to the
rigged crane swinging. This means increased risk of til-
ting!
You must therefore drive with utmost care.
“Driving in the configured condition” with steering program

“construction site mode” (switch (50) actuated) is PROHIBI-
TED!
The ground must be even and free of dips, it must also have suffi-
cient load−bearing capacity.
The road gradient may not exceed the following values:

− 2 % in direction of travel
− 1 % laterally (without additional equipment)
− 0.5 % laterally (with additional equipment)
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(Z 115 019, Z 115 291)
When driving in the configured condition:
− The main boom must be aligned in accordance with the de-

tails in the driving tables (see below).
− Apply the slew gear parking brake (110, S 14) (Z 115 019).
− The hook block must be secured on the chassis e.g. on the
manoeuvring / trailer coupling, or also on the outriggers (tele-
scoped out) to prevent swinging movements (or it must be rai-
sed).
− To set the crane down on the wheels from the outriggers, only
the outrigger cylinders are retracted, when starting from the
supported configuration, until the outrigger pads are located
close above the ground. The outrigger struts remain in outrig-
ger width, just as they were when the crane was previously
supported.
Unless otherwise specified in the driving tables, the large ou-
trigger span has been used as the basis for calculating the
driving tables.
− Keep the outrigger pads close above the ground while driving
the crane.
If the outrigger plate is not just above the ground with the
support strut (2) slid out accordingly or if the ground (un-
der the outrigger plate) does not have sufficient load−
bearing capacity, there is a risk of tilting if the crane
starts to rock during driving.
When driving, ensure that the position of the supports
and of the outrigger pads is correct and that the ground
has sufficient load−bearing capacity for the entire “tra-
velling distance” of the outrigger plates.
− All suspension cylinders must be in the road travel position

(”Crane in the level position”).
Control must be switched to “Operation of the crane”. For pro-
cedure and warning notes, see segment “Locking the sus-
pension for “Driving in the configured condition” in section 10
“Hydraulic suspension”.
The suspension is automatically locked by switching crane con-

trol over to the state “Operation of the crane”.
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When “Driving in the configured condition” (crane not
supported on outriggers; free on wheels), the main boom
may not be turned out of the vehicle’s longitudinal axle.
− Take care when there are side winds, particularly if they are
in the same direction as the prevailing transverse gradient.
− Driving speed only at walking pace.
When driving with a locked suspension, speeds

> 5 km/h (3 mph) would lead to heavy damage on the chas-
sis!
The following tables concerning superstructure position, boom

angles and lengths and axle loads correspond to the following
configuration:
Basic unit with:

− Counterweight in accordance with corresponding table page.
− Calculated hook block in accordance with corresponding ta-
ble sheet.
− Corresponding equipment (e.g. main boom extension).
Driving the crane with configurations other than those speci-

fied in the following table sheets (driving tables) is PROHIBI-
TED!
The driving tables are available in metric or alternately in Bri-

tish / American dimension units in the section. When using
the tables, make sure to use the correct units of measure-
ment.
In general balanced loads, as specified in the following table, are

to be aimed for.
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Z 115 333
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Driving 5

(in SI − Units)
(Z 115 333)
Axle load table: Correlation of the axle loads with the boom posi-
tion and configuration.
A B C D max. axle load min. axle load

7,8 m 30° 7,1 m 0° 9,6 t 9,0 t
7,8 m 43° 13 m 0° 9,7 t 9,1 t
7,8 m 0° 7,1 m 0° 10,7 t 9,7 t
7,8 m 29° 13 m 0° 10,5 t 9,8 t
7,8 m 32° 7,1 m 30° 9,6 t 9,0 t
7,8 m 48° 13 m 30° 9,7 t 9,1 t
7,8 m 30° 7,1 m 30° 11,2 t 8,6 t
7,8 m 33° 13 m 30° 10,6 t 9.9 t
* Superstructure to the front − Main boom to the front
The following hook block is included in the calculation:

− 1−sheave, type 16 (250 kg / 551 lbs)
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Z 115 333
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Driving 5

(in British / American Dimensions)
(Z 115 333)
A B C D max. axle load min. axle load

25.6 ft 30° 23.3 ft 0° 21.2 kip 19.8 kip
25.6 ft 43° 42.7 ft 0° 21.4 kip 20.1 kip
25.6 ft 0° 23.3 ft 0° 23.6 kip 21.4 kip
25.6 ft 29° 42.7 ft 0° 23.1 kip 21.6 kip
25.6 ft 32° 23.3 ft 30° 21.2 kip 19.8 kip
25.6 ft 48° 42.7 ft 30° 21.4 kip 20.1 kip
25.6 ft 30° 23.3 ft 30° 24.7 kip 19.0 kip
25.6 ft 33° 42.7 ft 30° 23.4 kip 21.8 kip
* Superstructure to the front − Main boom to the front
The following hook block is included in the calculation:

− 1−sheave, type 16 (250 kg / 551 lbs)
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Driving 5
5.11.3 Driving the Crane in the Operating Mode “360 De-

grees" (without Load)
5.11.3.1 General Instructions
Risk of tilting!
− It is expressly prohibited to raise loads when driving in
the operating mode ”360° free on wheels”.
− It is only permitted to raise loads when the vehicle is at
a standstill.
− The minimum radius, depending on the load capacity
table, may not be undercut (risk of tilting to the rear!).
− It is possible to rotate the superstructure in the opera-
ting mode ”360o free on wheels". Watch out for uncontrol-
led slewing movements of the superstructure.
(Z 115 303)

The overall stability of the system is determined by the
tyres during the procedure “Driving in the configured
condition”.
ting!
“Driving in the configured condition” with steering program

“construction site mode” (switch (50) actuated) is PROHIBI-
TED!

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5.11.3.2 Procedure
Initial situation:
− The main boom extension is folded on the side on the main

boom in the transport position or removed.
− Suspension is “fully retracted” (suspension cylinder fully rai-
sed (see sections 10 and 11))
− Main boom length and counterweight set in accordance with
the load table ”360° free on wheels”.
Procedure:
− Select the program for mobile loads: ”360° free on wheels”.

− Turn the main boom to the rear.
− Support struts retracted. Support cylinders extended so that
the outrigger plate is just above the ground.
Risk of tilting during driving!

− The crane may not be driven with the main boom slewed
out of the vehicle’s longitudinal axle.
− The load displayed in the LLD in the operating mode
”360° free on wheels” is a configured load during dri-
ving. It may not be raised.
− The loads from the load capacity tables ”360° free on
wheels” may only be raised when the crane is at a
standstill.
− If a tyre bursts during driving and the outrigger plate is
not just above the ground.
− Preselect the gear and release the retaining brake.

− Driving to the location of operation.
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5.11.4 Driving the crane with a load
(Z 115 303)

The overall stability of the system whilst ”Driving the
crane with a load” is determined by the tyres.
ting!
”Driving the crane with a load” with the ”Construction−site

operation” steering program switched on (switch (50) actua-
ted) is PROHIBITED!

CAUTION!
The ground must be even and free of dips and rises.

That could result in damage due to overloading!
Do not drive in the configured condition if ground conditions
are uneven!
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Z 115 404
110
S14
Z 115 019
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During driving, the support struts are extended to the large outrig-
ger support area and the outrigger plates must be held just above
the ground.
If the crane starts rocking during driving, there is a risk
of tilting.
Ensure that the ground − under the “travelling path” of
the outrigger plate as well (support struts extended, ou-
trigger plate just above the ground) − is sufficient for the
entire journey.
5.11.4.1 Procedure
(Z 115 404, Z 115 019)
− Support the crane on outriggers in accordance with the load

tables and the load and fit the corresponding counterweight.
− When supported on outriggers: Pull up ”fully retracted” sus-
pension (see sections 10 and 11).
Risk of damage!
Driving the crane with completely retracted suspension cy-
linders (suspension cylinder ”fully retracted”) is permitted
only at a slow walking pace (2 km/h; 1 mph).
− Pick up the load and set it down behind the crane.
On the display of crane control the display ”0°” (X, Z 115 404) will
appear.
− Apply the slew gear parking brake (110, S14), (Z 115 019).
It is prohibited to rotate the superstructure in this position!
In the operating mode ”Mobile 0°" to the rear, there are only car-
rying loads for the boom length of 7.8 m.(25.6 ft) for "synchro-
nous telecontrol operation. Telescoping out is prevented.
− Set the load limit device to ”mobile 0° mode (to the rear)”, (see
section 15).
The minimum operating radius specified in the load ca-

pacity table must be maintained at all times!
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Z 115 404
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(Z 115 291)
− Set the crane on wheels.

To do so, retract the support cylinders so that the outrigger
plates are just above the road surface.
The extension state of the outrigger struts (2) remains unchan-

ged so that the outrigger support width remains unchanged.
The suspension cylinders of the crane chassis remain telesco-
ped in the state ’fully retracted’.
(Z 115 404)
When the crane is not stabilised (free on wheels), then
the main boom must not be rotated out of the vehicle’s
longitudinal axis.
− Pick up load again and keep suspended above the ground for
a short while.
− For the LLD display to be maintained while the crane is mo-
ved, the crane must remain switched to ”Crane operation”.
− The steering is operational as soon as a gear is engaged.
The load capacities specified in the load table under ”free−

standing” (note the corresponding symbol) must not be ex-
ceeded.
Risk of accidents!
Under no circumstances:
− the engine is permitted to be switched off with suspen-
ded load.
− may the crane operator leave the crane operator’s cab
when there is a hanging load.
− may the crane be driven to its destination with a load hanging

to the rear.
− Keep the outrigger pads close above the ground while driving
the crane.
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(Z 115 291)
If the outrigger plate is not just above the ground with the
support strut (2) slid out accordingly or if the ground (un-
der the outrigger plate) does not have sufficient load−
bearing capacity, there is a risk of tilting if the crane
starts to rock during driving.
When driving, ensure that the position of the supports
and of the outrigger pads is correct and that the ground
has sufficient load−bearing capacity for the entire “tra-
velling distance” of the outrigger plates.
For driving, ensure there is sufficient clearance between outrig-

ger plates and the ground. The same applies to the load.
The load must not swing while driving. If necessary, lash it tight!
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Z 53 769
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5.12 Dolly Coupling / Supply Connections (Optional)
(Z 53 769)
If the crane is equipped for a dolly to be fitted, the following equip-

ment is available at the rear of the vehicle:
1 Electric connection for dolly lighting equipment, rear
2 Compressed air connection (yellow) for brake line
3 Compressed air connection (red) for supply line
4 ABS socket (7−pin)
If a dolly coupling is part of our scope of delivery:
5 Dolly coupling
Pay particular attention to the road safety of the dolly coupling (5).
Instructions on maintenance and care can be found in part 2 of
this publication.
Check the dolly coupling daily for longitudinal play.

Longitudinal play is not permitted. Risk of dolly ripping free!
5.12.1 Coupling and Decoupling a Dolly
The coupling and uncoupling, operation and maintenance of

a dolly is exclusively the sole responsibility of the crane ope-
rator. The crane operator is responsible for careful perfor-
mance of the coupling and uncoupling sequence, operation
and maintenance in accordance with national regulations.
The instructions of the manufacturer must be followed.
The dolly must be attached to the crane in such a way that
no dangers arise. For instance, the axles of the dolly must be
evenly burdened, in order to achieve an optimum braking ef-
fect.
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Z 53 769
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Risk of crushing!
The area between towing vehicle and dolly is not visible
during the steps in which the towing vehicle is moved.
It may be advisable to assign someone the job of monito-
ring that area.
Initial situation:
− Dolly is switched off with parking brake actuated and wheel
chocks in place.
Risk of accidents!
Automatic braking by disconnecting the brake line is not
sufficient.
Sequence for coupling:
1. For dollys with rotating towbars:

Release front axle brake (if present).
Risk of accidents!
When the front axle brake is released, the towing fork
can strike to the side if the wheels are not on a smooth,
level surface.
2. Move the towing vehicle up to approximately 1 m (3 ft) from

the coupling ring, then use the height adjustment device to
set the coupling ring at the coupling height.
3. Open the coupling on the towing vehicle.
4. Step out of the danger zone between towing vehicle and
dolly!
Risk of accidents!
Never step between the vehicles during the coupling se-
quence!
5. Carry out the coupling by moving the towing vehicle back-

ward, never by using the forbidden method of having the
dolly run up to it!
Risk of accidents!
Due to the extreme risk of accidents, it is prohibited − wi-
thout exception − to allow the dolly to move forward to
couple the vehicles.
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6. Connect the connecting lines:
6.1 Disconnect compressed air connection (yellow; 2) for

the brake line.
6.2 Disconnect compressed air connection (red; 3) for the

supply line.
6.3 Connect the electric connections for trailer lighting (1)

and ABS socket (4).
Risk of accidents!
The connections must be made in the sequence speci-
fied.
The brakes may release if this sequence is not adhered
to.
7. Remove the wheel chocks, release the dolly parking brake,

monitor departure.
Sequence for uncoupling
Uncoupling is accomplished in the same sequence as coupling,

but in reverse, whereby the vehicles should be positioned in a
straight line if at all possible.
Risk of accidents!
− Before uncoupling, first actuate the parking brakes of
the towing vehicle and the dolly!
− Before uncoupling, first put wheel chocks in place.
Sequence for disconnecting the connecting lines:

− Disconnect compressed air connection (red; 3) for the supply
line.
− Disconnect compressed air connection (yellow; 2) for the
brake line.
− Disconnect the electric connections for trailer lighting (1) and
ABS socket (4).
Risk of accidents!
The connections must be removed in the sequence spe-
cified.
The brakes may release if this sequence is not adhered
to.
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a b
3 2 4
5
c
Z 115 306
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5.13 Attaching and Removing the Spare Wheel (Spare

Wheel Holder, Hoist Arrangement, Optional)
(Z 115 306)
There is a spare wheel holder (1) (optional) on the superstructure

behind the driver’s cab for carrying along a spare wheel (2).
In order to attach and/or remove the spare wheel (2) from the
spare wheel holder (1), either the optionally available lifting de-
vice (3) or other equipment (e.g. an auxiliary crane or similar)
must be used.
To remove the spare wheel using the optionally available lifting

device (3), proceed as follows:
− Bring the swinging arm of the hoist arrangement (3) over the
spare wheel (2) into position (Z 115 306 “b”).
− Uncoil winch of the lifting device (3).
− Attach the spare wheel (2) to the hoist arrangement (3) using
the auxiliary reeving rope (4).
− Tighten the rope with the hoist arrangement (3) and remove
the screws (5) on the spare wheel.
Risk of crushing!
Do not stand in the danger zone underneath the suspen-
ded spare wheel until the spare wheel has been safely
placed on the floor.
− Swing the hoist arrangement (3) to the side (Z 115 306 “c”).
When swinging it out, turn the spare wheel (2) to the side
(Z 115 306 “c”).
− Lower the spare wheel (2) and set it on the ground.

Risk of crushing!
The spare wheel (2) must be secured against tipping over
while being moved over the ground.
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c
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(Z 115 306)
The spare wheel (2) is fitted in the same way, but in the opposite
sequence.
The spare wheel (2) must be fastened to the spare wheel hol-
der(1) using screws (5, 3x) (torque 500 Nm / 370 lbf ft).
Attachment/removal of the spare wheel (2) is to be carried out in

corresponding manner with one’s own crane apparatus and/or
an auxiliary crane.
Before slewing the superstructure or before driving the

crane, the hoist arrangement (3) must be brought back into
the transport condition (Z 115 306 “a”).
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Drive 6
40C−1060c_en 1/41
6
Z 115 582
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
2/41 40C−1060c_en
Drive 6
6 Drive
(Z 115 582)
The drive gearbox (1) an automatic gearbox is flanged with the

engine via a torque converter with lockup clutch. A two−stage
distributor gear (2) is subsequently connected to this
combination.
6.1 Drive Gearbox
6.1.1 Description of the System
(Z 115 262)
The driving range of the gear can be manually preselected using

the keypad so that no clutch is required for this version.
The switching operation is carried out by the electronic gearbox
control in dependence of the engine speed.
The forces required for the switching operation are supplied by

the hydraulic system.
The driver has access to all the necessary system information via
the display (26.1) of the keypad (26), e.g. neutral, selected
driving range, faults and diagnosis information.
40C−1060c_en 3/41
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26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
26
27
1
10
Z 115 405
4/41 40C−1060c_en
Drive 6
6.1.2 System Layout
(Z 115 262, Z 115 405)
The transmission system consists of a combination of

hydrodynamic torque converters with lockup clutch and a
downstream automatic gearbox.
The vehicle components keypad (26) with display, the engine

electronics, the electronic brake system with wheel speed
sensors, the accelerator (1) and the brake pedal (10) are also part
of the system.
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26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
6/41 40C−1060c_en
Drive 6
6.1.3 Driving Range Selection
6.1.3.1 Keypad
(Z 115 262)
The keypad is for

− the selection of the driving range
− Calling the ”error” display
− Selecting the driving modes ”POWER” and ”ECONOMY”
The following gears can be selected using the keypad (26) in the
cab.
− R − reverse
− N − neutral (no gear is applied)
− D − forwards
− Driving ranges ”1” to ”6”
The keypad also has selection options for the automatic change
of gear.
These can be selected by pressing the ”MODE” key:
− ”ECONOMY” driving programme (for economical driving with
low fuel consumption) (standard setting: start in 2nd gear).
The indicator (26.3) is off.
− ”POWER” driving programme (here higher revs are selected
for shifting gear to enable better acceleration). The indicator
(26.3) is on.
When changing down to lower gears, use the selection key

only in stages.
40C−1060c_en 7/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262 Z 115 267
8/41 40C−1060c_en
Drive 6
6.1.3.2 Neutral Position “N”
(Z 115 262)
To park the crane and to start the engine, ”N” must be selected
at the keypad (26).
Preselect neutral position only when the crane is stationary.

Do not preselect the neutral position while travelling.
6.1.3.3 Reverse Gear ”R”
Select ”R” to reverse.
Actuate the foot brake when shifting the gear.must bestationary.
If switch (Z 115 267) ”Engine speed limit” (optional) is available,

theengine speed is automatically reduced to a maximum of
1200 min −1 (rpm) during reversing.
6.1.3.4 Drive Position ”D”
Drive position ”D” is always selected when driving the crane on

the road under normal conditions. The transmission control then
switches between the power stages “1” to “6” to the power stage
best suited to the current speed.
Actuate the foot brake when shifting from position ”N” to position
”D” so that the vehicle does not begin to move unintentionally.
6.1.3.5 Driving Range Selection ”1” to ”6”
When driving on slopes or when the road is icy, you can avoid
changing over to the higher switching stages by pressing keys
(26.5) and (26.6) for preselecting the driving ranges ”5”, ”4”, ”3”,
”2” or ”1”. This causes the higher stages of the transmission to be
locked; the transmission only engages up to the preselected
gear.
The transmission can be stepped up from one drive position to

the next without the foot brake being actuated.
In order to apply a lower drive position, the vehicle can be braked
using the service brake until the gear transmission has switched
to the preselected maximum drive position.
Always observe:
When driving downhill, select the same ”maximum drive position”
(= driving range) with which one would also drive uphill.
40C−1060c_en 9/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
d 1
Z 56 089
10/41 40C−1060c_en
Drive 6
6.1.4 “Transmission Information” Display (26.1)
(Z 115 262)
All operating indicators (executed or preselected functions),

warning information and malfunctions / errors are indicated at the
“Transmission information” display (26.1) with numbers and
symbols.
Malfunctions, see error code table at the end of the section.
6.1.4.1 Operating Indicators
(Z 56 089)
1 On−road position
2 Transmission in neutral
3 Reverse gear
40C−1060c_en 11/41
6
26
27
1
10
Z 115 405
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
67 26.7
Z 115 264 Z 115 262
12/41 40C−1060c_en
Drive 6
6.1.5 Driving and Shifting Gears
If the engine is running and the driving range is

preselected, it is not permitted to leave the vehicle.
6.1.5.1 Starting the Engine
(Z 115 405, Z 115 264)
1. Apply the parking brake (27).
2. Switch on the ignition. (Ignition−starter switch (67), position

“3”)
At “Ignition on”, a self−test of the shifting system is done.
3. Starting the engine
“N” display; Transmission is in “neutral”.
If the engine is not running, driving range settings are not

possible. The automatic gearbox is in neutral position
6.1.5.2 Driving, Driving Forwards
(Z 115 405, Z 115 262)
Starting position:
Apply parking brake (27), engine running, transmission in
“neutral”.
1. Use the keypad (26) to preselect the desired driving range

(you might need to switch to POWER mode to change to first
gear).
The number of the selected driving range is then indicated

at the display.
The shifting system automatically selects the second gear as

programmed starting gear in ECONOMY driving mode.
2. Push the accelerator pedal (1) and at the same time, release
the parking brake (27).
The vehicle can roll away without pushing the

accelerator pedal (1).
3. The vehicle starts to drive (clutch engages automatically).
40C−1060c_en 13/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
26
27
1
10
Z 115 405
14/41 40C−1060c_en
Drive 6
Gear oil temperature and gear range of the gear

transmission
Gear oil Gear test light Gear range
temperature (27.3)
below − 8 °C OFF Neutral (N) reverse
(+17.6 °F) (R) and 2 forward
above − 7 °C OFF all functions
(+19.4 °F) possible
6.1.6 Reversing / Changing the Driving Direction
(Z 115 262, Z 115 405)
You can only shift gear in another driving direction if the

wheels are at a standstill. Engine at idle speed!
If the vehicle is rolling, it will not shift into the reverse gear;
the transmission shifts into “neutral”.
Apply reverse gear:
1. Stop vehicle; wait for standstill; Apply the parking brake (27).
2. Select ”R” using the keypad

“R“ is displayed (26.1)
3. Push the accelerator pedal (1) and at the same time, release
the parking brake (27).
4. The vehicle drives backwards.
As soon as R is pressed at the keypad, the reverse gear warning

signal is emitted.
40C−1060c_en 15/41
6
26
27
1
10
Z 115 405
16/41 40C−1060c_en
Drive 6
6.1.7 Stopping
(Z 115 405)
The vehicle can be braked until it stops using any driving range.
If the accelerator pedal (1) is not actuated, decelerate the vehicle

will decelerate using the service brake (10) until it comes to a halt.
Apply the parking brake (27).
The clutch opens automatically before the vehicle comes to a

halt, so that “stalling” the engine is avoided.
Risk of accidents!
If the vehicle is standing with a running engine and an
engaged gear, it is sufficient to actuate the accelerator
pedal (1) in order to bring the vehicle into motion.
Before leaving the vehicle with the engine running, the

vehicle must be in “neutral” gear and the parking brake
must be applied.
Applying the parking brake while driving on a smooth

surface can bring the engine to a standstill.
The hydraulic steering support is no longer available in
its previous form. A considerable amount of power is
needed for the steering wheel and the steering reacts
more slowly.
40C−1060c_en 17/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7 67
Z 115 262 Z 115 264
18/41 40C−1060c_en
Drive 6
6.1.8 Shutting Down the Engine and Vehicle
(Z 115 262, Z 115 264)
1. Stop vehicle; wait for standstill; Apply the parking brake.
2. Press ”N” (neutral) using the keypad (26).
3. Shut off the engine (ignition−starter switch (67), position “1”)
4. Place wheel chocks underneath (e.g. on inclines)
After “Ignition off”, the system automatically shifts to

neutral position. If no brake is applied, the vehicle can
roll away.
“Ignition off”, special case
If the ignition is switched off while driving, it is not possible to shift

to neutral position. The applied gear remains engaged, the clutch
remains engaged.
When the driving speed falls below a certain limit, the clutch and
the transmission shift into neutral position.
6.1.9 Slow Travel of the Crane
Operate the vehicle in POWER mode for slow driving (e.g.

coupling / uncoupling of a dolly). The gear transmission unit then
switches to the first forward gear.
In addition, the distributor gearbox (see 6.3 as from page 35)

should be switched to off−road gear.
6.1.10 Driving Downhill
Select a suitable gear before starting to drive downhill.
To prevent the engine from overspeeding, the transmission is

equipped with a downshift lock − if it is not possible to shift down,
the vehicle should be braked accordingly.
Do not exceed the rated engine speed of 2700 min−1 (rpm)

when driving on downgrades.
40C−1060c_en 19/41
6
20/41 40C−1060c_en
Drive 6
6.1.11 Towing
The towing operation is described in detail in section 13.

Observe the procedures defined there exactly.
6.1.12 Tow starting
It is not possible to start the engine by towing it along.

As the gear oil pump is not powered when the crane is towed,
there is no oil pressure build−up. The control device is therefore
unable to select a gear tensionally. Equally, of course, there is no
lubricating pressure.
Starting aid with external batteries, see section 5.
6.1.13 Rolling Downhill
Prerequisite for this procedure: a running engine.
Risk of accidents!
If the vehicle moves without preselected driving range −
“N” is displayed − then there is no engine braking effect.
Do not let the vehicle roll in the opposite direction of the

applied gear.
If the vehicle is moving − when the transmission is in neutral

position − after releasing the brakes and you shift from “N“ to “D“,
then the system selects the gear that fits to the speed. The drive
train is “closed” (actuated by force).
6.1.14 Exhaust Brake
The engine braking effect is interrupted when switching

gears. The vehicle can accelerate when travelling
downhill.
The exhaust brake is deactivated by the system when shifting

gears. The converter clutch is open during the shifting procedure.
After shifting gear successfully, the exhaust brake is
automatically switched back on again.
40C−1060c_en 21/41
6
160
165
Z 115 265
22/41 40C−1060c_en
Drive 6
In the first gear (power stage), the converter clutch is open (no
braking effect of the exhaust brake).
In the second gear the converter clutch is open at speeds of
greater than 20 km/h (12 mph) (no braking effect of the exhaust
brake).
From the third gear upwards the converter clutch is open (braking
effect of the exhaust brake available).
The manual limiting of the gear using the switching keypad will
cause the exhaust brake to work from 1100 min −1 (rpm).
6.1.15 Overspeed Protection
(Z 115 265)
To protect the entire drive train from excessive speed, the system
allows only gearshifts that are within a certain range.
Shifting and protective measures are in conjunction with the
permissible engine speed, that can be controlled at the display
unit (MFA10) (160) via button (165).
If speeds are excessive (over−revving), the warning buzzer

sounds until the revs are brought back down to an acceptable
level.
Be sure that the engine does not exceed the permissible

speed range; especially when driving downhill.
The engine can be damaged, if the vehicle accelerates when

going downhill and the engine comes in to the overspeed
range.
Risk of accidents!
The vehicle can accelerate when travelling downhill.
To protect the engine during excessive engine speed, the
system upshifts.
The − appropriately low − gear range in which the crane

can be maintained at a constant speed must be selected
before the crane is driven downhill.
When driving downhill, pay special attention to the
specifications given in section 6 referring to the gear
selection and braking.
40C−1060c_en 23/41
6
26
27
1
10
Z 115 405
24/41 40C−1060c_en
Drive 6
6.1.16 Roller Dynamometer
(Z 115 405)
After driving onto a roller dynamometer (brake dynamometer),

shift the transmission into “neutral”.
When rolling, the system recognises the function “Driving

vehicle”. If a gear is engaged, the clutch engages.
Risk of accidents!
The vehicle can drive off the roller even without the
accelerator pedal being pressed (1).
When rolling, it is not possible to shift into reverse gear.
40C−1060c_en 25/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
26/41 40C−1060c_en
Drive 6
6.2 System Malfunctions / Error Diagnosis
6.2.1 Transmission oil level information
(Z 115 262)
You have the option of having the transmission oil level displayed
via the display of the drive switch.
Conditions
− Engine at idle speed

− Transmission oil is at operating temperature
− Vehicle at standstill
− Transmission in neutral
− Oil level gauge functional
Procedure
1. Press arrow keys (26.5) and (26.6) once together to start the
keypad measurement countdown.
The oil level is displayed at the end of the two−minute countdown.

During the countdown, the display flashes and counts backwards
in a 15−second rhythm (8, 7, 6, 5, 4, 3, 2, 1).
If one of the above−mentioned conditions is not satisfied, the

countdown is broken off. The display then shows one of the
following codes, showing why the countdown has been
interrupted. As soon as all the conditions have been met, the
countdown is continued from the point at which it was interrupted.
The error codes (max. 5) are displayed by a sequence of digits
lighting up in the display (132.1):
Depending on the time when the gears were manufactured, the

possible error messages can be shown in two different ways
(indicated as variant 1 and variant 2).
40C−1060c_en 27/41
6
26.1
26 26.3
26.4
26.5
26.6
26.9
26.8
26.7
Z 115 262
28/41 40C−1060c_en
Drive 6
(Z 115 262)
Display Cause of fault

Variant 1 Variant 2
oL, −, X o, L, 0. X Stabilisation time for the oil level too
short
oL, −, EL o, L, 5, 0 Engine speed (rpm) too low
oL, −, EH o, L, 5, 9 Engine speed (rpm) too high
oL, −, SN o, L, 6, 5 Neutral is not engaged
oL, −, TL o, L, 7, 0 Oil sump temperature too low
oL, −, TH o, L, 7, 9 Oil sump temperature too high
oL, −, SH o, L, 8, 9 Output shaft is turning
oL, −, FL o, L, 9, 5 Fault in oil level sensor*
* This error message (error code) should be reported to the

customer service of Allison Gear Services or of the crane
manufacturer immediately.
2. After the two−minute countdown the gear selection switch

display shows the information on the oil level as in the
following examples:
Display Meaning
o, L, 0, K Oil level is okay
o, L, L, o, 1 Oil level is too low by approx. one litre (0.95
l/ 0.25 gallons (US))
o, L, H, l, 1 Oil level is too high by approx. one litre
(0.95 l/ 0.25 gallons (US))
Low or high fluid level can cause overheating and irregular

shifting patterns.
Exiting the oil level display mode
To exit the oil level display mode, press the neutral button (26.8)
or twice in sequence the buttons with the up and down arrows
(26.5 and 26.6).
40C−1060c_en 29/41
6
46
26.1
26 26.3
26.4
26.5
26.6
129 26.9
26.8
26.7
136 137
Z 115 266 Z 115 262
30/41 40C−1060c_en
Drive 6
6.2.2 Error Codes
(Z 115 266, Z 115 262)
If indicator light (129) comes on, the fault codeshave to be

read off the display of the keyboard.Carry out any required
measures immediately!
To do this, proceed as follows:
1. Stop the vehicle at the next available parking space.
2. Apply the parking brake and leave the transmission in the

same position as it was before the error code was indicated.
3. Leave the engine running at idle speed.
4. The fault codes are called up on the display (26.1) by

simultaneously pressing the arrow keys (26.5) and (26.6)
twice.
If no codes are available, a dash (−) is displayed.
If fault codes exist, these (max. 5) are displayed by the
numbers lighting up continually on the display (26.1).
The sequence for inputting the codes is displayed first,
followed by the two−digit main code and the two−digit
sub−code:
d1, d2, d3... numbers of the fault code
1, 2, 3, 4 4−digit fault code
Each display can be seen for approx. one second. This
process is repeated until the next code is called up by
pressing the MODE button (26.4).
The following overview shows a code display based on the

example of the code 25 11:
First stored code d 1 (digits are shown in sequence),
Main code 2 5 (digits are shown in sequence)
Sub−code 1 1 (digits are shown in sequence)
The displays are continually repeated.
The explanations of the 4−digit fault codes are contained in

the table in part 3 of these instructions.
5. By pressing the neutral button (26.8) or at the same time

pressing the up and down keys (26.5) and (26.6) on the
control pad the display (26.1) switches back to the
transmission display.
40C−1060c_en 31/41
6
32/41 40C−1060c_en
Drive 6
6.2.3 Troubleshooting with the Troubleshooting Table
(see part 3 of these operating instructions)
Detecting and rectifying faults using the error code table requires
basic knowledge in the field of electrical engineering.
The transmission control may only be measured and

checked by trained personnel. Incorrect measurement or
incorrect connection of the cables can lead to damage or
destruction of the ECU (transmission computer) or other
components.
As long as the warranty period applies, faults may only be

rectified by the customer service of Allison Gear Services or of the
crane manufacturer.
Even when the warranty period has expired it makes sense to

have faults inspected and rectified by a service technician from
the crane manufacturer or Allison Gear Services.
The customer or operating agent therefore detects and rectifies

faults at his own risk.
40C−1060c_en 33/41
6
A F
B H
C I
D J
E
Z 40 589
46
26.1
26 26.3
26.4
26.5
26.6
129
26.9
26.8
136 137 26.7
Z 115 266 Z 115 262
34/41 40C−1060c_en
Drive 6
(Z 40 589, Z 115 266, Z 115 262)
6.3 Distributor Gear
The distributor gear is subsequently connected to the actual drive

gearbox.
There is an emergency steering pump at the intermediate shaft
that ensures the steerability of the crane if the engine fails. It is
driven by the rolling crane.
There are two gear levels (on−road/off−road gear).
A = on−road gear, B = drive, C = emergency steering pump 1, D
= front drive, E = differential lock,
F = off−road gear, G = shift cylinder, H = lubricating oil pump, I =
emergency steering pump 2, (not fitted) J = rear drive
6.3.1 Operating the Distributor Gear
Apply the off−road gear early enough (horizontal road and before
entering difficult terrain); and not just when the crane is stuck.
On−road gear, off−road gear and the differential lock can only be
activated when the vehicle is at a standstill (dog−clutching).
On rare occasions, it is not possible to switch from on−road gear
to off−road gear in one go due to the gear teeth position.
To change the position of the teeth in the distributor gear, carry
out the following procedure:
1. Apply the parking brake.
2. Press ”N” (26.8) on the keypad (26): position “N” .
3. Press switch (46).
4. Press “D“ or / and “R“ on the keypad.
Do not push the accelerator pedal (1) (”no acceleration”).
5. If the indicator light (136) is displayed, the gear has been
successfully shifted. The off−road gear is engaged.
40C−1060c_en 35/41
6
46
129
136 137
Z 115 266
36/41 40C−1060c_en
Drive 6
− On/off−road gear
(Z 115 266)
When driving the crane off the road, the all−terrain

transmissioncan be engaged by pressing switch (46). The speed
ratio of the drive in the distributor gear isincreased.
The following conditions must be satisfied before the
allterraintransmission can be engaged:
1. The crane must be at a standstill.
2. The engine must be switched on.
3. The pressure in the compressed air reservoirs must beat
least 5 bar (72.5 psi).
When driving below walking speed or during manoeuvring
operation you should always switch to ”off−road driving” gear
because of the more favourable transmission ratio. This prevents
damage to the clutch.
− Distributor gear in ”on−road gear” position:
The on−road gear is always engaged under normal
circumstances. Indicator light (137) is illuminated.
− Distributor gear in ”off−road gear” position:
Press switch (46). Indicator light (136) is illuminated, indicator
light (137) goes out.
If a switch position for road travel, or all−terrain

transmissionis not definitely indicated by the indicator
lights, thecrane must not be driven. All−terrain transmission
should only be engaged when it isrequired. During normal
road travel, the all−terrain transmissionmust remain off, to
prevent any damage to axles anddistributor gear.
The off−road gear is primarily intended for:

− Driving on terrain
− “Driving with outriggers”
− Driving at the lowest speed possible.
40C−1060c_en 37/41
6
38/41 40C−1060c_en
Drive 6
− Differential lock
The differential in the distributor gear can be locked if the drive

wheels slip in difficult ground conditions.
When locked, there is a rigid connection between forward output
and backward output.
Detailed operating information regarding this can be found in

section 9 of these operating instructions.
Be sure to follow the instructions and regulations

outlined there.
− Neutral position
If towing is required (for certain specific types of damage), the

distributor gear can also be put into neutral position using a
manually actuated pneumatic valve.
For more details, see section 13 “Towing”.
− Driving backwards
Prolonged driving in reverse direction should be avoided. (The

lubricating oil pump does not operate!)
40C−1060c_en 39/41
6
46
129
136 137
Z 115 266
40/41 40C−1060c_en
Drive 6
6.4 Driving a Stuck Crane Free
(Z 115 266)
If the crane is stuck on difficult terrain, it can be driven ”free” by

driving forwards and backwards.
Action steps for driving the crane free:
1. Engage the differential lock (see section 9).
2. Engage off−road gear (press switch (46)).
3. Select drive position ”1” using selector button (26).
4. Press the accelerator pedal and start to drive forwards.
5. Release the accelerator pedal and apply the parking brake.
6. Engage the reverse gear ”R”.
7. Press the accelerator pedal and release the hand brake at

the same time etc.
Repeat this procedure as long as the crane is getting a bit further

with each change of direction.
If the wheels are spinning, stop the attempt; the crane will have
to be towed free.
”Towing free”: see section 13.3 of this operating manual.
You can only shift gear in another driving direction if the

wheels are at a standstill (engine at idle speed).
If the vehicle is rolling, it will not shift gears; the
transmission shifts into “neutral”.
Rocking the crane free is prohibited!
40C−1060c_en 41/41
Brakes 7
40C−1070d_en 1/15
7
125 101
H310
126 27
H310.6
12
10
Z 115 406
2/15 40C−1070d_en
Brakes 7
7 Brakes
The braking system is designed in accordance with German

road traffic regulations and European EU directives for axle
loads of up to 12 tons (26.4 kip).
Ensure therefore that these axle loads are observed.
Never drive with a defective brake system.
7.1 Emergency Pressure Supply − Braking System

(Z 115 406)
Display of the pressure supply
There is a pressure gauge (101) for monitoring proper braking

readiness in the dashboard which constantly informs you with
regard to the existing pressure in the braking system.
Fault / warning displays
If pressure in the braking system drops, warning light (126,

H310.6) ”Pressure in the braking system dropped below 5 bar
(73 psi)” is illuminated.
Risk of accidents!
If the pressure supply in the braking system is too low: Stop
the vehicle immediately there is a serious risk of accidents.
A leaking compressed air brake system endangers
theoperating and traffic safety of the vehicle.
Have the brakesystem checked in a specialist workshop.
40C−1070d_en 3/15
7
125 101
H310
126 27
H310.6
12
10
Z 115 406
4/15 40C−1070d_en
Brakes 7
7.2 Service Brake
(Z 115 406)
The service brake (10) is the brake for normal drivingoperation.

The dual−circuit brake system works on all wheels.
To brake, press down pedal (10) of the brake valve softly.
Immediately after driving, test the brakes on a dry, anti−skid

road surface (service and parking brake). When doing so,
make sure the crane brakes evenly, does not veer to the side
and that brake delay is faultless.
There must be no oil or water on the brake linings. If moisture

has seeped through to the brake linings, apply the service
brake lightly until braking is faultless.
Under no circumstances must the service brake be used

for sustained periods. Danger of overheating (fading)!
When travelling downhill, the service brake may only be

used to brake the crane until the speed is reached at
which the transmission shifts down to the next gear.
This is why you must select the gear before driving
downhill with which the speed of the crane can be
maintained when driving downhill.
Never drive with a defective brake system!
After the brakes have been used more intensively, do not switch
off the vehicle immediately but drive on for a little while in order
to allow the brakes to cool off faster from the driving wind.
40C−1070d_en 5/15
7
125 101
H310
126 27
H310.6
12
10
Z 115 406
6/15 40C−1070d_en
Brakes 7
7.3 Parking Brake
(Z 115 406)
The parking brake (hand brake) (27) must be applied when the
vehicle isparked.
Risk of accidents!
If required (e.g. on a hill), the vehicle must be additionally
secured with chocks to prevent it from rolling.
If the service brake fails, the parking brake can be used as an

emergency brake.
(Z 115 406)
The parking brake is released with compressed air and is applied

with springs which are fitted in the brake cylinders of the 2nd and
3rd axles.
As the parking brake does not work on all wheels, its braking
effect is less than that of the service brake. Only use the
brake to stop the crane in an emergency and immediately
repair the brake fault.
Apply the parking brake:
− Move lever (27) from the neutral position to the fully braked
position at the rear (lever locks in place). The indicator light
(125, H310) “parking brake applied” lights up. With partial
braking, the lever must be held in the desired position as it
otherwise automatically returns to the released (neutral)
position.
RISK OF ACCIDENTS!
Make sure that the lever locks correctly in the full brake
position, as it can otherwise return automatically to the
released position. The lever must not be able to be pushed
backed into the released position (without actuating the
lock).
40C−1070d_en 7/15
7
125 101
H310
126 27
H310.6
12
10
Z 115 406
111
112
113
Z 300 124
8/15 40C−1070d_en
Brakes 7
(Z 115 406)
Release the parking brake:
− Lift and hold the lock of the parking brake valve. Swing the
lever (27) forwards up to the stop. The indicator light“parking
brake applied” (125, H310) must go out.
When using the parking brake as an emergency brake,move

lever (27) on the hand brake valve quicklybut without jerking. Do
not allow the lever to lock in place! The braking effect can be
infinitely varied, similar to that ofthe service brake.
7.4 Emergency Filling of the Braking System (Optional)
(Z 300 124 principle illustration)
The emergency filling connection (111) of the braking system is

located on the left side of the vehicle and is provided with an
appropriate sign.
7.5 Test Points of the Braking Circuits

(Optional Equipment / National Regulations)
(Z 300 124 principle illustration)

Depending on customer requirements and national regulations,
the vehicle can be equipped with additional test points (112, 113)
for both braking circuits. The test points have been marked with
signs so they can assigned to a braking circuit.
The test points (112, 113) are on the left−hand side of the vehicle.
40C−1070d_en 9/15
7
125 101
H310
126 27
H310.6
12
10
Z 115 406
57
138 139
Z 115 308
10/15 40C−1070d_en
Brakes 7
7.6 Engine Brake (Sustained−action Brake)
(Z 115 406)
The engine brake is especially designed for use on longdownhill

stretches. The engine brake is engaged by depressing foot
switch (12) with the left foot.
The crane is then braked during travel when a gear is selected.
The accelerator must not be pressed when the

sustained−action brake is in operation!
Before driving up or downhill, the driving range must be

preselected for keeping the speed constant.
7.7 Anti−Blocking System (ABS)
(Z 115 308)
The vehicle is equipped with a blocking protection called “ABS”.
The ABS circuit covers all axles (of the vehicle) and possibly a
dolly as well.
The function is monitored as follows:
− Lamp 138 for the vehicle axles.
− Lamp 139 for any dolly axles.
The ABS stops the wheels from blocking when the vehicle starts
driving at walking speed − independent of the surface of the road
(water, iciness).
Risk of accidents!
ABS does not relieve you from driving in a way that is
suitable for traffic and road conditions. Track and
steerability of the vehicle are improved.
For example, ABS is not able to prevent the
consequences of keeping too small a safety distance or
of increased curve speeds.
40C−1070d_en 11/15
7
57
138 139
Z 115 308
12/15 40C−1070d_en
Brakes 7
(Z 115 308)
7.7.1 ABS: Full Function / Off−road Mode

ABS is always active, however, the driver can switch it to
”off−road mode” using switch (57).
ABS in ”off−road mode” is indicated by the flashing of the
indicator light (138).
The brake path can be reduced on terrain or unpaved roads (i.e.
soft or extremely bumpy surfaces as well as sloping roads) by
switching ABS to ”off−road mode”.
The control is speed−dependent; at higher speeds the ABS
control also switches to full function when in ”Off−road mode”.
ABS can be switched when the vehicle is at a standstill (key in the
ignition lock in driving position) or during driving.
After the engine has been switched off and started again, the full
functionality is automatically activated. When driving on terrain,
switch ABS over again.
Off−road mode may not be used on public roads.
7.7.2 ABS Functions Check / Fault Display

Insert the key in the ignition and turn to the driving position. The
indicator light ”ABS control, crane” (138) lights up for approx. 2
seconds. At the same time the warning buzzer sounds.
The indicator must light up and go out after 3 seconds

oronce the vehicle is driven. If the indicator does not light
upproperly, flashes or does not go out, anti−lock protection
isnot given.
If one of the indicator lights (138, ABS control of crane vehicle)

or (139, ABS control of dolly) is illuminated longer than 2 seconds
when starting the engine, there is a fault in the corresponding
ABS circuit.
Risk of accidents!
The indicator must light up and go out after 3 seconds
oronce the vehicle is driven. If the indicator does not
light upproperly, flashes or does not go out, anti−lock
protection isnot given.
Drive especially carefully.
Have the fault rectified immediately in a specialist
garage.
40C−1070d_en 13/15
7
57
138 139
Z 115 308
1 2 5 3 4
Z 53 769
14/15 40C−1070d_en
Brakes 7
(Z 115 308)
7.7.3 Braking with ABS
− In case of danger, fully activate the brake pedal. This ensures

that all wheels are monitored and an optimum delay of the
vehicle is achieved.
− If you drive with a dolly without ABS, it can overbrake if you
have to make an emergency stop. In this case, the driver
must observe the towed vehicle in the rearview mirror. The
towing vehicle with ABS remains steerable; this means that
the driver can keep his towed vehicle steady.
− If the indicator light (139, “ABS check, trailer, or fault”) or
indicator light (138, “ABS check, crane”) and indicator light
(139, “ABS check, trailer, or fault”) lights up, the ABS for
thetrailer or for the crane and trailer is switched off. If the fault
(139, “ABS check, trailer, or fault”) is shown on its own, the
trailercan be overbraked.
In this case, the driver must observe the towed vehicle in the
rearview mirror. The engine wagon remains steerable
allowing the driver to keep his trailerstable.
7.7.4 ABS with Dolly Operation
(Z 53 769)
If the crane vehicle has been fitted with a dolly coupling (optional)
ex works, there is a special ABS socket (4) for the transfer of the
ABS function at the rear of the vehicle rear.
4 ABS socket (7−pole)
When using a dolly, the relevant regulations must be observed

(e.g. if for example ABS is required due to the number of axles).
40C−1070d_en 15/15
Steering 8
8 Steering
8.1 General System Description
The steering of the crane chassis is made up of a hydraulic dual−

circuit steering system and an electric−hydraulic rear−axle stee-
ring (auxiliary steering system) for construction site mode.
In the road and construction site mode axle 1 is steered with the
steering wheel.
For operation on the road, axles 2 and 3 are pinned in the fixed
position.
In the construction site mode the axles 2 and 3 can be steered
by means of a separate steering circuit.
This enables various steering figures to be driven.
A computer regulates the control of the electric−hydraulic rear

axle steering. Possible fault codes can be read out there. (For in-
formation pertaining to this, see “Steering computer / fault dia-
gnosis / fault list”.)
The oil supply of the hydraulic components consists of two en-

gine−dependent driven steering pumps and a driving−depen-
dent driven emergency steering pump.
During driving, the emergency steering pump − which is driven by
the moving crane − controls the delivery rate from the main pump
2 and deactivates it as soon as the delivery rate is sufficient to
supply steering circuit 2.
If a steering circuit fails − or in case of engine failure − during dri-

ving, the crane vehicle can still be steered until it comes to a
standstill.
It does require increased effort, however, to move the steering
wheel and the steering reacts slower.
40C−1080d_en 1/41
8
2/41 40C−1080d_en
Steering 8
8.2 Safety Instructions
8.2.1 Safety Instructions for Protecting the System
Adjustments to the steering system may only be carried out

by our customer service team.
Inspections / maintenance work must be carried out by spe-

cialist personnel.
When working on the vehicle (painting, welding) suitable

measures must be taken to protect the electronic compo-
nents (protection against overloading and static charging).
In particular when carrying out welding work the steering

computer must be removed from the vehicle.
Never remove live plug connections.
40C−1080d_en 3/41
8
4/41 40C−1080d_en
Steering 8
8.2.2 Safety Instructions for the Protection of Life and Limb

for Maintenance / Adjustment Work
Caution risk of crushing!

When working on the steering system (e.g. inspections,
maintenance / adjustment work, manual emergency stee-
ring) there is an increased risk of crushing in the area of the
axles, wheels and track rods.
Always ensure that you have sufficient space for safe mo-
vement.
Unauthorised persons must stay well clear of the slewing

range of axles, wheels and track rods.
For maintenance work in the slewing range of axles,

wheels and track rods, it must be ensured that these are
prevented from moving (switch off engine or deactivate
steering system).
If servicing is required (e.g. balancing the angle transmit-

ters), particular caution is required.
It must be ensured that no movements can occur at axles,
wheels, or track rods.
This can be achieved by switching off the engine or remo-
ving the connector at the corresponding non−return val-
ves.
Caution following servicing work!

Errors in the steering system can lead to axle movements.
When starting the engine, keep a safe distance from the ax-
les; nobody should be in the turning area of axles, wheels
and track rods.
Caution with the manual emergency steering control!

Particular care is required in the case of manual emergency
steering. When the valves for the manual emergency stee-
ring control are actuated the track rods and the wheels
move at the affected axle.
40C−1080d_en 5/41
8
18
50 98 99
123
114 124
Z 115 213
6/41 40C−1080d_en
Steering 8
(Z 115 213)
8.3 Monitoring Functions for all Steering Programs
The most important components of the steering system (function

of the steering / emergency steering pumps and electric−hydrau-
lic rear−axle steering for construction site mode) are monitored
electronically.
Faults and functions are indicated by the following indicator

lights:
98 Flashing signal: axle 2 and/or axle 3 are not in the road tra-
vel condition − and are therefore not locked.
99 Function (permanently lit), fault (flashing light): electric−hy-

draulic rear−axle steering
123 Steering circuit 1 no flow
124 Steering circuit 2 (emergency steering) no flow
When the indicator lights (123), (124, for driving speeds grea-
ter than 10 km/h (6 mph)) light up and indicator light (99) flas-
hes there is a malfunction. Determine the cause of the mal-
function and rectify the problem as quickly as possible.
When one of the indicator lights (123), (124, for driving

speeds greater than 10 km/h (6 mph)) and (99, flashing
signal) lights up there is a serious malfunction.
The operational reliability of the vehicle is endangered.
Switch off the vehicle immediately and rectify the fault.
40C−1080d_en 7/41
8
18
50 98 99
123
114 124
Z 115 213
8/41 40C−1080d_en
Steering 8
(Z 115 213)
After rectifying the fault the warning display can be reset by swit-
ching off the ignition for approx. 10 seconds.
This also serves to check that the fault has actually been rectified.
Equally, if an indicator light lights up, the system can be ”reset”
to try and rectify the fault.
To do so, stop the vehicle, switch off the engine (switch off the
ignition for approx. 10 seconds) and restart.
8.3.1 Monitoring the Steering / Emergency Steering Pump

The steering / emergency steering pump is monitored by the indi-
cator lights (123) and (124) to ensure that it is working correctly.
These have the following meaning:
123: Steering circuit 1 no flow
124: Steering circuit 2 (emergency steering pump) no flow
When the vehicle is at a standstill, only indicator light (124) must

light up, as the emergency steering pump is not supplying at this
point.
When the indicator lights (123), (124, for driving speeds

above 10 km/h (6 mph)) light up there is a malfunction. Deter-
mine the cause of the malfunction and rectify the problem as
quickly as possible.
When indicator lights (123), (124, for driving speeds

above 10 km/h (6 mph)) light up, the operational reliabi-
lity of the vehicle is endangered.
Switch off the vehicle immediately and rectify the fault.
Function check
Check all steering components regularly for mechanical damage,

corrosion and wear.
In particular pay attention to the angle transmitters on the front
/ rear axles and their steering (firm fit, no corrosion).
Corroded parts must be replaced.
40C−1080d_en 9/41
8
18
50 98 99
123
114 124
Z 115 213
10/41 40C−1080d_en
Steering 8
(Z 115 213)
8.3.2 Monitoring the Electric−hydraulic Rear−axle Steering

(for Operation on the Construction Site)
The function of the electric−hydraulic rear−axle steering is moni-

tored during operation on the construction site by the function
and indicator light (99).
When indicator light (98) flashes, it is an indicator that axle 2 and/

or axle 3 are not in the road travel condition, i.e. not locked.
When the electric−hydraulic rear−axle steering is switched on,
lamp (99) lights up permanently.
Flashing of lamp (99) signals a fault on the electric−hydraulic rear
axle steering.
Function check
Regular inspections must be carried out to ensure that all stee-

ring units, control units and monitoring equipment are fully func-
tional. Check for irregularities, e.g. leaks, changing displays etc.
40C−1080d_en 11/41
8
18
50 98 99
123
114 124
Z 115 213
12/41 40C−1080d_en
Steering 8
(Z 115 213)
8.4 Steering Programs
8.4.1 Selection of the Steering Program “On−road Travel”

or “Construction Site Mode”
Using the lockable switch “Enable steering programs” (50), the

system can be set to the steering program “on−road travel”
(switch not actuated) or ”construction site mode” (switch actua-
ted). For “construction site mode” indicator light (99) lights up.
To change back to the program “road travel“, see point 8.4.4
of this section. No special measures need to be carried out for
normal road travel (no actuation of switch!).
For special construction site mode different steering figures

can be driven.
− “Narrow cornering”
− ”Diagonal steering”,
− ”Rear−axle steering”,
It is only possible to switch from road travel to construction site

operation (switch 123) when the speed is below the max. permis-
sible speed of 5 km per hour (3 mph).
40C−1080d_en 13/41
8
18
50 98 99
123
114 124
Z 115 214
14/41 40C−1080d_en
Steering 8
8.4.2 Steering Program “On−road Travel”
(Z 115 214)
Caution, the vehicle swerves.
The steering program “on−road travel” must be selected for dri-

ving on public roads.
In the program “on−road travel” the axles are steered as follows:
− Front axles 1 with the steering wheel.
− Axles 2 and 3 are pinned in the fixed position.
The “electric−hydraulic rear−axle steering” may not be

switched on for road travel, the indicator lights (98 and
99) must not light up or flash − extreme risk of accidents!
Always check this condition by monitoring indicator light (98) on

the dash panel of the driver’s cab. It always lights up when the
changeover from “electric−hydraulic rear−axle steering” to “stee-
ring for road travel” has been unsuccessful (e.g. engine of the
mobile crane was switched off when the “electric−hydraulic rear−
axle steering” was switched on).
40C−1080d_en 15/41
8
Z 115 210
18
50 98 99
123
114 124
Z 115 213
16/41 40C−1080d_en
Steering 8
8.4.3 Steering Program “Construction Site Mode”
(Z 115 210, Z 115 213)
With this steering system, axle 2 can be steered independently

of axle 1. Axle 3 is steered by means of a computer−controlled
separate hydraulic circuit and adapts to the steering angle, rela-
tive to the position of axles 1 and 2, of the desired driving direc-
tion.
The ”electric−hydraulic rear−axle steering” may not be swit-

ched on for either ”road travel” or for ”driving in the erect
condition”.
The following steering figures can be driven.

− ”Tight cornering” (steering figure ”a”)
− “Diagonal steering” (steering figure “b”)
− “Rear−axle steering” (steering figure “c”)
Enabling of the steering program ”construction site mode” is

only permitted:
− on construction sites / private roads
− if the crane is in transport condition
(boom set down, axle loads max. 17 t (37.5 kip))
The ground conditions must be suitable for driving, i.e. flat and
even ground, no dips or rises in the ground, no obstructions.
The ground must be able to support the individual axle loads (up
to 17 t (37.5 kip)) and the overall weight.
40C−1080d_en 17/41
8
18
50 98 99
123
114 124
Z 115 213
18/41 40C−1080d_en
Steering 8
(Z 115 213)
By actuating the lockable switch (50) the electric−hydraulic rear−

axle steering is activated (only at speeds below 5 km/h (3
mph)).The indicator light (99) lights up.
Mechanical pinning is then unlocked.
The indicator lights (98) ”steering (axle 2 and/or 3) not locked”
(road travel prohibited) shows when the system has been uncou-
pled.
The indicator light (99) also serves as a fault light of the elec-
tronically controlled steering. If the light flashes when the in-
dependent rear−axle steering is activated, there is a fault.
Please inform the customer service department.
Additional information on the subject of ”steering computer / fault

diagnosis / fault list” see 8.5.
When the rear−axle steering is switched on, a gear lock is activa-

ted. The automatic transmission only permits gear levels ”1” and
”R”.
When switching back to road operation, axles 2 and 3 must be
pinned again so that the gear lock is deactivated. This procedure
can be carried out when the vehicle is being driven.
(see section 8.4.4).
For reasons of stability, the suspension must be set to the

“four−circuit system”.
The differential locks must not be actuated in the steering fi-

gures “manual rear−axle steering” and “diagonal steering”.
For the steering figure ”narrow curve driving” switching on
the differential locks should be avoided.
The crane may only be driven at walking speed (max. 5 km/h

(3 mph)).
40C−1080d_en 19/41
8
Z 115 210
18
50 98 99
123
114 124
Z 115 213
20/41 40C−1080d_en
Steering 8
8.4.3.1 Shared Characteristics of all Steering Programs for

“Construction Site Mode”
(Z 115 210, Z 115 213)
The basic release of the various steering programmes “Construc-

tion site operation” is done by pressing the switch (50) at speeds
< 5 km/h (3 mph).
At a higher speed the switch (50) can be actuated. However the

steering program ”construction site mode” is not activated.
In this case, the buzzer sounds.
When the rear−axle steering is switched on, a gear lock is activa-

ted. The automatic transmission only permits gear levels ”1” and
”R”.
8.4.3.2 ”Tight Cornering” (Steering Figure ”a”)
(Steering centre point in extension of axle 2)

The front axle is steered with the steering wheel.
If the axle 2 is not adjusted manually and remains facing straight−
ahead, the 3rd axle steers in the opposite direction of axle 1.
The vehicle then achieves a smaller turning radius.
The gear lock is activated.
Driving the steering figure “Tight cornering”:
− Continue to reduce driving speed to < 5 km/h (3 mph).

− Actuate switch (50) ”enable steering programs”.
The indicator light (99) lights up.
The indicator light (98) ”axle 2 and/or 3 not locked” indicates
when the system has uncoupled.
− Turn the steering wheel in the direction of the cornering.
Axle 3 steers in the opposite direction to axle 1.
For the road travel mode, see 8.4.4
40C−1080d_en 21/41
8
Z 115 210
18
50 98 99
123
114 124
Z 115 213
22/41 40C−1080d_en
Steering 8
(Z 115 210, Z 115 213)
8.4.3.3 ”Diagonal Steering” (Crab Walk; Steering Figure ”b”)
Steer axle 1 into the direction subsequently required using the

steering wheel.
Switch on lockable switch (50) ”Enable steering programs” and
at the same time set axle 2 diagonally in the same direction as
axle 1 by pressing button (114).
Axle 3 is automatically set in the same direction as axle 2.
Driving steering figure “diagonal steering”:

− Steer axle 1 with the steering wheel into the subsequent dri-
ving direction.
− Set axle 2 in the same direction as axle 1 by pressing button
(114).
Axle 3 steers in the same direction as axle 2.
40C−1080d_en 23/41
8
Z 115 210
18
50 98 99
123
114 124
Z 115 213
24/41 40C−1080d_en
Steering 8
(Z 115 210, Z 115 213)
8.4.3.4 “Rear−axle Steering” (Steering Figure “c”)
Align axle 1 in the straight−ahead position.

Switch on lockable switch (50) “enable steering programs” and at
the same time set axle 2 diagonally by pressing button (114).
Axle 3 is automatically set in the same direction as axle 2.
When the crane is equipped with the tyres 20.5 R 25 the steering
figure “c” is not possible.
Axle 3 always steers then in the same direction as axle 2 (steering
figure “b”).
Use of the ”electric−hydraulic rear−axle steering” can lead to un-

favourable rolling conditions for some tyres and therefore to hig-
her tyre wear when the steering angle is too large.
Driving the steering figure ”rear−axle steering”:

− Set axle 2 in the desired driving direction by pressing button
(114).
Axle 3 steers in the same direction as axle 2.
40C−1080d_en 25/41
8
Z 115 210
18
50 98 99
123
114 124
Z 115 213
26/41 40C−1080d_en
Steering 8
(Z 115 210, Z 115 213)
8.4.4 Switching off the Electric−hydraulic Rear−axle Stee-

ring / Placing Axles 2 and 3 in Road Travel Position
To place the axles in the road travel condition, these must be pin-
ned in the straight−ahead position again.
This procedure can be carried out at a standstill or when driving
slowly.
If, for example, there is insufficient force in the actuating cylinders
to place the wheels straight ahead on loose underground, the
crane must be driven onto a more suitable surface first.
Recommended Procedure:
1. Place all axles in the straight−ahead position

− for steering figures (b) and (c) (see section 8.4.3.3)
using self−return rocker switch (114)
− for steering figure (a) (see section (8.4.3.2) using stee-
ring wheel (2)
2. Actuate lockable switch (50) again

− Indicator light (99) goes out.
− Indicator light (98) only goes out when axle 2 and 3 are
pinned in the straight−ahead position.
3. If pinning does not take place (indicator light 98 ”steering not

locked” remains lit) self−return rocker switch (114) must be
used to make short steering movements to the left and right
so that the locking bolts of axles 2 and 3 can engage.
Axle 3 can, if necessary, also be placed in the locking posi-
tion by turning on the steering wheel.
40C−1080d_en 27/41
8
”L” ”R”
A A
F1 F2 F3 F4 F2 F1 F4 F3
Z 115 215
28/41 40C−1080d_en
Steering 8
8.5 Steering Computer / Fault Diagnosis / Fault List
The steering computer is located in the main electrical unit in the

middle of the chassis on the right−hand side.
8.5.1 Operating Functions
(Z 115 215)
It is possible that the steering computer can be operated via the

CAN−diagnosis display (Z 115 215, ”L) (not TD−supplied)
Directly on the steering computer there are also control and dis-
play elements (A, F1 − F4) (Z 115 215, ”R”).
The buttons and DIP switches have the following basic functions:
ESCAPE button (F1):
− Exit the current menu.

− End without saving.
− Back one entry position.
MINUS button (F2):
− Back one selection point (e. g. previous fault).

− Reduce value by 1.
PLUS button (F3):
− One selection point further (e. g. next fault).

− Increase value by 1.
ENTER button (F4):
− Activate selected menu.

− Confirm value.
− Save value.
− One entry position further.
40C−1080d_en 29/41
8
18
50 98 99
123
114 124
Z 115 213
”L” ”R”
A A
F1 F2 F3 F4 F2 F1 F4 F3
Z 115 215
30/41 40C−1080d_en
Steering 8
(Z 115 213, Z 115 215)
8.5.2 Registration of a Fault
The electric−hydraulic rear−axle steering has a self−diagnosis

system.
When the system has recognised faults,indicator light (99) flas-
hes.
At the same time, although not visible to the driver while driving,
all faults are displayed on the steering computer (display A).
∗ Active faults are always displayed by a flashing indicator light
(99).
∗ Faults that occur remain active until the ignition is switched
off, regardless of whether the fault still exists or not.
∗ An active fault is automatically stored in the error memory.
Caution !
When the indicator light (99) is flashing, the system has reco-
gnised a malfunction.
Determine the cause of the malfunction and rectify the pro-
blem as quickly as possible.
An attempt can be made to rectify the fault by resetting the sy-

stem. To do so, stop the vehicle, switch off the engine (switch off
the ignition for approx. 10 seconds) and restart.
Caution RISK OF ACCIDENTS !

When the indicator light (99) is flashing, the operational
safety of the steering is no longer guaranteed.
Stop the vehicle immediately; there is a serious risk of
accidents.
Never drive with a defective steering system!
40C−1080d_en 31/41
8
”L” ”R”
Z 115 216
”L” ”R”
Z 115 217
32/41 40C−1080d_en
Steering 8
8.5.2.1 Fault Display on Screen (A) of the Steering Computer
Display in fault−free condition
CAN−diagnosis display (Z 115 216, ”L”)
In addition to the display “no error” in the second text line a “>”
character moves from left to right.
This moving display signals that the steering computer is active
and the software is being processed.
ON−BOARD−display (Z 115 216, ”R”)
On the 7−segment display the outer segments light up one after

the other.
Display of active faults
(Z 115 217)
As soon as the system has recognised a fault, the display chan-

ges to the fault code screen.
Faults are described according to location of fault, type of fault
and category of fault. All three individual codes are displayed.
− Example place of error: 10
− Example error type: 07
− Example error class: 01
If several faults exist at the same time, the display automatically

switches to the next fault after 2.5 seconds.
Once all faults have been rectified, the display changes back
again to the fault−free condition (”no error”, ” >” character) and
moving segments of the 7−segment display.
40C−1080d_en 33/41
8
F1 F2 F3 F4
3 sec.
Z 52 120
Z 52 121 Z 52 122
34/41 40C−1080d_en
Steering 8
8.5.3 Error Memory / Fault Codes
Up to 32 various faults with 3 fault codes each can be stored in

the error memory of each steering computer.
If the error memory is full, the first entered fault is overwritten.
The fault codes can be read off the display of the steering compu-
ter. They are subdivided according to the location, type and cate-
gory.
On the screen of the CAN−diagnosis display the first line contains
the fault number and the second line contains the 3 fault codes
that symbolise location, type and fault category.
On the ON−BOARD−display the 3 fault codes are displayed one
after the other.
The procedure for reading off the fault memory with the CAN dia-
gnosis display and/or. with the ON−BOARD operating elements
is the same.
8.5.3.1 Activating / Reading off the Fault Memory (explained

on the CAN diagnosis display)
(Z 52 120, Z 52 121, Z 52 122)
To read off the error memory at the display (A), first the menu item
”error memory” must be selected in the menu for special func-
tions.
Select special functions menu:

The menu for special functions is activated by pressing the ESC−
and ENTER−keys (F1, F4) at the same time for at least 3 se-
conds.
The change is made when the screen switches to “i/o data dis-
play”.
Move on to the menu item “error memory”:

The PLUS−key (F 3) switches from “i/o data display” to “error me-
mory”.
Activate error memory:

Use the ENTER−key (F4) to activate the error memory function.
The display changes to the first fault that is stored.
(Z 52 121)
40C−1080d_en 35/41
8
Z 52 121 Z 52 122
F1 F2 F3 F4
Z 52 116
36/41 40C−1080d_en
Steering 8
(Z 52 121, Z 52 122, Z 52 116)
Reading off the error memory:

Using the PLUS and MINUS keys (F2 / F3), all faults can be read
out one after the other.
At the end of the error memory (fault 32) the system automatically
returns to the beginning (fault 1).
As soon as the code display “255, 255, 255” appears on the

screen, there are no additional faults in the memory.
The fault before the display “255” is the last entered fault.
With a completely deleted error memory, only code entries with
“255” are maintained. (Z 52 122)
Exit error memory function:

Using the ESC−key (F1), the error memory function can be exited
at any time.
8.5.3.2 Deleting Error Memory
The error memory may only be deleted in consultation with our

customer service department.
40C−1080d_en 37/41
8
18
50 98 99
123
114 124
Z 115 213
38/41 40C−1080d_en
Steering 8
8.5.4 Fault Categories / Fault Reaction
(Z 115 213)
The faults are divided into the fault categories 0 to 3 and are ent-
ered in the error memory of the steering computer.
The fault category determines the reaction of the steering to the
fault and the subsequent effect on steering operation.
Fault category 0
Display: No
Reaction of the steering: Warning; steering behaviour is not af-
fected.
Effect: Unlimited driving mode possible.
Error class 1
Display: indicator light (99) + warning signal.

Reaction of the steering: the axle / system is steered to the next
straight position.
Effect: Limited driving operation
Error class 2
Display: indicator light (99) + warning signal

Reaction of the steering: Automatic steering in straight position.
Error class 3
Display: indicator light (99) + warning signal

Reaction of the steering: Self−centring / locking of the axles
(safe condition).
If faults of categories 1, 2 and 3 are present in the error me-

mory, these codes must be provided to our customer service
department; they will then determine the causes of the fault
and issue suitable measures to be taken.
8.5.5 Fault List (Following)
40C−1080d_en 39/41
8
40/41 40C−1080d_en
Steering 8
8.6 Manual Emergency Steering
Caution, increased risk of crushing!

When the valves for the manual emergency steering control
are actuated the track rods and the wheels move at the affec-
ted axle.
In the case of manual emergency steering, particular caution
is therefore required.
Make sure that you have sufficient space to move freely.
If the steering computer fails, the electrical current is cut off to all
valves; i.e. the steered rear axles are only locked in their current
position.
At the same time, the locking bolts of axles 2 and 3 try to fall into
place.
To enable these axles to be adjusted without the steering compu-
ter, each axle can be moved individually by manually actuating
the solenoid valves and placed in a usable position, for example
to drive the vehicle out of a hazardous zone.
The requirement for this is that the steering hydraulics are availa-
ble (vehicle engine running).
Each axle is assigned to its own solenoid valve.

The solenoid valves are located on the right−hand side of the ve-
hicle in the hydraulic carrier above the vehicle battery.
40C−1080d_en 41/41
Differential Locks 9
40C−1090c_en 1/7
9
95 129
H319 H440
Z 115 171
2/7 40C−1090c_en
9 Differential Locks
In order to distribute the drive torque from the engine to the driven
wheels and to equalise the wheel rotational speeds when driving
around corners or through curves, the mobile crane is equipped
with the following differentials:
All differentials can be locked. In the locked condition, a rigid con-

nection is made between the two outputs of the differentials.
The differential locks may only be engaged when the wheel-

sare stationary. All−terrain gear must be selected. Indicator-
light (136, H 352.2 ”all−terrain gear”) must light up (see sec-
tion 6.2).
The differential locks need to be switched on in the following cir-

cumstances:
− A wheel of a drive axle is standing on a loose surface and is
spinning:
The transverse differentials must be locked.
− Both wheels of a drive axle are spinning:
The longitudinal differential must be switched on.
The crane must not be driven on firm ground with the diffe-
rentiallocks engaged. The automatic transmission then only
allows gears “1”, ”2” and “R”. The speed limit with the diffe-
rentiallocks engaged is 20 km/h (12 mph).
If the transverse differential of axle 2 (optional) is to be effective,

the longitudinal differential must be switched on.
To avoid front wheel spinning during cornering, the longitudinal-

differential lock is automatically switched on if required.The lamp
(95, H 319; ”longitudinal differential lock) lights up for a short pe-
riodof time.
If there is an error in the corresponding electronicsof the distribu-
tor gear, the lamp flashes (129, H 440; ”Do not change gear”).
(Z 115 171)
40C−1090c_en 3/7
9
95 96 136
H319 H314 H352.2
47 48 49
S314.1 S314.2 S313
Z 115 036
4/7 40C−1090c_en
Engage the transverse differential lock as follows:

(Z 115 036)
1. Stop the vehicle.
2. Press switch (47, S 314.1) and/or (48, S 314.2).

The transverse differential locks of the driven axles are swit-
ched on.
For this machine type, the longitudinal differential lock is applied

in addition to the transverse differential locks by activating switch
(47, S 314.1).
3. The indicator light (96, H 314) lights up.
Disengage the transverse differential lock as follows:

(Z 115 036)
2. Press switch (47, S 314.1) and/or (48, S 314.2) again.

The transverse differential locks of the driven axles are swit-
ched off.
3. The indicator light (96, H 314) goes out.
Engage the longitudinal differential lock or drive 6 x 6

(optional) as follows:
(Z 115 036)
2. Press switch (49, S 313).

The longitudinal differential is engaged.
3. The indicator light (95, H 319) lights up.
Disengage the longitudinal differential lock as follows:

(Z 115 036)
2. Press switch (49, S 313).

The longitudinal differential lock is disengaged.
3. The indicator light (95, H 319) goes out.
40C−1090c_en 5/7
9
6/7 40C−1090c_en
If the corresponding indicator light does not go out when the diffe-
rential locks are engaged, turn the wheels of the axleslightly to
the left and right a few times and then disengage the differential
lock again.
When the differentials are locked, drive parts may become

overloaded. Particular care must therefore be taken when-
driving with locked differentials:
− Only use the differential locks to drive on difficult terri-

tory (sand, loose ground etc.).
− Engage the differential locks only shortly before coming

to the obstacle and switch off again immediately after ha-
ving overcome the obstacle.
− Engage and disengage the differential locks only with the

wheels at a standstill.
The risk of damage to the chassis is great if the differen-
tiallocks are engaged whilst drive wheels are still spin-
ning.
− Only drive straight ahead with the locked transverse dif-

ferential, otherwise it can cause damage to the axle.
− Use the differential locks only when the crane is in the

transport condition or when the gross weight does not
exceed the transport weight.
Under no circumstances may they be used when the
crane is in the configured state!
− Drive carefully! Do not start or stop abruptly!

Do not apply full throttle!
− Never drive for long distances or on normal, solid roads

with the differentials locked.
40C−1090c_en 7/7
Hydraulic Suspension 10
40C−1100c_en 1/25
10
Z 115 037
2/25 40C−1100c_en
10 Hydraulic Suspension
All axles of the crane chassis have hydraulic suspension.
Risk of crushing!
Caution when adjusting the hydraulic suspension!
There is a risk of crushing between the bottom of the
crane and the ground and between the chassis frame
and the axles and tyres.
Make sure that no−one is in the area at risk.
10.1 Suspension Circuits

(Z 115 037)
The hydraulic suspension system consists of 4 suspension cir-

cuits:
− Suspension circuit I − Axle 1, left
− Suspension circuit II − Axle 1, right
− Suspension circuit III − Axles 2 and 3, left
− Suspension circuit IV − Axles 2 and 3, right
40C−1100c_en 3/25
10
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
Z 115 037
4/25 40C−1100c_en
10.2 Operating and Monitoring Equipment (Overview)

(Z 115 038)
Operating equipment
The operating equipment for the hydraulic suspension system

are housed in the dash panel.
In order for the switches to work, the crane must be in the “Driving
the crane” configuration (locking switch (106) not activated). In
addition, the hand brake must be applied and the drive switched
to the neutral position.

left−hand side
right−hand side
left−hand side
right−hand side
62 S 370.1 Double key ”Raise”/”lower” together
Monitoring equipment
Four indicator lights are provided in the driver’s cab for constant
monitoring of the level in the hydraulic suspension circuits.

90 H 371 Indicator light Suspension circuit to the rear and left
not level
91 H 374 Indicator light Suspension circuit to the rear and right
not level
92 H 373 Indicator light Suspension circuit to the front and left
not level
93 H 372 Indicator light Suspension circuit to the front and right
not level
If one of the indicator lights (90, H 371), (91, H 374), (92,

H 373), (93, H 372) comes on or does not go out during dri-
ving, the crane must be stopped and the corresponding sus-
pension circuit/s must be ”levelled” again.
Flickering of the indicator lights while driving is normal.
40C−1100c_en 5/25
10
Z 155 087
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
6/25 40C−1100c_en
10.3 Setting the Suspension Circuits
(Z 155 087, 115 292)
The level of the 4 suspension units can be individually adjusted.

This can always be useful, e.g.:
− If the headroom is not sufficient for the crane;
− If more ground clearance is required;
− If the mobile crane is stuck during off−road operation;
When adjusting the height, always leave a small distance to up-

per or lower stop position of the suspension cylinders so that the
suspension still has a minimum effect in reserve.
It is only possible to set the suspension circuits when at a stand-

still (retaining brake applied, drive “in neutral”).
The locking switch (106, S 301.1) must be set to driving operation
(not activated).
If a suspension circuit is not in the road travel state (see 10.3.2

from page 13), the corresponding indicator light (90, H 371), (91,
H 374), (92, H 373), (93, H 372) is illuminated.
For the assignment of the indicator light to the suspension cir-
cuits, see 10.2.
Risk of damage!
In order to drive the mobile crane in the transport position
(construction site or road travel), the suspension must be in
the road travel level position (all suspension cylinders (1) in
the road travel position) (see 10.3.2, from page 13).
Risk of damage!
The suspension cylinders can be extended and retracted up
to the stop (”fully retracted”).
Driving with completely retracted suspension cylinders
(suspension cylinders “fully retracted”) is only for raising
loads in the LLD operating mode “on wheels 360°” and for
driving the crane with load” at a slow walking pace (2 km/h;
1 mph).
40C−1100c_en 7/25
10
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
Z 115 037
8/25 40C−1100c_en
10.3.1 Procedure
(Z 115 292, Z 115 037)
The suspension circuits can be set with the function “Raise / lo-
wer” of the dual button (58, 59, 60, 61).
To level the crane quickly and/or evenly, different (or all) circuits
must be filled or emptied at the same time.
It is not possible to set circuits in different directions (filling one
circuit while emptying another) at the same time.
Function of the dual buttons (58, 59, 60, 61, 62)

− Press dual button on item “A”: The corresponding suspen-
sion circuit is raised
− Press dual button on item “B”: The corresponding suspen-
sion circuit is lowered
Suspension circuit I (front left)
− Press dual button (58A):

“Raise level” (extend suspension cylinder)
− Press dual button (58B):
“Lower level” (retract suspension cylinder)
Suspension circuit II (front right)

Suspension circuit III (rear left)

40C−1100c_en 9/25
10
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
Z 115 037
10/25 40C−1100c_en
(Z 115 292, Z 115 037)
Suspension circuit IV (rear right)

Information for setting the overall level:
The difference with this compared to the individual settings is that

all suspension circuits can be reset together using key (62). Any
possibly existing level differences remain.
Press / hold key (62A) = raise total level
Press / hold key (62B) = lower total level.
40C−1100c_en 11/25
10
Z 155 087
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
12/25 40C−1100c_en
10.3.2 Setting for Driving in the Transport Position

(”Placing the Crane in the Level Position”)
(Z 155 087, Z 115 292)
When driving the mobile crane in transport position (construction

site or road travel) the suspension must be in the road travel level
position (all suspension cylinders (1) in road travel position).
Only in this condition can it be guaranteed that there is sufficient
suspension travel available for driving operation.
The road travel level position is approximately in the middle of the
adjustment area of the suspension cylinder (1).
In the road travel level position, the indicator lights (90, 91, 92, 93)
are not illuminated.
Initial situation:
− crane is parked on even and level ground with the engine run-
ning; parking brake applied; drive in the “neutral” position!
− switch (106, S 301.1) is set to driving operation (not activa-
ted).
− switch (63, S 360 Enable pull up axles) is not activated.
Procedure
1. Set the suspension circuits so that none of the indicator lights

(90, 91, 92, 93) are illuminated. The procedure for setting the
suspension circuits is described in segment 10.3.1 (from
page 9).
Risk of damage!
If one of the indicator lights (90, H 371), (91, H 374), (92, H
373), (93, H 372) comes on or does not go out during driving,
the crane must be stopped and the corresponding suspen-
sion circuit/s must be reset.
40C−1100c_en 13/25
10
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
14/25 40C−1100c_en
10.3.3 Setting for Raising Loads in the

LLD Operating Mode “on Wheels 360 Degrees” and
for
“Driving the Crane with Load”
(Suspension Cylinders “Fully Retracted”)
(Z 115 292)
The suspension must be lowered when raising loads in the LLD

operating mode “On wheels 360°” and for “Driving the crane with
load”.
Initial situation:
− The requirements for the ground composition and road slope
(see section 5) must be fulfilled.
− crane set down with the engine running; parking brake ap-
plied; drive in the “neutral” position!
− switch (106, S 301.1) set to driving operation.
− extend the outrigger struts and hold the support feet just
above the ground (see section 11).
− switch (63, S 360 Enable pull up axles) is not activated.
Procedure
1. Fully retract the suspension cylinders (suspension cylinder

“fully retracted”). The procedure for setting the suspension
circuits is described in segment 10.3.1 (from page 9).
As the crane is not in the road travel level position, the indicator
lights (90, 91, 92, 93) are illuminated.
Risk of damage!
Driving with completely retracted suspension cylinders
(suspension cylinder “fully retracted”) is only for raising
loads in the LLD operating mode “On wheels 360°” and for
“Driving the crane with load” at a slow walking pace (2 km/h;
1 mph).
As soon as operation with ”fully retracted” driven suspension cy-

linders is completed, the suspension must be set in the “level po-
sition” (see 10.3.2).
40C−1100c_en 15/25
10
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
Z 115 037
16/25 40C−1100c_en
10.4 Level Check (for Driving in the Transport Position)
(Z 115 292, Z 115 037)
Four indicator lights are provided in the driver’s cab for constant
monitoring of the level in the hydraulic suspension circuits.
They are assigned to the suspension circuits as follows:

− Indicator light (90, H 371):
Suspension axles 2 and 3, left (suspension circuit III)
Suspension axles 2 and 3, right (suspension circuit IV)
Suspension axle 1, left (suspension circuit I)
Suspension axle 1, right (suspension circuit II)
If one of the indicator lights (90, H 371), (91, H 374), (92,

H 373), (93, H 372) comes on or does not go out when driving,
the crane must be stopped and the corresponding suspen-
sion circuit/s charged again.
40C−1100c_en 17/25
10
18/25 40C−1100c_en
10.5 Locking the Suspension for

“Driving in the Configured Condition”
The hydraulic suspension system must be locked for driving in

the configured condition (see section 5).
When driving in transport position (on the road and con-

struction site) the hydraulic suspension must not be locked.
If the suspension were locked, it would cause great damage
to the chassis at speeds > 5 km/h (3 mph)!
Risk of tipping!
− When driving in the configured condition, the level of the
suspension may not be set.
− Driving in the configured condition always means dri-

ving without loads!
10.5.1 Activating the Suspension Lock
Before supporting the crane on outriggers:

− Align the crane horizontally (”Setting in level position”).
The crane can be lowered onto the wheels after it has been
supported on outriggers for driving in erect condition by re-
tracting the vertical outrigger cylinders.
The crane is aligned horizontally and the suspension cylin-
ders are in road travel position.
Before driving in the configured condition:

− The requirements for the ground composition and road slope
(see section 5) must be fulfilled.
− extend the outrigger struts and hold the support feet just
above the ground (see section 11).
− Before the crane is lowered onto the wheels for driving in the
configured condition, all suspension cylinders must be in the
road travel position (”Crane in level position”; see 10.3.2).
40C−1100c_en 19/25
10
106
S301.1
Z 115 020
20/25 40C−1100c_en
(Z 115 020)
1. Activate switch (106, S 301.1), switching over to crane ope-

ration.
The suspension is automatically locked by switching crane con-

trol over to the state “Operation of the crane”.
10.5.2 Switch−off Procedure
(Z 115 020)
1. Unlock switch (106, S 301.1), switching the crane to driving

operation.
By switching crane control to the “Driving operation” state, the

suspension lock is deactivated.
2. Retract outrigger cylinders and outrigger struts. Bring the

crane into the transport condition.
3. Place the hydraulic suspension in the road travel level posi-

tion (”Setting the crane in the level position”; see 10.3.2).
40C−1100c_en 21/25
10
106
67 S301.1
Z 115 283 Z 115 020
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 294
1 7
S501 S511
S508 S502
2 6
S503 S509
S510 S500
3 4
S360.1 S507
5
S505
S504 S360.2 S506 Z 170 532
22/25 40C−1100c_en
10.6 Pulling up and Lowering the Axles (Crane Supported

on Outriggers)
(Z 115 283, Z 115 020, Z 115 294, Z 170 532)
Risk of crushing!
If the ignition switch (67, S302) is in the park position
(position 1) and the parking brake is opened at the same
time, the axles could drop abruptly to the ground.
10.6.1 Raising the Axles
During the procedure of supporting the on outriggers, the axles

must be pulled up (see also section 11).
Initial situation:
− Crane is supported on outriggers (see section 11).
− switch (106, S 301.1) is set to driving operation (not activa-
ted).
Procedure
1. Activate lock switch (63) “Enable pull up axles” in the crane

operator’s cab. The indicator light of the lock switch (63)
lights up. The axles are still on the ground.
Risk of crushing!
There is a risk of crushing between the vehicle chassis
and the axles and wheels during the following procedure
of pulling up the axles.
2. Press button (4, S 360.1 or S 360.2) in the support operating

cases) and pull up the axles.
40C−1100c_en 23/25
10
67
Z 115 283
106
S301.1
27
92 93 90 91
H373 H372 H371 H374
58 59 60 61 62 63
S363.1 S362.1 S361.1 S364.1 S370.1 S360
Z 115 292
24/25 40C−1100c_en
10.6.2 Lowering the Axles
(Z 115 283, Z 115 292)
Initial situation:
− crane is supported on outriggers.
Procedure:
1. Make sure that the parking brake in the cab is applied.
Risk of crushing!
If the ignition switch (67, S302) is in the park position
(position 1) and the parking brake is opened at the same
time, the axles could drop abruptly to the ground.
2. When the lock switch (63, S 360) is actuated, the lowering

function for the axles is released again. The indicator light of
the lock switch goes out.
The axles could drop abruptly due to their dead weight.
Risk of crushing!
After unlocking the lock switch (63, S360), the axles can
drop to the ground abruptly.
3. Activate key (62, S 370.1) until the wheels of all axles are
pressed against the ground.
Every time the hydraulic suspension is adjusted, it must be

set again for driving in the transport position (see section
10.3.2).
40C−1100c_en 25/25
Outriggers 11
40C−1110−941b_en 1/67
11
5
1
2 4
3
Z 115 287 Z 115 290
2/67 40C−1110−941b_en
Outriggers 11
11 Outriggers
(Z 115 287, Z 115 290)
Outrigger components
1 Outrigger case (firmly welded component of the chas-

sis)
2 Outrigger strut
3 Outrigger pad
4 Support cylinder
5 Outrigger control (on both sides of the chassis)
6 Outrigger operating elements in the dashboard of the
crane operator’s cab
11.1 Notes on Outriggers

Always observe the following information, in order to ensure safe
working:
− Before stabilising:
Main boom in longitudinal direction;
superstructure locked in transport position.
− The superstructure may only be slewed out of the longi-
tudinal direction when the crane is supported on outrig-
gers.
An exception is the LLD operating mode “On wheels
360°" (see segment 11.5.7 of this section and section Sa-
fety equipment").
− Support the crane on outriggers before attaching the
load.
An exception is the LLD operating mode “On wheels
360°" (see segment 11.5.7 of this section and section Sa-
fety equipment").
− The outrigger plates (3) need some space for sideways
movement during the procedure of supporting on ou-
triggers.
− Always extend outrigger struts (2) up to the correspon-
ding (coloured) mark. The (coloured) mark indicates the
corresponding outrigger support area (Z 115 290).
40C−1110−941b_en 3/67
11
4/67 40C−1110−941b_en
Outriggers 11
− For safety reasons, the outrigger struts (2) can only be

extended on the side which has the corresponding ou-
trigger control (5).
The crane operator can thus only extend outrigger
struts (2) which he can constantly observe.
The outrigger strutson one side can be activated at the
same time.
Caution: risk of crushing and collision when the outrig-
gerstruts are driven at the same time!
The outrigger cylinders on the opposite, non−visible si-
demust be activated for levelling (see relevant section).
To prevent a risk of crushing, the crane operator may
only extend one outrigger cylinder up to setting down
of the outrigger plate if he is on the same side as the re-
levant support. However, before extending theoutrig-
ger cylinder further for supporting on outriggers orfor
levelling from one side he must make sure that thereis
no further risk of crushing or collision. If necessary,the
crane operator must assign a banksman.
− Make sure the ground is level and strong enough to
bear the load when setting the outrigger plates (3)
down; permitted inclination max. 55 (9 %)!!
There must be no foreign material (e.g. stones, metal
objects etc.) under the outrigger plates.
− Both outrigger controls (5) must always be kept closed.
An outrigger control (5) may only be opened (and only
one at a time) when it is to be used to operate the outrig-
gers.
Both outrigger controls (5) must be closed immediately
after supporting on outriggers and levelling.
40C−1110−941b_en 5/67
11
5
1
4
2
3
Z 115 287
6/67 40C−1110−941b_en
Outriggers 11
(Z 115 287)
− After extension of the outrigger cylinders, the axles

must be raised.
− The max. surface pressure with the standard outrigger
plates, front (ø 500 mm / 19.7 in), is approx. 160 N/cm2
(232 lb/in2). This is equivalent to a supporting force of
314 kN (32 t / 70.5 kip).
The max. surface pressure with the standard outrigger
plates, rear (ø 500 mm / 19.7 in), is approx. 145 N/cm2
(211 lb/in2). This is equivalent to a supporting force of
285 kN (29 t / 63.9 kip).
Depending on the ground’s load bearing capacity, the
surface pressure must be reduced using solid underlay
plates (see 11.7 from page 61).
− After the crane is supported (before commencing work
with the crane), the tyres may no longer have contact
with the ground.
− The maximum deviation after levelling is 0.15 (corres-
ponds with approx. 0.2 %)!
− The crane must be levelled in all directions (360°).
− Only level the crane with counterweight and fitted
equipment by extending the vertical support cylinders.
See “Instructions on levelling with counterweight”
(11.5.4) in this section.
− In order to protect the support cylinders from overloa-
ding, they must not be extended to the limit; there must
always be a remaining lift of 2 to 3 cm (0.4 to 0.8 in) after
levelling. The remaining lift is also necessary, so that
actual support pressure values can be displayed.
− The crane should generally be supported for all opera-
tions. The crane may be used without supports only in
the cases which are expressly stated in the load table.
− The outriggers should generally be extended to the ma-
ximum support area of 6.30 x 6.20 m (20 ft 10 in x
20 ft 4 in).
40C−1110−941b_en 7/67
11
106
63
S360
Z 115 281 Z 115 279
1 7
S501 S511
8
2
S503
6
S509
3
S505
5
S507
4
S360.1 Z 115 277
8/67 40C−1110−941b_en
Outriggers 11
11.2 Control Elements

11.2.1 Control Elements on the Chassis
(Z 115 281)
The outrigger controls are on the left− and right−hand sides of the
mobile crane on the crane chassis.
In order for the outrigger controls to work, the crane must be in
the “Driving operation” state (lock switch (106) not activated). In
addition, the hand brake must be applied and the drive switched
to the neutral position.
Outrigger control, left−hand side

(Z 115 277)
1 S 501 “Outrigger cylinder front right−hand
side”
2 S 503 “Outrigger cylinder front left−hand
side”
3 S 505 “Outrigger front left−hand side”
4* S 360.1 Raise axles
5 S 507 “Outrigger rear left−hand side”
6 S 509 “Outrigger cylinder rear left−hand
side”
7 S 511 “Outrigger cylinder rear right−hand
side”
8 Tilt display (spirit level with bubble)
* This function is only possible if the “raise axles enabled” switch

(63, Z 115 279) in the crane operator’s cab has first been activa-
ted.
40C−1110−941b_en 9/67
11
1 7
S508 S502
8
2
S510
6
S500
3
S504
5
S506
4
S360.2 Z 115 278
63
S360
Z 115 279
10/67 40C−1110−941b_en
Outriggers 11
Outrigger control, right−hand side

(Z 115 278)
1 S 508 “Outrigger cylinder rear left−hand
side”
2 S 510 “Outrigger cylinder rear right−hand
side”
3 S 504 “Outrigger rear right−hand side”
4* S 360.2 Raise axles
5 S 506 “Outrigger front right−hand side”
6 S 500 “Outrigger cylinder front right−hand
side”
7 S 502 “Outrigger cylinder front left−hand
side”
8 Tilt display (spirit level with bubble)
* This function is only possible if the “raise axles enabled” switch

(63, Z 115 279) in the crane operator’s cab has first been activa-
ted.
40C−1110−941b_en 11/67
11
20
52 53 54
S802 S803 S804
55 56 110
S805 S801 S14
Z 115 062 Z 115 288
12/67 40C−1110−941b_en
Outriggers 11
11.2.2 Control Elements in the Crane Operator’s Cab
(Z 115 062, Z 115 288)
The switches for outrigger activation are on the dashboard of the

The hand brake must be applied and the drive switched to the
neutral position in order for the switches to function.
Item Element Designation Function
20 Box level Straight level display
52 S 802 Dual button Enable left outriggers
53 S 803 Dual button Enable right outriggers
54 S 804 Button Enable all outriggers
55 S 805 Dual button Retract/extend horizontal outrig-
gers
56 S 801 Dual button Retract/extend vertical outriggers
110 S 14 Rocker switch Slew gear parking brake
40C−1110−941b_en 13/67
11
Z 115 447
20
Z 115 288
N PO
S1 Q S2
M1 M2
S4 S3
M4 M3
Z 115 444
14/67 40C−1110−941b_en
Outriggers 11
11.2.3 Tilt display
(Z 115 447, Z 115 288, Z 115 444)
CAUTION!
The tilt display must be observed during the levelling proce-

dure.
The inclination of the crane vehicle is displayed at the following

points:
− at the switch panels of the left and right outrigger controls on
the crane chassis: spirit level (8, Z 115 447)
− in the crane operator’s cab: spirit level (20, Z 115 288)
− in the ”Support pressure / support base area display” (optio-
nal) screen on the operator−interface computer of crane con-
trol (Z 115 444)
Legend:
(N) Spirit level
(O) Electronic level
(P) Tilt of the lateral chassis axis
(Q) Tilt of the longitudinal chassis axis
40C−1110−941b_en 15/67
11
N PO
S1 Q S2
M1 M2
S4 S3
M4 M3
Z 115 444
16/67 40C−1110−941b_en
Outriggers 11
11.2.4 Support Pressure Display (Optional)
(Z 115 444)
If the crane is equipped with a support pressure display, the sup-

porting force is registered by pressure transducers in the four ou-
trigger cylinders. The support pressure values are displayed on
the operator−interface computer of crane control in the ”Support
pressure / support base area display” (M1 − M4).
Legend:
(M) Support forces on the struts (optional)

M1 = Support force, front left
M2 = Support force, front right
M3 = Support force, rear right
M4 = Support force, rear left
Note on the figure:

Depending on the design of the crane, either the tilt display or a
symbolic crane is displayed in the centre of the screen.
CAUTION!
The following support forces must not be exceeded:

32 t (70.5 kip) at the front outrigger cylinders
29 t (63.9 kip) at the rear outrigger cylinders.
Important note on complying with limit values:

The limit values to be followed are not monitored automati-
cally.
NOTE:
The support pressure display shows tolerance values. The dis-

play value can differ from the actual value by up to approx. 10%
(plus / minus). Keep this in mind, e.g. in relation to limited load−
carrying capacity of the ground.
40C−1110−941b_en 17/67
11
N PO
S1 Q S2
M1 M2
S4 S3
M4 M3
Z 115 444
18/67 40C−1110−941b_en
Outriggers 11
11.2.5 Support Base Display and Support Base Surveillance

(Optional)
(Z 115 444)
If the crane is equipped with an optional support base area dis-

play or support base surveillance, there is a length measuring de-
vice at each support to register the support position of each sup-
port.
The values (S1−S4) displayed in the ”Support pressure / support

base area display” screen on the operator−interface computer of
crane control indicate the position of each strut.
Support positions:
S1 = Support position, front left

S2 = Support position, front right
S3 = Support position, rear right
S4 = Support position, rear left
If a numerical value is shown, there is a valid ou-

6.2 m trigger support area / support width (see sec-
tion 11.6, page 57).
If the numerical value ”0.00” is displayed, the strut
is at an invalid support base area. In this case,
0.0 m drive the support to a valid support base area /
support width (see section 11.6, page 57).
Note
Screen variants dependent on the version:
− Either the tilt display or a symbolic crane is displayed in the
centre of the screen.
− If the crane does not have a support pressure display, the va-
lues (S1−S4) are displayed where normally the support pres-
sure values (M1 − M4) would be displayed.
40C−1110−941b_en 19/67
11
Z 115 446
20/67 40C−1110−941b_en
Outriggers 11
Support base area display (optional)
(Z 155 446)
If the support base area has not been approached correctly, the
letters ”STB” appear in the crane control display in the ”Crane
operation” screen and all the outriggers flash in the crane figure.
DANGER!
Risk of tilting due to incorrect support positions!

The display of the support position of each support is for
information purposes only. The displayed value is not
transmitted to the LLD. There is no shut−down.
The struts must be at one of the designated support posi-

tions (see section 57, page 57).
Outrigger Support Area Surveillance (optional)
(Z 155 446)
If the support base area has not been approached correctly, the
letters ”STB” appear in the crane control display in the ”Crane
operation” screen and all the outriggers flash in the crane figure.
There is a shutdown. It is only possible to continue work when the
required support width has been achieved.
40C−1110−941b_en 21/67
11
Z 115 285 Z 115 284
Z 115 358
22/67 40C−1110−941b_en
Outriggers 11
11.3 Outrigger Plate Fixing Positions

(Z 115 285, Z 115 284)
In order to fix the outrigger plates in the transport condition

(Z 115 285) and in the extended outrigger position (Z 115 284),
there are two pins (marked in colour in the depictions) each on
the outrigger plates. These pins have a locking position to pre-
vent accidental release.
When pulling the outrigger plate forward into the operating posi-
tion (Z 115 284), make sure that the subsequent supporting area
of the outrigger cylinder on the outrigger plate is clean. The bot-
tom of the outrigger cylinder’s piston rod and the top of the outrig-
ger plate must be cleaned if contaminated.
Risk of accidents!
The contact surface between the support cylinder’s piston
rod and the outrigger pad must be clean. In particular, no
foreign matter is permitted (for example: stones, sand,
etc.).
11.4 Extension Locks of the Outrigger Struts
(Z 115 358)
In order to prevent the outrigger sections from being extended

during driving, an extension lock (3) must be applied to all four ou-
trigger struts.
The extension lock (3) is fastened to the fixed point of the horizon-
tal cylinder using a safety chain.
Driving state
Figure Z 115 358 shows the extension lock (3) as it must be ap-
plied for driving the crane.
You must make sure that the safety chain is not hanging out on
the side from the crane.
State for supporting the crane on outriggers
In order to support the crane on outriggers, the extension lock (3)

must be removed. This then hangs from the safety chain.
40C−1110−941b_en 23/67
11
110
S14
52 53 54 55 56
S802 S803 S804 S805 S801
Z 115 062
24/67 40C−1110−941b_en
Outriggers 11
11.5 Support procedure
(Z 115 062)
The procedure for stabilising the crane (supporting on outriggers)

consists of “Extend outriggers” (11.5.1) and the subsequent “Le-
velling”.
The relevant segment must be selected, regardless of whether
levelling is done from the control elements (outrigger controls) of
the chassis (standard procedure 11.5.2) or from the crane opera-
tor’s cab (for later levelling; 11.5.3).
The superstructure may not be slewed if the crane is not
supported on outriggers.
Exception:
Only slew the crane when not supported on outriggers if
the LLD program ”On wheels 360°” is selected (extend ou-
trigger struts; outrigger plates close to the ground; see
11.5.7 from page 53).
Horizontal movement of the outrigger case from the crane

operator’s cab (optional)
Provided that your crane is equipped with button (55, S 805), the
outriggers can also be moved horizontally using buttons (52,
S 802) or (53, S 803).
Risk of crushing!
− The outrigger struts can only be driven if the crane ope-
rator has direct clear visibility or using the mirror (op-
tional). Check all mirror positions before operating the
outriggers.
− Generally, the crane should be supported on outriggers
using the controls of the chassis.
40C−1110−941b_en 25/67
11
106
26
27
Z 115 282 Z 115 281
52 53 54
S802 S803 S804
55 56 110
S805 S801 S14
Z 115 062 Z 115 359
26/67 40C−1110−941b_en
Outriggers 11
11.5.1 Extending the Outriggers (from the Controls of the

Chassis)
(Z 115 282, Z 115 281, Z 115 062, Z 115 359)
Risk of crushing!
Make sure that no−one is in the area at risk before exten-
ding the outrigger struts or outrigger cylinders! A person
in charge of safety must be appointed if the situation requi-
red.
Initial situation:
− Main boom to the rear or slewed to the front.
− Vehicle engine started.
− Transmission in the neutral position.
− Vehicle secured against rolling away with parking brake (27).
When supporting the crane on outriggers on a slope along

the length of the vehicle, the vehicle must be additionally se-
cured by placing chocks beneath the wheels of the last free−
lifting axle.
− Slew gear parking brake (110, S14) applied.
Procedure:
1. Remove the extension lock (3) (see segment “Extension

locks of the outrigger struts” in this section).
To do so, activate all outrigger struts briefly to relieve the ex-
tension locks (3) of load and remove the extension locks (3).
2. Open the outrigger controls on the crane chassis (for the

overview, see 11.2.1 from page 9)
40C−1110−941b_en 27/67
11
1 7
S501 S511
8
2
S503
6
S509
3
S505
5
S507
4
S360.1 Z 115 277
1 7
S508 S502
8
2
S510
6
S500
3
S504
5
S506
4
S360.2 Z 115 278
Z 115 284
28/67 40C−1110−941b_en
Outriggers 11
(Z 115 277, Z 115 278, Z 115 284)
Risk of crushing!
Before extending the outrigger struts, make sure that no−
one is standing in the hazardous area near the horizontally
extending struts.
3. To extend the support struts to the corresponding support

base area for the support variants 6.3 m x 6.2 m (20 ft 10 in
x 20 ft 4 in) and 6.3 m x 4.4 m (20 ft 10 in x 14 ft 5 in), press
key (3, S 505) or (5, S 507) in the switch panel on the left−
hand side (and/or (3, S 504) or (5, S 506) in the switch panel
on the right−hand side).
Observe the corresponding markings on the support struts which

indicate the support width (see 11.6 from page 57).
For safety reasons (horizontal), the support struts can only be ex-
tended /retracted at the switch panel on the respective side.
Extend outrigger struts individually.
Hold on to the rocker switch while extending.
4. Bring the outrigger plates into the outrigger position.

Observe the instructions and warnings in this section in this
regard 11.3 (page 23).
Figure (Z 115 284) shows the final support position.
Risk of damage!
The outrigger plates must be brought into the operating po-
sition before extending the vertical outrigger cylinders to
prevent damage to the attachment device (transport condi-
tion).
Risk of crushing!
The following must be observed for the subsequent exten-
sion of the outrigger cylinders:
Until the outrigger plates have contact with the ground,
only the outrigger cylinders may be extended which are on
the side where the crane operator is at that moment.
40C−1110−941b_en 29/67
11
1 7
S501 S511
8
2
S503
6
S509
3
S505
5
S507
4
S360.1 Z 115 277
1 7
S508 S502
8
2
S510
6
S500
3
S504
5
S506
4
S360.2 Z 115 278
63
S360
Z 115 279
30/67 40C−1110−941b_en
Outriggers 11
(Z 115 277, Z 115 278, Z 115 279)
Risk of accidents!
When attaching the outrigger plates in the following opera-
ting step, you must make sure that there is no foreign mat-
ter (for example: stones, metal objects, etc.) under the ou-
trigger plates!
5. In order to extend the outrigger cylinders, press button (1,

S 501 / S 508), (2, S 503 / S 510), (6, S 509 / S 500) and (7,
S 511 / S 502) in the switch panel on the left−hand or right−
hand side.
Extend each outrigger cylinder individually until all outrigger
plates are touching the ground.
6. Activate lock switch (63) “Raise axles enabled” in the crane

operator’s cab. The indicator light of the lock switch (63)
lights up. The axles are still on the ground.
7. Press button (4, S 360.1/2) and raise axles.
8. Continue to extend the support cylinders individually using

keys (1, S 501 / S 508), (2, S 503 / S 510), (6, S 509 / S 500)
and (7, S 511 / S 502) in the switch panel on the left− and/or
right−hand side until the crane is almost level.
If the crane is tilting visibly, this must be corrected by continuing

to extend the corresponding support cylinder. When doing so,
make sure that the support cylinders can be further extended for
the subsequent levelling procedure.
When the crane is almost level, it must be levelled out. Depen-

ding on whether levelling is to be done with the controls on the
chassis (11.5.2) or from the crane operator’s cab (11.5.3), the
corresponding segment must be selected in the following.
When the level in the crane operator’s cab has been set (11.5.3):
9. Close the outrigger controls again!
40C−1110−941b_en 31/67
11
1 7
S501 S511
8
2
S503
6
S509
3
S505
5
S507
4
S360.1 Z 115 277
1 7
S508 S502
8
2
S510
6
S500
3
S504
5
S506
4
S360.2 Z 115 278
32/67 40C−1110−941b_en
Outriggers 11
11.5.2 Levelling the Crane (from the Controls

of the Chassis)
(Z 115 277, Z 115 278)
Risk of crushing!
The following must be observed when extending the outrig-
ger cylinders for levelling:
For correct levelling of the crane, all outrigger cylinders for
fine adjustment must be operated from the outrigger con-
trols on one side. (In this case operate extremely carefully
if outrigger cylinders are extended which cannot be obser-
ved directly).
A person in charge of safety must be appointed if the situa-
tion required.
Risk of accidents!
Up to a certain support force, the outrigger cylinders can be
extended and retracted for levelling.
If this support force is exceeded, levelling can only be done
by extending the outrigger cylinders.
The hydraulic pump pressure required for adjusting the ou-
trigger cylinder is limited.
Possibly shift the centre of gravity by slightly moving the
superstructure or the main boom or the equipment.
Initial situation:
− Outriggers extended (in accordance with 11.5.1)
Procedure:
1. Extend or retract the outrigger cylinders further and level the

crane to a maximum tilt of 0.1°.
Use the straight position indicator (8) for checking that the
crane is level.
When the crane has been levelled, the bubble in the spirit
level must not pass the 0° ring by more than 1 mm (0.04 in).
40C−1110−941b_en 33/67
11
34/67 40C−1110−941b_en
Outriggers 11
2. Check the set level once more.
If the transverse axis has shifted, the levelling procedure must be

repeated.
a.) Balance the rear transverse axis.

b.) Retract the front support cylinders slightly and then extend to
level the longitudinal axis.
Risk of damage!
If the crane is level, the wheels must no longer have contact
with the ground.
40C−1110−941b_en 35/67
11
110
S14
52 53 54 55 56
S802 S803 S804 S805 S801
Z 115 062
20
Z 115 288
36/67 40C−1110−941b_en
Outriggers 11
11.5.3 Levelling the Crane (from the Controls in the

Crane Operator’s Cab)
(Z 115 062, Z 115 288)
Generally, the outriggers should be levelled using the controls on

the crane chassis (see section 11.5.2 on page 33).
However, it is possible to operate the outriggers from the crane
operator’s cab for re−levelling the crane.
This should only be done in exceptional cases and only when the
crane operator has full view of all the outriggers.
(If necessary, a banksman should be used)
Risk of crushing!
The following must be observed when extending the outrig-
ger cylinders for levelling:
It may be necessary to operate all outrigger cylinders for
fine adjustment in order to level the crane correctly. (Pro-
ceed with special caution when outrigger cylinders are
operated which cannot be observed directly).
A person in charge of safety must be appointed if the situa-
tion required.
Risk of accidents!
Initial situation:
− Outriggers extended (in accordance with 11.5.1)
40C−1110−941b_en 37/67
11
110
S14
52 53 54 55 56
S802 S803 S804 S805 S801
Z 115 062
20
Z 115 288
38/67 40C−1110−941b_en
Outriggers 11
(Z 115 062, Z 115 288)
Procedure:
1. Actuate button (54, S 804) to enable the outriggers.
2. Retract or extend the outrigger cylinders using self−return-

rocker switch (56, S 801) together with self−return rockers-
witch (52, S 802) or (53, S 803).
(Symbols on or next to the buttons indicate the outriggers to
be driven.)
3. Extend or retract the outrigger cylinders further and level the

crane to a maximum tilt of 0.1°.
Use the straight position indicator (20) for checking that the
crane is level.
When the crane has been levelled, the bubble in the spirit
level must not pass the 0° ring by more than 1 mm (0.04 in).
4. Check the set level once more.
If the transverse axis has shifted, the levelling procedure must be

repeated.
a.) Balance the rear transverse axis.

b.) Retract the front support cylinders slightly and then extend to
level the longitudinal axis.
Risk of damage!
If the crane is level, the wheels must no longer have contact
with the ground.
40C−1110−941b_en 39/67
11
40/67 40C−1110−941b_en
Outriggers 11
11.5.4 Notes on Levelling with the Counterweight
Counterweight elements can be removed optionally for this

crane type to achieve reduced axle loads.
Before fitting the counterweight, the crane must be suppor-

ted on outriggers and levelled.
After fitting the counterweight, the crane must be relevel-
led.
The crane must be levelled in all directions (360°).
Risk of accidents!
40C−1110−941b_en 41/67
11
62 63
S370.1 S360
67
Z 115 283 Z 115 286
42/67 40C−1110−941b_en
Outriggers 11
11.5.5 Retracting the Outriggers

(for Driving the Crane in Transport Condition)
(Z 115 283, Z 115 286)
Extending and retracting the supports with a load attached

is not permitted.− RISK OF OVERTURNING!
Initial situation:
− Crane is supported on outriggers.
− Main boom is in the transport condition.
Procedure:
Risk of crushing!
If the ignition switch (67, S302) is in the park position (posi-
tion 1) and the parking brake is opened at the same time, the
axles can drop to the ground abruptly.

the lock switch goes out.
Risk of crushing!
After unlocking the lock switch (63, S360) the axles can
drop abruptly to the ground.
3. Press key (62, S 370.1) until the wheels of all axles are pres-
sed down onto the ground.
When retracting the support cylinders on a slope in the lon-

gitudinal direction of the vehicle, the vehicle must be secu-
red against rolling away by placing chocks at the axle which
has contact with the ground first.
40C−1110−941b_en 43/67
11
1 7
S501 S511
S508 S502
2 6
S503 S509
S510 S500
3 4 5
S505 S360.1 S507
S504 S360.2 S506
Z 170 532
Z 115 285 Z 115 358
44/67 40C−1110−941b_en
Outriggers 11
(Z 170 532, Z 115 285, Z 115 358)
Risk of crushing!
Crushing can occur between the outrigger plates and ou-
trigger struts during the following retraction of the outrig-
ger cylinders.
Make sure that no persons are present in the danger area!
4. Press button 1 (S 501), 2 (S 503), 6 (S 509) or 7 (S 511) on

the left−hand side or 1 (S 508), 2 (S 510), 6 (S 500) or 7
(S 502) on the right−hand side and hold until the outrigger
cylinders have been fully retracted individually.
Risk of crushing and shearing!

When retracting the outrigger struts, shearing and crus-
hing movements around the retracting parts and the carrier
frame are possible.
5. Bring the outrigger plates into the transport condition

(Z 115 285) (see 11.3).
6. Press button (3, S 505) or (5, S 507) on the left−hand side

and (3, S 504) or (5, S 506) on the right−hand side and hold
until the outrigger struts have been fully retracted indivi-
dually.
7. Apply the extension locks (3) to all 4 outrigger struts (see

segment “Extension locks of the outrigger struts” in this sec-
tion).
Figure Z 115 358 shows the back of the outrigger strut with
an applied extension lock (3).
9. Level all axles (see section 10).
40C−1110−941b_en 45/67
11
106
52 53 54
S802 S803 S804
55 56 110
S805 S801 S14
Z 115 281 Z 115 062
67
Z 115 283
46/67 40C−1110−941b_en
Outriggers 11
11.5.6 “Lock Suspension” for

“Driving the Crane in the Configured Condition”
(Z 115 281, Z 115 062, Z 115 283)
RISK OF TILTING!
It is prohibited to ”drive the crane in the configured condi-
tion” with a suspended load.
Initial situation:
− Crane is supported on outriggers (6.30 m x 6.20 m /
20 ft 10 in x 20 ft 4 in).
− Ground composition and tilt allows “driving in the configured
condition”. See section 5.
− The crane is in the state ”Crane operation” (lock switch (106)
activated).
If the crane is in the state ”Crane operation” (lock switch (106)

activated), the suspension is blocked as well.
− The superstructure / main boom is configured in the driving

mode in accordance with the driving tables from segment
“Driving in the configured condition” in section 5.
− Slew gear parking brake (110) is applied.
Procedure:
Risk of crushing!
40C−1110−941b_en 47/67
11
62 63
S370.1 S360
Z 115 286 Z 115 291
1 7
S501 S511
S508 S502
2 6
S503 S509
S510 S500
3 4 5
S505 S360.1 S507
S504 S360.2 S506
Z 170 532
48/67 40C−1110−941b_en
Outriggers 11
(Z 115 286, Z 115 291, Z 170 532)

the lock switch goes out (Z 115 286).
Risk of crushing!
After unlocking the lock switch (63, S360) the axles can
drop abruptly to the ground.
3. Press key (62, S 370.1) until the wheels of all axles are pres-
sed down onto the ground.

gitudinal direction of the vehicle, the vehicle must be secu-
red against rolling away by placing chocks at the axle which
has contact with the ground first.
Risk of crushing!
Crushing can occur between the outrigger plates and ou-
trigger struts during the following retraction of the outrig-
ger cylinders.
4. Press and hold button 1 (S 501), 2 (S 503), 6 (S 509) or 7 (S

511) on the left−hand side or 1 (S 508), 2 (S 510), 6 (S 500)
or 7 (S 502) on the right−hand side and retract the outrigger
cylinders individually until the outrigger plates are just above
the road surface.
5. Bring all axles to the proper level (see section 10).
6. If required, press and hold button 1 (S 501), 2 (S 503), 6 (S

509) or 7 (S 511) on the left−hand side or 1 (S 508), 2 (S 510),
6 (S 500) or 7 (S 502) on the right−hand side and drive the
outrigger cylinders individually up or down until the outrigger
plates are just above the road surface.
40C−1110−941b_en 49/67
11
Z 115 291
50/67 40C−1110−941b_en
Outriggers 11
(Z 115 291)
The outrigger struts (2) remain extended during “Driving in
the configured condition”.
The outrigger cylinders are extended so that the outrigger
plates are lowered near to the ground.
40C−1110−941b_en 51/67
11
106
52 53 54
S802 S803 S804
55 56 110
S805 S801 S14
Z 115 281 Z 115 062
67
Z 115 283 Z 115 291
52/67 40C−1110−941b_en
Outriggers 11
11.5.7 “Suspension Fully Retracted” Driven for Raising

Loads in the LLD Operating Mode “On Wheels 360 De-
grees" and for Driving the Crane with Load"
(Z 115 281, Z 115 062, Z 115 283, Z 115 291)
RISK OF TILTING!
The crane may not be driven outside of the vehicle’s longi-
tudinal axis with load.
Initial situation:
− Crane is supported on outriggers (6.30 m x 6.20 m /
20 ft 10 in x 20 ft 4 in).
− Ground composition and tilt allows “Supporting on wheels”
and / or “Driving the crane with load”. To do so, the conditions
for “Driving in the configured condition” must be fulfilled. See
section 5.
− The crane is in the “crane operation” state (lock switch (106)
activated).
− The operating mode “On wheels 360°" is set on the LLD.
− Slew gear parking brake (110) is applied.
Procedure:
Risk of crushing!
2. If not already occurred:

When supported on outriggers: raise suspension fully (see
section 10).
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11
Z 115 291
54/67 40C−1110−941b_en
Outriggers 11
(Z 115 291)
3. Set the crane on wheels.

To do so, retract the support cylinders until the support plates
are just above the road surface.

gitudinal direction, the vehicle must be secured against rol-
ling away by placing chocks under the axle which first has
contact with the ground.
The outrigger struts (2) remain extended when driving the
crane with lowered suspension (”suspension fully retrac-
ted”).
The outrigger cylinders are extended so that the outrigger
plates are lowered near to the ground.
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11
Z 115 290 Z 115 289
56/67 40C−1110−941b_en
Outriggers 11
11.6 Supporting variants
(Z 115 290)
There are two triangular marks on each outrigger strut (2) (for in-
struction arrows, see figure). Depending on the desired outrigger
basis, the corresponding tip of the triangle must correspond with
the outer edge of the chassis. Figure (Z 115 290) shows the left
front strut supported in the “normal outrigger support area” (6.30
m x 6.20 m (20 ft 10 in x 20 ft 4 in).
11.6.1 Outrigger Support Area 6.30 m x 6.20 m (Normal Ou-

trigger Support Area)
(20 ft 10 in x 20 ft 4 in)
(Z 115 290)
For the procedure, see 11.5.1.

The outrigger struts (2) are extended up to the marking the furt-
hest on the inside. Both triangular markings are visible.
Level thecrane in accordance with segment 11.5.2 or segment

11.5.3.
Figure (Z 115 290) shows the left front strut supported in the “nor-
mal outrigger support area”.

(20 ft 10 in x 14 ft 5 in)
(Z 115 289)

The outrigger struts (2) are extended to the outermost mark.

11.5.3.
Figure (Z 115 289) shows the left−hand front strut supported in

the “outrigger support area 6.30 m x 4.40 m (20 ft 10 in x 14 ft 5
in)”.
40C−1110−941b_en 57/67
11
2
2
Z 115 293 Z 115 291
58/67 40C−1110−941b_en
Outriggers 11
(Z 115 293)

(20 ft 10 in x 7 ft 8 in)

The outrigger struts (2) are extended in this case. Only the outrig-
ger cylinders are extended.

11.5.3.
Figure (Z 115 293) shows the left−hand front strut supported in

the “outrigger support area 6.30 m x 2.34 m (20 ft 10 in x 7 ft 8
in)”.
11.6.4 Free on Wheels

(Z 115 291)
As described under 11.5.7, the crane’s outrigger struts (2)
must be extended in accordance with the normal support
base area. The outrigger cylinders are extended so that the
outrigger plates are lowered near to the ground.
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11
Z 41 654
60/67 40C−1110−941b_en
Outriggers 11
11.7 Supporting the Outrigger Plates Due to Insufficient

Load−bearing Capacity of the Ground
The load capacity of the ground must be sufficient to absorb the

maximum support forces which can occur.
As a rule, the surface of the outrigger plates for the crane will not
be sufficient for safely positioning a crane on backfilled or firm
ground.
If necessary, increase the support area by stacking suitable ma-
terials under the support plates.
Suitable materials (for example, timbers with the same di-

mensions, special panel constructions made of wood or
metal) must be used for the support! The crane operator
must make these available.
(Z 41 654)
The struts must be in the centre of the support and must co-
ver all supporting timbers sufficiently.
In addition, check whether there are any channels, covered

ditches or cellars in the area where the crane is to be opera-
ted and in which direction they are running. You must also
take hidden dangers such as melting ice or flooding into
consideration.
These dangers are often the cause for cranes falling over.
The following section contains specifications for ”Permitted

ground pressure” for different types of ground and details on de-
termining the necessary support area from this information.
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11
62/67 40C−1110−941b_en
Outriggers 11
11.7.1 Permitted Ground Pressure
The permitted loading of the ground is determined by type and

condition of the ground. Instructions on permitted ground pressu-
res can be found for example, in the standard DIN 1054 “Permit-
ted loading of the construction ground” (for excerpt see the follo-
wing table).
Permitted
Type of ground
ground pressures
N/cm2 psi
1. Organic ground in general:
Peat, sapropel, marshy ground 0 0
2. Non−compressed rubble: rubble, etc. 0 − 10 0 − 15
3. Non−cohesive ground:
Sand, gravel, stones and mixtures of the same 20 29
4. Cohesive grounds:
a) Course clay, mixed with e.g. topsoil 12 17
b) Coarse clay, consisting of all−weather clay and 13 19
clay from slopes
c) Rich clay, consisting of clay and fillers
stiff 9 13
semi−firm 14 20
firm 20 29
d) Mixed granular ground: Clay to sand, gravel and
stone areas
stiff 15 21
semi−firm 22 32
firm 33 47
5. Consistently firm rock:
− cracked with weather wear 150 217
− not cracked 400 580
An examination of the ground must be carried out (for exam-

ple, with a penetrometer) if there are doubts regarding the
load−carrying capacity of the ground.
40C−1110−941b_en 63/67
11
p [N/cm 2] 4 10 15 20 40 150
p [psi] 6 15 21 29 58 217
1 2 3 4 5 6
Fs (kip) Fs (t)
242.5 110
6 5 4 3
220.5 100 2
198.4 90
176.4 80
154.3 70
132.3 60
110.2 50
88.2 40
1
32
66.1 30
44.1 20
22.0 10
As/(m2)
2,2
0 0,5 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0
As/(ft 2)
5.4 10.8 21.5 32.3 43.1 53.8 64.6 75.3 86.1 96.9 107.6
Z 115 351
64/67 40C−1110−941b_en
Outriggers 11
11.7.2 Determining the Required Support Area
The maximum support force for this type of machine is 32 t

(70.5kip).
The outrigger plates supplied as standard have a diameter of
500 mm (19.7 in) (support area of 0.2 m2 / 2.1 ft2).
Procedure
(Z 115 351)
The permitted ground pressure “p” for the type of ground on

which the supporting procedure is to be carried out can be found
in the table in segment “11.7.1 Permitted ground pressure” (page
63).
The corresponding curve (1 to 6) must then be selected for the

assigned graph out of the table in figure (Z 115 351 top).
The support force FS is depicted on the y−coordinate (ordinate)

in the graph in figure (Z 115 351 bottom).
The required support surface AS is noted on the x−coordinate
(abscissa).
Curves 1 to 6 show the relation between the support force FS and
the required support area AS with regard to the permitted ground
pressure “p”.
Example
For a “stiff” mixed−granular ground (clay to sand, gravel and

stone areas) (p=15 N/cm2 (21 PSI)) in accordance with the table
“Permitted ground pressure” in segment (11.7.1), the following
values can be taken for the adjacent diagram:
For p=15 N/cm2 (21 PSI), the values of the curve 3 are the deci-
sive ones (see table (Z 115 351 top).
This results in the support surface area of (As = 2.2m / 23.7 ft) that
is required for the outrigger pads at a maximum support force (Fs
= 32 t / 70.5 kip).
In order to increase the outrigger plate’s support surface area −
which is too small in this example − to the required support sur-
face area, suitable supports (f.e: timber planks) must be laid un-
derneath.
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11
> 6.6 ft
Z 115 307
66/67 40C−1110−941b_en
Outriggers 11
11.8 Safe Distance to Slopes and Pits
(Z 115 307)
Erect the crane with a sufficiently safe distance to slopes or pits.

For non−reinforced slopes or ditches, the distance also depends
on the type of ground.
The distance to the edge of a slope (X) must be at least 2 m

(6.6 ft).
A general rule is:

− For loose or backfilled soils, the safety distance (a) must be
twice the size of the ditch depth (b)
The slope angle a β must be < 30°.
− for natural, firm soils the safety distance (a) must be as large
as the ditch depth (b).
The slope angle a β must be < 45°.
The safety distance is measured starting at the base of the ditch

(C).
If the safety clearance cannot be maintained, the slope or

ditch must be additionally sectioned off.
40C−1110−941b_en 67/67
Parking 12
40C−1120a_en 1/7
12
26
27
Z 115 282
2/7 40C−1120a_en
Parking 12
12 Parking
The mobile crane must be parked so that it is safe from accidents

before it is left.
The following basic instructions must be observed.
12.1 . . . . in the Transport Condition
(Z 115 282)
1. Apply retaining brake (27) of the crane chassis.
The parking brake cannot hold the mobile crane at every slope
or descent that it can drive!
If you must park on a slope or descent, the wheels must be secu-
red additionally using chocks.
2. Switch the drive to the neutral position using the gear selec-
tion switch (26).
3. Move all control levers to the ”Off” or middle ”0” position.
4. Switch heating off it was switched on previously (for engine−

independent heating).
Risk of damage!
If the crane has an engine−independent heating, the engine
may only be switched off after 1 to 2 minutes.
If the engine has to be switched off immediately, the ignition
key must be switched to position ”1” for 1 to 2 minutes.
(Follow−up time of the heater fan for cooling off the heating).
5. Switch off the engine.
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67
Z 115 283
4/7 40C−1120a_en
Parking 12
(Z 115 283)
The position must be observed when the ignition key is removed

in the following:
The ignition key must be removed in position ”1” if, for example,
the hazard warning lights (or similar) are to be left on when the
crane is shut down.
The ignition key must be removed in position ”2” if all electric con-
sumers are to be switched off when the crane is shut down.
6. Pull out ignition key
7. Lock the crane operator’s cab.
8. Place the crane in the transport condition (see segment “Dri-

ving the crane in the transport condition” in section 5).
12.2 . . . . in the Erected State, Supported on Outriggers
1. Set the crane load down on the ground and detach (whene-
ver the crane operator leaves the crane operator’s cab).
2. Lock slew gear brake (see section 17 “Slewing”).
3. Retract telescopic sections.
4. Move all control levers to the ”Off” or middle ”0” position.
5. Switch off the engine.
6. Switch off the heating if it is on.
If the crane is fitted with an engine−independent heating,

switch off the ignition key or battery circuit breaker (optio-
nal) only after 1 to 2 minutes (after−run time of the heater fan
for cooling of the heating system).
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67
Z 115 283
6/7 40C−1120a_en
Parking 12
The position must be observed when removing the ignition key

in the following:
The ignition key must be removed in position ”1” if, for example,
the hazard warning lights (or similar) are to be left on when the
crane is shut down. The ignition key must be removed in position
”2” if all electric consumers are to be switched off when the crane
is shut down.
7. Remove the ignition key in the corresponding position.
8. Lock the crane operator’s cab.
Observe the permitted wind speeds! See section 16 “Wor-

king instructions”.
If required, the main boom or the equipment must be set
down!
40C−1120a_en 7/7
Towing the Crane and Towing the Crane to Start 13
13 Towing the Crane and Towing the Crane to Start
13.1 Towing the Crane to Start
The engine cannot be started by towing. If the engine does not

fire during starting because the battery is partially or completely
discharged, the engine may be started using a jump lead from the
battery of another vehicle (24 V−system).
13.2 General Towing Regulations
The conditions listed in the following sections 13.2.1 to 13.3 must

be observed. They serve to make the crane safer and prevent
further damage.
It is entirely the responsibility of the crane owner or the reco-

very service commissioned by him to tow the mobile crane.
The towing procedure is an exceptional situation, which ent-
ails an increased risk.
If it is possible to repair the crane at the respective site, it

may not be towed away. The crane may be towed only to the
nearest workshop which can be reached. For questions re-
agarding this matter, please refer to our customer service in
Zweibrücken.
In addition to the regulations listed below the respective sta-

tutory national regulations, in particular those concerning
traffic are to be observed.
13.2.1 Towing the Crane in case of Engine demage or defec-

tive Automatic Transmission
To tow the crane in the event of engine failure or defective auto-

matic transmission, the distributor gear must be placed in neutral.
In this condition, the crane must not be towed any faster than 20
km/h (12 mph) and no further than 30 km (18.6 mi).
40C−1130c_en 1/9
13
1
3
2
5
A3
A2
4
A1
Z 115 051
Z 75 071
2/9 40C−1130c_en
If the distributor gear is in neutral, the drive shaft must not

turn, no gear must be engaged.
The indicator light ”all−terrain transmission” must come on.
Check that the ”road travel transmission” and ”all−terrain trans-

mission” indicator lights are functioning.
− If the distributor gear cannot be placed in neutral, the joint

shaft (3) between the distributor gear (2) and automatic trans-
mission (1) must be removed (Z 115 051).
The crane can now be towed in road travel transmission or
all−terrain transmission.
Engaging neutral position on the distributor gear
Initial position:
− Vehicle switched to road travel, corresponding indicator light
comes on.
− The vehicle engine is switched off.
− The air supply in the compressed air system must be at least
approx. 6 bar (87 psi).
To switch to neutral position, proceed as follows:

(Z 75 071)
− Unscrew T−union (2) on shift cylinder (X) and line (3).

− Unscrew plug (1) on shift cylinder (X).
− Firmly secure T−union (2) with the connecting line to connec-
tion (C) on the distributor gear.
− Connect line (3) with union (4) and screw them firmly to con-
nection ”A”.
− Screw plug (1) into connection ”B”.
− Move the selector switch in the cab from ”road travel mode”
to ”all−terrain mode”.
Indicator light ”road−travel mode” continues to be lit.

The joint shaft between the distributor gear and the automa-
tic transmission must not turn.
40C−1130c_en 3/9
13
Z 115 195
Z 115 088
4/9 40C−1130c_en
General points to be observed when towing:
1. The driver of the towing vehicle must be able to communicate

with the driver of the vehicle being towed.
2. An authorized towbar only may be used for towing.
3. To recover the crane in the transport condition using the front

of the vehicle, the towing device (1) contained in the acces-
sories supplied must be used. To this end, the underride
guard must be removed and the towing device bolted to the
middle sheave axis on the main boom head section and sa-
feguarded. During the recovery, extreme caution is required,
in order to avoid damage to the boom head (front) or the en-
gine cowl (rear).
When drawing on the boom head it is important that the hook
block is reeved at least 3 times, and that it is firmly fastened
in the draw bar (on the lower chord of the support case). In
addition, the boom sections must be mechanically secured
to prevent them from extending (1, Z 115 088). To recover
from difficult terrain, the recovery eyes on the bottom of the
support cases should be used.
The towing device may only be used to recover the crane

from a hazardous zone and must be dismantled again imme-
diately upon completion of the recovery procedure. The to-
wing device may not be used to raise loads.
4. Avoid causing any oblique pull during the towing operation.
The hydraulic steering operates at a reduced output (depen-

dent on the speed) and is supplied with hydraulic oil during
the towing procedure by the emergency steering pump atta-
ched to the distributor gear. This means:
− The steering times (time required to engage full left or
right−hand lock from forward steering position) for the
vehicle being towed are approx. 3 to 4 times longer than
those of the towing vehicle.
− When negotiating tight corners, a certain amount of ma-
noeuvring may e required.
− Considerably more effort is required to turn the steering
wheel.
40C−1130c_en 5/9
13
106
S301.1
Z 115 020
1
3
2
5
A3
A2
4
A1
Z 115 051
6/9 40C−1130c_en
5. The braking system and the traction power of the towing ve-
hicle must be sufficient to perform this task.
6. The spring accumulators − brake cylinders may not be lok-

ked mechanically.
7. The compressed air for the brakes on the defective vehicle

must be fed into the braking system upstream of the four cir-
cuit safety valve of the defective vehicle via a hose line from
the towing vehicle. Air is fed from the outside into the air sy-
stem on the left hand side of the vehicle.
(Connection M 22 x 1,5)
Stop the vehicle immediately if:

− The indicator light for the emergency steering pump co-
mes on during towing.
− The air pressure in the supply tanks has dropped below
5 bar (72.5 psi) and the corresponding indicator light co-
mes on.
13.2.2 Towing the Crane with Defective Distributor Gear
When the crane is towed with a defective distributor gear, the

speed of the chassis engine is to be set to approx. 1200 min−1
(rpm) using the manual control. Then switch the crane to super-
structure operation using rocker switch (106, S 301.1; Z 115 020).
No gear should be engaged.
If the distributor gear is damaged, the following drive shafts must

be removed before the crane is towed.
(Z 115 051)
− Drive shaft (3) between the automatic transmission (1) and
the distributor gear (2),
− drive shaft (4) between axle 2 and distributor gear
− drive shaft (5) between axle 1 and distributor gear
To ensure that the road and operational safety of the vehicle

is not endangered, this work may only be performed by trai-
ned specialist personnel.
40C−1130c_en 7/9
13
8/9 40C−1130c_en
13.3 Towing the Crane Free on Soft Ground
Towing of the stuck vehicle where the wheels have dug into the
loose or soft ground must be performed with great care, particu-
larly if the crane superstructure is in configured condition.
Pulling out in the direction of travel is not permitted. The ring in

the front bumper brace is only intended for towing the vehicle on
solid ground.
If it is not possible to tow the crane out in a straight line, a deflec-

tion point between crane and towing vehicle may be arranged.
Ensure that the air pressure in the brake system is sufficient.
40C−1130c_en 9/9
Heating and Ventilation 14
40C−1140−602a_en 1/25
14
2
1 3
78
0 4
69
79
68
66
Z 54 859
2/25 40C−1140−602a_en
14 Heating and Ventilation

(Z 54 859)
14.1 Engine−independent heating
14.1.1 General
(Z 54 859)
This heating system has its own water circuit. The heating
temperature in the cab is regulated using rotary switch (68).
The fan can be set to four different levels using rotary switch (69)
or can be switched off (level “0”). The fan can be used to speed
up circulation of the air in the cab.
Luminous switch (78) can be used to select between fresh air−

and circulation air modes:
− Luminous switch (78) not activated; the indicator light in the
switch does not light up: fresh air operation.
− Luminous switch (78) activated; the indicator light in the
switch lights up: surround air operation.
In the cab there are several vent nozzles. The vent nozzles can
be opened and closed individually as required.
To achieve a maximum effect of the defroster nozzles at the front
window, the other air vents should be closed.
40C−1140−602a_en 3/25
14
2
1 3
78
0 4
69
79
68
66
Z 54 859
4/25 40C−1140−602a_en
In addition, observe the operating instructions of the

manufacturer in part 3 of this documentation.
These are much more detailed and cover additional areas
(for example fitting, safety devices etc.).
The heater may only be used for the purpose specified by the
manufacturer, and all operating instructions supplied must
be observed.
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 enclosed spaces (e.g. garages) due to the 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.
40C−1140−602a_en 5/25
14
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
6/25 40C−1140−602a_en
14.1.2 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.
Before the heating period, a test run should be carried out

using the heater assembly. If strong smoke develops or if
unusual burner noises or the smell of burning fuel occurs,
the heater 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.
40C−1140−602a_en 7/25
14
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
8/25 40C−1140−602a_en
14.1.3 Setting
(Z 36 739)
After connecting the power supply the display shows all signals
flashing − the complete timer must be set. In this condition, the
heater assembly cannot be switched on.
14.1.3.1 Setting the 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. After this, the
weekday flashes.
Set the current week day.
As soon as this stops flashing, it is saved.
With the ignition “ON” the display remains set, with the
ignition “OFF” it goes out after 10 s.
14.1.3.2 Adjusting the time and day of the week
Press longer until the time flashes. Now continue as

described above in section 14.1.3.1 .
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. When the ignition is switched off the
display goes out after 15 s.
Voltage interruptions are bridged by the heater timer.
All signals flash in the display after power failures. The
system must be completely reset!
40C−1140−602a_en 9/25
14
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
10/25 40C−1140−602a_en
14.1.4 Heating operation without pre−set times

(Z 36 739)
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
805C (176 5F) engine temperature so that the heating system
can be vented 100%.
14.1.4.1 ... with the 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

changed one−off or permanently.
Modifying the heating period once

Switch on the heating.
Press − shorten (min. 1 minutes) or lengthen (max. 120
minutes) heating time
Modifying the heating period permanently

Do not switch on the heating
Press and hold approx. 3 s until the display appears 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.
40C−1140−602a_en 11/25
14
MO ºC
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3 20:30
P
1 2 3 4 5
Z 36 739
12/25 40C−1140−602a_en
14.1.4.2 ... with 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 switching off the ignition, 15 minutes residual
heating time remains.
Changing the residual heating time

Switch on the heating.
Press − shorten (min. 1 minute) or lengthen (max. 120
minutes) residual heating time.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
14.1.5 Heating operation with preselection

(Z 36 739)
Starting point: Neutral position, as long as the display is visible.

No memory activated.
Three starting times can be set within the next 24 hours or 1

starting time within up to 7 days.
Only one switch−on time can be activated.
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
80°C (176 5F) engine temperature so that the heating system
can be vented 100%.
40C−1140−602a_en 13/25
14
MO ºC
6
3 20:30
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1 2 3 4 5
Z 36 739
14/25 40C−1140−602a_en
14.1.5.1 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
setting is 12 00.
and is displayed as follows.
Press briefly and release. The selected 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.
The selected time and day are stored as soon as the time
display goes out or switches to time of the day.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for5 s)
40C−1140−602a_en 15/25
14
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
16/25 40C−1140−602a_en
14.1.5.2 Heating start after 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
setting is 12 00.
and is displayed as follows.
Press briefly and release. The selected 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

Approx. 5 s after setting the selected time the selected day is
displayed flashing.
Press to set the preselected day for the heater.
The selected time and day are stored as soon as the time
display goes out or switches to time of the day.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for5 s)
40C−1140−602a_en 17/25
14
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
18/25 40C−1140−602a_en
14.1.6 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 a fault occurs when the heating is switched on and the

diagnosis line is connected, the service indicator light flashes
and the code no. of the fault is displayed (contact garage).
40C−1140−602a_en 19/25
14
2
1 3
78
0 4
69
79
68
66
Z 54 859
20/25 40C−1140−602a_en
14.2 Air conditioning equipment

(Z 54 859)
The air conditioning only works when the engine is running and
the fan is switched on. To operate the air conditioning, proceed
as follows:
1. Set switch (69) to the desired fan level.
2. Press luminous switch (79); the indicator light in the switch

lights up.
The air conditioning works permanently with maximum power.

The actual cooling performance is then determined by selecting
the fan setting.
To achieve the highest level of cooling in the cab:

− Set the fan to the highest level using switch (69)
− Turn the switch (68) fully to the left (anti−clockwise) up to the
stop
− Open the vent nozzles fully
− Press the luminous switch (78) for circulation air mode
− Close the windows and doors in the cab.
Notes on operating the air conditioning equipment
If the cooling output of the air conditioning equipment is

noticeably lower with the setpoint value unchanged and the fan
setting lower, it is possible that the vaporiser has iced up.
In this case, switch off the air conditioning equipment for approx.
3 minutes with the evaporator fan still running. The ice on the
evaporator will melt.
On damp days the air conditioning unit can dehumidify the cab
air. This cooling−off is compensated for using the heater. This
then achieves a pleasant cab climate and prevents windows
fogging up.
Do not direct cold air from the vent nozzles directly onto
unprotected parts of the body.
The air conditioning equipment must be switched on briefly

once a month (compressor lubrication).
40C−1140−602a_en 21/25
14
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
22/25 40C−1140−602a_en
14.3 Liquid gas heating (optional)

There is an operating panel for operating the liquid gas heating
system in the cab.
Depending on the design of the crane, operating panels with
sliding switches or a combined rotary switch are used.
Operating panel with sliding switches
(Z 56 140, principle drawing)
Set the desired room temperature at the control knob (1) of the
operating panel.
Using sliding switch (3), either operating modes “Heat” (C) and
“Ventilation” (E) can be set or the system can be switched off
(switch in middle position ’D’).
Using sliding switch (2), the heating performance can be set in
two stages.
Operating panel with combined rotary switch
(Z 56 138)
The upper part of the rotary switch is designed as a rotating knob

(1.1) and is used as a temperature selection switch.
The lower part (1.2) of the rotary switch is used to switch the
system on and off (d) and is used to set the two operating modes
“Heat” (c) and “Ventilation” (e).
The heater setting and ventilation output can be set in two
stages.
Heating
Proceed as follows to switch on the heating:
1. If fitted, remove the flue cap.
2. Open the bottle valve and quick−action stop valve in the gas
line.
3. Set the desired room temperature using the control knob (1,
Z 56 140 or 1.1, Z 56 138) of the operating panel.
4. Depending on the operating panel, set heating using the

sliding switch (2, Z 56 140) or, if the operating panel has a
combined rotary switch, set heating (”FULL, large flame” or
”1/2, small flame”) using the lower part of the rotary switch
(1.2). At low ambient temperatures start the heating at
“FULL”.
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2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
24/25 40C−1140−602a_en
Ventilation
If the operating panel has sliding switches, slide sliding switch (3)
to position (E) in order to activate the fan.
If the operating panel has a combined rotary switch, the lower

part of the rotary switch (1.2, Z 56 138) is set to the desired
ventilation degree (”FULL” or ”1/2”) in order to activate the fan.
Notes on heating operation

(Z 56 140, Z 56 138)
If the system is activated, the green indicator light under the

control knob must be illuminated. The fan is in operation.
If the control lamp is not illuminated, the fuse in the electronic
control unit must be replaced (see maintenance and lubrication
instructions).
If the heating is switched off after a heating phase, the green light
means that the fan is still running to use up the residual heat. The
ignition switch may therefore only be switched off once the fan
has come to a standstill.
When refuelling and in enclosed spaces (garage, etc.) the

heating may not be operated.
Uninterrupted display of the red control lamp can, amongst other

things, point to a lack of gas, air in the gas line, heavily clogged
blower or malfunction in one of the safety units.
The fault is deactivated by switching the heating off and on again.
Flashing of the red indicator lamp points to low operating voltage

for the heater.
Make sure that the flue for the exhaust and combustion air is
always free of dirt and obstructions (sludge, foliage etc.).
The cap for the flue should always be fitted when the heating is
not in use.
For operation and servicing of your heater, see also the operating
instructions of the manufacturer in part 3.
Before carrying out any welding work, the corresponding

automatic breaker must be switched off.
40C−1140−602a_en 25/25
Safety Equipment 15
40C−1150−941a_en 1/111
15
102
39
38 71
Z 115 414 Z 115 382
106 97 104
73
Z 115 420 Z 115 212
2/111 40C−1150−941a_en
Safety Equipment 15
15 Safety Equipment
15.1 Operating Controls and Display Elements

(Z 115 414)
Item Designation
(75) Operator−interface computer of the crane control sy-
stem
F1 Function key 1
F2 Function key 2
ENTER Enter key
QUIT Quit key
− Deactivate the warning buzzer
− to leave the menu points without saving the
changes
Arrow button up / down
Arrow button to the left / to the right
In this system, all entries are made by ”tapping” on the keys loca-
ted on the housing of the operator−interface computer of crane
control.
The keys are assigned depending on the currently displayed
screen.
The key symbols are shown at the corresponding locations in the
screen for better user guidance.
(Z 115 382, Z 115 420, Z 115 212)

Item Designation
(38) Warning Light
(39) Key switch
(71) Key switch
(73) Key switch
(97) Indicator light for the operating mode switch (106)
(102) Indicator light for the key−operated pushbutton (71)
(104) Indicator light for the key−operated pushbutton (73)
(106) Operating mode switch
Warning buzzer
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Z 115 414
4/111 40C−1150−941a_en
Safety Equipment 15
15.2 Crane Control
15.2.1 Warnings / General

(Z 115 414)
The crane control system combines several devices which pro-

vide the crane operator with essential information for operating
the crane within the parameters stipulated by the manufacturer:
− Overload cut−off device (load limit device LLD)
− Telescoping display
− Display of crane data
− Warning (visual and acoustic) of prohibited conditions.
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 capacity, the total load suspended from the
boom, etc. and gives warning when an overload condition is
being approached or when the hook block gets too close to the
boom head.
Risk of accidents!
This safety equipment does not replace the judgement and
experience of the crane operator or application of recogni-
sed, safe operating methods when operating crane vehi-
cles.
The crane operator is not relieved of his responsibility for
safe crane operation.
Risk of influencing crane control!

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!
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1
106 97
AC40 CITY
4 3
Z 115 420 Z 115 417
6/111 40C−1150−941a_en
Safety Equipment 15
It is essential for the operating safety of the crane that the

crane control functions in its original condition.
Necessary updates must be obtained from the customer
service department of the crane manufacturer.
15.2.2 Operation of Crane Control
15.2.2.1 System Start

The crane control system is automatically started when the igni-
tion is switched on.
Crane control is started in ”Driving mode” to drive the crane (see

15.2.2.2; page 7).
Crane control is started in ”Crane operation” to raise loads (see

15.2.2.3; page 9).
15.2.2.2 Crane Control in Driving Mode

(Z 115 420)
When driving the crane, the operating mode switch (106) is not
actuated. The indicator light (97) is not illuminated.
The ”Driving mode” screen is displayed in the control panel of
crane control.
”Driving mode” screen

(Z 115 417)
Item Designation
(1) Monitoring the position of the lateral platform
(optional):
Platform not completely retracted
(2) Function button F1
to call up the ”Main menu” screen (see 15.3.4 /
page 77)
(3) Display of time
(only for EN 13000)
(4) Display of date
(only for EN 13000)
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106 97
Z 115 420 Z 115 421
Z 115 448
8/111 40C−1150−941a_en
Safety Equipment 15
15.2.2.3 Crane Control during Crane Operation
(Z 115 420, Z 115 421)
The operating mode switch (106) is switched on during crane

operation. The indicator light (97) lights up.
The ”Selection of the operating mode” appears (Z 115 421).
”Selection of Operating Mode” Screen
The crane configuration parameters which were last set are

shown in the ”Selection of the operating mode” screen.
For detailed information on the ”Selection of the operating mode”

screen, see 15.3.2.1, page 47.
If set parameters must be modified due to a change in the assem-

bly and operative state, see segment ”15.3.2.5 Setting the opera-
ting mode parameters” (page 51).
If the set parameters correspond with the actual assembly and

operative state, the ”Selection of the operating mode” screen is
exited by pressing the ENTER key.
The ”Crane operation” screen appears.
”Crane Operation” Screen

(Z 115 448)
This is the screen during crane operation.
For detailed information on the ”Crane operation” screen, see

15.3.3, page 69.
The overload cut−off by the load limit device (LMI) incl. displays,
warnings and interventions of crane control are described in seg-
ment ”Crane operation” (page 13).
The control lever assignment is described in segment ”15.5 Con-

trol lever assignment” (page 101).
If the speed of the crane movements is to be changed, see seg-

ment ”15.4 Speeds” (page 99).
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15
Z 115 449
10/111 40C−1150−941a_en
Safety Equipment 15
If functions must be ”bridged” during crane operation, the corres-

ponding key switches are in and on the crane operator’s cab.
In this case, instructions on using the key−operated pushbuttons
are explained in the corresponding segment.
The weight of the load can be checked using crane control. See
the segment ”91 Load monitoring assembly“ (page 91) in this re-
gard.
”Main Menu” Screen

(Z 115 449)
The ”Main menu” screen must be called up if there are malfunc-

tions in the crane, if brightness and contrast must be set in the
screen, etc.
Several submenus can be called up here for this purpose.
For detailed information on the ”Main menu” screen, see 15.3.4,

page 77.
Procedure in the Event of Faults
If there are malfunctions in the crane, the fault messages, for ex-
ample, can be displayed using the submenus of the ”Main menu”
screen.
The procedure in case of faults is described in segment
”15.3.6 Malfunction procedure” (page 93).
The crane can be operated using the emergency control system
if crane movements must be completed for safety reasons in the
case of a malfunction.
See segment 15.3.6.3, page 95.
15.2.2.4 Switching the System off

Crane control is shut down when the ignition is switched off.
40C−1150−941a_en 11/111
15
12/111 40C−1150−941a_en
Safety Equipment 15
15.3 Crane Operation
15.3.1 Overload Cut−off Using the Load Limit Device (LLD)
15.3.1.1 Normal Operation
15.3.1.1.1 Function
If, when raising a load or increasing the working radius with load,
the permitted load moment/the permitted load is exceeded, both
the movements which increase the load moment and which de-
crease the load moment − ”Raise luffing gear” and ”Raise load on
hook” − are switched off. It is permitted to lower the load on the
hook.
Only movements which decrease the load moment may be initia-
ted after a shutdown by the load limit device.
Risk of accidents!
It is absolutely forbidden to override the load limit device
to overload the crane above its load bearing capacity!
It is prohibited to raise a load with the load limit device brid-
ged.
The load limit device should be triggered only in an emer-

gency. Under no circumstances may it be used as a standard
operating tool!
This means that the crane operator must be satisfied, before
raising the load, that the capacity of the crane is not excee-
ded by the load to be lifted. Loads which are too heavy and
exceed the capacity of the crane may not be picked up even
though a load limit device is fitted.
Even without load, the boom may only be moved within

those ranges for which capacities are specified.
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15
14/111 40C−1150−941a_en
Safety Equipment 15
Detailed information on the display of the load limit device status

can be found in segment ”15.3.3.2 ”Crane operation” screen from
page 69.
Before a load is raised, its weight must be known. The safety de-
vice may not be used to determine the weight!
To make sure 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 con-
figuration is achieved) after the ignition/engine is switched
on.
− be reset by the crane operator after changing the crane confi-
guration.
Risk of accidents!
The crane operator is responsible for the correct setting!
Only when the load limit device has been correctly set by
the crane operator in accordance with the current opera-
ting mode/crane configuration, can it operate automati-
cally!
40C−1150−941a_en 15/111
15
16/111 40C−1150−941a_en
Safety Equipment 15
Risk of accidents − 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 capacity of the ground at 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
− dismantling work, if loads are unscrewed / burnt off after
attaching, 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!
Risk of crushing!
Despite using automatic safety devices, swinging of the

load cannot always be prevented when shutting down.
It can be avoided only by customised accelerations/
speeds of all crane movements.
To do so, also observe the continuous load utilisation dis-
play with advanced warning at 90% of the permitted load
utilisation before shutdown.
40C−1150−941a_en 17/111
15
102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
18/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.1.2 Displays, Warnings and Interventions of the Control

System
(Z 115 418, Z 115 382)
Differentiation in two designs

There must be a differentiation between the ”EN 13000” version
and the ”Non−EN 13000” version.
If the crane is equipped with control software in accordance with

EN 13000, the ”Caution” symbol appears under item (10) when
key switch (71) is activated with a load utilisation of less than
90%.
The ”STOP” symbol appears under item (10) when key switch
(71) is operated with a load utilisation of less than 90% in the
”Non−EN 13000” version.
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15
102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
20/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.1.2.1Design “EN 13000”
(Z 115 418, Z 115 382)
(X) (Y)
Load utilisation Warning Warning Warning (Z)

”Crane Operation” Screen buzzer light siren
(38)
Normal range
(below 90%)
Load utilisation display (1) or (11)
below 90% illumina- unlimited
ted in
green
Advanced war- Warning symbol at item
ning range (10)
(90% − 100%) + interrup-
illumina-
ted war-
Load utilisation display (1) or (11) ning ted in unlimited
between 90% − 100% yellow
sound
Overload range Warning symbol at item
(from 100%) (10)
+
interrup-
Load utilisation display (1): illumina-
Continu- ted war-
100%, ted in stopped
ous tone red ning
load utilisation display (11):
sound
above 100%
− After crane movements have been stopped, load−reducing crane
movements can be carried out again.
In an emergency, it is possible to change to “Operation with activa-
ted set−up button” (see 15.3.1.2.1).
− The overload data are recorded.
All acoustic warnings listed here can be acknowledged / switched off after 5 seconds with
the QUIT key.
Legend:
(X) − Signals for drivers of the crane in the crane cab
(Y) − Signals for people in the crane’s danger zone
(Z) − Execution speed of the crane movements
40C−1150−941a_en 21/111
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102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
22/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.1.2.2 Design ”Non−EN 13000”

(Z 115 418, Z 115 382)
(X) (Y)
Warning Warning Warning
Load utilisation buzzer light siren (Z)
”Crane Operation” Screen (38) (optio-
nal)
Normal range
(below 90%)
below 90% illumina- unlimited
ted in
green
ning range (10)
(90% − 100%) + interrup- interrup-
illumina-
ted war- ted war-
Load utilisation display (1) or (11) ning ted in unlimited
ning
sound sound
(from 100%) (10)
+
Continu- Continu-
100%, ted in stopped
ous tone red ous tone
above 100%
It is possible to switch to “Operation with bridged crane control” (see
15.3.1.2.3.2 ) during emergencies.
− The overload data are recorded if there is an activated overload re-
corder (optional).
the QUIT key.
Legend:
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15
24/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2 Bridging the Load Limit Device
After the crane movements have been switched off by the load
limit device, bridging this safety equipment is only permissible for
special operative states and in emergency situations.
Bridging may only be carried out if the control levers are in

the neutral position and / or the initiated working movement
has been completed.
Risk of accidents!
The overriding of the load limit device may not, under any
circumstances, be used for the purpose of being able to
use the crane for operations which exceed its load carrying
limit!
40C−1150−941a_en 25/111
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102
39
38 71
1 10
15 11
Z 115 382 Z 115 418
26/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2.1 Bridging with the ”Setup” Button

(Z 115 382, Z 115 418)
Bridging with the ”Setup” key is only possible in the ”EN 13000”
version.

90%.
(71) is operated with a load utilisation of less than 90 % in the
Press the ”Set−up” (71) pushbutton to activate the override. To

accomplish this, rotate the key for this key−operated pushbutton
clockwise and then release it.
Effects of the overriding
− The permitted work load of the max. load moment is briefly

increased from 100% to 110%.
− The increased permitted work load continues to be monito-
red. Crane movements are enabled and/or switched off ac-
cordingly.
− The speed of all of the crane movements is limited to a maxi-
mum of 15% of the speed permitted in the case of the respec-
tive load.
Pressing the ”Set−up” pushbutton creates a situation where no

movements are permitted which might lead to component failure
or to the loss of standing stability.
Cancelling bridging is done:
− by actuating pushbutton ”Set−up“ (71) once again

− by setting the control levers into neutral position. Bridging is
then cancelled with a delay (after 10 seconds). If a new crane
movement is initiated within these 10 seconds, bridging will
remain active.
− with an engine stop.
40C−1150−941a_en 27/111
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102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
28/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2.1.1 Displays, Warnings and Interventions of the Control

System
(Z 115 418, Z 115 382)
(X) (Y)
(38)
Normal range Warning symbol at item
(below 90%) (10)
+ illumina-
Continu- greatly
Load utilisation display (1) or (11) ous tone ted in reduced
below 90% green
ning range (10)
(90% − 100%) + illumina-
Continu- greatly
Load utilisation display (1) or (11) ous tone ted in reduced
(100% − 110%) (10)
+
Load utilisation display (1): Continu- flashes greatly
100%, ous tone in yellow reduced
load utilisation display (11): bet-
ween 100% − 110%
(from 110%) (10)
+
interrup-
Continu- ted war-
100%, ted in ning stopped
ous tone
load utilisation display (11): red
sound
above 110%
It is possible to switch to “Operation with bridged crane control” (see
15.3.1.2.3.1 ) during emergencies.
the QUIT key.
CAUTION!
All data is recorded during crane operation with activated setup button (71).
Legend:
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104
73
Z 115 212
30/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2.2 Bridging the Shut−down of the Movement ”Raising

Luffing Gear”
15.3.1.2.2.1 Function
If a prohibited overload condition has occurred, then the ”Luff up”
movement will also shut down by the load limit device. Only lowe-
ring the load on the hook is still permitted.
Once an overload condition has been switched off by the load li-
mit device, this movement can be carried out to move a freely
suspended load out of the overload range again, back into the
normal operating range.
(Z 115 212)
The key−operated pushbutton (73) can then be used to override

the load limit device in order to enable the ”luff up” movement.
To do so, the key in the key−operated pushbutton (73) must be

turned clockwise and held in this position. Indicator light (104, H
705) comes on when the load limit device is bridged.
It is prohibited to lock the key−operated pushbutton me-

chanically!
Risk of accidents!
This movement is only permitted if it is clear that no dange-
rous situations can arise as a result! The crane movement
is executed without the crane controls monitoring whether
or not the executed movement leads to any dangers! Make
sure that this is the case before pressing the key−operated
pushbutton!
The load may only be taken up by the hoist in hook opera-

tion!
If the load is still touching the ground and raising the hoist
was switched off, the load is too heavy. In this case, activa-
ting the ”Luff up” movement is not permitted!
Under no circumstances may the movement “Luffing up”

be used to raise the load.
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102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
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Safety Equipment 15
15.3.1.2.2.2 Displays, Warnings and Interventions of the Control

System
(Z 115 418, Z 115 382)
(X) (Y)

(38)
(from 100%) (10)
+
Continu-
100%, ted in unlimited
ous tone red (*)
above 100%
(*) = Depending on special national regulations, the red lamp in the war-
ning light (15) could possibly also flash in this status.
The overload data are recorded if there is an activated overload recorder (optional).
Legend:
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15
102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
34/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2.3 Bridging the Shut−down of All Movements

(Z 115 418, Z 115 382)
Risk of accidents!
The load limit device may only be bridged as an exception,
for example, for repairs, when fitting a rope or for similar
things.
All crane movements will then be executed without the
crane controls monitoring whether or not the executed mo-
vement leads to any dangers!
This may only be carried out by authorised persons who
are fully familiar with operation of the crane.
Under no circumstances may the load limit device be brid-
ged to increase the load moment.
It is prohibited to raise a load with the load limit device brid-
ged.
There must be a differentiation between the ”EN 13000” version

(see from 39) and the ”Non−EN 13000” version (see from
page 43).

90%.
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15 11
Z 115 418
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Safety Equipment 15
(Z 115 418)
The load limit device can be bridged using a key−operated push-

button.

chanically!
The load limit device may be bridged only in exceptional

cases, for example, for repairs, when fitting a rope or for si-
milar things.
This may only be carried out by authorised persons who
are fully familiar with operation of the crane.
Under no circumstances may the load limit device be brid-
ged to increase the load moment.
It is prohibited to raise a load with the safe load indicator
bridged.
Risk of damage!
Bridging may only be initiated if the control levers are in the
neutral position and/or the initiated working movement has
been completed.
The ”STOP” symbol appears in the crane operating screen under

item (10).
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15
39
102
39
38 71
39.1
Z 115 382 Z 115 442
39
39.2
Z 115 443
38/111 40C−1150−941a_en
Safety Equipment 15
15.3.1.2.3.1 Design “EN 13000”

(Z 115 382, Z 115 442, Z 115 443)
There is a housing (39) with a key−operated pushbutton on the

outside of the rear cab wall for bridging the load limit device.
Proceed in accordance with the following steps in order to over-

ride:
1. Using the required key, step onto the rear area of the lateral
platform while holding on.
2. Open the housing (39). Proceed as follows:
(Z 115 442)
2.1 Press the position lock (39.1) in the direction of the rear
cab wall to unlock the cover of the housing.
(Z 115 443)
2.2 Fold the cover (39.2) back completely and insert the
key in the key−operated pushbutton.
Turn the key in the clockwise direction up to the stop

and then allow it to return to its original position.
Effects of the overriding
− The permitted work load of the maximum load moment will

not longer be limited (and thus also no longer monitored).
− All crane movements will be enabled accordingly.
− The speed of all of the crane movements is limited to a maxi-
mum of 15% of the speed permitted in the case of the respec-
tive load.
Cancelling bridging is done:
− by actuating the key−operated pushbutton once again

− automatically after 30 minutes
− with an engine stop.
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15
102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
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Safety Equipment 15
Displays, Warnings and Interventions of the ControlSystem

(Z 115 418, Z 115 382)
(X) (Y)

(38)
over all load uti- Warning symbol at item
lisation ranges (10)
+
Load utilisation smaller than
100%:
shows the current value
Continu- flashing Continu- greatly
Load utilisation higher than ous tone red ous tone reduced
100%:
Load utilisation display (1):
100%,
load utilisation display (11) shows
the current value
− All crane movements will be carried out without the crane controls
monitoring whether the movements carried out are leading to dan-
gers.
The acoustic warnings cannot be switched off.
CAUTION!
All data is recorded during crane operation with bridged crane control.
Legend:
After ending the override
Once the override has ended, the key for the override pushbutton
must be removed once again and put back in its proper place.
Housing (39) on the outside of the rear cab wall must be closed
again.
Proceed as described on page 39 in the opposite sequence.
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102
39
38 71
Z 115 382
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Safety Equipment 15
15.3.1.2.3.2 Design ”Non−EN 13000”

(Z 115 382)
The load limit device can be bridged using the key−operated

pushbutton (71).
To do so, the key in the key−operated pushbutton (71) must be

turned clockwise and held in this position.
The override will stay in effect for as long as the key−operated

pushbutton is kept in this position.
It is prohibited to lock the key switch mechanically!
The key−operated pushbutton (39) on the rear side of the cabin

(see version ”EN 13000”, p. 39) is indeed also present, but it is
not activated.
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15
102
39
38 71
1 10
15 11
Z 115 418 Z 115 382
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Safety Equipment 15
Displays, Warnings and Interventions of the ControlSystem

(Z 115 418, Z 115 382)
(X) (Y)
Warning Warning Warning
Load utilisation buzzer light siren (Z)
”Crane Operation” Screen (38) (optio-
nal)
over all load uti- Warning symbol at item
lisation ranges (10)
+
Load utilisation smaller than
100%:
shows the current value illumina-
Continu- Continu-
Load utilisation higher than ted in unlimited
ous tone red (*) ous tone
100%:
Load utilisation display (1):
100%,
load utilisation display (11) shows
the current value
− All crane movements will be carried out without the crane controls
monitoring whether the movements carried out are leading to dan-
gers.
(*) = Depending on specific national regulations, the red light of warning
light (38; Z 115 382) can flash in this state as well.
the QUIT key.
The overload data are recorded if there is an activated overload recorder (optional).
Legend:
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1 2 3 4 5
6
7
8
9
10
11
13
Z 115 415
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Safety Equipment 15
15.3.2 ”Selection of Operating Mode” Screen
15.3.2.1 Calling up the ”Selection of the Operating Mode”

Screen
This screen appears:
− after every new start
− by confirming ”ENTER” in the ”Crane operation” screen
15.3.2.2 Structure of the ”Selection of the Operating Mode”

Screen
(Z 115 415)
(1) Scroll up
through the input parameters (see 15.3.2.5 from page 51)
(2) Scroll down

through the input parameters (see 15.3.2.5 from page 51)
(3) Calling up the ”Crane operation” screen

(see 15.3.3.1, page 69)
(4) Display type screen
(5) Calling up the ”Main menu” screen

(see 15.3.4.1, page 77)
(6) Display of the software version
(7) Display of the firmware version
(8) Display of the date

(only for EN 13000)
(9) Calling up the ”Set date and time” screen

(only for EN 13000; see segment 15.3.2.3, page 49)
(10) Display of time

(only for EN 13000)
(11) Operating hour counter hoist 1
(13) Calling up the ”Support pressure / support base area

display” (optional)
(see section 11 ”Outriggers”)
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00:27 01.01.00
00:26 01.01.00
F1 SET
Z 115 416
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Safety Equipment 15
15.3.2.3 ”Set Date and Time” Screen

(Z 115 416)
(only for EN 13000)
Select the number to be changed using the right / left arrows,

change the number using the up / down arrows and confirm with
”F1”.
The ”System time” is updated in the top line.
Exit the screen with ”ENTER”.
15.3.2.4 ”Support Pressure / Support Base Area Display”

Screen (Optional)
Detailed information on this can be found in section 11 ”Outrig-

gers”.
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2 3 4
Z 115 419
2 3 4
Z 115 423
50/111 40C−1150−941a_en
Safety Equipment 15
15.3.2.5 Setting the Operating Mode Parameters

The following screens for operating mode selection are run
through one after the other by repeatedly pressing the ”up / down”
arrows.
15.3.2.5.1 ”Support Base Area” Screen

(Z 115 419)
This screen appears by pressing the ”Down arrow” (2) in the ”Se-
lection of the operating mode” screen.
This screen enables setting of the corresponding support base
area:
− Support base area 2.34 m (7.7 ft); 4.4 m (14.4 ft); 6,2 m
(20.3 ft)
− mobile operation with and without load (0°)
− Operation free on wheels 360°
The operating modes ”Mobile operation” and ”2.34 m (7.7 ft) sup-
port base area” cannot be selected in the crane configuration with
main boom extension or assembly jib and are therefore faded
out.
To change the operating mode, select the desired support base

area using arrows (3) or (4) and confirm with ”ENTER”.
15.3.2.5.2 ”Reevings” Screen

(Z 115 423)
This screen appears by pressing the ”Down arrow” (2) in the

”Support base area” screen.
Select the desired reeving number using the arrow buttons (3) or
(4) and confirm with ”ENTER”.
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2 3 4
Z 115 431
”a” ”b”
Z 115 432
52/111 40C−1150−941a_en
Safety Equipment 15
15.3.2.5.3 ”Crane Configuration” Screen

(Z 115 431)

”Reevings” screen.
To change the operating mode, make the desired selection using
arrows (3) or (4) and confirm with ”ENTER”.
15.3.2.5.3.1 ”Operation with Main Boom” Screen

(Z 115 432)
If the operating mode ”Main boom” is selected in the ”Crane con-

figuration” screen (Z 115 432 ”a”), a selection can be made bet-
ween the settings listed below:
(Z 115 432 “b”)

Operation with ”hoist rope”
Operation with ”0°−hoist” (lifting beam, optional)
Function not assigned
Detailed information on operation with ”0°−hoist” (lifting beam)

can be found in section 26 ”Lifting beam (optional)”.
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”a” ”b”
Z 115 434
Z 115 134
”a” ”b”
Z 115 433
54/111 40C−1150−941a_en
Safety Equipment 15
15.3.2.5.3.2 ”Operation with Boom Point” Screen (Optional)

(Z 115 434)
If the operating mode ”Assembly jib” is selected in the ”Crane

configuration” screen (Z 115 434 ”a”), a screen for setting the as-
sembly jib position appears (short, medium, long):
(Z 115 434 “b”)

short pegging
medium pegging
long pegging
(Z 115 134)
If loads are to be raised with the assembly jib without a hoist rope,
this option must be selected in addition to the position of the
boom point (short, medium, long) by pressing the ”F2”−key.
Detailed information on this can be found in section 27 ”Assem-

bly jib (optional)”.
15.3.2.5.3.3 ”Operation with the Main Boom Extension”

(Optional)
(Z 115 433)
If the operating mode ”Main boom extension” is selected in the

”Crane configuration” screen (Z 115 433 ”a”), a screen
(Z 115 433 ”b”) for setting the main boom length and angle ap-
pears.
Detailed information on this can be found in section 21 ”Main

boom extension (optional)”.
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2 3 4
”a” ”b”
Z 115 436
Z 115 438
56/111 40C−1150−941a_en
Safety Equipment 15
15.3.2.5.4 ”Counterweight” Screen

(Z 115 436)

”Crane configuration” screen.
If the crane is equipped with a standard counterweight (remova-
ble 2.3 t (5.1 kip) counterweight plate), two counterweight sym-
bols appear for selection:
− ”upper” counterweight symbol: Counterweight Combination
5.4 t (11.9 kip)
− ”lower” counterweight symbol: Counterweight Combination
3 t (6.6 kip)
To change the operating mode, make the desired selection using
arrows (3) or (4) and confirm with ”ENTER”.
Only the ”upper” counterweight symbol appears if the crane is

equipped with the 5.4 t (11.9 kip) counterweight combination
which is firmly screwed in place.
It is then possible to scroll in the ”Operating range limit” screen
directly.
15.3.2.5.5 ”Operating Range Limits” Screen

(Z 115 438)
This screen appears by pressing the ”Down arrow” (2) in the ”Co-
unterweight” screen.
Select the operating range to be set using the arrow keys and
change the setting display using the ENTER key.
The crane control system has programmable limit values for the
operating range of the crane. Programming is made easy by in-
teractive menu prompts.
The functions can be used separately or combined. Several ope-

rating range limits can be active at the same time.
If operating range limits are active, the ”LIM” symbol appears in

the screen.
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Safety Equipment 15
Limit values which have not been saved are lost when the ignition
is switched on again (see 15.3.2.5.5.6 ”LIM settings”).
Already set operating range limits can be switched to passive

mode at short notice.
When an active limit value is approached, the symbol “LIM” flas-

hes in the display and the pilot control speed is automatically re-
duced.
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 (see 15.3.2.5.5.1 , page 61)
− Head height limit (see 15.3.2.5.5.2 , page 61)
− Radius limit (see 15.3.2.5.5.3 , page 63)
− Luffing angle limit (see 15.3.2.5.5.4 , page 63)
− Virtual wall (see 15.3.2.5.5.5 , page 65)
This safety equipment is no substitute for the judgement

and experience of the crane operator and application of re-
cognised safe operating procedures for the use of cranes.
The crane operator is not relieved of his responsibility for
safe operation of the crane.
Remember to deactivate the activated limits as soon as ope-

ration within a limited operating range is completed.
Otherwise, during a subsequent crane operation which can
be carried out without limits, shutdown may be unintentional
and abrupt, causing the hook block/load to swing outwards
widely.
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Z 115 181
Z 115 182
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Safety Equipment 15
15.3.2.5.5.1 Slewing angle limit

(Z 115 181)
Programmable function used to limit the left and / or right slewing

angle.
− Bring main boom into the left (right) limit position.
− Program slewing angle position with “F2” as left (right) limit.
− The ”Slewing angle limit” function can be switched to ”pas-
sive” and back to ”active” again using QUIT.
The screen switches from ”active” to ”passive” and vice versa.

The symbol “LIM” appears when the function is “active”. The ac-
tual value is always shown in the centre of the display.
− Both limits can be switched on / off separately or completely

using the F1 key. The function that has been switched off ap-
pears crossed through.
15.3.2.5.5.2 Head height limit

(Z 115 182)
Programmable function used to limit head height.

− Extend boom head up to required height limit.
− Program boom head height as the height limit using “F2”.
− The ”Height limit” function can be switched to ”passive” and
back to ”active” again using QUIT.

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Z 115 183
Z 115 184
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Safety Equipment 15
15.3.2.5.5.3 Radius limit

(Z 115 183)
Programmable function used to limit the smallest and / or largest

working radius.
− Move main boom to smallest (largest) required radius.
− Program radius as smallest (largest) limit using “F2”.
− The ”Radius limit” function can be switched to ”passive” and


15.3.2.5.5.4 Luffing Angle Limit

(Z 115 184)
Programmable function used to limit the top and / or bottom main

boom angle.
− Luff up (luff down) main boom to required limit angle.
− Program main boom angle as top limit (bottom limit) using
“F2”.
− The ”Luffing angle limit” function can be switched to ”passive”
and back to ”active” again using QUIT.


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Z 115 185
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Safety Equipment 15
15.3.2.5.5.5 Virtual Wall

(Z 115 185)
Programmable function used to limit the operating range with one

or two walls.
Both walls must be left and right of the centre of rotation. The
walls cannot both be on the same side of the centre of rotation.
− Drive up to the 1st limit value P1 (radius and slewing angle)

as definition point 1 for the virtual wall 1 (2).
− Program 1st limit value using “F2”.
− Drive up to the 2nd limit value P2 (radius and slewing angle)
as definition point 2 for the virtual wall 1 (2).
− Program 2nd limit value using “F2”.
− The ”Virtual wall” function can be switched to ”passive” and

tual value is always shown in the centre of the screen.
The virtual wall is defined by the vertical level that runs through
both limit values P1 and P2. The precision of the virtual wall is in-
creased by a sufficiently large distance between P1 and P2 in the
horizontal.

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Z 115 186
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Safety Equipment 15
15.3.2.5.5.6 LIM Settings – Saving the Limit Values

(Z 115 186)
After exiting each operating range limit, you can save your most
recently set limit values, i.e. the most recently programmed limit
values are still available after a system restart.
If you would like to save the most recently programmed values,

press “Enter” (YES).
If you do not want to save the most recently programmed values,

press “QUIT” (No).
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15
31 1 2 3
30
29
28 4
27
26 5
25
24
23 10
22 11
21 20 19 18 17 16 15 14 13 12 Z 115 413
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Safety Equipment 15
15.3.3 ”Crane Operation” Screen

(Z 115 413)
15.3.3.1 Calling up the ”Crane Operation” Screen

This screen appears by pressing ”ENTER” in the ”Selection of the
operating mode” screen (see page 47).
15.3.3.2 Structure of the ”Crane Operation” Screen

(1) Bar display of the exploited load capacity
Description Load utilisation
Normal range below 90%
Advanced war- 90% − 100%
ning range
Overload range from 100%
When the overload range has been reached, the load limit device
switches off the load moment increasing movements and ’Raise
luffing gear’.
In addition to the load utilisation display screens, other acoustic

and visual warning signals within and outside of the crane opera-
tor’s cab are emitted. See segment 15.3.1.1.2 “Crane control
characteristics in relation to loading” (from page 19) in this regard.
(2) current gross load

The gross load includes the weight of the hook block, the
hoist rope and all load−handling devices.
(3) Max. load in accordance with load table
(4) current net load

See segment ”15.3.5 Load monitoring assembly” (page
91).
(5) Load radius
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15
6
7
8
Z 115 422
31 1 2 3
30
29
28 4
27
26 5
25
24
23 10
22 11
21 20 19 18 17 16 15 14 13 12 Z 115 413
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Safety Equipment 15
Setting the speeds
(Z 115 422)
For adjustment of the working speeds, please refer to the section

on operating instructions.
(6) Slewing speed
(7) Hoist speed
(8) Speed of lowering luffing movement
Positions (6), (7) and (8) only appear if crane movements are
being finely tuned using the rocker switches of the control levers.
(Z 115 413)
(10) Warning symbols

Symbol Meaning
LMI advance warning
Load limit device shut−down
(11) Percentage display of exploited load capacity
(12) Display
Symbol Meaning
Request for telescoping in:
Flashing display if there is currently no syn-
chronicity with synchronous extension se-
quences.
Remedy: Telescope the main boom in again
briefly until there is synchronicity again.
Then the symbol ”Request for telescoping
in” will disappear.
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31 1 2 3
30
29
28 4
27
26 5
25
24
23 10
22 11
21 20 19 18 17 16 15 14 13 12 Z 115 413
72/111 40C−1150−941a_en
Safety Equipment 15
(13) Telescopic operating mode

Figure Description
Field mar- Field mar-
ked with ”1” ked with ”2”
black black Extension sequence ”Syn-
chronous”: both telescopic
sections extend simulta-
neously
black white Extension sequence ”1”:
first extend telescopic sec-
tion 1 and then telescopic
section 2
white black Extension sequence ”2”:
First telescope out tele-
scopic section 2 and then
telescopic section 1
The symbol displayed on the left appears in the correspon-

ding field when the telescopic section is completely telesco-
ped in.
(14) Percentage display of extended telescoping lengths
(15) Display of max. / min. main boom angle achieved

When luffing to the maximum or minimum main boom an-
gle, the load limit device switches off and the corresponding
symbol flashes:
Symbol Meaning
Maximum main boom angle
Minimum main boom angle
(16) Head height
(17) Radius
(18) Angle of main boom (to the horizontal)

When the main boom is telescoped out, the load limit device
switches the movement off when a main boom angle of 0°
to the horizontal has been achieved.
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31 1 2 3
30
29
28 4
27
26 5
25
24
23 10
22 11
21 20 19 18 17 16 15 14 13 12 Z 115 413
74/111 40C−1150−941a_en
Safety Equipment 15
(Z 115 413)
(19) ”MIN”
This display appears as soon as the limit value for the load
radius has been achieved and the corresponding display
(5) is flashing. The load limit device then switches off the
crane movement.
(20) Superstructure position ”180° to the front”
(21) Superstructure position ”0° to the rear”
(22) Support base area

The set support base area is shown black.
(23) Counterweight
(24) Reeving number
(25) ”SES”
Lower limit switch is triggered
(26) Main boom length
(27) ”HES”
Hoist limit switch is triggered
(28) ”MAX”
This display appears as soon as the limit value for the main
boom length has been achieved and the corresponding dis-
play (26) is flashing. The load limit device then switches off
the crane movement.
(29) ”STB” (optional)

If the support base area has not been approached correctly,
the letters ”STB” appear here and all the outriggers flash in
the crane figure.
(30) ENTER
Call up the ”Selection of the operating mode” screen
(31) F1
Call up the ”Main menu” screen
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1 2 3 4 5 6 7
8
9
13
10
12 11
Z 115 424
76/111 40C−1150−941a_en
Safety Equipment 15
15.3.4 ”Main Menu” Screen
15.3.4.1 Calling up the ”Main Menu” Screen

This screen appears by pressing ”F1” in the ”Selection of the ope-
rating mode” screen, ”Crane operation” screen and in the ”Driving
mode” screen.
15.3.4.2 Calling up the ”Main Menu” Screen

(Z 115 424)
(1) Scroll up
to select the submenu
(2) Scroll down

to select the submenu
(3) to change to the selected submenu

(4) Contrast screen
(see 15.3.4.3, page 79)
(5) Visual display computer inputs / outputs screen

(see 15.3.4.4, page 79)
(6) Fault messages screen

(see 15.3.4.5, page 81)
(7) Datalogger screen (optional)

(see 15.3.4.6, page 85)
(8) Superstructure inputs / outputs screens

(see 15.3.4.7, page 87)
(9) Service screen

(only for the customer service team)
(10) to exit the screen

jumps back to the screen from which the ”Main menu”
screen was selected
(11) Chassis inputs / outputs screen

(see 15.3.4.8, page 89)
(12) Valve settings screen

(only for the customer service team)
(13) Brightness screen

(see 15.3.4.9, page 89)
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15
F2
Z 115 430
CGC E/As 1/5

I2.9.9 on Q2.1.9 off
I2.9.10 on Q2.1.10 off
I2.9.11 on Q2.1.11 off
I2.9.12 off Q2.1.12 off
I2.9.13 off Q2.1.13 off
I2.9.14 off Q2.1.14 off
I2.9.15 off Q2.1.15 off
I2.9.16 off Q2.1.16 off
Z 115 425
78/111 40C−1150−941a_en
Safety Equipment 15
15.3.4.3 ”Contrast” Screen

(Z 115 430)
This screen appears when item (4) is pressed in the ”Main menu”
screen.
The contrast of the screen can be selected in the ”Contrast”
screen using the arrow buttons (right/left) and then saved with
”ENTER”.
In the case of strong sunlight, the display can be inverted with

”F2” (optional).
15.3.4.4 ”Visual Display Computer Inputs / Outputs” Screen

(Z 115 425)
screen.
The individual inputs and outputs of the visual display computer
are shown in this screen. You can scroll through the pages using
the arrow buttons.
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E524
E505
Z 115 426
80/111 40C−1150−941a_en
Safety Equipment 15
15.3.4.5 ”Fault Messages” Screen

(Z 115 426)
screen.
If there is a fault in the control system, a fault list appears in the
display (for list of the fault codes, see from page 33). Each fault
must be confirmed with the ”Acknowledge key“. Each time the
ignition is switched on, all faults which have not yet been rectified
are displayed again.
Faults in the electronic microprocessor must be dealt with by trai-

ned service personnel from the crane manufacturer.
Malfunctions in the load limit system which have been caused by

the stipulated ranges being exceeded or by mistakes in operation
on the part of the crane operator, are indicated on the LCD dis-
play together with an explanation.
The crane operator can usually rectify these malfunctions him-
self.
Only the last 10 fault codes can be called up. If a new fault occurs,
the oldest stored fault code is deleted.
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82/111 40C−1150−941a_en
Safety Equipment 15
Fault code Fault description

E501 Length transducer tele 1 defective
E502 Length transducer tele 2 defective
E503 Angle transmitter defective
E504 Pressure transmitter defective
E505 Slewing angle transmitter defective
E506 Hoist limit switch: short circuit or potential dividerre-

sistance is too small
E507 Hoist limit switch: circuit break or potential divider
resistance too large
E510 Data logger not functioning
E521 CGC fault to chassis DIGSY

E522 CGC fault to superstructure DIGSY
E523 CGC fault to superstructure and chassis DIGSY
E524 Malfunction of the CAN connection
E525 Front left strut length indicator not active

E526 Front right strut length indicator not active
E527 Rear left strut length indicator not active
E528 Rear right strut length indicator not active
E530 Signal interruption joystick left

E531 Signal interruption joystick right
E532 Direction contacts joystick left
E533 Direction contacts joystick right
E540 No internal or external release ofhydraulic module 1

E541 No internal or external release ofhydraulic module 2
E542 No system data and/or magnetic data storedin hy-
draulic module 1
E543 No system data and/or magnetic data storedin hy-
draulic module 2
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Z 115 437 Z 115 435
84/111 40C−1150−941a_en
Safety Equipment 15
Fault code Fault description

E551 Proportional valve channel open or short circuit
inhydraulic module 1
E552 Proportional valve channel open or short circuit
inhydraulic module 2
E570 Short circuit marker of the CGC outputs

E571 Short circuit marker of the binary board super-
structure outputs
E572 Short circuit marker of the binary board chassis
outputs
15.3.4.6 Data Logger (Optional)

(Z 115 437)
If the diskette symbol (7) appears in the display, a data logger is

installed and active.
Risk of accidents!
If the fault message ”E510 − data logger not functioning”
appears, the data logger must be repaired as soon as
possible.
Please consult the crane manufacturer’s customer ser-
vice team in this regard.
(Z 115 435)
The battery symbol appears in the ”Crane operation” screen if the

datalogger battery must be replaced.
If the battery is not replaced immediately, any data to be saved
could be lost.
40C−1150−941a_en 85/111
15
0
1 2
8.1 598 75 % +0 600 50 % +0 +0
8.4
8 0 0 0 1 1 0 0 0 1 1 1 1
8.2
LG1 LG2
+918 0 +908 0
1 2
WG
606 SYN +0 +0 +858 0 8.5
P
0 0 0 1 1 1 1 +382
Binary inputs of the superstructure 1/4

E1.1 on E2.1 off
E1.2 off E2.2 off
0 E1.3 off E2.3 off
8.3 596 40 % +0
E1.4
E1.5
off
off
E2.4
E2.5
on
off 8.6
E1.6 on E2.6 off
E1.7 off E2.7 off
E1.8 off E2.8 off
0 0 0 1 1
Z 115 427
86/111 40C−1150−941a_en
Safety Equipment 15
15.3.4.7 ”Superstructure Inputs / Outputs” Screens
15.3.4.7.1 Calling up the ”Superstructure Inputs / Outputs” Screens

(Z 115 427)
These screens appear when item (8) is pressed in the ”Main

menu” screen.
15.3.4.7.2 Superstructure Inputs / Outputs That Can Be Viewed

You can scroll through the individual screens using the corres-
ponding arrows. This is done in a fixed sequence.
Information concerning the different superstructure inputs / out-

puts can be obtained in the screens below:
(8.1) Slewing the superstructure
(8.2) Telescoping
(8.3) Luffing gear
(8.4) Hoist
(8.5) LMI sensor system
(8.6) Binary inputs of the superstructure
These screens can be exited using ”QUIT”.
40C−1150−941a_en 87/111
15
Binary inputs of the carrier 1/8

E1.1 off E2.1 off
E1.2 off E2.2 off
E1.3 off E2.3 off
E1.4 off E2.4 off
E1.5 off E2.5 off
E1.6 off E2.6 off
E1.7 off E2.7 off
E1.8 off E2.8 off
11
Z 115 428
F2
13
Z 115 429
88/111 40C−1150−941a_en
Safety Equipment 15
15.3.4.8 ”Chassis Inputs / Outputs” Screen

(Z 115 428)
This screen appears when item (11) is pressed in the ”Main

menu” screen.
The individual inputs and outputs of the control unit are displayed
in the ”Chassis inputs / outputs” screen. You can scroll through
the pages using the arrow buttons.
15.3.4.9 ”Brightness” Screen

(Z 115 429)
This screen appears when item (13) is pressed in the ”Main

menu” screen.
The brightness of the screen can be selected in the ”Brightness”
screen using the arrow buttons (right/left) and then saved with
”ENTER”.
In the case of strong sunlight, the display can be inverted with

”F2” (optional).
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15
Z 115 439
90/111 40C−1150−941a_en
Safety Equipment 15
15.3.5 Load Monitoring Equipment

(Z 115 439)
It is possible to check the weight of the raised load (net load)

using the computer of the load limit device.
The load monitoring equipment may not be used to calculate

the weight of the load, but is used to check the weights of
loads which have been previously calculated. This helps to
estimate the load lift better and prevent possibly hazardous
situations.
Before raising the load, the maximum load for the operative state
must be determined. It is shown in relation to the selected opera-
ting mode in the screen in the ”MAX” display (3).
Load monitoring
1. If the hook block is suspended (without load, with load hand-

ling equipment), press the ”QUIT” key. The lifting tackle is ta-
red and set to 0.0 t net load (”NET” (4)).
The load may only be raised with the hoist. Raising the load
by extending the telescopic sections or luffing cylinders is
prohibited!
2. Raise the load with the hoist.

The net display now shows the net load (actual load on the
hook without load handling devices).
The gross load includes − besides the weight of the load − the
weight of the hook block, the hoist rope and all load handling devi-
ces. The net load is the actual load on the hook block without the
load handling devices. Display errors are possible due to external
factors, such as wind acting on the crane and the load, for exam-
ple.
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Safety Equipment 15
15.3.6 Procedure in the Event of Faults
15.3.6.1 Fault−free Operation

If operation is free of malfunctions, the currently set menus and
screens are shown in the display. Crane movements can be ex-
ecuted with the aid of the control lever.
15.3.6.2 Operation with Fault Messages Whose Cause

Cannot be Rectified
DANGER!
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.
In this event, please contact our customer service depart-
ment!
The faults must be rectified before crane operation can be
continued.
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15
94/111 40C−1150−941a_en
Safety Equipment 15
15.3.6.3 Emergency control system
Function of emergency control
Emergency control enables the crane operator to bring the crane

into a safe state if crane control fails.
All crane movements (telescoping, luffing, slewing, hoists) can
be carried out.
Caution − increased risk of accidents!

If emergency control is activated all safety equipment is
DEACTIVATED.
You must observe the following:
− The crane operator must be aware that all safety equip-
ment is deactivated when emergency control is activa-
ted. Activating emergency control is the sole direct re-
sponsibility of the crane operator.
− Emergency control may only be activated in order to
move the crane out of a dangerous situation or to lower
the load.
− Emergency control may only be activated by persons
who are acquainted with operation of the crane!
− Under no circumstances may emergency control be
used to increase the load moment!
− It is prohibited to raise a load with the emergency control
system activated.
The fault must be rectified before continuing crane opera-

tion.
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15
29
39
105
Z 115 380 Z 115 381
96/111 40C−1150−941a_en
Safety Equipment 15
(Z 115 380, Z 115 381)
Proceed as follows to activate emergency control.

1. Activate key switch (29, S 710) in the main electrical unit.
2. For cranes with the ”EN 13000” version:
Activate key−operated pushbutton (39) on the exterior of the
rear cab wall.
If the emergency control system is activated, indicator light
(105) is illuminated.

90%.
Time limits
Once the emergency control system has been activated in cra-

nes with the ”EN 13000” version, there is only a limited time in
which it is possible to carry out a crane movement (30 min).
Once this time has passed, emergency control switches off

again.
Indicator light (105) goes out.
Key−operated pushbutton (39) must be pressed again in order
to carry out further crane movements.
Crane movements with activated emergency control
Crane movements are carried out at significantly reduced

speeds.
Risk of accidents!
As standard crane control is not functioning, it is not
possible carry out the movements sensitively. Crane mo-
vements might be jerky.
Carry out crane movements with particular care.
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Safety Equipment 15
15.3.7 Service and Maintenance

Maintenance of the LLD systems involves the following tasks:
1. Checking all cable connections in the system.

Damaged cables must be replaced immediately.
2. Checking the insulation of the length transducer cables and

the cable guides.
Worn insulation and damaged cable guides must be repla-
ced.
3. Checking that the hoist limit switches operate smoothly.
4. Checking that the cable drum is sufficiently pretensioned.
5. Checking the pressure contacts on the luffing cylinder and

the connection hoses for oil leakage.
Personnel that has not been specially trained may only rectify
faults listed in the maintenance table and may not replace defec-
tive mechanical components and cables.
15.4 Speed
Any required information on the subject of speed can be found

in section 16 ”Working Instructions” under segment ”Operating
information on pilot control”.
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15
+YL +YR
−XL +XL −XR +XR
−YL −YR
25
11
Z 115 335
100/111 40C−1150−941a_en
Safety Equipment 15
15.5 Control Lever Assignment
(Z 115 335)
Left−hand control lever (11)

Direction Function
+XL Superstructure slews clockwise
(to the right)
−XL Superstructure slews anticlockwise (to the
left)
+YL Main boom telescopes out
−YL Main boom telescopes in
Right−hand control lever (25)

Direction Function
+XR Lower main boom (luff down)
−XR Raise main boom (luff up)
+YR Lower hoist (load)
−YR Raise hoist (load)
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Z 115 440
102/111 40C−1150−941a_en
Safety Equipment 15
15.6 Limit Switches
15.6.1 Hoist Limit Switch
Before working with the crane, the electrical connections listed

below must be checked to ensure that the components of the LLD
system are functioning correctly and are connected in accor-
dance with the crane configuration.
15.6.1.1 Function
(Z 115 440)
Hoist limit switches are safety devices that limit the upwards mo-
vement of hoist ropes and hook blocks.
This prevents collisions between the hook block and boom head
and therefore possible damage to these parts or also to the hoist
rope, which could cause the load to be dropped.
For this reason, the crane may only be operated with fully func-
tional hoist limit switches that have not been triggered.
RISK OF ACCIDENTS!
The hoist limit switch must be activated daily and chek-
ked that it functions properly.
If the hoist limit symbol (HES) lights up, this indicates that a hoist
limit switch has been tripped. The alarm sensor sounds. The follo-
wing 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 to end this prohibited

state.
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Safety Equipment 15
If the crane is only operating with the main boom without the main
boom extension, no additional connections are required.
You should, however, ensure that the hoist limit switch weight of
the main boom hoist rope is fitted.
With an even number of rope falls, the hoist limit switch weight is
fitted to the ”dead end” of the hoist rope.
With an odd number of rope falls, the hoist limit switch weight is
fitted to the rope fall with the lowest operating speed. (see Sect.
22)
When the crane is being operated with a main boom extension

or top section, the particular plug−in cable connections must be
changed round.
The hoist limit switch shift weight of the main boom is then uncou-
pled, and is fitted and secured to the main boom head on the ap-
propriate bracket (see section 21).
The hoist limit switch can be fitted on the right− and on the left−
hand side.
If the hoist limit switch shift weight has not been correctly
positioned, the hoist limit system cannot function properly.
When working with an extension / top section, a weight may
not be fitted on the hoist limit switch of the main boom.
15.6.1.2 Function Test of the Hoist Limit Switch
The following inspections must be carried out carefully

to prevent damage to the crane or injury to persons.
The way these inspections are carried out determines
whether the load limit system will function smoothly or
not.
If the crane operator is not able to clearly observe the approach

of the hook block towards the sheave head, he should appoint a
banksman for the purpose.
The crane operator must be prepared to stop the crane immedia-
tely if the load limit device is not functioning correctly, ie if the
STOP symbol fails to light up, the acoustic alarm does not sound
and dangerous crane movements are not shut down.
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15
106/111 40C−1150−941a_en
Safety Equipment 15
1. Check the hoist limit switch warning and the acoustic alarm
by lifting the hoist limit switch weights manually.
2. Carefully pull the hook block with the main hoist against the
hoist limit switch weight.
As soon as the hook block raises the weight, the acoustic
alarm must be triggered, the hoist limit switch warning must
light up and the main hoist must be switched off.
Lower the hook block somewhat to rectify this condition.
3. Then telescope out in order to create a possible hoist limit

state.
As soon as the hook block raises the weight, the acoustic
alarm must go off, the hoist limit switch warning must light up
and the telescoping procedure must be switched off.
If the warning and the acoustic alarm do not function as descri-

bed and the crane movements are not switched off, the system
does not function correctly.
The fault must be rectified before work with the crane is resumed.
4. If the crane is fitted with the main boom extension or a top

piece, the testing procedure must be repeated for the hoist
limit switch on these.
Once correctly adjusted, the load limit system operates fully auto-
matically.
The crane operator must therefore be fully conversant with the
controls of the load limit device and must set all switches correctly
before carrying out work with the crane.
All settings must be checked by raising a known load and compa-
ring it to the information displayed on the load limit device.
The values of the load table comprise the weight of the hook
block, the sling ropes and the other load handling devices.
These weights must be deducted from the values of the load ta-
ble in order to attain the net load to be raised.
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15
103
H701
72
S701
Z 115 027
108/111 40C−1150−941a_en
Safety Equipment 15
15.6.1.3 Bridging the Hoist Limit Switches
(Z 115 027)
Bridging may only be carried out if the control levers are in

the neutral position and/or the initiated operating movement
has been completed.
The limit switches may only be bridged in exceptional ca-

ses, for example, when configuring the crane (fitting or chan-
ging equipment parts, fitting ropes, etc.).
Operating the crane with the limit switches bridged is

prohibited. RISK OF ACCIDENTS!
Key−operated pushbutton (72) is used to override the hoist limit

switches ”raise hoists”.
Turn the key in a clockwise direction and hold it in this position.

chanically.
The indicator light (103) must light up when the limit switch is brid-
ged.
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Z 115 440
110/111 40C−1150−941a_en
Safety Equipment 15
15.6.2 Lower Limit Switches
15.6.2.1 Function
(Z 115 440)
Lower limit switches are safety devices that switch off unreeling
of the hoist rope once it has been unreeled with 3 turns remaining
on the drum. This prevents the rope being wound back on in the
opposite direction.
If one of the lower limit symbols (SES) lights up, this indicates that
the corresponding lower limit switch has been tripped and the
warning buzzer sounds. ”Lower hoist” is switched off. Only ”raise
hoist” is possible.
15.6.2.2 Bridging the Lower Limit Switches
A lower limit switch must be bridged directly at the corresponding

proximity switch.
The lower limit switches may only be bridged in exceptional

cases (for example, to change or fit ropes).
Operating the crane with the limit switches bridged is

prohibited. RISK OF ACCIDENTS!
40C−1150−941a_en 111/111
Notes on Operation 16
40C−1160−818b_en 1/39
16
2
3
Z 53 496
160
P100
168
Z 115 057
2/39 40C−1160−818b_en
16 Notes on Operation
16.1 Wind Forces on the Crane
It is essential that you observe the permitted maximum wind

speeds.
16.1.1 Measuring the Wind Speed

(Z 53 496, principle drawing Z 115 057)
Depending on the design of your crane, it is equipped with a ma-

nual wind speed indicator or with a firmly fitted wind speed indica-
tor (optional).
The firmly fitted variant consists of two elements:

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 tigh-
ten.
(Z 115 057)
2. the display on the display unit MFA 10 (160) in the crane
operator’s cab. By activating switch (168), the wind speed
can be read in km/h.
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.
40C−1160−818b_en 3/39
16
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16.1.2 Behaviour in Relation to the Wind Speed
Erecting the boom system
For all crane configurations the boom system may only be erec-
ted (raised from the ground) if the expected wind speeds (wea-
ther forecast) are also permitted for operation of the crane.
Measures to be taken in accordance with the wind speed
Risk of accidents!
− When planning operation of the crane, you must obtain
information from the relevant weather station concer-
ning the expected wind forces for the period of time the
crane is to be used.
− Adhere to the maximum wind speeds listed in the load
capacity table.
− Observe the valid national regulations.
Wind speed What you have to do....

up to 9.8 m/s operation of the crane is per-
(35 km/h; 21.9 mph) mitted without any restrictions
or the maximum wind speed
listed in the load capacity ta-
ble
exceeding 9.8 m/s Cease working with the
(35 km/h; 21.9 mph) crane; place the main boom
in the high position and tele-
scope in fully;
the main boom extension can
remain in the operating posi-
tion.
If possible, place the boom
system into the wind.
from 15 m/s Main boom telescoped in and
(54 km/h; 33.6 mph) set down in the transport po-
sition
Also observe the information in the “Instructions on crane opera-

tion”, which are with the load capacity tables.
40C−1160−818b_en 5/39
16
6/39 40C−1160−818b_en
Setting down at the right time when the wind speed is too
high
Risk of accidents!
If wind speeds over 15 m/s (33.6 mph) are expected, place
the boom system in the transport position at the right time.
Planning to set down the crane in an emergency
Risk of accidents!
− At the work site make sure that sufficient space is left in
the vicinity of the crane so that the main boom can be te-
lescoped 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 lo-
wered to the ground, a weather forecast must be obtai-
ned 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.
Crane without supervision
Risk of accidents!
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.
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16
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16.1.3 Wind Forces on the Crane
For the wind speeds considered in the load capacity tables, a

wind surface for a load of 1.0 m2/t (4.88 ft2/kip) − however, at least
2 m2 (21.5 ft2) − and a wind resistance coefficient cw of 1.2 is cal-
culated.
If the relation between surface area exposed to wind and the load
or the cw value is greater than the values indicated above, there
are greater wind forces at work around the crane than used as
the basis for the calculation.
In this case the actual load on the boom system could be so large
that the LLD switches off even though the load value in the load
table has not yet been reached nominally.
If required, please consult the crane manufacturer concerning

loads with a larger area exposed to wind.
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16
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16.2 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 operated if the control panels of the outrig-
gers are closed.
To increase the operating speed, crane movements can be car-

ried out simultaneously or independent of each other.
Before each load case, the corresponding limit switches must be

checked to make sure that they are functioning correctly.
The procedure for operation of the crane with equipment (for ex-
ample, main boom extension) is described in the following seg-
ment or in the corresponding sections.
Simultaneous raising of a load on the main boom extension and

on the main boom is not permitted.
Two−hook operation is not secured by the load limit de-
vice and can lead to overloads and tilting of the crane.
For this reason, two−hook operation is prohibited.
It is not permitted to raise a load on the main boom with the main
boom extension in operating position (loaded or unloaded).
Some lifting capacity tables require that a permissible minimum

radius must be complied with. The corresponding crane move-
ments are then switched off.
This minimum radius must not be exceeded!

Risk of falling backwards!
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16
Z 53 410
12/39 40C−1160−818b_en
The load capacity table in accordance with the assembly state of

the crane when raising loads must be set.
Failure to observe this will result in a RISK OF TIPPING!
Unless otherwise specified in the load capacity tables, the num-

ber of reevings must not be lower than 2 rope lines.
If, however, single−line reeving is required, the lifting capacities
specified in the table must be reduced by 20%. This is also valid
when the lifting capacity lies below the maximum permissible
rope pull of 4.3 t / 9.7 kip per line.
(Z 53 410 Principle drawing)

If the main boom is in the high position and is telescoped in
fully, the crane movements must be carried out with the ap-
propriate care and at low speeds. By doing this you prevent
swinging movements of the hook block (1), which could
cause collisions with the luffing cylinder (2).
Risk of damage!
The weight of the hook blocks and lifting tackle must be taken
from the values in the load capacity tables.
If no hoist rope is reeved, the shift weight of the hoist limit

switch must be hung in the prescribed receptacle.
When raising a load on the main boom with the main boom exten-
sion fitted in the transport position, the load capacities listed in the
load capacity tables are reduced. You must 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.
40C−1160−818b_en 13/39
16
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Operation of the crane is only permitted when supported on ou-

triggers and horizontally aligned. For the support base area, the
only values that apply are those listed in the load capacity tables.
If there are no details in the load capacity tables concerning the

support base area, crane work must be carried out when in the
configured state (outrigger support area: 6.2 m (20 ft 4 in).
RISK OF TIPPING!
If, contrary to the details in the load capacity tables, other
counterweights are fitted or if the support is with a smaller
support base area, there is a risk of tilting!
Handle the slewing gear and slewing brake with care. Select a
low slewing 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 automatic safety equipment, the load

cannot always be prevented from swinging out when a mo-
vement 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 chan-

ging 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.
40C−1160−818b_en 15/39
16
16/39 40C−1160−818b_en
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−
stop switch in the crane operator’s cab. First, where possi-
ble, 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 section 12 ”Parking”).
To prevent the unintentional activation of crane movements, both

control levers are fitted with an additional button (dead man’s
switch).
Only when one of the buttons is pressed is it possible to carry out
a crane movement.
The dead man’s switch in the control levers may only be actuated
(pressed and released) and the limit switches may only be brid-
ged at the instrument panel if the corresponding lever is in 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 ab-
ruptly.
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16.3 Operation with Main Boom Extension
− When operating the crane with the main boom extension, the
following must be observed:
∗ there must be an electric connection of the hoist limit

switch on the hoist rope to the plug of the main boom head
(see Section 21).

∗ the shift weight of the hoist limit switch must be secured on
the main boom head or refitted to the main boom exten-
sion.
If a hoist rope is not reeved, the shift weight of the hoist limit
switch must be hung in the prescribed receptacle.
− The working loads indicated in the load tables are reduced in

operation with the main boom extension in the travel lock (see
Notes on Crane Operation).
− Operation of the crane with fitted additional equipment
∗ Raising a load on the main boom extension and on the
main boom at the same time is prohibited.
∗ The lifting of a load on the main boom with main boom ex-
tension free of load is prohibited.
Special duty charts including working load reductions for
configurations not designated must be obtained.
These duty charts can be purchased from the spare parts
centre.
− The crane may be operated with the main boom extension
only with the crane supported on outriggers.
The crane may be operated without being supported on ou-
triggers only during main boom operation, and in specific ca-
ses only.
The lifting capacity of the crane in consideration of the main
boom length can be taken from the load tables.
40C−1160−818b_en 19/39
16
20/39 40C−1160−818b_en
16.4 Monitoring Safety Measures
Before work is begun, i.e before a load is lifted, the followingpo-

ints are to be checked:
− Crane chassis suspension system is switched to ”raise ax-
les”.
− Underlying ground is firm enough to support the weight of the
crane.
− All 4 outrigger struts are extended to the support area indica-
ted in the load capacity chart.
− Outrigger plates are secured.
− Crane is in level position.
− Crane is not situated near a ditch or sloping ground.
− All axles are without load, i.e no wheel is in contact with the
ground.
− No live cables are situated within the operating radius of the
crane.
− Crane is positioned such that it can be operated with a mini-
mal operating radius.
− There are no obstructions which may restrict necessary
crane movements.
− the axles are locked during travel operation
40C−1160−818b_en 21/39
16
70
S160
Z 115 450
22/39 40C−1160−818b_en
16.5 Operating Instructions on Pilot Control /

Setting the Speed of the Movements
The control levers have differing effects on the various crane mo-
vements.
16.5.1 Engine−Speed−Dependent Crane Movements

(Z 115 450)
− Hoist up / down
− Luffing gear up
− Retract / extend the telescopic sections (for the ”synchro-
nous” operating mode,
rotary switch (70, S 160) to position ”SYN”)
For these crane movements, proportional valves which are de-

pendent on engine speed are activated. This means that with the
lever of the pilot control sensor (control lever) in the same posi-
tion, the valves are opened wider at high than at low engine
speeds.
This ensures an adequate supply to the valves.
As a result:
with the lever in the same position, movement is, for example, slo-
wer at 1200 min−1 (rpm) than at 2350 min−1 (rpm).
16.5.2 Engine−Speed−Independent Crane Movements

(Z 115 450)
− Retract / extend telescopic sections (for ”Tele 1” operating
mode: Rotary switch (70, S 160) to position ”1”) or ”Tele 2”:
Rotary switch (70, S 160) to position ”2”)
− Luffing gear down
− Slew gear left / right
These movements operate in accordance with a fixed control

characteristic which cannot be altered by external control ele-
ments
As a result:
movement speed remains the same even if engine speed is in-
creased (throttle opened).
40C−1160−818b_en 23/39
16
117
118
119 25
25
116
115
11
70
S160
Z 115 441
6
7
8
Z 115 422
24/39 40C−1160−818b_en
16.5.3 Fine Tuning of the Movement Speed / Crane Move-

ments Which Can be Modified Using Pushbuttons
The movement speed of the following crane movements can be

fine tuned for more sensitive operation:
− Luffing gear down
− Hoist up / down
− Slew gear right / left
Procedure
(Z 115 441, Z 115 422)
39. Call up the ”Percentage settings” screen (Z 115 422).

To do so, briefly press one of the rocker switches (116) or
(117) on the control levers.
The ”Percentage settings” screen appears briefly on the
right−hand side of the ”Crane operation” screen.
The speed settings can only be modified as described in the
following if the ”Percentage settings” screen is displayed.
Then the ”Crane operation” screen is displayed again.
40. To set the speed:

Movement Control elements
Luffing gear down Rocker switch (117)
Hoist up / down Pushbutton (115) and rocker
switch (117) simultaneously
Slew gear right / left self−return rocker switch
(116)
To change the speed percentage value at rocker switches
(116) or (117):
to reduce − press rocker switch to the left.
to increase − press rocker switch to the right.
Risk of accidents!
There is a risk of accidents if crane movements are carried
out inappropriately quickly.
Observe an appropriate speed of movement.
40C−1160−818b_en 25/39
16
117
118
119 25
25
116
115
11
70
S160
Z 115 441
26/39 40C−1160−818b_en
16.5.4 High speed mode
(Z 115 441)
The following crane movements can be carried out in high speed

mode:
− Hoist up / down
− Luffing gear up
When the listed crane movements are carried out, key (119) in
the right−hand control lever (25) is pressed at the same time to
steer the control lever.
Risk of accidents!
It is only permitted to carry out the crane movements in the
high−speed mode in relation to the load utilization situa-
tion.
Please observe the relevant instructions in the section in
which the crane movement is described.
Switching to high speed mode is not permitted in the follo-

wing cases:
− when working with loads > 30% of the load capacity
− with fitted fly jib
− to raise the fully or partially extended main boom
It is only permitted to activate the luffing gear in high−speed

mode during main boom operation without loads well before
shut−down by the load limit device (at latest until the advan-
ced warning is given).
Risk of overturning due to dynamics!
40C−1160−818b_en 27/39
16
Z 115 267
28/39 40C−1160−818b_en
16.6 Limiting the Engine Speed (Optional)
Due to regulations in some countries (optional), the noise level

must be limited during superstructure operation.
For this reason the engine speed is always limited to a maximum

of 1200 min−1 (rpm) by activating switch (Z 155 267) ”Engine
speed limit” in the crane cab.
16.7 Operation Planning / Monitoring Safety Measures
Before commencing work, i.e. before taking up a load, the condi-

tions described below must be fulfilled.
16.7.1 GeneralInformation
For every crane operation that is planned, the crane operator /

operation planner must provide a suitable crane with sufficient lif-
ting capacity, hoist height and working radius.
For the intended crane configuration there must exist a valid ca-
pacity chart and it must be enabled by the crane control.
The weight of the load must be known. The crane must not be
taken for a device to determine the load weight.
Move the load as near to 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.
Section “Safety instructions” in particular supplies additional in-

structions for planning crane operation.
The capacities stated in the capacity charts are valid if all instruc-
tions in the “Notes on crane operation” – provided together with
the capacity charts – are observed. This includes among other
things:
− Crane is set on horizontally level ground ( 0,5%)
− Ground must have sufficient bearing capacity for the resulting
ground pressures.
40C−1160−818b_en 29/39
16
30/39 40C−1160−818b_en
Interpolation of capacities
The crane control comprises the capacities stated in the capacity

charts. The crane control also automatically calculates values for
differing boom positions. This is called interpolation of interme-
diate values.
Such an interpolation may be performed:

− for load radii
For operation planning these intermediate values may be deter-

mined using a suitable Software (Cranimation). This Software
should be applied by trained personnel only.
16.7.2 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 vertical outrigger cylinders extended so that all axles
are relieved of load i.e. so that no tyres are in contact with the
ground.
− crane control / load limit device set in accordance with the
crane assembly state and the suitable load tables.
− support plates locked.
− the suspension blocked when “driving the configured state”.
− the suspension cylinders driven ”on block” when “driving the
crane with load” and in the LLD operating mode “on wheels
360°”.
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16
32/39 40C−1160−818b_en
16.7.3 Ambient Conditions
− The ground must have sufficient load−bearing capacity to

take the maximum occurring support pressures. If required,
increase the support surface by supporting the outrigger pla-
tes with suitable materials.
Details on the maximum occurring support forces for calculation

of the required support surfaces and for safety distances to slo-
pes and ditches can be found in section 11 “Outriggers”.
− No live wires or cables in the operating area of the crane.

− no obstacles which hinder the necessary crane movements.
Maintain sufficient safety clearances in order to prevent the
risk of crushing (e. g. on the counterweight).
− Location selected so that the crane operation can be carried
out with as low a working radius as possible.
− In case of poor visibility or darkness, the immediate area in
front of the crane operator’s cab, the outriggers and the win-
ches must be illuminated by the spot lights, which are fitted
on the crane (rear outside lighting, front outside lighting, side
outside lighting).
Other surrounding areas (load, load path, slewing range, dri-
ving path, and similar) must be lit using suitable means, inde-
pendent of the crane. The responsibility for this belongs to the
crane operator.
− Consult the relevant weather station concerning the expec-
ted wind forces and weather conditions for the time period du-
ring which the crane is to be used.
The effect of wind on planning operation is discussed in this
section in segment “16.1 Wind forces on the Crane“ (from
page 3).
40C−1160−818b_en 33/39
16
34/39 40C−1160−818b_en
− Lateral deformation of telescopic boom through solar irradia-

tion:
Because of continuous one−sided solar irradiation, tempe-

rature differences occur between the left and right side of the
boom. This results in a difference between the lengths of the
right and left side. The result is a lateral deformation of the
unloaded boom which is clearly visible.
Example:
− Assumed temperature difference: 30° C / 86° F
− Boom length: 60 m / 197 ft
− Boom width: 0.6 m / 2 ft
In this case, the expected lateral deformation is approx. 1 m
/ 3.3 ft.
When utilising the maximum loads, a visual inspection must

be performed to ensure that no lateral deformation is present
in the unloaded state.
Danger:
Risk of accidents from component overloading.
Turn the crane to ensure that both boom sides have
approximately the same temperature.
− If the crane is to be driven in the configured condition, the

road surface must have sufficient load−bearing capacity and
must be level.
40C−1160−818b_en 35/39
16
36/39 40C−1160−818b_en
16.8 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)
To Convert from to 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 (metrisch) kip 2.2046
kip t (metrisch) 0.0004535924
t (metric) ton (US) 1.103
ton (US) t (metric) 0.907
kip ton (US) 0.5
ton (US) kip 2.0
mm inch (in) 0.039
inch (in) mm 25.4
cm inch (in) 2.54
inch (in) 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
sq.ft. (ft2) m2 9.2903 x 10−2
m2 sq.ft. (ft2) 10.746
40C−1160−818b_en 37/39
16
38/39 40C−1160−818b_en
To Convert from to 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
N/cm2 psi 1,478
psi N/cm2 0.677
Nm lbf−ft 0.7376
lbf−ft Nm 1.3558
KW HP 1.3410
HP KW 0.7457
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
40C−1160−818b_en 39/39
Slewing 17
40C−1170−686c_en 1/9
17
4
3
Z 115 043
110
S14
Z 115 019
2/9 40C−1170−686c_en
Slewing 17
17 Slewing
17.1 Preparations for Slewing

(Z 115 043) (Z 115 019)
Ensure that the crane has been supported correctly on the outrig-
gers (see Sect. 11).
When operating with the crane on the wheels, the axles must be
raised and locked. The load limit device program ”on wheels
360°” must have been selected.
The mirror bracket must be folded away before slewing

(collision with the counterweight; risk of the mirror being rip-
ped off when the boom angle is too low).
− To fold down the mirror arm (1) remove cover (2). Loosen the
clamp fixtures (3) and the retaining hook (4), pull out the mir-
ror arm (1) and fold down completely (Z 115 043).
The mirror arm is folded into the driving position analogously
in the reverse order.
Release the slew gear brake by pressing switch (110, S 14) on

the console of the left pilot control lever. (Z 115 019)
Raise the boom sufficiently high for it not to catch on other parts
of the crane.
(See Section 19)
All control equipment for slewing is located in the cab.
40C−1170−686c_en 3/9
17
0
L R
116 R
L
11
Z 115 081
4/9 40C−1170−686c_en
Slewing 17
17.2 Slewing the Superstructure

(Z 115 081)
To slew the superstructure, proceed as follows:

Turn lever (11) to the right R Slewing clockwise
Turn lever (11) to the left L Slewing anticlockwise
Lever (11) must not be switched from one slewing position to the
other; it must first be allowed to rest in the ”Off” position. Do not
switch on slewing in the opposite direction until the superstruc-
ture has come to a halt.
The control levers have been allocated in accordance with your

specification and may differ from the allocation shown here.
Please observe the symbols on the side screen of the cab.
− The superstructure may be slewed only within the range

of reach for which lifting capacity values are specified in
the tables.
− Do not slew above people.
− Do not jump off the crane during slewing.
Depending on the country, the superstructure’s slewing move-

ment is indicated for persons in the crane’s danger zone:
− by an acoustic warning signal (sound interrupted)
− by additional flashing lights on both sides of the superstruc-
ture
40C−1170−686c_en 5/9
17
0
L R
116 R
L
11
Z 115 081
Z 115 407
6/9 40C−1170−686c_en
Slewing 17
17.3 Slew Speeds

(Z 115 081)
The slew gear is electrically pre−controlled. Slew speed depends

on the position of control lever (11). A precision setting is also
possible using button (116) in control lever (11) (switch to the right
− fast; switch to the left − slow). While they are being actuated,
this is displayed in the display of the Cockpit−Graphik−Center
(CGC) (7, Z 115 407) (See also Section 16.4).
Make sure slew speed is reduced (lower scale range) when:

− working with loads > 30 % of the maximum load
− working with a long boom
− working with main boom extension fitted
40C−1170−686c_en 7/9
17
0
R
L
110 11
S14
13
Z 115 082
8/9 40C−1170−686c_en
Slewing 17
17.4 Braking the Superstructure

(Z 115 082)
To brake the superstructure, proceed as follows:
1. Place lever (11) in the ”Off” position.
2. Depress pedal (13) until the superstructure comes to a halt.
If the load swings, there is a danger of the crane tipping;

therefore do not suddenly brake slewing movements.
Only work at a low slewing speed when the main boom ex-
tension is mounted.
Before starting crane operation, release the slew gear brake by

means of switch (110, S 14) once the crane is supported on ou-
triggers.
With the slew gear brake released and the pedal not depressed,
the slew gear is switched to idle to prevent oblique pull as a load
is raised.
− With the slew gear brake released, the superstructure

can slew of its own accord if the crane is at an angle or
as a result of wind forces. (Keep clear of buildings.)
− Before the crane cab is left, the slew gear brake must be
locked by pressing switch (6, S 14).
40C−1170−686c_en 9/9
Telescoping 18
40C−1180−026b_en 1/15
18
Z 115 042
0
a
b
11
Z 115 085
2/15 40C−1180−026b_en
Telescoping 18
18 Telescoping
18.1 Telescoping the Main Boom
Before telescoping, the turnbuckle (1) on the main boom

head must be removed (Z 115 042).
The main boom comprises 5 boom sections.

The outer section, i.e. the base section, which is pin locked to the
luffing cylinder and superstructure frame and 4 telescopic inner
boom sections (telescopic sections).
Telescopic section 1 is extended and retracted via a hydraulic cy-

linder 1.
Telescopic section 2 is extended and retracted via a hydraulic cy-

linder 2.
The telescopic sections 3 and 4 are connected to telescopic sec-

tion 2 by means of cables. They are retracted and extended syn-
chronously with telescopic section 2 as soon as you move control
lever (11). (Z 115 085)
The main boom can be telescoped out from 10.1 m (33.1 ft) to
31.2 m (102.4 ft).
For telescoping with a load, please refer to Sect. 18.2.2.
When working with the crane, it is essential that the prescribed

boom lengths are observed.
When the hook has been raised up to the top and the hoist limit
switch has tripped, the main boom cannot be extended any furt-
her. The hook must first be lowered using the hoist (see Sect. 20).
All control equipment for telescoping is located in the crane ope-

rator’s cab.
40C−1180−026b_en 3/15
18
(25.6 ft)
(35.1 ft)
(44.6 ft)
(44.6 ft)
(44.6 ft)
(64.0 ft)
(63.6 ft)
(83.0 ft)
(83.0 ft)
(93.2 ft)
(92.8 ft)
(102.3 ft)
Z 115 348
4/15 40C−1180−026b_en
Telescoping 18
18.1.1 Extension Length of the Telescopic Sections
The display for the load limit device (see Section 15) is located
in the crane operator’s cab and is used to control the extension
length.
The display indicates the extension lengths of the individual tele-
scopic sections as a percentage.
For crane operation, the extension lengths and individual

telescoping lengths corresponding to the respective confi-
gurations and lifting capacity must be taken from the load
tables supplied.
If the extension length of the telescopic sections is at an interme-

diate length not stipulated in the load table (and see Z 115 348)
and a load is to be raised, the load displayed by the load limit de-
vice can still be raised, using the hoist. These load values can be
smaller than the load values of the next highest extension se-
quence in the load table.
40C−1180−026b_en 5/15
18
0
a
a
11
b
Z 115 083
70
S160
Z 115 072 Z 115 409
6/15 40C−1180−026b_en
Telescoping 18
18.1.2 Control Levers for Telescoping
(Z 115 083)
Use the left−hand lever for telescoping:

Lever (11) forwards a extend telescopic sections
Lever (11) backwards b retract telescopic sections
− If the hook has reached the top and the hoist limit switch has
actuated, the main boom cannot be extended further. The ho-
ist must first be lowered (see Section 20.1).
The signal ”<<” (Y, Z 115 409) always flashes when it is possible
to overcome the cut−off function of the load limit device by retrac-
ting the system.
− The control levers have been allocated in accordance with

your specification and may differ from the allocation shown
here. Please observe the symbols on the side screen of the
cab.
18.1.3 Telescopic Control
(Z 115 072)
To control the telescopic sections you must preselect the exten-

sion sequence with switch 70, S 160.
Switch 70, S 160 to SYN:

− All telescopic sections are extended or retracted synchrono-
usly. If, for some reason, a distance of greater than approx.
300 mm (11.8 in) is created between telescopic sections 1
and 2, the telescoping movement is shut down.
Switch 70, S 160 to 1:

− If telescopic section 1 is to be extended or retracted alone,
telescopic section 2 must be fully retracted. The control lever
is used to extend or retract telescopic section 1 completely.
As soon as telescopic section 1 is 100% extended telescopic
section 2 follows automatically. If telescopic section 2 is not
fully retracted, the telescoping−out function is shut down and
telescopic section 2 is retracted first during telescoping in.
40C−1180−026b_en 7/15
18
70
S160
Z 115 072
8/15 40C−1180−026b_en
Telescoping 18
(Z 115 072)
Switch 70, S 160 to 2:

− The telescopic sections 2, 3 and 4 are to be extended indivi-
dually, or special lengths, eg telescopic section 1 50%, tele-
scopic sections 2, 3 and 4 100% are to be selected.
Telescopic section 1 must be fully retracted. The control lever
is used to telescope telescopic sections 2, 3 and 4 in and out
completely. As soon as telescopic sections 2, 3 and 4 are ex-
tended 100%, telescopic section 1 follows automatically. If te-
lescopic section 1 is not fully retracted, the telescoping out
procedure is switched off and, during telescoping in, telesco-
pic section 1 is retracted first.
Example:
The boom is positioned at telescopic section 1 50% and telesco-
pic sections 2, 3 and 4 100%. You want to change it to telescopic
section 1 100%, telescopic sections 2, 3 and 4 0%. Turn switch
70, S 160 to position 1. Move the control lever to telescope in. Te-
lescopic sections 2, 3 and 4 are retracted first. When telescopic
sections 2, 3 and 4 are completely retracted, telescopic section
1 follows automatically. Move the control lever to telescope out.
Telescopic section 1 is extended fully to 100%.The movement is
switched off.
In this example, telescoping only occurs once the configuration

load is authorised.
40C−1180−026b_en 9/15
18
0
a
b
11
Z 115 085
10/15 40C−1180−026b_en
Telescoping 18
18.2 Telescoping Procedure
18.2.1 Telescoping without Load
(Z 115 085)
To telescope without load, move control lever (11) forwards (a) or

backwards (b).
The boom length can therefore be observed continuously on the

digital display of the LMB (Sect. 15). (See Sect. 18.1.1)
18.2.2 Telescoping Loads
The load tables supplied show the loads which can be lifted by
telescoping relative to boom length, extension length of the indi-
vidual telescopic sections, boom angle and hoist rope reeving.
The telescopic loads stated in the tables are attained under the
following conditions:
− Sliding surfaces of the telescopic sections well greased.
− Normal ambient temperature (major reductions should be an-
ticipated if the temperature is below 0°C (32°F)).
− The actual loads to be telescoped must be reduced to the va-
lues of the corresponding load tables.
− The values specified apply to the extension of the telescopic
sections. The values are reduced when retracting the tele-
scopic sections at a shallow angle.
− The extension length of the individual telescopic sections is
prescribed to form the whole length. This boom length must
not be exceeded.
− The boom angle must not exceed the values stated in the ta-
bles.
18.2.3 Telescoping Speeds
(Z 115 085)
The telescoping system is electrically pre−controlled. The tele-

scoping speed depends on the position of control lever (11) (see
also Sect. 16.4, operating instructions for pilot control).
40C−1180−026b_en 11/15
18
12/15 40C−1180−026b_en
Telescoping 18
Telescoping loads in (t) (SI units)
Main boom (m)

í EXTENSION RETRACTING
main
10,7 13,6 10,7 7,8
boom
(50/0) (100/0) (50/0) (0/0)
77° 9,5 6,2 14,9 13,2
70° 9,5 5,3 14,9 13,2
60° 9,5 4,4 14,9 13,2
50° 9,5 3,9 7,8 13,2
1. 40° 9,5 3,7 4,4 13,2
30° 9,5 3,6 2,7 13,2
20° 9,5 3,6 1,7 13,2
10° 9,5 3,6 1,0 13,2
0° 9,5 3,6 0,6 13,2
13,6 19,4 25,3 28,3 31,2 28,3 25,3 19,4 13,6 7,8
(0/33) (0/66) (0/100) (50/ (100/ (50/ (0/100) (0/66) (0/33) (0/0)
100) 100) 100)
77° 9,0 7,6 3,7 7,2 2,9 7,1 9,5 10,0 13,3 12,0
70° 8,8 7,0 2,9 6,2 1,9 2,7 8,8 4,9 13,3 12,0
60° 8,8 6,4 2,1 5,3 1,1 0,8 6,8 2,4 13,3 12,0
50° 8,8 6,1 1,7 4,7 0,6 − 4,9 1,4 10,8 12,0
2. 40° 8,8 6,0 1,4 3,4 − − 3,4 0,9 8,0 12,0
30° 8,8 6,0 1,3 2,8 − − 2,8 0,6 6,3 12,0
20° 8,8 5,1 1,2 2,3 − − 2,4 − 5,1 10,5
10° 8,8 4,5 1,2 1,8 − − 1,8 − 4,5 8,8
0° 8,8 4,5 1,2 1,8 − − 1,4 − 4,5 8,8
13,6 19,5 25,3 31,2 25,3 19,5 13,6 7,8
(25/25) (50/50) (75/75) (100/ (75/75) (50/50) (25/25) (0/0)
100)
77° 9,3 8,4 6,3 2,9 7,1 14,0 12,8 12,0
70° 9,1 7,6 5,2 1,9 2,7 13,2 12,8 12,0
60° 9,1 7,0 4,2 1,1 0,8 10,3 12,8 12,0
50° 9,1 6,7 3,6 0,6 − 5,9 10,3 12,0
3. 40° 9,1 6,6 3,3 − − 3,5 7,5 12,0
30° 9,1 5,7 3,0 − − 2,2 5,7 12,0
20° 9,1 4,5 2,5 − − 1,4 4,5 10,2
10° 8,5 4,0 2,5 − − 0,9 4,0 8,5
0° 8,5 4,0 2,0 − − − 3,6 8,5
The values apply to well lubricated booms. Under poor operating conditions (eg
poor lubrication) the telescoping load can be reduced by up to 50%. The telesco-
ping loads only apply at a maximum outrigger support area and 5.4 t (11.9 kip) co-
unterweight.
40C−1180−026b_en 13/15
18
14/15 40C−1180−026b_en
Telescoping 18
Telescoping loads in (kip) (U.S. units)
Main boom (ft)

í EXTENSION RETRACTING
main
35.1 44.6 35.1 25.6
boom
(50/0) (100/0) (50/0) (0/0)
77° 20.9 13.7 32.8 29.1
70° 20.9 11.7 32.8 29.1
60° 20.9 9.7 32.8 29.1
50° 20.9 8.6 17.2 29.1
1. 40° 20.9 8.2 9.7 29.1
30° 20.9 7.9 6.0 29.1
20° 20.9 7.9 3.7 29.1
10° 20.9 7.9 2.2 29.1
0° 20.9 7.9 1.3 29.1
44.6 63.6 83.0 92.8 102.4 92.8 83.0 63.6 44.6 25.6
(0/33) (0/66) (0/100) (50/ (100/ (50/ (0/100) (0/66) (0/33) (0/0)
100) 100) 100)
77° 19.8 16.8 8.2 15.9 6.4 15.7 20.9 22.0 29.3 26.5
70° 19.4 15.4 6.4 13.7 4.2 6.0 19.4 10.8 29.3 26.5
60° 19.4 14.1 4.6 11.7 2.4 1.8 15.0 5.3 29.3 26.5
50° 19.4 13.4 3.7 10.4 1.3 − 10.8 3.1 23.8 26.5
2. 40° 19.4 13.2 3.1 7.5 − − 7.5 2.0 17.6 26.5
30° 19.4 13.2 2.9 6.2 − − 6.2 1.3 13.9 26.5
20° 19.4 11.2 2.6 5.1 − − 5.3 − 11.2 23.1
10° 19.4 9.9 2.6 4.0 − − 4.0 − 9.9 19.4
0° 19.4 9.9 2.6 4.0 − − 3.1 − 9.9 19.4
44.6 64.0 83.0 102.4 83.0 64.0 44.6 25.6
(25/25) (50/50) (75/75) (100/ (75/75) (50/50) (25/25) (0/0)
100)
77° 20.5 18.5 13.9 6.4 15.7 30.9 28.2 26.5
70° 20.1 16.8 11.5 4.2 6.0 29.1 28.2 26.5
60° 20.1 15.4 9.3 2.4 1.8 22.7 28.2 26.5
50° 20.1 14.8 7.9 1.3 − 13.0 22.7 26.5
3. 40° 20.1 14.6 7.3 − − 7.7 16.5 26.5
30° 20.1 12.6 6.6 − − 4.9 12.6 26.5
20° 20.1 9.9 5.5 − − 3.1 9.9 22.5
10° 18.7 8.8 5.5 − − 2.0 8.8 18.7
0° 18.7 8.8 4.4 − − − 7.9 18.7
The values apply to well lubricated booms. Under poor operating conditions (eg
poor lubrication) the telescoping load can be reduced by up to 50%. The telesco-
ping loads only apply at a maximum outrigger support area and 5.4 t (11.9 kip) co-
unterweight.
40C−1180−026b_en 15/15
Luffing 19
40C−1190e_en 1/5
19
0 117
119
R
25
L
L
Z 115 084 Z 115 064
Z 115 408
2/5 40C−1190e_en
Luffing 19
19 Luffing
19.1 Raising and Lowering the Main Boom

(Z 115 084) (Z 115 064)
The main boom must only be raised when the mobile crane is
supported on outriggers (see Sect. 11).
Lever (25) to the right R lower main boom
Lever (25) to the left L raise main boom
Lever (25) springs back automatically into the 0 position when re-
leased.
When the hook has been raised up to the top and the hoist limit
switch has tripped, the main boom cannot be lowered any further.
First activate ”lower hoist” (see Sect. 20).
As soon as the main boom reaches an angle of less than 0o to

the horizontal and the main boom is not completely retracted, the
load limit device shuts down the movement. The main boom can
only be luffed further if the load limit device is bridged.
The crane operator, however, carries full responsibility if

the load limit device is bridged.
When luffing to the minimum or maximum main boom angle, the

load limit device also switches off and the symbol or
flashes (Z, Z 115 408).

19.2 Luffing Speeds

(Z 115 084)
The luffing gear is electrically pre−controlled. The speed when

raising the main boom depends on the speed of the hydraulic
pump and the position of control lever (25).
40C−1190e_en 3/5
19
0 117
119
R
25
L
L
Z 115 084 Z 115 064
Z 115 407
4/5 40C−1190e_en
Luffing 19
(Z 115 084) (Z 115 064)
For luffing down, fine adjustment can be made using button (117)
in control lever (25) (actuate button to the right − faster; actuate
button to the left − slower). While they are being actuated, this is
displayed in the display of the Cockpit−Graphik−Center (CGC)
(9, Z 115 407) (see also Sect. 16.4).
When raising the main boom you have the option of operating
with the high−speed button (119) which is located on the end of
the right−hand control lever.
Ensure that the luffing speed is kept low (lower scale value)
when operating:
− with loads > 30 % of the working load value
− with long main boom
− with fitted main boom extension
Using the high range is not permitted here.
40C−1190e_en 5/5
Hoist 1 20
40C−1200d_en 1/5
20
0
118
a
b
25 b
Z 115 086
2/5 40C−1200d_en
Hoist 1 20
20 Hoist 1
20.1 Raising and Lowering the Load

(Z 115 086)
The hoist of the crane is located on the base section of the boom.
Lever (25) forwards a lower load
Lever (25) backwards b raise load
− The ”raise load” movement is automatically shut down when:

∗ the load limit device has shut down.
∗ The hook block has reached the hoist limit shut−down.
It is possible to lower the load.
− The “lower load” movement is automatically shut down when
the lower limit switch for hoist 1 has been reached.
It is possible to raise the load.
− Control lever (25) springs back automatically to the 0 position
when released.
− As soon as the hoist begins to turn, you will feel a definite vi-
bration in control lever (25) at point (118).

40C−1200d_en 3/5
20
0 117
a 118
119 b
25
b
Z 115 087
Z 115 407
4/5 40C−1200d_en
Hoist 1 20
20.2 Hoist Speeds
(Z 115 087)
The hoist is electrically pre−controlled. The hoist speed depends

on the speed of the hydraulic pump and the position of control le-
ver (25).
A precision setting (switchover via button (115)) is also possible
using button (116) in control lever (11) (switch to the right − fast;
switch to the left − slow).
While they are being actuated, this is displayed in the display of
the Cockpit−Graphik−Center (CGC) (8, Z 115 407) (see also
Sect. 16.4).
It is also possible to increase the speed using the high range (see
also Sect. 16.4).
The high−speed function for the hoist functions as long as the
button (119) in the right−hand control lever remains pressed
down.
The high range for the hoist must only be actuated :

− with a small load (max. 30 % of the working load value)
− without load
− when the main boom extension is not fitted.

40C−1200d_en 5/5
Main Boom Extension (MBE) (Optional) 21
21 Main Boom Extension (MBE) (Optional)
21.1 GeneralNotes
The tension bars of the main boom extension (”MBE” in the

following) must be checked at least once a year by a techni-
cal expert (in accordance with the accident prevention re-
gulations ”Load receptacle devices in lifting devices opera-
tion”, VBG 9a).
They should also be checked by a specialist in the meantime
depending on the applications of use and the operating
conditions. The inspection intervals are generally determi-
ned by the operating and site conditions. This means that in-
spections are carried out more frequently as the crane
equipment is used more.
The performance of these inspections must be recorded

(e.g. in the crane log book).
The following checks should be made:

* Check for cracks
* Check the length
* Check for wear
* Check the paintwork
* Check for plastic deformation
Instructions on how to carry out the inspection can be found
in the ”Lubrication and maintenance instructions”, part 2,
section 24 ”Equipment”.
The inspection of the tension bars must be documented, along

with the results, in the crane log book under ”Inspection reports”.
The MBE is marked with the construction number of the

crane. It may only be fitted on the crane with this construc-
tion number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).
40C−1210−001c_en 1/37
21
4
3
5.2
2 5
5.1
Z 115 043 Z 115 310
Z 75 094
62
61
Z 55 526
2/37 40C−1210−001c_en
Risk of falling!
A ladder is supplied with the machine to carry out all as-
sembly work with as little risk as possible. It is not permit-
ted to climb or walk on the main boom extension.
- Before fitting the main boom extension to the main boom

head, the mirror (1, Z 115 043) must be folded away (see sec-
tion 17), the protecting bracket (5.2, Z 115 310) of the under-
ride guard (5, Z 115 310) must be folded down and the optio-
nal hazard light (61, Z 55 526 principle depiction) (if existing)
must be removed.
In order to fold down the protecting bracket (5.2) on the underride

guard (5), pull out pin (1) in point (A) and after folding it, pin the
bracket again in point (B), (Z 75 094).
Now place the main boom in the 0° position (horizontal).
Risk of damage!
Before fitting the main boom extension to the main boom, the
optional anemometer (62) (if existing) on the main boom
head must be removed (Z 55 526 principle depiction).
40C−1210−001c_en 3/37
21
2 1
Z 115 311
”a” ”b” ”c”

32A 32B 32C
31 Z 115 312
4/37 40C−1210−001c_en
21.2 Components
(Z 115 311)
Depending on the state of assembly, the MBE consists of the fol-

lowing components:
− 7.1 m MBE (23.3 ft): Part 1
− 13 m MBE (42.7 ft): parts 1, 2
The components of the MBE can be carried along for transporta-

tion on the side of the main boom if the relevant devices have
been fitted. The permissible axle loads must be observed.
When raising a load with the main boom extension folded in

the transport position, the actual loads which can be raised
are reduced compared to the corresponding values in the
load tables.
Folding the MBE from the transport position into the operating po-
sition and back is described in section 21.5 from page 15.
Information on fitting the parts for separate transportation can be

found in section 21.4.2 (from page 13).
Risk of accidents!
Observe the instructions on “Connections between the in-
dividual components of the main boom extension” on the
following page.
Connection between the individual components:
The connections between:

− the basic boom (1) and the main boom head
− Tip section (2) with the basic boom (1),
are all made using 4 biconical pins (31).

Each biconical pin must be secured against falling out with two
functioning securing elements.
Depending on the design of your machine, securing elements
“Type (32A)”, “Type (32B)” or “Type (32C)” are used.
40C−1210−001c_en 5/37
21
2 1
Z 115 311
”a” ”b” ”c”

32A 32B 32C
31 Z 115 312
b 1 a
d c
2
Z 115 360
6/37 40C−1210−001c_en
(Z 115 311, Z 115 312 principle illustration)
(Z 115 312 “b”)

RISK OF ACCIDENTS!
If safety plug “Type (32B)” is used, only pins (31) may be
used which are cylindrical at one end. Safety plugs (32B)
may not be used for the other pin designs, as they fall out
on their own!
Risk of accidents!
Each pin (31) must be secured against falling out using two
functioning securing elements.
Only securing elements may be used which were fitted
when the crane was first delivered.
All different types of securing elements (32) can be seen or refer-

red to in the graphics illustrations or in the associated text of this
section.
The only securing elements which may be used are those which
were installed in the corresponding position at the time of the ori-
ginal delivery of the crane.
In cases of pins that are difficult to insert, the biconical pins (31)
should be greased before the pinning procedure.
21.2.1 Transport Dimensions / Weights
(Z 115 360)
Part Designation Nominal Transport dimensions Approx.

no. length Length Width Height weight
(m / ft) mm mm mm (kg / lbs)

(in) (in) (in)
1 Basic boom 7.1 m / 7540 mm 540 mm 990 mm 550 kg /
23.3 ft (296.8 in) (21.3 in) (39.0 in) 1213 lbs
2 Tip section 5.9 m / 5875 mm 340 mm 555 mm 255 kg /
19.5 ft (231.3 in) (13.4 in) (21.9 in) 562 lbs
40C−1210−001c_en 7/37
21
b 1 a
d c
2
Z 115 360
8/37 40C−1210−001c_en
21.3 Attachment Points

(Z 115 360)
The main boom extension is comprised of various component

parts. Observe the adjacent diagrams to attach the parts. They
show which attachment points need to be used so that the parts
are attached at their centre of gravity.
Risk of accidents!
The parts must not swing out or dangle at an angle when they
are raised. If necessary, lifting chains fitted with shortening
claws must be used.
The securing equipment must be supplied by the customer.
The length as well as the weight of the individual components can

be found in section 21.2.1 “Transport dimensions / weights”
(page 7). Select the auxiliary crane and the securing equipment
accordingly.
Risk of accidents!
If no attachment points are welded to the basic boom, this
must be attached using slung−around lifting gear.
Risk of accidents!
The suspension points are dimensioned in such a way that
the individual parts of the main boom extension can only be
suspended singly.
It is forbidden to suspend several parts of the main boom ex-
tension when they are bolted together or folded against one
another.
Part Designation Slinging points

no. “a” “b” ”c” ”d”
1 Basic boom x x
2 Tip section x x
40C−1210−001c_en 9/37
21
C B 21
Z 115 313
15−2
15−1 15−3
Z 115 319
10/37 40C−1210−001c_en
21.4 Transport Instructions
21.4.1 Transport Instructions for the MBE in the Transport

Position
The following applies for driving the crane with the MBE folded
into the transport position:
(Z 115 313, Z 115 319)

− Observe the permitted axle loads.
− The MBE must be pinned in the front rotation point “B” and
in the rear fixing point ”C”.
− The connecting pins between the basic boom−MBE and tip
section (if fitted) must be pinned and locked.
− The tension bars of the basic boom MBE must each be fitted
with pin (21). The pins must be secured against falling out.
− The runway must be folded up.
Depending on the design of your machine, there is a lock pin

(15−3, Z 115 319) or a gas−operated positioner on the runway for
this purpose.
Risk of accidents!
When folding the mobile part of rollway (15−2), the rollway
must be held until locking pin (15−3) has fully locked in
place. This prevents unchecked folding.
− All pins must be in a fail−safe transport position.

− The shift weight of the hoist limit switch (depending on the de-
sign) must be fitted to the tip of the MBE or to the main boom
and secured against falling out.
− The ladders’ fastening catches must be without damage and
hooked in.
40C−1210−001c_en 11/37
21
15−2
15−1 15−3
Z 115 319
2
3
Z 550 103
12/37 40C−1210−001c_en
Driving the crane with the main boom extension fitted in the
transport position
(Z 550 103) Depending on the each country’s regulations, a
cover (1) must be fitted to the outer fork heads for driving on
public roads. This cover (1) is fastened using the standard
connecting pins (2) of the main boom extension and the cor-
responding securing elements (3) of the connecting pins.
21.4.2 Transport Instructions for Separate Transportation

(Z 115 319)
There are attachment points on the basic boom MBE and on the
tip section.
Use these attachment points when attaching components.
Thebasic boom MBE and the tip section must be fitted separately.
Risk of tipping!
When the components of the main boom extension are fol-
ded together and transported separately, there is a risk of
tipping over!
This is therefore prohibited!
The runway must be folded up.
Depending on the design of your machine, there is a lock pin

(15−3, Z 115 319) or a gas−operated positioner on the runway for
this purpose.
Risk of accidents!
40C−1210−001c_en 13/37
21
Z 75 093
14/37 40C−1210−001c_en
21.5 Folding up and down Procedure
When the MBE is not required, the 7.1 m (23.3ft) and 13 m (42.7
ft) MBE can be stored alongside the main boom − folded into the
transport position and pinned.
When driving in this condition, observe the applicable axle

loads!
For crane operation with the main boom extension locked

in the transport position, the loads specified in the load ta-
ble 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).
21.5.1 General Instructions for Folding over the Equipment

The conditions listed in the following must be observed when fol-
ding over equipment from the operating into the transport posi-
tion and vice versa.
∗ Support the crane and MBE in accordance with the planned
configuration (MBE, counterweight, etc.) and fit the counter-
weight (for details, see load tables).
∗ Slew gear brake applied.
∗ Main boom completely telescoped in, pinned and horizontal).
∗ The anti−twist catches must be flush (right and left on the
main boom) (Z 75 093).
To enable the folding procedure to be carried out without any pro-

blems, the main boom must be completely retracted. The stops
between the telescopic sections must be flush. Some of the stops
have been fitted so that they are covered. It is not always possible
from a casual glance to recognise whether the stops are fitted
correctly.
∗ The mirror on the side of the chassis must be folded down.
40C−1210−001c_en 15/37
21
2−EXPLICIT
3−EXPLICIT
Z 75 093 Z 55 536
Z 75 094
Z 75 142
16/37 40C−1210−001c_en
∗ The protecting bracket on the underride guard must be folded

forward. For this, withdraw pin (1) in point (A) and pin the bar
in point (B) again after folding it, (Z 75 094).
∗ There must be no obstacles hindering the folding procedure.
(Z 55 536)
Use the supplied ladders to carry out the MBE assembly
work. Walking on the MBE or on the top of the main boom
is prohibited.
The supplied folding / sliding ladders can be fastened to the side

of the main boom extension for transportation.
Risk of accidents!
Never try to fold the main boom extension into the transport
position of the crane (main boom set down on the chassis).
(Z 75 142)
If the safety plugs (1) are used in place of lock springs (2),
you may only use the pins (3) which are cylindrical (A) in
shape at one end. The safety plugs (1) may not be used in
pins (4) as these fall out by themselves.
40C−1210−001c_en 17/37
21
C*
24
C
2
C*
24 14
25
Z 115 355
15−2
7 15−3
Z 115 397 Z 75 098
Z 75 097
18/37 40C−1210−001c_en
21.5.2 Folding the 7.1 m (23.3 ft) Basic Boom out of the
Transport Position into Operating Position
(Z 115 355, Z 115 397, Z 75 098, Z 75 097)
To a large extent, it is irrelevant for the procedure of folding the

MBE 7.1 m (23.3 ft) whether only the MBE 7.1 m (23.3 ft) or the
MBE 13 m (42.7 ft) is fitted.
There are detailed notes when there are differences in the opera-
ting procedure.
If the MBE 7.1 m (23.3 ft) is fitted, the basic boom is folded over
to the extent that it can be pinned directly in point (C*) using pins
(24).
Operating position 0°
1. If the MBE 13 m (42.7 ft) is folded on the side of the main

boom:
release hook tensioner (14, Z 115 355).
2. Fold the runway (15−2) down.
Depending on the design of your machine, there is a lock pin or

a gas−operated positioner on the runway for this purpose.
Risk of accidents!
3. 7.1 m MBE (23.3 ft):

Unlock pin (24) in point (C*) at the actuating lever (25).
13 m MBE (42.7 ft):
Remove pin (2) in point (C) and after swinging, insert it again
at the same place and secure it;
4. Unlock the locking pin (7) at the runway (B) (Z 115 397).
5. Swing the main boom extension around lateral rotation point

(E) (Z 75 097) until the right−hand fork heads line up with the
holes of the locking eyes on the boom head (D).
It is advisable to fasten a rope to the head of the basic boom

of the extension for guiding it.
Using this, the main boom extension can then be pulled as
well as braked (Z 75 098).
40C−1210−001c_en 19/37
21
Z 75 099
Z 75 100
20/37 40C−1210−001c_en
(Z 75 099, Z 75 100)
6. Lock the main boom extension in fixing points (D1) and (D2)
with pins (3) and secure with lock spring (4).
7. Withdraw pins (5) and (6) from lateral rotation point (E) and
(G) using a bell crank. (Z 75 100)
Do not remove the pins from rotation point (E and G) until

the extension has be pinned and secured in points (D1 and
D2).
40C−1210−001c_en 21/37
21
Z 75 101
Z 75 102 Z 75 103
22/37 40C−1210−001c_en
(Z 75 101, Z 75 102, Z 75 103)
8. Slew the main boom extension round to the front.

At this point it must be ensured that lock pin (8) slots into
place on the left−hand cross axle (Z 75 101).
9. Fit the main boom extension by inserting pins (9 and 10) into
points (H1) and (H2) and secure it with lock springs
(Z 75 102).
The pins are inserted at the top and bottom respectively.

Both pins are driven in alternately until the lock springs for secu-
ring the pin can be inserted.
10. Refit the hoist limit switch (1) and shift weight (2) from the
main boom head in the prescribed position on the main boom
extension.
Remove the plug (11) of the hoist limit switch from theright−
hand socket on the main boom head and plug into the socket
on the front end of the main boom extension. (Z 75 103)
Check that all pins and locking elements are fitted cor-
rectly.
40C−1210−001c_en 23/37
21
Z 75 105 Z 115 090
24/37 40C−1210−001c_en
(Z 75 105, Z 115 090)
11. Insert plug (19) on the basic boom into the left−hand socket
on the main boom head (Z 75 105).
12. Reeve hook block. (see section 22)
13. Set the load limit device according to the current configura-
tion of the crane (see section 15)
Conversion to the travel position is the reverse of the above pro-

cedure.
Fold the guide rail (1) up again after folding the main boom exten-
sion into the transport position (Z 115 090).

Risk of accidents!
When folding the mobile part of rollway (1), the rollway
must be held until locking pin (2) has fully locked in place.
This prevents unchecked folding.
The pins in points (D1) and (D2) must not be removed until
the main boom extension has been swung back and is pin-
ned and secured again in points (E) and (G).
The use of high range during operation with the main boom
extension is prohibited.
40C−1210−001c_en 25/37
21
Z 75 106
Z 75 107
Z 75 108
26/37 40C−1210−001c_en
21.5.3 Folding the 13 m (42.7 ft) Main Boom Extension from

the Transport Position into Operating Position
(Z 75 106, Z 75 107 principle illustration, Z 75 108)
When operating with the main boom extension (basic boom and
tip section), the following must be ensured:
− the tip section must be fitted to the rear end of the basic boom
with pins (12) and (13) and secured. (Z 75 107)
− The tip section must be braced at the front using hook tensio-
ner (14) in position (R) on the basic boom and secured.
(Z 75 108)
40C−1210−001c_en 27/37
21
C*
24
C
22
25
25 23
14
Z 115 356
15−2
7 15−3
Z 115 397 Z 75 098
Z 75 111
28/37 40C−1210−001c_en
(Z 115 356, Z 115 397, Z 75 098, Z 75 111)
Operating position 0°
1. Fold the runway (15−2) down.

Risk of accidents!
2. Release the tip section on the basic boom section of the main
boom (if this has not already been done).
To do so, unlock pin (23) using the bellcrank. Unlock pin (24)
in point (C*) on the actuating lever (25).
3. Swing the main boom extension around lateral rotation point

(E) and the main boom extension has to be pinned and secu-
red on the main boom head (see section 21.5.2; points 4. −
9.). (Z 75 111)

of the extension for guiding it (Z 75 098).
The main boom extension can be pulled and braked with the
aid of the rope.
40C−1210−001c_en 29/37
21
Z 75 112 Z 75 113
Z 75 098 Z 75 103
Z 75 114
30/37 40C−1210−001c_en
(Z 75 112, Z 75 113, Z 75 098, Z 75 103, Z 75 114)
4. Release hook tensioner (14) in point (R). (Z 75 112)
5. Slew tip section round pins (12) and (13).

Here it must be ensured that lock pin (16) slots into place aft-
erwards. (Z 75 113)
of the extension for guiding it.
With this, the tip section can then be pulled as well as braked
(Z 75 098).
6. Fit and secure the tip section in points (L1) and (L2) using
pins (17 and 18). (Z 75 114)
Pins (17) and (18) are inserted at the top and bottom respectively.
Both pins are driven in alternately until the lock springs for secu-
ring the pin can be inserted.
7. Refit the hoist limit switch (1) and shift weight (2) from the
main boom head in the prescribed position on the tip section.
Remove plug (11) of the hoist limit switch from the right−hand
socket on the main boom head and insert it into the socket
on the front end of the tip section. (Z 75 103)
40C−1210−001c_en 31/37
21
Z 75 105
Z 75 114
32/37 40C−1210−001c_en
(Z 75 105, Z 75 114)
8. Insert plug (19) on the basic boom into the left−hand socket
on the main boom head (Z 75 105).
9. Insert plug (20) of the tip section into the socket of the basic
boom thus ensuring power supply for the hoist limit switch of
the tip section. (Z 75 114).
Check that all pins and locking elements are fitted cor-
rectly.
10. Reeve hook block. (see section 22)
11. Set the load limit device according to the current configura-
tion of the crane (see section 15)
The use of high range during operation with the main boom
extension is prohibited.
40C−1210−001c_en 33/37
21
Z 75 100
Z 115 090
Z 75 115
34/37 40C−1210−001c_en
(Z 75 100, Z 115 090, Z 75 115)
Conversion to the travel position is the reverse of the above pro-

cedure.
Fold the guide rail (1) up again after folding the main boom exten-
sion into the transport position (Z 115 090).

Risk of accidents!
When folding the mobile part of rollway (1), the rollway
must be held until locking pin (2) has fully locked in place.
This prevents unchecked folding.
The pins in points (D1) and (D2) must not be removed until
the main boom extension has been swung back and is pin-
ned and secured again in points (E) and (G) (Z 75 100).
21.5.4 Folding the Main Boom Extension

(7.1 m or 13 m (23.3 ft or 42.7 ft)) from
0 Degrees to Operating Position 30 Degrees and Back
1. Swing the main boom extension as described above and pin
it to the main boom head.
2. Luff the main boom downwards until the supporting roller

rests on the ground and pins (3) and (9) in points (D1) and
(H1) are relieved of strain.
Remove the pins and store them in the bearing plates provi-
ded on the main boom extension; secure it with lock springs
(Z 75 115).
40C−1210−001c_en 35/37
21
Z 75 116
Z 75 117
36/37 40C−1210−001c_en
3. Remove pin (21) and fold tension brackets (’X’) into the fitting
position ; using pin (21), pin it to the main boom head (P) and
secure (Z 75 116).
4. Luff the boom upwards until the plastic idler lifts off the
ground.
5. Conversion to the 0°−position is done in the reverse order.
21.6 Fitting and Removing for Separate Transportation

(Z 75 117)
If the main boom extension is transported separately, it can be

fitted as follows:
1. Set the main boom extension down on the ground and then
support it so that when the main boom is telescoped out, the
fixing pins can be inserted and secured in points (D1), (D2),
(H1) and (H2). For this, the boom must be luffed upwards
slightly.
The main boom and the main boom extension form a straight
line (Z 75 117).
Risk of tipping!
Max. extension length is 16 m (52.5 ft).
When the crane is only supported on a support base area (4.4

m / 14 ft 5 in) or a support base area (2.34 m / 7 ft 8 in), it is
only permitted to fit the main boom extension in the longitu-
dinal direction of the chassis.
2. Pin the fixing points and secure.
3. The further procedure is as described under 21.5 (from page

15).
When fitting or removing the main boom extension, the basic

boom and tip section must always be fitted individually −
there is otherwise a risk of the main boom extension overtur-
ning.
Removal is done in the same way, but in the reverse order.
40C−1210−001c_en 37/37
Reeving 22
40C−1220h_en 1/23
22
Z 60 159 Z 170 889
Z 75 361 Z 42 978
2/23 40C−1220h_en
Reeving 22
22 Reevings
22.1 Rope Equipment and Reeving

The safety of the crane is impaired by incorrect reeving.
Each crane configuration is assigned a corresponding ree-

ving number, which can be taken from the load table sup-
plied.
The crane must be operated only with the reeving numbers
stated in the load table.
In particular, when the crane is operated with the main boom

extension, the reeving must not be smaller than that speci-
fied in the load table for the appropriate crane configuration.
In order to achieve the reeving numbers required in the load

tables, the free hoist rope end must be fastened to the main
boom head or the hook block. To do so, a suitably sized rope
lock must be fitted to the hoist rope end.
(Z 170 889)
Installation of the rope lock, rope wedge and cable clamp (3)
is described in section 22.2.1.2 ”Rope end connections“.
(Z 42 978)
During reeving, the hoist rope (1) must be pulled by the shift
weight (2) of the hoist limit switch. If this is not done, the top
hoist limit will not function. There is a risk of damage to the
rope, sheave and shift weight.
To keep wear on the hoist rope and shift weight to a mini-

mum, the weight should, where possible, be secured to the
”idle” rope (Example: Z 42 978).
40C−1220h_en 3/23
22
2
a b
1
Z 75 361 Z 115 357
Z 170 889
4/23 40C−1220h_en
Reeving 22
Spin problems can occur when fitting a hoist rope which has
never been subjected to a load before. We therefore recom-
mend the use of a spin stabiliser in such cases (Example:
see Z 75 361).
Transport dimensions spin Approx.

stabilizer weight
Length Width Height
mm mm mm kg (lbs)
(in) (in) (in)
285 mm 75 mm 75 mm 5.5 kg
(11.2 in) (3.0 in) (3.0 in) (12.1 lbs)
Before reeving and before starting crane work, check the

status of all accessible ropes (including the end connec-
tions), winches and sheaves.
22.1.1 Uneven Reeving

Z 115 357 indicates the rope attachments points (1) and (2)
on the hook block with uneven reeving.
Depending on the construction of the hook block, the rope
attachment point (2) can be designed in two ways.
Figure (Z 115 357 “a”) shows the rope attachment point (2)
as a swinging metal plate in the centre, between the hook
block’s side plates.
Figure (Z 115 357 “b”) shows the rope attachment point (2)
directly on the side plate.
(Z 115 357, Z 170 889)

In order to attach the hoist rope to one of the rope attachment
point variants (2) on the hook block (Z 115 357), a rope lock
(Z 170 889) in the suitable size must be fitted to the free hoist
rope end.
In order to fasten the hoist rope to the rope attachment point

(1) on the hook block (Z 115 357 “a”) the hoist rope has to be
pulled directly through the rope lock welded to the side
shield (Z 170 889).
The further procedure for installation from this point is the
same as for installation of a separate rope lock (Z 170 889).
40C−1220h_en 5/23
22
A
3
1 4
6
5 2
B
1
Z 115 203 Z 115 172
6/23 40C−1220h_en
Reeving 22
22.1.2 Even Reeving

If the reeving numbers are even, the rope end connection can be
fastened to the main boom head in two ways (depending on the
equipment) using a rope lock.
2− and 4−fold reeving

Z 115 203 shows the central rope attachment point on the main
boom head.
− Remove the rope jump protection (5) and the guide compo-
nent (6).
− Feed the rope end connection (1) between the lower rope rol-
ler set and the boom head steel construction, pin at rope at-
tachment point (A) and secure.
− Insert the guide component into the plates on the main boom
head designed for this purpose.
− Lay the hoist rope into the groove of the guide component.
− Install rope jump protection (5) in point (B) and secure against
falling out.
If your crane does not have the central rope attachment point
described above, you must use the side rope attachment point
for 2− and 4−fold reeving (as in 6− and 10−fold reeving).
6− and 10−fold reeving
Z 115 172 shows the side rope attachment point on the main
boom head.
− Slide the rope end connection (1) and hoist limit switch (2)
onto the sheave axle (3) and secure (4).
40C−1220h_en 7/23
22
8/23 40C−1220h_en
Reeving 22
22.2 Load Lifting Equipment

If a load is to be raised with the crane, so−called load lifting devi-
ces are required to raise the said load. These are:
− Carrying equipment
Carrying equipment is permanently connected to the crane.
This includes:
− Hoist ropes
− Hook blocks
− Load−handling devices
Load−handling devices are equipment such as concrete hop-
pers, which do not belong to 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. It connects 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 safe utilization of the load−handling equipment,

the corresponding national regulations, such as, for exam-
ple, the accident prevention regulation ”Load−handling de-
vices in lifting operations (GUV−V9a)“ must be observed.
40C−1220h_en 9/23
22
1
2
Z 41 377
4a
4a 4b
Z 41 378 Z 41 379
10/23 40C−1220h_en
Reeving 22
22.2.1 Hoist Ropes
22.2.1.1 General
When reeving there is a risk of becoming caught and entan-

gled in the head and deflection rollers as well as in the hook
blocks!
Proceed with appropriate caution and make sure that all sa-
fety guards, for example anti−snag guards, are fitted.
Risk of accidents!
There is a risk of accidents when stepping onto the main
boom due to slipping / stumbling.
For this reason, it is prohibited to step onto the main boom.
Risk of overloading and accidents!

If a rope has to be replaced, the new rope must satisfy the
technical parameters of the original rope, for example with
regard to rope diameter, nominal tensile strength, calcula-
ted breakage force, minimum breakage force, type of lay
etc. in accordance with the rope certificate in the crane log-
book.
If this is not the case, the operational reliability of the crane
is no longer guaranteed in the normally permitted lifting
range!
22.2.1.2 Rope End Connections

(Z 41 377, Z 41 378, Z 41 379)
The illustrations of the rope socket (1) and the cable clip (3)
are principle illustrations and do not correspond exactly
with the components supplied by the crane manufacturer.
Only use original parts supplied by the crane manufacturer.
In order to fit the rope socket (1), first the free rope end is pulled
through the conical rope pocket, laid in a loop and then pulled out
of the rope pocket again. The rope key (2) is laid into the rope loop
and the hoist rope is pulled through the rope socket (1), so that
the free end juts out by approx. 8 times the width of the rope dia-
meter.
Danger of the load and / or the hook block falling down!
40C−1220h_en 11/23
22
4a
4a 4b
Z 41 378 Z 41 379
Z 41 380 Z 41 381
12/23 40C−1220h_en
Reeving 22
Using a cable clip (3), the ”unloaded“ rope end (4a; Z 41 378) is
now secured where it comes out of the rope socket at a distance
of approx. 3 times the width of the rope, so that the hoist rope is
not pulled through.
(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 41 380)
When fitting the rope socket you must make sure that the ”loa-
ded” rope fall (4b) runs into the rope socket in such a way that
when the end connection is loaded, the active line of the tension
force runs right through the fastening pin without bending the wire
cable.
(Z 41 381)
If fitted incorrectly, the end connection will align itself every
time it is loaded so that the active line of the tension force
runs through the fastening pin, bending the heavily−loaded
”loaded” fall of the wire cable where the rope pocket exits
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.
40C−1220h_en 13/23
22
14/23 40C−1220h_en
Reeving 22
22.2.2 Hook Blocks
22.2.2.1 Definition
In the DIN 15002, the hook block is defined as a ”multiple stran-

ded suspension of a carrying device with a hook“.
A single−line suspension would be referred to as hook suspen-

sion gear. As this differentiation is not relevant for the following
cases, only the term ”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.
22.2.2.2 Markings
The following details must be permanently and legibly marked on

hook blocks:
− Warning mark
− Manufacturer or supplier
− Year of construction
− Type, if type designation applies
− Factory or serial number
− Permitted load
− Rope diameter
− Drive group
− Dead weight.
40C−1220h_en 15/23
22
Z 42 980
16/23 40C−1220h_en
Reeving 22
22.2.2.3 Operation
(Z 42 980)
When reevingthere is a risk of persons becoming caught

and dragged into equipment and crushed near rotating and
moving components at 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 immedia-
tely.
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 fitter.
Before starting movements of the winches (raising or lowe-

ring) all persons must leave the danger zone in the proxi-
mity of the rope drums and sheaves.
The crane operator must maintain visual contact with the

operating personnel and must give a warning signal before
starting the drive motor or initiating crane movements.
40C−1220h_en 17/23
22
Z 42 975
Z 42 974 Z 42 976
18/23 40C−1220h_en
Reeving 22
(Z 42 974, Z 42 975, Z 42 976)
− Touch the hook block only using the handrails provided.

Hands MUST be kept clear of the following areas at all times:
∗ between the sheaves, side plates and covers.
∗ in the area of the fixing points (sometimes of a folding de-
sign), the hook, the hook nut, the lifting beam or the protec-
ting cages.
− Make sure that items of clothing do not get caught in rotating
parts.
− Work on the hook block may only be carried out (reeved), if
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!
Proceed with appropriate caution!
− Only use the hook block for lifting in vertical direction. Pulling
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.
40C−1220h_en 19/23
22
20/23 40C−1220h_en
Reeving 22
22.2.2.4 Hook Block Types / Transport Dimensions / Weights
Hook blocks − Description Hook Transport dimensions

type size * Length Width Height
mm mm mm
(in) (in) (in)
63−6/16/E 6−sheave, max. falls 10, 12 1300 mm 490 mm 435 mm
(40 t / 88.2 lbs) single hook, (51.2 in) (19.3 in) (17.1 in)
weight 480 kg (1058 lbs)
63−6/16/D 6−sheave, max. 10 falls, 12 1210 mm 490 mm 435 mm
(40 t / 88.2 lbs) double hook, (47.6 in) (19.3 in) (17.1 in)
32−3/16/E 3 sheave, max. falls 7, 6 891 mm 460 mm 380 mm
(30.1 t / 66.4 lbs) single hook, (35.1 in) (18.1 in) (15.0 in)
32−3/16/D 3 sheave, max. 7 falls, 6 900 mm 460 mm 380 mm
(30.1 t / 66.4 lbs) double hook, (35.4 in) (18.1 in) (15.0 in)
32−3/16/D/−40°C 3 sheave, max. 7 falls, 6 900 mm 460 mm 380 mm
double hook, (35.4 in) (18.1 in) (15.0 in)
16−1/16/E 1 sheave, max. falls 3, 4 860 mm 460 mm 330 mm
(12.9 t / 28.4 lbs) single hook, (33.9 in) (18.1 in) (13.0 in)
16−1/16/D 1 sheave, max. 3 falls, 4 750 mm 460 mm 330 mm
(12.9 t / 28.4 lbs) double hook, (29.5 in) (18.1 in) (13.0 in)
5−0/16−E Hook suspension gear, 4 840 mm 250 mm 250 mm
(4.3 t / 9.5 lbs) weight 130 kg (287 lbs) (33.1 in) (9.8 in) (9.8 in)
5−0/16−E/−40°C Hook suspension gear, 4 650 mm 260 mm 260 mm
(4.3 t / 9.5 lbs) weight 130 kg (287 lbs) (25.6 in) (10.2 in) (10.2 in)
* Hook size in accordance with DIN 15401 (single hook) or DIN 15402 (twin hook)
The weights of the hook blocks, hook suspension gear, lifting de-
vices, etc. must be deducted from the working loads in the tables.
Only use original hook blocks suitable for this crane. If you
wish to use other hook blocks, you must first contact our
customer service departments.
40C−1220h_en 21/23
22
Z 115 049
22/23 40C−1220h_en
Reeving 22
22.3 Reeving the Hoist Rope on the Main Boom Head

The safety of the crane is impaired by incorrect reeving.
Attention should therefore be paid to the reeving examples.
(Z 115 049)
Alternative reevings impair operation of the load limit device.
As an exception, when there is a 7−fold reeving, the shift

weight of the hoist limit switch may not be attached to the
rope which is not in operation, but instead to the rope of
sheave U3 to K4.
Otherwise the hoist rope will be destroyed!
40C−1220h_en 23/23
Counterweight 23
40C−1230f_en 1/11
23
1
4
2
5 4
3 5
7 7
6
6
Z 115 068
2/11 40C−1230f_en
Counterweight 23
23 Counterweight
23.1 Standard Counterweight
23.1.1 Attachment Points Standard Counterweight
(Z 115 068)
(1) Left counterweight block 3 attachment eyelets *

(2) Right counterweight block 3 attachment eyelets *
(3) Counterweight section 4 x at cast−in pins
* Attachment eyelets are not part of the standard delivery. They

must be fitted additionally.
RISK OF TIPPING !
If the counterweights are not attached at all indicated attach-
ment points, there is a risk of tilting!
23.1.2 Weights and Transport Dimensions Standard Coun-

terweight
(Z 115 068)
Item Nominal weight Transport dimensions

Length Width Height
t mm mm mm
(kip) (in) (in) (in)
1 2.0 t 809 mm 690 mm 780 mm
(4.4 kip) (31.9 in) (27.2 in) (30.7 in)
2 1.1 t 709 mm 690 mm 780 mm
(2.4 kip) (27.9 in) (27.2 in) (30.7 in)
3 2.3 t 2500 mm 880 mm 295 mm
(5.1 kip) (98.4 in) (34.7 in) (11.6 in)
40C−1230f_en 3/11
23
1
4
2
5 4
3 5
7 7
6
6
Z 115 068
4/11 40C−1230f_en
Counterweight 23
23.1.3 Counterweight 5.4 t (11.9 kip)
The maximum counterweight of this crane has a weight of 5.4 t

(11,9 kip) and is pinned firmly to the superstructure.
Components (Z 115 068):

2.0 t (4.4 kip) Left counterweight block (1)
1.1 t (2.4 kip) Right counterweight block (2)
2.3 t (5.1 kip) Counterweight section (3)
With the maximum configuration of the crane in the transport con-

dition (see section 5) the maximum axle load is less than 12 t
(26.4 kip). It is therefore not normally necessary to dismantle a
counterweight.
23.1.4 Counterweight 3 t (6.6 kip)
The components of this counterweight combination are firmly

screwed onto the superstructure or pinned optionally.
Components (Z 115 068):

2.0 t (4.4 kip) Left counterweight block (1)
1.1 t (2.4 kip) Right counterweight block (2)
For removal or assembly of the 2.3 t (5.1 kip) counterweight sec-

tion, see segment 23.1.5.
40C−1230f_en 5/11
23
1
4
2
5 4
3 5
7 7
6
6
Z 115 068
Z 115 205
Z 115 069
6/11 40C−1230f_en
Counterweight 23
23.1.5 Dismantling the 2.35 t (5.2 kip) Counterweight Section

(Optional)
Depending on the applicable regulations (e.g. lower maximum

axle load), it may be necessary to dismantle the 2.3 t (5.1 kip) co-
unterweight section (3).
There are 2 counterweight hoist cylinders on the chassis for lowe-
ring the 2.3 t (5.1 kip) counterweight section. These are controlled
via a mobile control panel (Z 115 205).
Procedure:
1. Place the main boom in the boom support.
2. Connect the mobile control panel to the chassis (point X,
Z 115 205, Z 115 069).
Depending on the design of the machine, the connection point

”X” is on the rear of the vehicle (Z 115 205) or on the left−hand
side of the chassis (Z 155 069).
3. Start the engine, extend the outriggers to the maximum sup-

port area.
4. Raise the counterweight hoist cylinders (6) and slightly raise
the 2.3 t (5.1 kip) counterweight section (Z 115 068).
The cams (7) of the counterweight hoist cylinders (6) must

latch into the grooves provided in the 2.3 t (5.1 kip) counter-
weight section.
40C−1230f_en 7/11
23
6 6
Z 115 070
8 8
X X Z 115 071
8/11 40C−1230f_en
Counterweight 23
5. Remove the locking fixtures (4) from the pins (5) and pull out
pins (5).
6. Lower the 2.3 t (5.1 kip) counterweight plate (3) until the co-
unterweight lift cylinders (6) are fully retracted.
7. Rotate the main boom to the rear (see section 17) and lift
down the 2.35 t (5.2 kip) counterweight section (3) from the
crane with suitable lifting tackle.
8. Disconnect the plug of the mobile control panel from the
chassis connection point. The counterweight hoist cylinders
(6) must first be fully retracted for this purpose.
The 2.3 t (5.1 kip) counterweight section is assembled analo-

gously in the reverse order.
23.1.6 Removal of the Side Counterweight Blocks

(Optional: Pinned Design)
The 2.0 t (4.4 kip) and 1.1 t (2.4 kip) counterweight blocks (1; 2)
are pinned in a fixed position to the superstructure as standard.
These counterweights are not designed to be removed. If they
were removed, the overall weight of the crane would shift drama-
tically forwards.
As an alternative to this standard version, the 2.0 t (4.4 kip) and
1.1 t (2.4 kip) counterweight blocks (Z 115 071) on the superstruc-
ture can be pinned to the superstructure (optional equipment).
Proceed as follows to dismantle the pinned counterweight
blocks:
1. Support the crane at the maximum outrigger support area.
2. Remove the locking fixtures from the pins (8) and pull out
pins (8).
3. Hook up the counterweight blocks individually (at the points
X) to the auxiliary crane using suitable lifting tackle, raise and
lift down from the support arms on the superstructure.
The driving and braking behaviour of the crane is affected by
removing the counterweight blocks.
To drive the crane, both counterweight blocks on the super-
structure must be secured to the superstructure or comple-
tely dismantled. Driving with only one counterweight block
on the superstructure is not permitted.RISK OF TIPPING !
The counterweight blocks are assembled analogously in the re-

verse order.
40C−1230f_en 9/11
23
Z 115 368
10/11 40C−1230f_en
Counterweight 23
23.2 Special Counterweight 5.4 t (11.9 kip)
(Z 115 368)
This counterweight combination is firmly screwed onto the super-

structure as a whole and usually it is not removed.
23.2.1 Attachment Points Special Counterweight
(Z 115 368)
This entire counterweight combination must be attached at both

load blocks.
23.2.2 Weights and Transport Dimensions Special Counter-

weight
(Z 115 368)
Item Nominal weight Transport dimensions

Length Width Height
t mm mm mm
(kip) (in) (in) (in)
5.4 t 2500 mm 710 mm 1030 mm
(11.9 kip) (98.4 in) (28.0 in) (40.6 in)
40C−1230f_en 11/11
Central Lubricating System (Optional) 25
40C−1250a_en 1/17
25
6
Z 55 936
P I
8
9
15
4
M
7 10
T
11
Z 58 663
2/17 40C−1250a_en
25 Central Lubricating System (Optional)

For this type of crane, an optional central lubricating system can
be supplied for the chassis.
The central lubricating system consists of a pump unit which sup-

plies the connected lubricating points with grease via the lubrica-
ting leads and subdistributors.
25.1 Pump
25.1.1 Components
(Z 55 936, Z 58 663)
(1) Grease container (2 l. / 0.5 gal)

(2) Pump element (K6, approx. 2.8 cm#/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
After the sealing cap (6) has been removed, the control board
with the following details becomes visible (Z 58 663):
(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 impulses
40C−1250a_en 3/17
25
6
Z 55 936
P I
8
9
15
4
M
7 10
T
11
Z 58 663
4/17 40C−1250a_en
25.1.2 Function
(Z 55 936, Z 58 663)
The central lubrication pump automatically supplies the connec-

ted lubricating 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.
Running of the pause and operating time is activated when the
corresponding ignition equipment is switched on.
The pause time
− determines the time period in which no lubrication cycle takes
place (an exception is possible via additional lubrication im-
pulse 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 section 25.1.3, page 7.
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 section 25.2 ”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 additional 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.
40C−1250a_en 5/17
25
P I
8
9
15
4
M
7 10
T
11
Z 58 663
6/17 40C−1250a_en
25.1.3 Setting the Pause and Operating Times

(Z 58 663)
25.1.3.1 GeneralInformation
The pause and operating times are controlled electronically via
the control circuit board.
As soon as the ignition equipment has been switched on the
pause time begins.
When the pause time has expired, the operating time starts,
which is the actual lubrication cycle.
25.1.3.2 Setting the Time

The pause and operating times are dependent on the lubrication
requirements of the connected lubricating points.
The pause and operating times are set at the factory .

In order to ensure sufficient lubrication of the connected lu-
bricating points, the set times may not be changed.
The crane operator is responsible for any damage caused by
adjusting the set values.
The pause time is set at the rotary switch (8).

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
The operating time is set at rotary switch (9).

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Minutes 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
40C−1250a_en 7/17
25
P I
8
9
15
4
M
7 10
T
11
Z 58 663
8/17 40C−1250a_en
Example:
− Pause time: 4 hours
− Switch position, rotary switch blue (8) = 4
− Operating time: 4 minutes
− Switch position, rotary switch red (9) = 2
Pause time
If the preset time of 4 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.
40C−1250a_en 9/17
25
6
Z 55 936
P I
8
9
15
4
M
7 10
T
11
Z 58 663
10/17 40C−1250a_en
(Z 55 936, Z 58 663)
25.1.4 Additional Lubrication Impulse
When you are not within an automatic lubrication cycle, it is possi-

ble to end the interval time prematurely and to introduce additio-
nal lubrication procedures. To do so:
1. Switch on ignition unit, the integrated LED (7) must light up.
2. Hold down the additional 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.
25.1.5 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.
25.1.6 Filling the Grease Container
The grease container (1) is filled via the filling nipple (5) up to the
”Max.” marking, capacity = 2 l. (0.5 gal)
The filling takes place in an appropriate manner with a standard
commercial grease pump or a hand lever press.
During filling, the pump must be set in motion (by first activating
the additional lubricating pulse).
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”!
40C−1250a_en 11/17
25
12/17 40C−1250a_en
25.2 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.
Malfunction: Pump engine not running

Cause Remedy
Electricity supply interrupted. Check electricity supply / (safety) fuses. Rec-
tify malfunction / if required replace (safety)
fuses.
Malfunction: Pump is not pumping

Cause Remedy
Container is empty. Fill up container with clean grease, let pump
run (additional lubrication), until lubricant
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. Carry out an additional lubricating pulse. Re-
move exhaust screw from the safety valve.
The lubricant must emerge without any bub-
bles.
Unsuitable lubricant used. Renew lubricant, see lubrication table (“Main-
tenance and lubrication instructions of the su-
perstructure”, part 2).
Suction bore hole of the pump element blok- Remove pump element, check suction bore
ked. hole impurities and remove.
Pump piston worn. Replace the pump element.
Non−return valve in the pump element defec- Replace the pump element.
tive or blocked.
Malfunction: Different lubricant quantity at the lubricating point

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.
40C−1250a_en 13/17
25
Z 29 549
14/17 40C−1250a_en
Malfunction: Blockage in grease distribution system connected in series (Z 29 549, prin-

ciple diagram)
Cause Remedy
Bearing, lines or distributor blok- Find and remove cause of blockage − as described in the
ked. following example.
The malfunction can be identi- 1. Let the pump run (additional lubrication impulse).
fiedby the following characteri- 2. At the main distributor (B), remove all main lines (G) to
stics: the subdistributors one after the other. If, for example,
a) Grease coming out at the grease emerges when there is pressure on the exhaust
safety valve. (1) of the main distributor (B) you must search for the
blockage in the lubrication circuit of the subdistributor (D).
b) Check pins at the distributor 3. Let the pump continue to run.
pistons (if they exist) are not 4. Remove all lubricating point lines (E) of the subdistributor
moving. (D) one after the other. If, for example, grease escapes at
the exhaust (3) of the distributor (D) when pressure is ap-
plied, you must search for the blockage in the line of the
exhaust (3) or in the connected bearing.
5. Replace safety valve A.
Note: In order to check the individual exhausts leave each
exhaust released for a longer period of time, as there is
only one stroke per pump rotation. However, several stro-
kes are required for a complete run of all distributors.
c) If a distributor is blocked, no Pump through blocked line / bearing using a hand pump.
lubricant emerges at any ex- Replace distributor or clean as described in the following:
haust. 1. Remove all hose connecting screws.
2. Unscrew piston sealing screws.
3. If possible, drive the piston out using a soft mandrel
(ø$smaller than 6 mm / 0.24 in).
Caution: The pistons are fitted to the distributor’s drilled
holes. After they have been removed, mark the fitting po-
sition and direction of the pistons for refitting. They must
not be confused 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 /
0.06 in) through at the thread ends of the piston bore
holes.
6. Clean and blow out distributors again.
7. Assemble distributors.
8. Renew copper washers.
9. 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 (362.8 psi).
If this happens, replace the distributor.
40C−1250a_en 15/17
25
B
6 5
4 3
2 1
1.1 1.1 1.1

1.2 1.2 1.2
2.1 2.1 2.1
2.2 2.2 2.2
E D C
6
8
6
8
3
1
2
4
2
4
7
5
1
3
5
7
1
3
5
7
8
6
4
2
2.2 2.2 2.2

2.1 2.1 2.1
1.2 1.2 1.2
1.1 1.1 1.1
Z 115 259
P I
8 3
9
6
15 M
7 10
T
11
Z 58 671
16/17 40C−1250a_en
25.3 Lubricating Points and Setting Times
25.3.1 Lubricating Points

(Z 115 259)
Legend “A − D”:
(A) Pump element with control circuit board and safety valve
(B) Main distributor
(C) Distributor (1st axle)
(D) Distributor (2nd axle)
(E) Distributor (3rd axle)
Legend “1.1 − 2.2”:

(1.1 / 1.2) Steering knuckle top / bottom
(2.1 / 2.2) Suspension cylinder top / bottom
25.3.2 Setting Times

(Z 58 671)
The length of a lubricating cycle is dependent on the lubrication

requirements of the lubricating points.
The pause and operating times are determined at the factory and
are set as follows:
− Pause time: 6 hours
− Switch position, rotary switch blue (8) = 6
− Operating time: 6 minutes
− Switch position, rotary switch red (9) = 3
The pause and operating times are set at the factory .

In order to ensure sufficient lubrication of the connected lu-
bricating points, the set times may not be changed.
The crane operator is responsible for any damage caused by
adjusting the set values.
40C−1250a_en 17/17
Searcher Hook (Optional) 26
40C−1260−001c_en 1/13
26
1
1
2
2
3
Z 75 126
2/13 40C−1260−001c_en
26 Searcher Hook (Optional)
26.1 General
(Z 75 126)
It is possible to lift loads up to 15 t (33.1 kip) without using the ho-

ist or hoist rope. To do so, the searcher hook can be fitted to the
main boom head or to the boom point. The searcher hook can
also be described as a 0° hoist apparatus.
When working with the searcher hook, select the ”0° hoist
apparatus” program on the CTC display.
Transport dimensions Approx.

searcher hook with clevis and weight
hook
Length Width Height
mm mm mm kg
(in) (in) (in) (lbs)
710 mm 370 mm 200 mm 25 kg
(28.0 in) (14.6 in) (7.9 in) (55 lbs)
26.1.1.1 Attachment Points
Risk of accidents!
No attachment points have been welded onto the sear-
cher hook. For this reason, it must be attached with a
looping tackle.
The actual attachment procedure must be undertaken
with the utmost care.
RISK OF ACCIDENTS!
The parts must not swing out or dangle at an angle when they
are raised. If necessary, lifting chains fitted with shortening
claws must be used.
The securing equipment must be supplied by the customer.
40C−1260−001c_en 3/13
26
1
1
2
2 112
3
Z 75 126 Z 115 074
Z 115 089
4/13 40C−1260−001c_en
26.2 Fitting the Searcher Hook

(Z 115 074, Z 115 089)
1. The underride guard on the main boom head must be remo-

ved.
2. Unreeve the hook block and draw the hoist rope under ten-
sion onto the hoist rope drum. Insert the rope eye (1) on the
collar of the boom basic case and draw the hoist rope taut
(Z 115 089).
(Optional)
3. Activate switch (112; Z 115 074) to switch off the hoist func-
tion. Otherwise there is a risk of damage due to unwanted
hoist movements.
4. Secure the searcher hook on the main boom head using pins
(1) and guard with fore locks (2) (Z 75 126).
5. If required:
− Variant 1: only clevis (3) or
− Variant 2: fit clevis (3) and spin stabilizer hook (4)
(Z 75 126)
Dismantling is carried out in the same manner, but in the opposite

order.
40C−1260−001c_en 5/13
26
6/13 40C−1260−001c_en
26.3 Operating with the Searcher Hook

1. . Raise the main boom out of transport position.
2. The searcher hook can be used anywhere in the slewing

range (360°).
The boom must not be raised higher than max. 40° as the
sheaves may otherwise be damaged by the searcher hook.
The load values in the main boom table apply.
Observe the safety instructions on the next two pages.
40C−1260−001c_en 7/13
26
2 2
3 3
90? 90?
”B” ”C” ”B” ”C” ”D”
30? 30?
”A” ”A”
Z 300 078
Z 300 079
8/13 40C−1260−001c_en
WARNINGS AND INSTRUCTIONS FOR USE

(Z 300 078, Z 300 079)
Important safety information − please read carefully and ob-
serve precisely.
Periodical visual checks for cracks, notches, wear, grooves
and deformation should be carried out by qualified person-
nel within the fixed time periods as part of a comprehensive,
documented inspection program (for example, see mainte-
nance and lubrication instructions, ANSI B30.10).
Hooks which are used very often or are subjected to pulsa-
ting loads must be checked periodically using the magnetic
powder test or the dye penetration test (note: disassembly
might become necessary).
Never use a hook with an enlarged jaw or a hook, whose top
piece is bent more than 10 degrees from the hook horizontal
or a hook which is bent or twisted in any other way.
Note: a protect trap will not function correctly with a hook
with a bent or worn down top piece.
(Z 300 078)
Do not use hooks which are worn beyond the limits.
− Zone A: Repairs not required
− Zone B: 10% of the original measurements
− Zone C: 5% of the original measurements
− Zone D: see minimum winch sizes table
Hooks with cracks, notches or grooves should be taken out
of operation. They can be repaired with longitudinal grinding
(following the hook’s contour), under the condition that the
reduced dimensions are still within the listed limits.
(Z 300 078)
Never treat, change or deform a hook with welding, heating,
burning or bending.
Never load a hook from the side, in a jerky fashion or at the
top piece (Z 300 079).
40C−1260−001c_en 9/13
26
S −319 S −320 S −322
Z 300 080
”A” ”B” ”C”
Z 300 081
10/13 40C−1260−001c_en
(Z 300 080, Z 300 081)

Eyelet hooks, shaft hooks and swivel hooks are designed for
use with cables or chains. When used with synthetic mate-
rial the load capacity can be diminished.
When under load, the S−322 swivel hook must not be rotated.
Always make sure that the hook carries the load (see fi-
gure “A”). The load must never be carried by the protect trap
(figure “B”).
When two ropes are suspended by a hook, be sure that the
angle between the ropes is not greater than 90 degrees (see
figure ”C“).
For angles with more than 90 degrees or more than two falls,
a link or an anchoring clevis with pins must be used in order
to hang the falls onto the hook.
Additional information can be found under ANSI/ASME
B30.10 “Hook”, for example.
WARNING:
The loads can become disengaged from the hook during in-
correct operation.
Falling loads can cause serious or fatal injuries.
Threads can become corroded or sheared off so that the

load is no longer held.
The load must always be held by the hook and never by the
protect trap.
Never load the hook with more than the permitted lifting ca-
pacity.
Before using the hook these instructions must be read ca-

refully and completely understood.
40C−1260−001c_en 11/13
26
0o
45 o
90 o
Z 300 082
max. 120 o
Z 300 083
12/13 40C−1260−001c_en
(Z 300 082)
Angle load must be attached at the end of the holder.
Side load lifting capacity reducer − only for clevises with

screws and pins
Angle between side load and Lifting capacity
straight pulling direction
0° straight fall * 100 % lifting capacity
45° angle * 70 % lifting capacity
90° angle * 50 % lifting capacity
* Direct fall is attached perpendicular to the pin.
DO NOT ATTACH A SIDE LOAD TO CLEVISES WITH ROUND

PINS.
(Z 300 083)
Never exceed an involved angle of 120°. ONLY use clevises with

pins and screws.
As long as the involved angle does not exceed 120°, the load
evaluation of the clevis is based on the load.
40C−1260−001c_en 13/13
Boom Point (Optional) 27
40C−1270−001a_en 1/25
27
”a” k
25
m l
25 >40
H H
”b” ”c”
Z 115 334
2/25 40C−1270−001a_en
27 Boom Point (Optional)
(Z 115 334)
Using the boom point (Z 115 334) on the main boom head makes
it possible to achieve the maximum lift (H) for this assembly state
with an interfering edge / obstacle above the crane (for example,
hall roof).
It is possible to raise loads with the hook block (using the hoist
rope) and with a separate hook (without the hoist rope).
Figure Z 115 334 shows the 3 settings which are possible for the
boom point. The tension bars must be set in relation to the main
boom angle at which the load is to be raised. Figure (Z 115 334)
shows the boom point with a reeved hook block. If the hook (wi-
thout the hoist rope) is used, the setting options are similarly va-
lid.
27.1 General
The tension bars of the boom point (MS) must be checked at

least once a year by a technical expert (in accordance with
the accident prevention regulations ”Load receptacle devi-
ces in lifting gear operation”, VBG 9a).
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 inspections are carried
out more frequently as the crane equipment is used more.
The performance of these inspections must be recorded

(e.g. in the crane log book).
The following inspections should be performed:

* Check for cracks
* Check the length
* Check for wear
* Check the paintwork
* Check for plastic deformation
40C−1270−001a_en 3/25
27
4
3
5.2
2 5
5.1
Z 115 043 Z 115 310
62
61
Z 55 526
4/25 40C−1270−001a_en
Instructions on how to carry out the inspection can be found

in the ”Lubrication and maintenance instructions”, part 2,
section 24 ”Equipment”).
The inspection of the tension bars must be documented, along

with the results, in the crane log book under ”Inspection reports”.
The boom point is marked with the construction number of

the crane. It may only be fitted on the crane with this con-
struction number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).
- Some of the assembly steps cannot be carried out on the

ground or standing on the chassis. A ladder is supplied in or-
der to carry out these steps.
Risk of falling!
It is not permitted to walk on the main boom.
- Before fitting the boom point to the main boom head, the mir-
ror (1, Z 115 043) must be folded away, the underride guard
(5, Z 115 310) removed and the optional hazard light (61,
Z 55 526 principle depiction) (if existing) removed.
Risk of damage!
Before fitting the boom point to the main boom, the optional
anemometer (62) (if existing) must be removed from the main
boom head (Z 55 526 principle depiction).
40C−1270−001a_en 5/25
27
Z 115 372
6/25 40C−1270−001a_en
27.1.1 Attachment Points
(Z 115 372 principle diagram)
The prescribed attachment points are marked on the boom point

with an ”A” in figure (Z 115 372).
The supplied 3−strand rope lashing is used for attachment.
The hook (15 t / 33 kip) can be fastened to the actual double load
hook for lifting.
Designation Transport dimensions Approx.

Length Width Height weight
mm mm mm kg
(in) (in) (in) (lbs)
Boom point 1390 mm 515 mm 510 mm 205 kg
(54.7 in) (20.3 in) (20.1 in) (452 lbs)
Hook 395 mm 240 mm 240 mm 40 kg
(15 t (33 kip)) (15.6 in) (9.5 in) (9.5 in) (88.2 lbs)
40C−1270−001a_en 7/25
27
1
2 ’A’
Z 115 159 Z 75 127
’B’
’B’
Z 115 345 Z 115 342
5
’C’
2
5
’F’
Z 115 343 Z 115 339
8/25 40C−1270−001a_en
27.2 Fitting the Boom Point
(Z 115 159, Z 75 127, Z 115 345, Z 115 342, Z 115 343, Z 115 339)
Risk of accidents!
Observe the instructions in segment 27.1 “General”.
1. Fold away the side mirror of the chassis. Remove the under-
ride guard and the hazard light from the main boom head, if
fitted. As described under 27.1 “General” (from page 3).
2. Lift the boom point from its storage cradle using the main
crane equipment. (Z 115 159).
3. Pin and lock supporting rods (1) in middle hole at point ’A’
(Z 75 127)
4. Set down boom point on level ground before the crane and
secure to stop from rolling away. Radius indicator in crane
control: 10.7 m (35.1 ft).
5. Fold down draw bar (2) forwards (Z 75 127).
6. Luff down main boom (length: 12.8 m / 42.0 ft) to −9° and po-
sition behind the boom head (Z 115 345)
7. Slide the boom point into head axle ’B’ from the front. Using
pin (4), pin in point ’B’ on both sides. Secure pin (4) against
falling out (Z 115 343).
Risk of crushing!
When the draw bars are swung over in the following for pin-
ning in point ’C’, ensure that the inner and outer parts of the
draw bars are not pinned together.
If the inner part is pulled out too far, the outer part can fall
down unchecked.
8. Swing the draw bars to the main boom head. Using pin (5),
pin in point ’C’ on both sides. Secure pin (5) against falling
out (Z 115 339).
9. Luff the main boom down and pin the draw bars (2) in the
”medium” position in point ’F’ using two further pins (5). Se-
cure both pins (5) against falling out (Z 115 339).
40C−1270−001a_en 9/25
27
2
5
2 ’F’
5
’F’
’D’
Z 115 339 Z 115 340
2
5
’G’
Z 115 341
k m
25
25
H H
”a” ”b”
Z 115 337
10/25 40C−1270−001a_en
10. Luff the main boom up slightly and remove the support rods.
The position of the boom point then corresponds to the position

for raising loads at a main boom angle of 25° to 40°. See also
27.3.2 on page13 .
27.3 Setting the tension bars for Raising Loads with Diffe-
rent Main Boom Angles
27.3.1 Boom Point Fitted in the ”Short” Position (for a Main

Boom Angle of less than 25 Degrees)
(Z 115 339)
1. Fit the boom point to the main boom head, as described in

steps 1. to 9. (page 9) from segment 27.2 “Fitting the boom
point”.
(Z 115 340)
2. Luff the main boom up and fit support rods on both sides in
point ’D’.
3. Luff the main boom down until the support rods are set on the
firm ground.
4. Remove pins (5) from point ’F’.
(Z 115 341)
5. Luff the main boom down and pin draw bars (2) in the ”short”
position using pins (5) in point ’G’. Secure both pins (5)
against falling out.
(Z 115 337 “a”)
7. Depending on the further procedure, fit the hoist rope and

the hoist limit switch or hook. Set crane control as described
in the relevant segments.
Figure (Z 115 337 “a”) shows the boom point with the draw bars
fitted in the ”short” position in the finished state with a reeved hoist
rope.
40C−1270−001a_en 11/25
27
”a” k
25
m l
25 >40
H H
”b” ”c”
Z 115 334
5 2
’C’ 5
’E’
Z 115 343 Z 115 344
12/25 40C−1270−001a_en
27.3.2 Boom Point Fitted in the ”Medium” Position (for the

Main Boom Angle of 25 − 40 Degrees)
(Z 115 334 “b”)
1. Fit the boom point to the main boom head as described in

steps 1. to 10. (page 9) from the segment 27.2 “Fitting the
boom point”.

27.3.3 Boom Point Fitted in the ”Long” Position (for a Main

Boom Angle Larger Than 40 Degrees)
(Z 115 343)
1. Fit the boom point to the main boom head as described in the
steps 1. to 8. (page 9) from the segment 27.2 “Fitting the
boom point”.
(Z 115 344)
Risk of crushing!
During the following luffing up of the main boom ensure
that you do not luff up too far. If the main boom is luffed up
too far, components of the tension bar will fall unchecked
on the boom point. The boom point could fall on the bottom
part of the main boom head.
2. Luff the main boom up. Pin draw bars (2) in the ”long” position
in point ’E’ using pins (5). Secure both pins (5) against falling
out.
40C−1270−001a_en 13/25
27
”a” k
25
m l
25 >40
H H
”b” ”c”
Z 115 334
Z 115 158
14/25 40C−1270−001a_en
(Z 115 334 “c”)

Figure (Z 115 334 “c”) shows the boom point with the draw bars
fitted in the ”long” position in the finished state with a reeved hoist
rope.
27.4 Reeving the Hoist Rope
1. Set the tension bars in accordance with segment 27.3 (from

page 11) with regard to the main boom angles at which the
load is to be raised.
2. Reeve the hoist rope in accordance with the load table.
The reeving diagrams from segment “Reeving the hoist rope on

the main boom head” in section 22 are similarly valid. The hoist
rope is reeved on the boom point sheaves instead of the bottom
sheave row of the main boom head.
3. Fit the hoist limit switch to the boom point and the hoist limit
switch shift weight to the hoist rope.
With even reeving (2−, 4−, 6−fold), the fixing point of the rope
(rocker arm) must be selected as shown in figure Z 115 158.
The rope attachment point on the side of the steel construction

is used when the boom point on the AC 30C (old designation:
AC 75) is used.
40C−1270−001a_en 15/25
27
17 16
6
14
7
9
1 8 13
4 17 5 4 15
10
5 11
3
Z 75 137 Z 115 346
9
1 8
4
8
5
Z 75 135
16/25 40C−1270−001a_en
27.5 Raising Loads without the Hoist Rope (15 t / 33 kip)

on the Boom Point (Optional)
27.5.1 Clevises / Single Hooks (15 t / 33 kip) (Optional)
(Z 75 137)
Loads to a max. of 15 t (33 kip) can be lifted without using the hoist
or hoist rope.
For this purpose, a hook can be fitted to the boom point.
To do so, proceed as follows:

− Set the tension bars in accordance with segment 27.3
(from page 11) with regard to the main boom angles at
which the load is to be raised.
− Set main boom in transport position;
− Unreeve the hoist rope and wind up in a controlled fashion
with an assistant who holds the rope taut;
− Fasten the hoist rope at the front on the basic boom sec-
tion and continue to wind up until it is “taut”;
Secure hoist rope to basic boom section; there is otherwise

a risk of injury from a falling hoist rope.
(Z 115 346)
− Release pin lock (4);
− Draw out sheave axle (5) to half−length;
Danger of injury from falling parts when extending the

sheave axle.
− Rope protection bars (14), rope protection plate (6), di-

stance sleeve (16), roller set (7) and idler (15) must be
completely removed.
− Sheave axle (5) must be completely drawn out with the
rope protection plate (13) removed.
(Z 75 135)
− Drive in sheave axle (5) to approx. half length;
− Push both distance sleeves (8) and clevis holder (9) onto
the sheave axle;
− insert the sheave axle (5) fully once more and secure with
pin locks (4).
40C−1270−001a_en 17/25
27
9 9
1 8 1 8
4 4
10 10
5 11 5 11
3
Z 75 137
12 Z 75 136
17 16
6
14
13
17 5 4 15
Z 115 346
18/25 40C−1270−001a_en
(Z 75 137, Z 75 136)
The clevis holder must be mounted in the middle of the

sheave axle and protected from displacement by the di-
stance sleeves (8).
The sheave axle (5) must be securely locked with the pin lok-
king (4) (torque MA of pins M 10= 49 Nm / 36 lbf−ft). Otherwise
there is a risk of the load falling or the boom point being des-
troyed.
− Fit clevis (11) and lock with cotter pin (10);
Max. clevis load is 15 t (33 kip).

Only the original clevis may be used.
The load must be raised and may only be transported when
hanging freely. The load may not be dragged across the
ground.
The load may not exert any torque (12) upon the clevis (11)
or the clevis holder (9) (Z 75 136).
In order to avoid torque on the boom point, a rotating hook

(3) should be used (optional), (Z 75 137)
For this, remove clevis (11), fit rotating hook (3) and refit clevis
(11), locking with cotter pin (10).
Select the crane configuration Boom point (short, medium, long)

for raising loads.
(Z 115 346)
The dismantling of the sheave axle (5) must be carried out

using the same procedure in exactly the opposite order.

sheave axle.
40C−1270−001a_en 19/25
27
17 16
6
14
13
17 5 4 15 1
Z 115 346 Z 115 165
20/25 40C−1270−001a_en
(Z 115 346)
king (4) (torque MA of pins M 10 = 49 Nm / 36 lbf−ft). Other-
wise there is a risk of the load falling or the boom point being
destroyed. The rope protecting bars (14) must be secured
with fore locks (17).
27.5.2 Double Hook (15 t / 33 kip) (Optional)
(Z 115 165)
Loads to a max. of 15 t (33 kip) can be lifted without using the hoist
or hoist rope.
To do so, a double hook can be fitted to the boom point.
To do so, proceed as follows:

− Set the tension bars in accordance with segment 27.3
(from page 11) with regard to the main boom angles at
which the load is to be raised.
− Set main boom in transport position;
− Unreeve the hoist rope and wind up in a controlled fashion
with the help of an assistant who holds the rope taut.
− Fasten the hoist rope to the front on the basic boom sec-
tion and wind up until it is “taut”;
Secure hoist rope to basic boom section; there is otherwise

a risk of injury from a falling hoist rope!
(Z 115 346)
− Release pin lock (4);
− Draw out sheave axle (5) to half−length;

sheave axle.
− Rope protection bars (14), rope protection plate (6), di-

stance sleeve (16), roller set (7) and idler (15) must be
completely removed;
− Sheave axle (5) must be completely drawn out with the
rope protection plate (13) removed;
40C−1270−001a_en 21/25
27
17 16
6
4
14
7
20
21 13
4 17 5 4 15
21
20
Z 115 166 Z 115 346
22/25 40C−1270−001a_en
(Z 115 166)
− Pin the double hook by inserting the pins (20) on the boom
point.
Make sure that the equipment is properly fitted and that the two
bushings (21) in the bores of the double hook are well lubricated.
− Secure the pins (20) with the two pin locks (4).
The pins (20) must be secured with the pin locks (4) (tighte-
ning torque MA of the pins M 10 = 49 Nm / 36 lbf−ft). Otherwise
troyed.
Max. clevis load is 15 t (33 kip).

The load must be raised and may only be transported when
hanging freely. The load may not be dragged across the
ground.
Select the crane configuration Boom point (short, medium, long)

for raising loads.
The double hook is dismantled and the roller set assembled ana-
logously in the reverse order.
(Z 115 346)
The dismantling of the sheave axle (5) must be carried out

using the same procedure in exactly the opposite order.

sheave axle.
40C−1270−001a_en 23/25
27
17 16
107
6
14
13
17 5 4 15
Z 115 346 Z 115 338
3
3
Z 115 160 Z 115 161
24/25 40C−1270−001a_en
(Z 115 346)
king (4) (torque MA of pins M 10 = 49 Nm / 36 lbf−ft). Otherwise
troyed.
The rope protecting bars (14) must be secured with fore
locks (17).
27.6 Raising Loads
(Z 115 338)
− Assemble the crane with the boom point in the corresponding
fitting and reeved hoist rope or fitted hook.
− Set and / or observe the values of the load table in crane con-
trol.
− When using the hook, switch off the hoist function with switch
(107).
27.7 Boom Point in the Transport Condition
(Z 115 160, Z 115 161)
Using your own crane equipment, set the boom point down in the
transport support and fasten with tension belts (1 + 2).
The boom point must be secured vertically with tension

belt 1. Using tension belt 2, the draw bars and the support
rods must be secured against falling out when opening the
flap (3).
40C−1270−001a_en 25/25
Radio Remote Control (Optional) 34
40C−1340−733c_en 1/31
34
SYN 1 2
201
Z 115 410
202
Z 200 424
2/31 40C−1340−733c_en
34 Radio Remote Control (Optional)

(Z 115 410, Z 200 424 schematic diagram)
Your crane is equipped with a radio remote control which mainly

consists of two components:
− mobile radio transmitter with control panel (201, Z 115 410)
− radio receiver (202, Z 200 424)
All crane movements can be ”remote controlled” from outside the

cab using this radio remote control.
34.1 General
Before operating the radio remote control you must read and
observe the notes in the manufacturer’s operating instruc-
tions!
If instructions are unclear, please contact our customer ser-

vice department before operating the remote control sy-
stem.
Every crane movement activated by the radio remote corres-

ponds exactly with a crane movement activated from the
All instructions and descriptions of the corresponding sec-
tions of the crane operating manual must therefore be obser-
ved.
The minimum response time for a command and the response

time of the crane are marginally increased by the radio remote
control.
All movements of the crane and the load must be in the field
of view of the crane operator. If necessary a spotter must be
used
You, too, as the operator of the radio remote control must

remain clear of the hazardous area of the crane during
crane operations!
40C−1340−733c_en 3/31
34
24 24
1 2 3 4 5
21
8
20 SYN 1 2
19
18 17 16 15 14 13 12 11 10
26 25 26 25
22
9
Z 115 411
4/31 40C−1340−733c_en
34.2 Safety Regulations

(Z 115 411)
Applicable regulations on work safety and accident preven-

tion for operations using radio remote control must be ob-
served!
The radio remote control may only be placed in operation

upon receipt of a special radio permit.
34.3 Important Information before Using the Radio Remote

Control
The radio transmitter may only be used with the belt sup-
plied in the delivery (risk of confusing the operating ele-
ments)!
Before working with the radio remote control, make sure

that you are fully conversant with how the system works!
Only authorised and suitably trained personnel may there-
fore work with the radio remote control.
Always be very careful and observant when using the radio

remote control!
Select a safe operating location from which you can see the
workplace in its entirety.
During operating breaks or at the end of operation, switch

off the transmitter using key switch (22) “Transmitter
on / off” or quick stop switch (9) and pull the connection
plug from the receiver!
Check the function of the quick stop switch (9) every time
before beginning work! After the unlocking which follows,
the switch (22) “Transmitter on / off” on the radio transmit-
ter must be reactivated.
If one procedure with radio remote control has been com-

pleted, the slew gear brake (retaining brake) must be ap-
plied for safety reasons!
40C−1340−733c_en 5/31
34
24 24
1 2 3 4 5
21
8
20 SYN 1 2
19
18 17 16 15 14 13 12 11 10
26 25 26 25
22
9
Z 115 411
6/31 40C−1340−733c_en
(Z 115 411)
Never leave the activated transmitter unattended!

After approx. 15 minutes, the radio transmitter switches off
(see section 34.8.1).
In case of a malfunction, an emergency or any faults within

the operating range of the radio remote control, stop the
crane immediately in order to rectify the fault, i.e:
− switch off the radio transmitter using the quick stop
switch (9)
− pull out the key (22) “Transmitter on / off” from the radio
transmitter
− remove the connection cable from the radio receiver.
Do not disregard even small faults in the radio remote con-
trol system. They can lead to serious malfunctions.
Do not continue to work with a defective radio remote con-

trol!
Only have a specialist repair a defective radio remote con-

trol. Only use original spare parts of the manufacturer!
Depending on country specifications or as an optional extra there

could be a green lamp, which flashes during operation with radio
remote control.
40C−1340−733c_en 7/31
34
202
202.1 202.2 202.3 202.4
Z 200 426
8/31 40C−1340−733c_en
34.4 Radio Receiver

The radio receiver is on the superstructure.
Make sure that neither the radio receiver nor the antenna come
into contact with any other objects.
There are 4 indicator lights (LEDs) in the lid of the radio receiver
which indicate the operating condition of the radio remote control:
(202.1) − ”On”
The yellow LED lights up as soon as the receiver is live. A connec-
tion to the crane’s electrical system has been made, the internal
operating voltage is applied.
(202.2) − ”HF”
The red LED is illuminated with the transmitter switched off and
goes out as soon as the transmitter is switched on, i.e. if the recei-
ver receives a signal on its radio frequency.
If the ”HF” LED also goes out with the transmitter switched off, it
is an indication that the radio channel is also being used by an-
other transmitter.
If the system shuts down due to radio interference, you must
switch your transmitter off and monitor whether the ”HF” LED
goes out anyway.
(202.3) − ”SI 1”
The green LED flashes briefly, approx. twice per second, with the
transmitter switched off. In this time the safety circuit is checked.
After switching on the transmitter, the LED lights up permanently,
i.e. the receiver has recognised its transmitter at the same system
address (code). Safety circuit ”SI 1” is enabled.
(202.4) − ”SI 2”
The green LED relates to the internal safety circuit ”SI 2”, which
switches off the driving commands twice if the command sensor
is in the ”Off” position, i.e. ”SI 2” is not illuminated.
Only when one or more drive commands (e.g. slew, hoist, etc.)
are output should the display ”SI 2” light up!
40C−1340−733c_en 9/31
34
24 24
1 2 3 4 5
21
8
20 SYN 1 2
19
18 17 16 15 14 13 12 11 10
26 25 26 25
22
9
Z 115 411
10/31 40C−1340−733c_en
34.5 Operating Elements of the Radio Transmitter

(Z 115 411)
Item Designation Function

1 Control lever, left Telescopic sections / slew gear
2 Buzzer Acoustic warning signals
3 Display Details on load, load utilisation, ho-
ist limit switch and telescoping sy-
stem (see page 13)
4 Indicator light Charging state of the battery
5 Control lever, right Hoist / luffing gear
8 Button Horn
9 Switch Engine quick stop
10 Flip switch luffing gear down “+” faster −“−” slo-
wer
11 Toggle switch “ + ” = increase engine speed
“ − ” = lower engine speed
12 Rotary switch Radio channel: A, B, C or D
13 Flip switch Engine start = up
Engine stop = down
14 Pushbutton Display switchover (see page 13)
15 Flip switch Precision control for crane move-
ments Slew gear left/right, hoist up/
down
16 Rotary switch Telescoping operation
17 Toggle switch Switchover slew gear − top/hoist −
bottom
18 Toggle switch Slew gear brake:
top − closed
bottom − open
19 Key−operated pushbut- Overriding ”Raise luffing gear”
ton M1
20 Button light display
21 Button High speed
22 Key switch M2 Transmitter on/off Function
24 Handle
25 Attachment eyelets for harness
26 Harness
The keys for both key switches / buttons are marked with “M1” or “M2”
and only fit in accordance with their designation.
40C−1340−733c_en 11/31
34
3.1
3.2
3.3
3.6 3.5 3.4
3.8
3.7
3.9 3.10
14
SYN 1 2
Z 115 412
12/31 40C−1340−733c_en
34.6 Control Lever Assignment
Control lever, left Control lever, right
Slewing Luffing
SLH = SRH =
gear gear
SLV = Tele SRV = Hoist 1
S = control lever, R = right, L = left, H = horizontal, V = vertical
34.7 Display
(Z 115 412)
The various displays can be selected with pushbutton (14).

(3.1) − Bar display of the load utilisation
(3.2) − Percentage display of load utilisation
(3.3) − Radius
(3.4) − Hoist limit symbol
When the hoist limit symbol lights up (HES) the hoist limit
switch has been triggered.
(3.5) − Current gross load
The gross load includes the weight of the hook block, the
hoist rope and all load lifting attachments.
(3.6) − Max. load capacity in accordance with the load capacity
table
(3.7) − Display of whether telescopic section 1 or 2 iscompletely
retracted
(3.8) − Percentage display of the extended telescoping lengths
(3.9) − Prewarning symbol
Prewarning range (90 − 100 % of the load moment)
Prewarning symbol flashes.
(3.10)− Overload symbol
Overload range (from 100 % of the load moment)
Overload symbol flashes up.
The LLD switches off the movement ”Raise load”, ”tele-
scope out” and ”lower luffing gear”.
40C−1340−733c_en 13/31
34
106
67
74
Z 115 153 Z 115 258
22
9
Z 115 332
202.1 202.2 202.3 202.4
Z 115 276
14/31 40C−1340−733c_en
34.8 Commissioning of the Radio Remote Control

(Z 115 153 principle diagram, Z 115 258, Z 115 332, Z 115 276
principle diagram)
The sequence described below for starting operations must be

followed (for finishing operation, in the reverse order).

1. With the decals facing outward, insert the charged battery
into the corresponding compartment at the bottom of the
control panel. Make sure the battery’s poles are in the correct
place.
2. Switch on the ignition (67; Z 115 258) in the cab (see section
3).
3. Operation of the crane (106; Z 115 258) in the cab (see sec-
tion 3).
4. Switch key switch (74; Z 115 258) to radio control and re-
move key (see section 3).
In order to avoid undesired crane movements or interrup-

tions, lock the crane operator’s cab and take the cab key and
the key from the key switch (74) with you.
As soon as crane operations are switched to radio remote,(key

switch 74), it is no longer possible to change the craneconfigura-
tion on the CGC.
5. Unlock the quick stop switch (9, Z 115 332) by turning it.
6. Activate radio transmitter using key switch (22, “Transmitter

on / off” Z 115 332).
The transmitter is now under operating voltage.
The radio connection to the receiver is now established, if,
after switching on the transmitter, the red LED ”HF” (202.2,
Z 115 276) on the radio receiver goes out, and the green LED
”Si1” (202.3, Z 115 276) lights up, i.e. the radio system is re-
ady for operation, and control commands can be entered.
(Z 115 332)
If the transmitter was switched off using the quick stop switch (9),
the following conditions must be met in order to switch the trans-
mitter on again using the key switch (22): ”Transmitter on / off”
must be switched off, the quick stop switch must be unlocked and
then switched on again using the key switch!
40C−1340−733c_en 15/31
34
24 24
1 2 3 4 5
21
8
20 SYN 1 2
19
18 17 16 15 14 13 12 11 10
26 25 26 25
22
9
Z 115 411
202
202.1 202.2 202.3 202.4
Z 200 426
16/31 40C−1340−733c_en
(Z 115 411, Z 200 426 schematic diagram)
The transmitter must always be switched on with the key

switch (22) “Transmitter on / off”, and not using the quick
stop switch (9).
7. Switch on the radio transmitter. To do so, turn the key

switch M2 (22) “Transmitter on / off” in the direction of the ar-
row. The state display (202.3) flashes green, the transmitter
is ready for operation.
After switching the transmitter on again (without pressing thekey

switch again (74) in the cab) the last activated craneconfiguration
must be confirmed by pressing the horn (8).
If the red LED of the state display (202.3) is illuminated and / or

an acoustic signal goes off via buzzer signal (2), it means that the
battery is almost empty. In this case, you must immediately:
− Replace the discharged battery with a charged one.
− recharge empty battery (see section 34.11 ”Battery”, from
page 25).
The transmitter will switch itself off after a few minutes if the di-
scharged battery is not replaced with a charged one.
The radio connection to the receiver (Z 200 426) has been made
if the red ”HF” (202.2) goes out on the radio receiver after the
transmitter has been switched off and the green LED ”Si1”
(202.3) is illuminated.
Control commands can then be given using the control panel of
the radio transmitter.
8. Start the crane engine using the radio remote control (engine
start: flip switch ”13” − top)
You must always do the following every time before starting

work:
Press button (8) ”Horn”. This warns your colleagues to ex-

pect crane or hook movements at this point in time.
40C−1340−733c_en 17/31
34
24 24
1 2 3 4 5
21
8
20 SYN 1 2
19
18 17 16 15 14 13 12 11 10
26 25 26 25
22
9
Z 115 411
18/31 40C−1340−733c_en
(Z 115 411)
Control commands can be transmitted even when the

crane is out of sight. For this reason, when not using the
key (22) “Transmitter on / off”, remove it from the transmit-
ter and keep in a safe place.
34.8.1 Automatic Shut−down of the Transmitter
The transmitter is equipped with an automatic transmitter switch−

off and switches itself off approx. 15 minutes after the last control
command has been entered.
The automatic transmitter shut−down is for safety reasons and
improves the durability of the battery.
For reactivation, the switch (22) “Transmitter on / off” must be re-
activated.
Under no circumstances does the automatic transmitter

shut−down relieve operators of their responsibility to
switch off the radio transmitter when it is no longer needed.
Unintended or improper use of the radio remote control will lead

to its manufacturer’s warranty being invalidated!
40C−1340−733c_en 19/31
34
3.1
3.2
3.3
3.6 3.5 3.4
3.8
3.7
3.9 3.10
14
SYN 1 2
Z 115 412
20/31 40C−1340−733c_en
34.9 Crane Operation Using Radio Remote Control

(Z 115 412)
All crane movements can be ”remote controlled” from outside the

cab using this radio remote control.
Any activation of a crane function using this radio remote control

unit corresponds exactly to the corresponding operation of crane
movements using the operating controls in the cab.
Risk of accidents!
The minimum response time for a command and the re-
sponse time of the crane are marginally increased by the
radio remote control. The time delay between releasing the
control lever and the cessation of movement can be parti-
cularly dangerous for the person handling the load when
attaching and removing the load.
For this reason, the radio remote control must be handled
with special care in this case and with forward planning in
mind.
When a work step has been completed with the radio re-
mote control, for safety reasons the slew gear brake (par-
king brake) must be engaged.
In the case of a defect, an emergency or if there are any

faults in the operating range, switch off the radio remote
control immediately until the fault can be rectified.
When the load utilisation of the crane reaches the prewarning

range, the ’Caution’ symbol appears (3.9).
If the LLD switches off crane movements, the ’Stop’ symbol ap-
pears (3.10)
In this case, the crane operator must check the cause of the shut−
down on the operating unit of the crane control in the crane ope-
rator’s cab.
Using this information, the crane operator can decide how to get
out of the shut−down.
For other malfunctions, see section 34.12 “Troubleshooting” (p.
29).
40C−1340−733c_en 21/31
34
41
Z 60 243
22/31 40C−1340−733c_en
34.10 Battery
(Z 60 243)
The battery (41) must be in the corresponding compartment under-

neath the control panel of the radio transmitter − as shown.
The operating period of the battery depends on the age of the battery
and the surrounding temperature. The capacity of older batteries de-
creases over time. If temperatures are below 0° C / 32° F, the battery
does not achieve full capacity.
With proper handling, more than 500 charging cycles can be achieved.
For this reason, follow these instructions:
− only charge the battery when it is empty, i.e. if the red display is flas-
hing on the transmitter and / or the acoustic signal goes off.
Charge the batteries before they are used the first time.
Batteries which have been stored for a longer period of time must
be charged before use.
− Do not keep the battery in the toolbox or in your trouser pocket (risk
of short circuiting).
− Always use the supplied protection caps for storage.
− Store the batteries at room temperatures (approx. 20° C / 68° F).
40C−1340−733c_en 23/31
34
51
56
55
54
53
52
Z 60 382
24/31 40C−1340−733c_en
34.11 Battery Charging Device

(Z 60 382)
When using the charging set FLG 110D, only HBC batteries
of the type FuB 10 AA and FuB 10 XL may be charged!
Only use original HBC batteries. If original HBC batteries

are not used, there can be problems with performance and
safety (from overheating to batteries exploding)!
Do not operate the charging device in areas at risk of explo-

sions.
Operate the charging device only at the supply voltage indi-

cated on the underside.
Only use the charging set in vehicles!
Only operate the charging set within the indicated tempera-

ture range and protect it from overheating, dust and damp!
Disconnect the charging set from the power supply before

opening the machine!
Do not cover the charging device during operation.
Disconnect the charging device from the power supply if it

is not being used.
Stop operation of the machine immediately if there is a fault

in the machine or the cable.
Do not make any technical modifications to the charging

device or the cables.
Only have an expert carry out repairs.
40C−1340−733c_en 25/31
34
51
56
55
54
53
52
Z 60 382
26/31 40C−1340−733c_en
Charging the battery

(Z 60 382)
1. Connect the charging set to a vehicle socket.
2. Insert the battery into the charging compartment (52) with

the decals facing upward. Make sure the battery polarity is
correct.
The charging state of the inserted battery is displayed using 4

LEDs:
LED (56), red − Battery defective or exhausted

LED (55), yellow − battery is charged.
LED (54), green − Battery is charged.
LED (53), yellow − Battery is discharged
Technical data
Operating voltage 10 − 30 V DC
Charging time approx. 3 hours
Operating tempera- +10° C − +40° C
ture (+50° F − +104° F)
Device protection II
class
Function ”Discharging”
The battery’s capacity can become diminished as time goes on.

In this case, the battery’s charging set can improve the available
battery capacity using the function ”Discharging”. To do so, all
you must do is briefly press the key (51) ”Discharging”. The bat-
tery is then completely discharged and recharged automatically.
40C−1340−733c_en 27/31
34
28/31 40C−1340−733c_en
34.12 Troubleshooting
Please check the functions with the cab or cable control first.
Fault Possible cause Measures

No response when There is no operating Check the battery contacts for damage or
the transmitter is voltage. dirt.
switched on
Place a charged battery in the battery com-
partment.
Charge the battery fully.

An undervoltage war- The battery contacts Check the battery contacts for damage or
ning will appear after are dirty or damaged. dirt.
a short operating
time, i.e. the state The battery is not Charge the battery fully.
display in the trans- charged.
mitter flashes red. Check that the charging procedure is pro-
The battery is faulty. ceeding correctly.
Check the transmitter function with a fully

charged or a replacement battery.
The transmitter The receiver does Check the connection cable to the receiver.
shows a normal ope- not have any opera-
rating display, but no ting voltage. Check the fuses in the receiver.
control commands
can be carried out There is no radio Check the functions using the LEDs in the
connection. cover of the receiver.
Individual commands The receiver is de- Check that the connection cable is securely
are not being carried fective. fitted.
out
The connection cable If required, contact a service technician.
to the crane is bro-
ken.
40C−1340−733c_en 29/31
34
30/31 40C−1340−733c_en
34.13 Servicing
The radio system is largely maintenance−free. However, the fol-

lowing points should be observed:
− Make sure that the quick stop switch moves easily. Mortar
remnants and dirt can obstruct or even prevent activation of
the switch.
− Check the control lever’s bellows regularly to make sure they
are sealed. Change bellows early enough if cracks start to ap-
pear as invading damp and dirt hinder the function of the con-
trol lever.
− Charge and discharge the transmitter batteries regularly.
− Never ”clean” the radio system with high−pressure cleaners
or with steam cleaners. If necessary, use a paintbrush or soft
cloth.
− If electrical welding is to be carried out on the crane:
− Switch off the radio system
− Unplug the connection plug on the receiver.
Failure to carry out these safeguards will result in the recei-
ver electronics being destroyed.
If problems occur with the radio remote control, please contact

our service department.
Do not disregard even small faults in the radio remote con-

trol system. They can lead to serious malfunctions.
Only have qualified personnel repair defective radio re-

mote control systems. Only use original spare parts of the
manufacturer!
40C−1340−733c_en 31/31
Emergency Activation (optional) 36
Z 115 170
40C−1360h_en 1/5
36
76
(AC40C)
61
(AC25)
6 19
5 1 (AC30C)
L UW T
TUW 4
PUW
X600
X601
Z 600 167 Z 115 168
Z 115 167
2/5 40C−1360h_en
36 Emergency Activation (optional)
If the drive engine or the hydraulic pump fail, it is possible to move

a small load from a danger zone by using an emergency control
power unit with the help of another crane or emergency pump
power unit.
When emergency activation is underway (emergency power unit
connected, ignition and superstructure operation switched on)
the movements ”hoist up/down”, ”luffing up/down” or ”slew right/
left” can be carried out using the pilot control in the superstructure
cab (only one movement at a time can be carried out). Proceed
as follows:
AC 50 / AC 80−1:
1. To bridge the proportional valves the standard plug X 600
must be removed from the superstructure cab and replaced
with the plug X 601.To bridge the signal ”engine running”, the
plug SG3 must be plugged into FG3 in the main electrical unit
of the undercarriage in the chassis cab.
AC 50−1 / AC 80−2 / AC 90−R:
with the plug X 601. To generate the signal ”Engine running”,
the ignition−starter switch in the superstructure cab must be
turned to ”Start position” for approximately 1 second (but wi-
thout actually starting the engine). The ignition−starter
switch then remains in the condition ”Ignition on”.
The main electrical unit of the engine is then switched as if
the engine were running. To check the function, the super-
structure can be turned slightly.
AC 25 / AC 30C / AC 40C (Z 115 168):
with the plug X 601 and emergency operating mode selected
using key−operated switch (61, S 710 (AC 25); 19, S 710 (AC
30C) or 76, S 710 (AC 40C))
Figure Z 600 167 shows one possible design for an emergency

power unit.
2. The engine (4) of the emergency activation power unit

(Z 600 167) is connected (by another crane, prepared for
emergency activation or by an emergency pump power unit)
to the pump as well as the tank using the pressure (PUW) and
return hose (TUW) leakage oil (L) is existing) (Z 115 167).
40C−1360h_en 3/5
36
Z 115 167
29
(AC25 / AC30C)
4
(AC40C)
Z 115 169
4/5 40C−1360h_en
(Z 115 167, Z 115 169)
The pump (5) of the emergency power unit is connected with suc-
tion (T) and pressure line (1) to the superstructure hydraulic sy-
stem of the malfunctioning crane (Z 115 167).
3. The ball valve (6, Z 600 167) of the emergency power unit is
set to ”through flow” and is only closed if a movement is to
be carried out immediately thereafter.
The movements “hoist up/down” or ”luffing up/down” are now
enabled.
To actuate the slew gear, the hose line (7) must be refitted from
1.1 to 2.1 (Z 115 167).
Now only the slew gear can be rotated left and right.
The flow quantity of the oil for the slew gear is preset by means
of a throttle and should not be changed.
When the emergency power unit is connected, the normal hy-

draulic output of the crane is no longer available.
p 9 0,6 x pNOM
Q 9 0,1 x QNOM
These values depend on the performance of the emergency

activation power unit as well as the type of drive. The move-
ments are slower and can be driven with reduced pressure,
i.e. the full performance capacity of the machine is not
achieved.
All instructions and descriptions in the operating instruc-

tions for the crane with regard to the corresponding crane
functions must be observed.
In the case of the AC 25 / AC 30C or AC 40C the movements, in

addition to the adjustable speed of the emergency power unit and
the characteristic curve of the pilot control, can be regulated
using the potentiometer (29, R 710 (AC 25 / AC 30C) or 4, (AC
40C)) (Z 115 169).
When you are finished with emergency operation, all plugs

in the main electrical unit and all hydraulic connections must
be removed or changed over again.
40C−1360h_en 5/5

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Translation

of the Original Operating Instructions

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

5.4.4 Possible axle loads / permitted speeds . . . . . . . . . . . . . . . . . . . . . . . 25

10.5 Locking the Suspension for

13 Towing the Crane and Towing the Crane to Start . . . . . . . . . . . 1

14 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15.3.4.2 Calling up the ”Main Menu” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 77

21 Main Boom Extension (MBE) (Optional) . . . . . . . . . . . . . . . . . . . 1

25 Central Lubricating System (Optional) . . . . . . . . . . . . . . . . . . . . 3

26 Searcher Hook (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

27 Boom Point (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

36 Emergency Activation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The operating, lubricating and maintenance instructions included

Crane classification Mobile crane

Crane type AC 40C

Construction number ___________________

Manufacturer Terex Cranes Germany GmbH

This document provides you

We have assembled all the information required for operation,

Among other things, these documents contain operating instruc-

The operating instructions of this crane consists of 3 parts:

Please note that the information contained in this manual corres-

In such cases we make every effort to bring your documentation

Give these operating instructions to your crane operator and

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

Should you discover any mistakes when reading this manual or

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

Please contact the service department if you have any questions

The manufacturer’s address can be found in the section ”Manu-

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 operating instructions of this crane consists of 3 parts:

These parts are divided by index sheets.

“Wind speed” deals with matters concerning operation of the

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

3. In this section 16 I then find ”Wind speeds” as item 16.2.

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 gene-

The safety instructions for lubrication, maintenance and service

1.2 Intended Use

The crane is designed for lifting loads.

Risk to life and limb!

The crane is not intended for lifting people. It is prohibited to

The crane may only be used to lift people in a so−called ”person-