EX5800 82212g Part1 - en

Translation
of the Original Operating Instructions

Explorer 5800
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.
082−0000−82201_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 power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.5 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.6 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.7 Scrapping / Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.8 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 25
1.3.9 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.2 Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4.3 Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4.4 Protection from physical effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4.5 Combination of Hazards with Combined Operation
of Two or More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4.6 Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4.7 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4.8 Power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.4.9 When Assembling and Dismantling Crane Components . . . . . . . . 89
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 99
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 101
2 Structure of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Main Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Getting onto and off the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.2 Overview of Ladders / Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.3 Before Getting on / off Using Ladders / Steps . . . . . . . . . . . . . . . . . 11
2.3.4 Getting onto and down from the Crane Using Folding Ladders . . 15
2.3.5 Getting onto and down from the Crane Using Integrated Steps . . 23
2.3.6 Getting onto and down from the Crane Using Mobile
Multi−purpose Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.7 Surfaces Permitted for Walking and Standing on the
Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3.8 Attachment Eyelets for Personal Protective Equipment . . . . . . . . . 41
2.4 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
082−1000−82212f_en 1
Index
4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Operating Elements and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Entering / Exiting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Ignition−starter Switch (29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.1 Adjusting the Crane Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.2 Setting the Arm Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5.3 Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5.4 Lighting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.5 Opening / Closing Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.5.1 Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.5.2 Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5.6 Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Damage−prevention measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.3.1 Checks before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.3.2 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3.2.1 Safety Regulations during the Starting Procedure . . . . . . . . . . . . . 5
5.3.2.2 Starting the Engine (Starting Operation) . . . . . . . . . . . . . . . . . . . . . . 7
5.3.2.3 Starting the Engine (with the Ignition Already Switched on) . . . . . 11
5.3.2.4 Starting at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3.3 Jump Starting with External Batteries . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3.4 Battery Charging Device (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3.5 After starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Engine during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.1 Setting the Required Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.2 Checks during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3 Engines with SCR System Exhaust Gas After−treatment . . . . . . . 29
5.5 Switch off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.1 Switching the Engine off under Normal Conditions (with the Ignition
Switched on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.2 Switching the Engine off under Normal Conditions
(End of Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.3 Switching off the Engine in an Emergency . . . . . . . . . . . . . . . . . . . . 33
5.6 Engine Display in the Crane Control Screen . . . . . . . . . . . . . . . . . . 35
5.6.1 ”Engine display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.6.2 In the ”Automotive driving” screen, manually set the engine speed 41
5.7 Multifunction display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.7.1 Fitting Location of the Multifunctional Display . . . . . . . . . . . . . . . . . 43
5.7.2 Structure of the Multifunctional Display . . . . . . . . . . . . . . . . . . . . . . . 43
5.7.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.7.4 Warnings and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7.4.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.7.4.2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.8 Warming up the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
082−1000−82212f_en 2
Index
7 Supporting the Crane on Outriggers from theCrane Operator’s

Cab (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1 General Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.1 General Instructions on Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.2 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.1.3 Operating Modes of the Slewing Circuit . . . . . . . . . . . . . . . . . . . . . . 9
8.1.4 Slewing Angle / Slewing Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2 Initiating a Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.3 Braking the Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.4 Regulating the Slewing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.5 Preparation for Dolly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.6 Monitoring the Right−hand Side of the Superstructure . . . . . . . . . . 29
8.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.6.2 Monitoring Using A Mirror (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.6.3 Monitoring Using the Camera (Optional) . . . . . . . . . . . . . . . . . . . . . 29
9 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 Counterweight Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.2.1 Counterweight Combination 0 t (0 kip) . . . . . . . . . . . . . . . . . . . . . . . 3
9.2.2 Counterweight Combination 5.1 t (11.2 kip) . . . . . . . . . . . . . . . . . . . 3
9.2.3 Counterweight Combination 13.1 t (28.9 kip) . . . . . . . . . . . . . . . . . . 3
9.2.9 Counterweight Combination 46 t (101.4 kip) . . . . . . . . . . . . . . . . . . 9
9.2.10 Counterweight Combination 51.6 t (113.8 kip) . . . . . . . . . . . . . . . . . 9
9.2.11 Counterweight Combination 70.2 t (154.8 kip) . . . . . . . . . . . . . . . . . 11
9.3 Fitting the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.3.1 Anti−fall Protection Using a Safety Mast (Optional) . . . . . . . . . . . . 13
9.3.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.3.3 Setting Down the Counterweight Combination on the
Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3.4 Fitting the Counterweight Combination to the
Superstructure Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.3.4.1 Automatic Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3.4.2 Manual Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.4 Removing the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 Behaviour in Case of a Fault / Bridging Control . . . . . . . . . . . . . . . . 47
9.6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.6.1 Slewing Radius and Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.6.2 Transport Dimensions and Weights of the
Counterweight Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
082−1000−82212f_en 3
Index
10 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 IC−1 Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1.1 Overload Cut−off Using the Load Limit Device (LLD) . . . . . . . . . . . 5
10.1.1.1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.1.1.1.2 Displays, Warnings and Interventions of the Control System . . 11
10.1.1.1.2.1 Design “EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10.1.1.1.2.2 Design ”Non−EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.1.1.2 Bridging the Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1.1.2.1 Bridging with the key−operated pushbutton ”Setup” . . . . . . . . . . 27
10.1.1.2.1.1 Displays, Warnings and Interventions of the Control System . 29
10.1.1.2.2 Overriding shutdown of the ”Luff up” movement . . . . . . . . . . . . . 33
10.1.1.2.2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.1.1.2.2.2 Displays, Warnings and Interventions of the Control System . 37
10.1.1.2.3 Bridging the Shut−down of All Movements . . . . . . . . . . . . . . . . . . 39
10.1.1.2.3.1 Design “EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10.1.1.2.3.2 Design ”Non−EN 13000” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.2 Operating Controls and Display Elements . . . . . . . . . . . . . . . . . . . . 51
10.1.2.1 Control Panel of Crane Control (Structure) . . . . . . . . . . . . . . . . . . . 53
10.1.3 Operating Crane Control (IC−1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.1.4 System Start / Switching the System off . . . . . . . . . . . . . . . . . . . . . . 57
10.1.5 Central Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1.5.1 ”Crane Operation” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1.5.1.1 Section (A): Display of the Current Configuration Information . . 63
10.1.5.1.2 Section (B): Display of Load and Radius . . . . . . . . . . . . . . . . . . . . 65
10.1.5.1.3 Section (C): Load Utilisation Display . . . . . . . . . . . . . . . . . . . . . . . 65
10.1.5.1.4 Section (D): Display of Status Information on the
Crane Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1.5.1.5 Section (E): Function−dependent Screens (Here: Quick Menu) 75
10.1.5.1.6 Section (F): Base Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1.5.2 ”Main Menu” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.1.6 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.1.6.1 Submenus − Basic Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.1.6.2 Calling up the “System Settings (User)” Screen . . . . . . . . . . . . . . . 87
10.1.6.3 “Colour Profile Settings“ Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.6.4 “System Settings (Expanded)” Screen . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.6.5 ”Crane Operation” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.6.6 ”Selection of Operating Mode” Screen . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.6.6.1 ”Table View” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.1.6.6.1.1 Capacity Table on Paper or CD−ROM . . . . . . . . . . . . . . . . . . . . 105
10.1.6.6.1.2 ”Search Configuration for Load Case” Screen . . . . . . . . . . . . . 109
10.1.6.6.1.3 ”Length Code LC” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.1.6.7 ”Operating Range Limit” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.1.6.7.1 Procedure for Defining, Activating and
Deactivating Operating Range Limits . . . . . . . . . . . . . . . . . . . . . . 119
10.1.6.7.2 Slewing Angle Limit, Field (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.1.6.7.3 Radius Limit, Field (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.1.6.7.4 Limitation by a Virtual Wall, Field (F) . . . . . . . . . . . . . . . . . . . . . . . 127
10.1.6.7.5 Height Limit, Field (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.1.6.8 ”Control Lever Assignment” Screen . . . . . . . . . . . . . . . . . . . . . . . . . 131
10.1.6.8.1 Structure of the ”Control Lever Assignment” Screen . . . . . . . . . . 131
10.1.6.8.2 Display / Change to the Control Lever Assignment . . . . . . . . . . . 135
082−1000−82212f_en 4
Index
10.1.6.8.3 Control Lever Assignments (6 Modes) . . . . . . . . . . . . . . . . . . . . . 137

10.1.6.9 ”Parameters” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.1.6.10 ”Datalogger” Screen (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.6.10.1 Call−up and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.6.10.2 Copy and download datalogger file (optional) . . . . . . . . . . . . . . . . 149
10.1.6.11 ”Operating Hour Meter” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.1.6.12 Activate / Deactivate the ”Emergency hydraulic lowering” /
”Emergency operation” functions (options) . . . . . . . . . . . . . . . . . . . . 151
10.1.6.13 “Function Display” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.1.6.14 “I/O−Display”Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.1.6.15 ”Can Status”Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.1.6.16 ”LoadSensing” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.1.6.17 ”Joystick” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.1.6.18 ”Fault Messages” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.1.6.19 ”Telescoping display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.1.6.20 ”Configure Counterweight” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.1.6.21 ”Support Base Area” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.1.6.21.1 Support Force Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.1.6.21.2 Support Base Area Display (Optional) . . . . . . . . . . . . . . . . . . . . . . 171
10.1.6.21.3 Tilt display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.1.6.21.4 Outrigger Support Area Monitoring (optional) . . . . . . . . . . . . . . . . 175
10.1.6.22 ”Engine display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.1.6.23 The ”HAVHY” screen (hydraulically luffable main boom
extension, optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.1.7 Load Monitoring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.1.8 Procedure in the Event of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10.1.8.1 Fault−free Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10.1.8.2 Error messages are displayed on a visual display computer . . . . . 181
10.1.8.3 What to do for safety−relevant faults whose cause
cannot be directly remedied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
10.1.8.4 Screen failure − The screen’s display is black . . . . . . . . . . . . . . . . . 185
10.1.8.5 Connection Problems − Crane Control’s
Control Panel to Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.1.8.6 Total Failure of Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.2 Maintenance, Repairs and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.3 Release Switch System for Crane Movements . . . . . . . . . . . . . . . . 189
10.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.3.2 Assignment of the Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.3.3 Activating the Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10.4 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.4.1 Fine tuning of the movement speed . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.4.2 High speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
10.5 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
10.5.1 Hoist Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
10.5.1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
10.5.1.2.1 ”EN 13000” Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.5.1.2.2 ”Non−EN 13000” Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.5.2 Lower Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10.5.2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10.5.2.2 Bridging the Lower Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
082−1000−82212f_en 5
Index
10.6 Electric Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

10.6.1 Fitting the Anemometer and the Hazard Light . . . . . . . . . . . . . . . . . 209
10.6.2 Connecting the Distributor Box on the Main Boom Head . . . . . . . . 213
10.6.3 Hoist limit switch on the main boom head . . . . . . . . . . . . . . . . . . . . 215
10.6.3.1 Crane Operation on the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.6.3.2 Instructions on the Shift Weight of the
Hoist Limit Switch in the Transport Condition . . . . . . . . . . . . . . . . . 215
11 Working Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Wind Forces on the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.1 Measuring the Wind Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.2 Behaviour in Relation to the Wind Speed . . . . . . . . . . . . . . . . . . . . . 7
11.1.3 Wind Forces on the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.2 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.3 Operation Planning / Monitoring Safety Measures . . . . . . . . . . . . . 21
11.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.3.2 Condition of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.3.3 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.4 Cameras on the crane (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.4.1 General / Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.4.2 Components of the camera system (optional) . . . . . . . . . . . . . . . . . 31
11.4.3 Monitor, camera monitoring (optional) . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4.3.2 Operating Controls and Display Elements . . . . . . . . . . . . . . . . . . . . 35
11.4.4 Hook camera (overall system; optional) . . . . . . . . . . . . . . . . . . . . . . 39
11.4.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.4.4.2 Important Information / Warning Information . . . . . . . . . . . . . . . . . . 39
11.4.4.3 Operation of the hook camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.4.4.4 Assembling/dismantling of the hook camera at the
main boom head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.4.4.5 Operating panel, hook camera (optional) . . . . . . . . . . . . . . . . . . . . . 45
11.4.4.6 Hanging light on the main boom head. . . . . . . . . . . . . . . . . . . . . . . . 47
11.5 Conversion of Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
082−1000−82212f_en 6
Index
12 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Assembly, Function of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . 5
12.2.1 Components of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12.2.2 Extension States of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 5
12.2.3 Telescoping System’s Mode of Operation . . . . . . . . . . . . . . . . . . . . 7
12.2.4 Locking and Pinning Unit (LPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.4.1 Function of the LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.4.2 Supply of the LPU with Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.2.4.2.1 Automatic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.2.4.2.2 Hydraulic accumulator pressure display . . . . . . . . . . . . . . . . . . . . 13
12.2.4.2.3 Manual loading of the hydraulic accumulator . . . . . . . . . . . . . . . . 15
12.2.4.2.4 Exit screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.2.5 Correlation of the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.3 Operating Elements / Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . 21
12.3.1 Control Levers in the Crane Operator’s Cab . . . . . . . . . . . . . . . . . . 21
12.3.2 Input and Monitoring Screens on Crane Control . . . . . . . . . . . . . . . 21
12.4 Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.4.2 Automatic telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.4.2.2 Input and Monitoring Screens at Crane Control
(Automatic Telescoping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.4.2.2.1 ”Telescoping display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.4.2.2.1.1 Call up the ”Telescoping display” screen. . . . . . . . . . . . . . . . . . . 29
12.4.2.2.1.2 Structure of the ”Telescoping display” screen . . . . . . . . . . . . . . 31
12.4.2.2.2 The “Select length code” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.4.2.2.2.1 Call up the ”Length code (LK) selection” screen . . . . . . . . . . . . 35
12.4.2.2.2.2 Structure of the ”Length Code (LK) selection” screen . . . . . . . 37
12.4.2.2.3 ”Length Code (LK) selection in accordance with
capacities (pinned−unpinned)” screen . . . . . . . . . . . . . . . . . . . . . . 43
12.4.2.2.3.1 Structure of screen call up ”Length Code (LK) selection” acc.
to capacities (pinned−unpinned)” . . . . . . . . . . . . . . . . . . . . . . . . 43
12.4.2.2.3.2 Structure of the ”Length Code (LK) selection in accordance
with capacities (pinned−unpinned)” screen . . . . . . . . . . . . . . . . 45
12.4.2.3 Procedure for Automatic Telescoping . . . . . . . . . . . . . . . . . . . . . . . . 47
12.4.3 Manual telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
(Manual Telescoping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.4.3.2.1 ”Manual Telescoping” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.4.3.2.2 ”Visual Depiction of the LPU States”Screen . . . . . . . . . . . . . . . . . 63
12.4.3.2.3 ”Teaching” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12.4.3.2.4 ”Length Code (LK) Selection − Teaching”Screen . . . . . . . . . . . . . 67
12.4.3.3 Manual Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.4.3.3.1 Moving the Telescopic Sections or the LPU . . . . . . . . . . . . . . . . . 71
12.4.3.3.2 Teaching the Extension State of the Telescopic Sections . . . . . 89
12.4.3.4 Bridging the Load Limit Device (LLD)
(for Electric Faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.4.3.5 Locking and Pinning Positions of the Telescopic Drive . . . . . . . . . . 97
082−1000−82212f_en 7
Index
12.5 Capacities in the Unpinned State . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

12.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.5.2 Display of the ”Unpinned Load Capacities” Table
at the Crane Control’s Operating Unit . . . . . . . . . . . . . . . . . . . . . . . 103
12.5.3 Example: Permitted capacity / display in the
”Crane operation” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
12.5.4 Lifting loads in unpinned intermediate positions . . . . . . . . . . . . . . . 107
12.5.5 Telescoping with a suspended load . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12.6 Put the main boom into transport condition . . . . . . . . . . . . . . . . . . . 109
13 Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1 Luffing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1.1 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1.2 Procedure for Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13.2 Regulating the Luffing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13.2.1 High speed mode ”Raise main boom” . . . . . . . . . . . . . . . . . . . . . . . . 11
13.2.2 Fine tuning “Lowering main boom” . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13.3 Setting down the Main Boom in the Support Device
for the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13.4 Dolly Preparation / Preparation for Dismantling
the Main Boom (Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14 Hoist 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Hoist operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1.1 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1.2 Procedure for reeling the hoist rope in and out . . . . . . . . . . . . . . . . 3
14.2 Regulating the hoist speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.2.1 High speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.2.2 Fine tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.3 Camera monitoring of the hoist (optional) . . . . . . . . . . . . . . . . . . . . . 9
15 Hoist 2 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Transport Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.2 Fitting and Removing Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.2.2 When Fitting and Removing Hoist 2with the Auxiliary Crane . . . . 5
15.2.3 When Fitting and Removing Hoist 2 with the Forklift Truck . . . . . . 17
15.2.4 When Fitting and Removing Hoist 2 with Your Own Crane . . . . . . 19
15.3 Hoist operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15.4 Regulating the hoist speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15.5 Camera monitoring of the hoist (optional) . . . . . . . . . . . . . . . . . . . . . 33
082−1000−82212f_en 8
Index
16 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Cab heater arrangement, engine−independent . . . . . . . . . . . . . . . . 3
16.1.1 Operating / Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.1.2 Operating Elements in the Crane Operator’s Cab . . . . . . . . . . . . . 7
16.1.3 Operating Control of the Heater Timer . . . . . . . . . . . . . . . . . . . . . . . 9
16.2 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.3 Petrol Gas Heating (Engine−independent), Optional . . . . . . . . . . . 13
16.3.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
16.3.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16.3.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16.3.4 Shutting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
16.3.5 Notes on heating operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
17 Reevings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.2 Load Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17.2.1 Hoist Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17.2.2 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17.2.2.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17.2.2.2 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
17.2.2.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
17.2.2.4 Vario Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
17.3 Reeving the Hoist Rope on the Main Boom Head . . . . . . . . . . . . . . 53
17.3.1 Reevings 10−, 9−, 8−, 7−falls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
17.3.2 Reeving 7−, 6−, 5−, 4−, 3−fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
17.3.3 Reeving 3−, 2−, 1−fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
17.4 Reeving the Hoist Rope on the Main Boom Head
with Two Auxiliary Sheaves (HD Attachment, Optional) . . . . . . . . 59
17.4.1 Fitting and Removing the HD Attachment . . . . . . . . . . . . . . . . . . . . 59
17.4.2 Reeving 14−, 12−fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
17.5 Reeving the Hoist Rope on Additional Equipment . . . . . . . . . . . . . . 69
082−1000−82212f_en 9
Index
18 Main Boom Extension (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.2 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18.3 Construction of the Main Boom Extension . . . . . . . . . . . . . . . . . . . . 19
18.3.1 Main Components of the Main Boom Extension . . . . . . . . . . . . . . . 19
18.3.2 Combination of the Main Components . . . . . . . . . . . . . . . . . . . . . . . 19
18.4 Operation of the Crane with Main Boom Extension . . . . . . . . . . . . 21
18.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
18.4.2 Setting the Operating Mode in the ”Selection of the Operating Mode”
Screen in the IC−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
18.4.3 Raising Loads with the MBE
11.4 m / 21 m (37.4 ft / 68.9 ft) Folded in the Transport Position . 29
18.5 Main Boom Extension Fitted to the Main Boom . . . . . . . . . . . . . . . 31
18.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
18.5.2 Transport Instructions for the MBE in the Transport Position . . . . 31
18.5.3 Folding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
18.5.3.1 General Instructions for Folding over the Equipment . . . . . . . . . . . 35
18.5.3.2 Folding over the 11,4 m MBE (37.4 ft) . . . . . . . . . . . . . . . . . . . . . . . 39
18.5.3.2.1 MBE (11,4 m (37.4 ft)) Fitted in the Transport Position . . . . . . . . 41
18.5.3.2.1.1 Folding over the MBE 11,4 m (37.4 ft)
from the Transport into the Operating Position . . . . . . . . . . . . . 41
18.5.3.2.1.2 Folding from the Operating into the Transport Position . . . . . . 67
18.5.3.2.2 MBE (21 m (68.9 ft)) Fitted in the Transport Position . . . . . . . . . 81
from the Transport into the Operating Position . . . . . . . . . . . . . 81
18.5.3.2.2.2 Folding from the Operating into the Transport Position . . . . . . 87
18.5.3.3 Folding over the 21 m MBE (68.9 ft) . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.5.3.3.1 Folding over the MBE 21 m (68.9 ft) from the Transport
into the Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.5.3.3.2 Folding the 21 m MBE (68.9 ft) from the Operating
into the Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
18.6 Transporting the Main Boom Extension Separately . . . . . . . . . . . . 111
18.6.1 Transport Instructions for Separate Transportation . . . . . . . . . . . . . 111
18.6.2 Transport Dimensions / Weights, Attachment Points . . . . . . . . . . . 113
18.6.2.1 Transport Dimensions / Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
18.6.2.2 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
18.6.3 Fitting and Removing for Separate Transportation . . . . . . . . . . . . . 117
18.6.3.1 General Instructions for Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
18.6.3.2 Fitting the 11.4 m MBE (37.4 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
18.6.3.3 Fitting the 21 m MBE (68.9 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
18.6.3.4 Fitting the 23.4 m MBE (76.8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
18.6.3.5 Fitting the 33 m MBE (108.3 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
18.6.3.6 Converting from One Length to Another . . . . . . . . . . . . . . . . . . . . . . 161
18.7 Rope Guide / Reeving the Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . 161
082−1000−82212f_en 10
Index
18.8 Setting the Operating Angle (Design with Fixed Operating Angles;
with Tension Plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
18.8.1 Instructions on Risks and General Instructions . . . . . . . . . . . . . . . . 169
18.8.2 Switching from the 0 − Degree to the 20 − Degree Position
(and Vice Versa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
18.8.3 Switching from the 0 − Degree to the 40 − Degree Position
(and Vice Versa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
18.8.4 Hinged Support on the Basic Boom MBE . . . . . . . . . . . . . . . . . . . . . 189
18.8.4.1 Placing the Hinged Support in the Operating Position . . . . . . . . . . 189
18.8.4.2 Placing the Hinged Support in the Transport Position . . . . . . . . . . 191
18.9 Setting the Operating Angle on the Hydraulically
Luffing MBE (”HAVHY”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
18.9.1 Instructions on Risks and General Instructions . . . . . . . . . . . . . . . . 195
18.9.2 Operating Elements and Auxiliary Equipment . . . . . . . . . . . . . . . . . 199
18.9.2.1 Hydraulic Adjusting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
18.9.2.2 Hydraulic Power Pack with Hatz Engine . . . . . . . . . . . . . . . . . . . . . . 201
18.9.2.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.9.2.2.2 Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.9.2.2.3 Checking the Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.9.2.2.4 Filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.9.2.2.5 Starting / Switching off the Engine of the
Hydraulic Power Pack (Hatz Diesel Engine) . . . . . . . . . . . . . . . . . 205
18.9.2.2.5.1 General / Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
18.9.2.2.5.2 Starting / Switching off the Hatz Diesel Engine
Using the Control Panel (during Configuring) . . . . . . . . . . . . . . 207
at the Operating Unit of Crane Control . . . . . . . . . . . . . . . . . . . . 207
18.9.2.3 Displays in Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
18.9.2.3.1 State of the Crane Area in the ”Crane Operation” Screen . . . . . 209
18.9.2.3.2 ”HAVHY” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
18.9.2.4 Tasks to Be Carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
18.9.2.4.1 Pinning the Adjusting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
18.9.2.4.2 Setting the Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
18.10 Emergency Set down in the Case of Telescoping Problems . . . . . 221
21 Head Sheave (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

21.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21.3 Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21.4 Fold down in operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
21.6 Fold backwards into transport position . . . . . . . . . . . . . . . . . . . . . . . 21
082−1000−82212f_en 11
Index
31 Dismantling and Assembly of the Main Boom (Optional) . . . 1

31.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31.2 Before Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
31.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
31.3.1 Perform Preparative Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
31.3.2 Pulling the Luffing Cylinder Headpin . . . . . . . . . . . . . . . . . . . . . . . . . 15
31.3.3 Pulling the Main Boom Foot Section Pin . . . . . . . . . . . . . . . . . . . . . 25
31.4 Fitting the Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

34.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
34.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
34.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
34.4 Radio Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
34.5 Radio Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
34.5.1 Operating Elements of the Radio Transmitter . . . . . . . . . . . . . . . . . 17
34.5.2 Screens on the Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
34.6 Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
34.7 Commissioning of the Radio Remote Control . . . . . . . . . . . . . . . . . 29
34.8 Crane Operation Using Radio Remote Control . . . . . . . . . . . . . . . . 37
34.9 Putting the Radio Remote Control Out of Operation . . . . . . . . . . . 39
34.9.1 Standard Switch−down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
34.9.2 Shutting down Using the Quick Stop Switch . . . . . . . . . . . . . . . . . . 41
34.9.3 Automatic Shut−down of the Transmitter . . . . . . . . . . . . . . . . . . . . . 43
34.10 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34.10.1 Nickel Metal Hydride Accumulator Battery (Battery) . . . . . . . . . . . . 45
34.10.2 Battery Charging Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
34.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
34.12 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
082−1000−82212f_en 12
Index
36 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
36.2 Emergency Hydraulic Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.2.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.2.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
36.2.4 Connecting the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
36.2.5 Recovering a Small Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
36.2.6 After recovering a small load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
36.2.7 Interface for Drive of the Hydraulic Emergency Lowering
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
36.3 Electrical emergency control system . . . . . . . . . . . . . . . . . . . . . . . . . 25
36.3.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
36.3.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
36.3.3 Function and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
36.3.4 Mobile Manual Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
36.3.4.1 Operating Elements of the Locking and Pinning Unit (LPU) . . . . . 33
36.3.4.2 Position Sensor System of the LPU . . . . . . . . . . . . . . . . . . . . . . . . . 33
36.3.4.3 State Sensor System of the LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
36.3.4.4 Telescopic Section Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
36.3.4.5 Function Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
36.3.4.6 Crane Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
36.3.4.7 Accumulator Loading Pressure ”LPU” . . . . . . . . . . . . . . . . . . . . . . . . 41
36.3.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
36.3.6 General Instructions on Driving the
Crane Movements during Emergency Control Operation . . . . . . . 51
36.3.7 Slew gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
36.3.8 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
36.3.9 Luffing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
36.3.10 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
36.3.10.1 Telescoping the LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
36.3.10.2 LPU states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
36.3.10.3 Telescopic Section Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
36.3.10.4 Hydraulic oil supply to the LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
36.3.10.5 Move the LPU to the home position(unlocked and
pinned, max. telescoped in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
36.3.10.6 Retraction of the Boom from the LPU to the Basic Position . . . . . 75
36.3.10.7 Example of manual telescoping procedure . . . . . . . . . . . . . . . . . . . 81
36.3.11 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
37 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

37.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
37.2 Emergency Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
37.2.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
37.2.2 Main Components of the Emergency Unit . . . . . . . . . . . . . . . . . . . . 5
37.2.3 Operating and monitoring controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
37.2.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
37.2.5 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
37.3 Connecting the Emergency Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
37.4 Carrying out Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
37.5 After Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
082−1000−82212f_en 13
Index
41 Assembly Jib (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

41.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41.3 Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
41.4 Lowering in the Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . 11
41.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
41.6 Fold backwards into transport position . . . . . . . . . . . . . . . . . . . . . . . 23
46 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . . 3

46.1 Fitting Location of the Lubricant Pump . . . . . . . . . . . . . . . . . . . . . . . 5
46.2 Components of the lubricant pump . . . . . . . . . . . . . . . . . . . . . . . . . . 5
46.3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
46.4 Setting the Interval and Operating Times . . . . . . . . . . . . . . . . . . . . . 9
46.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.4.2 Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.5 Additional Lubrication Impulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
46.6 Manual Lubrication in the Case of an Emergency . . . . . . . . . . . . . . 15
46.7 Filling the Grease Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
46.8 Malfunctions/Elimination of Malfunctions . . . . . . . . . . . . . . . . . . . . . 17
082−1000−82212f_en 14
Manufacturer’s Specifications
Manufacturer’s Specifications
These operating, lubricating and maintenance instructions are valid

for the mobile crane described in greater detail below.
Its design and manufacture are based on a quality management
system in accordance with DIN EN ISO 9001.
Crane classification Mobile crane

(in accordance with DIN
15001,
15018 T3)
Type of crane Explorer 5800
Construction number ___________________
Manufacturer Terex Cranes Germany GmbH

Dinglerstraße 24
D−66482 Zweibrücken
Phone: +49 6332 83−0
Fax: +49 6332 16715
www.terexcranes.com
082−1001−82201_en 1/1
Foreword
Foreword
For you,
the owner of the crane built by us, we have assembled in this ac-
companying documentation all of the information needed for
operation, lubrication and servicing.
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 compiled for the understanding of trained personnel.
The operating instructions of this crane consists of 4 parts:

Part 1 − Operating manual Superstructure
Part 2 − Operating manual crane chassis
Part 3 − Lubrication and maintenance instructions for the
crane
Part 4 − Various
At least the operating instructions of the superstructure (part 1)

and of the crane chassis (part 2) must always be available on lo-
cation.
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.
082−1002−82201_en 1/13
2/13 082−1002−82201_en
Foreword
Pass this manual on to your crane operator and driver and to

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

malfunctions attributable to improper use and operation and/or
inadequate maintenance.
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 technical editorial team will be very glad to hear from you.
”Putting experience into practice”
082−1002−82201_en 3/13
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Foreword
Handover of the crane
The crane is supplied to you from the factory ready for operation,
fuel and hydraulic oil are included.
All lubrication points have been greased.
If the crane is supplied to you from the factory with a paint protec-
tion coating (preserving wax), this does not necessarily have to
be removed. It provides added protection against corrosion.
The protective coating can be removed using:
Washing thinners, e.g. Conrad thinners RV 5339 E 45430

Cold cleaners, e.g. Allpur 150 X or Purtex 65
Stream spray gun
Before commissioning
You should inspect the crane thoroughly together with our service
engineer.
Spare parts
Use only original spare and wear parts authorised by the crane
manufacturer.
082−1002−82201_en 5/13
6/13 082−1002−82201_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 point out that any modifications to the crane (e.g. the
purchase of boom parts, etc.) may invalidate the information in
these operating instructions or make it insufficient.
After modifications or repairs to parts which affect the safety of

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

tions which you carry out or have carried out on your crane.
082−1002−82201_en 7/13
8/13 082−1002−82201_en
Foreword
...and you can find your way around this manual as follows:
From the example given here, you can see how fast and accura-
tely I can arrive at the required information.
WHAT do I want to know?
I would like to know for instance what control elements are pro-
vided for outriggers.
WHERE do I find the information required above?
The operating instructions of this crane consists of 4 parts:

Part 1 − Operating manual Superstructure
Part 2 − Operating manual crane chassis
Part 3 − Lubrication and maintenance instructions for the
crane
Part 4 − Various
These parts are divided by index sheets.
“Wind speed” deals with matters concerning operation of the

crane, which includes the superstructure 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 11, Working Instructions”.
3. In this section 11 I then find ”Wind speeds” as item 11.1.

The page details on the right−hand side of the page refer to
the page number within the section.
082−1002−82201_en 9/13
Z 26 350
10/13 082−1002−82201_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 desired 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. It is listed next to the total
number of pages in that section. This means, for instance, that
3 is given as the page number in the contents and the page itself
is numbered 3/39. This provides a better overview within each
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.
082−1002−82201_en 11/13
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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, assembly se-

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

quences, etc. where failure to observe the stipulations made
can result in damage to the crane or equipment.
NOTE:
”Note” is used to indicate an important operation or assembly 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.
082−1002−82201_en 13/13
Safety Instructions 1
082−1010−82201b_en 1/101
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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 this, for example
handling of general cargo or grab crane operation, is classified
as not in accordance with regulations. The manufacturer shall
not be held liable for any damage which results. The operator car-
ries 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 power units
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 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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1.3.5 Required Ambient Conditions
Ambient temperature
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:
− Adjust the consumables
The consumables and lubricants may not cover the entire
temperature range. They must therefore be replaced if ne-
cessary.
Please observe the detailed information in section 2 ”Consu-
mables (and Capacities)” of the applicable lubrication and
maintenance instructions.
− Optional equipment
The crane has to be equipped with auxiliary heating and fuel
preheating.
The corresponding consumables and optional equipment can be

supplied.
− Warming up
Please observe the detailed specifications in the operating
instructions for the superstructure, section 5 ”Engine” under
”Warming up the hydraulic system” and in the lubrication and
maintenance instructions for the crane chassis, 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 the corresponding conversion.
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1.3.6 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.
1.3.7 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.
1.3.8 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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1.3.9 Dangers to Air Traffic
As considerable heights are reached when the crane is operated,

this can lead to air traffic being endangered.
For this reason, 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.
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Provide instructions on the location and use of fire extinguishing

equipment.
The supplied fire extinguisher is in a holding device in the driver’s

cab. It must be kept there during driving or when the crane is not
in operation.
If there is a second holding device in your crane outside of the
cab, the fire extinguisher must be stored there during crane ope-
ration.
If there is no such holding device, ensure that the fire extinguisher
can be accessed quickly and easily at all times.
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 authorised with the activities on the crane

must have read the operating instructions before starting opera-
tion, and especially the section ”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.
Impairment of the crane’s 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 Protection from physical effects
Noise
The crane complies with the limit values of the relevant EC Direc-
tive on Noise Emission in the Environment by Equipment for use
Outdoors.
The concrete values for sound power level (LWA) of the crane can
be found in the EC declaration of conformity (part of the crane log
book) and on the corresponding adhesive label on the outside of
the crane operator’s cab.
The A−assessed equivalent permanent sound level at the crane

operator’s workplace in the cab, averaged over the shift duration
of 8 hours, is below 70 dB(A). For this purpose, measurements
were taken during operation on construction sites using dosime-
ters. The measurements were taken at the ear position of the
crane operator using a sound level meter with a test microphone.
To reduce noise during crane operation, we recommend keeping

the cab doors and windows and the cover flaps of all drive units
closed.
Vibrations
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 which the upper

body extremities are subject to, 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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1.4.5 Combination of Hazards with Combined Operation

of Two or More Cranes
1.4.5.1 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.
1.4.5.2 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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1.4.6 Driving Operation
1.4.6.1 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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1.4.6.2 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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1.4.7 Crane Operation
1.4.7.1 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 95)
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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1.4.7.2 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 accidental crane movements being initiated
when entering and exiting the crane operator’s cab.
The operating position is monitored by a corresponding release
switch system.
The crane operator must only assume the designated operating
position if the corresponding control lever is in the “neutral posi-
tion” and must only leave it once the initiated crane movement
has been completed.
RISK OF ACCIDENTS!
If the operating position is assumed or quit while the con-
trol lever is steered, this will cause the corresponding mo-
vement to be started or braked abruptly.
Keep the controls lever within reach as long as a load is suspen-

ded on the crane or the crane is driven.
During all crane movements keep your eye especially on the

load, or if no load is fitted, the load handling devices and the boom
top section. Also observe the slewing radius of the counter-
weight, among other things.
In all crane movements, approach the limit ranges especially

slowly and carefully. Limit ranges can be recognised, for example
in the utilization display of the LLD.
If shut−downs must be bridged in order to once again place the

crane in a safe operative state, the control levers must then be
in the “neutral position”.
RISK OF ACCIDENTS!
The corresponding crane movement will be initiated or bra-
ked abruptly if bridging is executed or cancelled when the
control levers are steered.
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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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1.4.7.3 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.
1.4.7.3.1 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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1.4.7.3.2 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 77). 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.
1.4.7.3.3 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.
1.4.7.3.4 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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1.4.7.4 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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1.4.8 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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1.4.9 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
operating instructions.
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, persons may only access operational areas where
there is no risk of falling equipment/loads.
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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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.
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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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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.
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1
Z 26 024
96/101 082−1010−82201b_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 hands facing forwards.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
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1
Z 26 026
98/101 082−1010−82201b_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
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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.
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Structure of the Crane 2
2 Structure of the Crane
2.1 Technical data
Length see part 2, section 2

Height ”Crane chassis” under
Width ”Technical data”
Max. capacity See capacity tables
Max. main boom length 6 telescopic sections =
70 m (229.7 ft)
Max. system length with main 33 m + 68,8 m
boom extension (108.3 ft + 225.7 ft)
Max. rope speed hoist 120 m/min (394 ft/min)
Operating voltage 24 V
082−1020−82201c_en 1/43
2
12
11
13
1
10
9
3
4a
4b
5
Z 81 985
2/43 082−1020−82201c_en
2.2 Main Elements

(Z 81 985)
The main elements of the crane and possible additional equip-

ment is listed below:
(1) − Main boom
(2) − Luffing cylinder
(3) − Hoist rope
(4a) − Hoist 1
(4b) − Hoist 2 (optional)
(5) − Counterweight
(7) − Crane operator’s cab
(8) − Crane chassis
(9) − Hook block
(10) − Main boom extension (optional, shown folded in the

transport position on the main boom)
(11) − Assembly jib (optional)
(12) − Head sheave, can be folded to the side (optional)
(13) − Hook suspension gear (optional)
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2
25
22 23, 24
Z 81 986
21 22 23 24 25
Z 81 987
4/43 082−1020−82201c_en
(Z 81 986, Z 81 987)
(21) − Roller bearing slewing rim
(22) − Slew gear
(23) − Switch box ”X0002” with fuses (central electrical unit)
(24) − Hydraulic reservoir
(25) − Superstructure frame
The listed elements are for the most part only visible and accessi-
ble after opening/removing the corresponding cover.
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2.3 Getting onto and off the Crane
2.3.1 General
You must get onto (and subsequently, down from) the crane to do
certain activities (e.g., entering the cab of the superstructure).
When getting onto and off the crane and carrying out work at
heights, suitable measures must be taken at all times to prevent
a risk of falling.
Therefore, always carry out work on the ground as long as possi-

ble. This can be done using suitable auxiliary equipment (e.g.
using an auxiliary rod to fit the hoist rope). This is the only way to
eliminate a potential risk of falling to 100%.
Risk to life and limb / risk of injury due to falling!

Use the auxiliary equipment described below in accor-
dance with regulations to get onto/off the crane.
The crane is equipped with ladders and holding devices. These

must be used to get onto and off the crane. Personnel must have
at least three points of contact at all times with the ladder / holding
device or crane to get onto / off the crane safely (e.g. 2 feet, 1
hand).
Additional suitable auxiliary equipment (platform ladders, hoist
platforms, etc.) must be used in situations in which it is not possi-
ble to get on / off the crane safely in such a way.
All areas which are authorised for getting onto / off and walking
on are designed so that they are slip resistant.
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2
1c
1a 1b
Z 81 988
1d 1a 1b
1a 1b
Z 81 989
8/43 082−1020−82201c_en
2.3.2 Overview of Ladders / Steps

(Z 81 988, Z 81 989)
(1a) − Folding ladder, one on the left and one of the right
(1b) − Steps, integrated in the frame of the chassis
(1c) − Steps, integrated in the superstructure trim
(1d) − Multi−purpose ladder, mobile
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2.3.3 Before Getting on / off Using Ladders / Steps
Risk to life and limb / risk of injury due to slipping and fal-
ling!
The regulations listed below must be observed.
− Ensure that all equipment described for getting onto / off the
crane:
− is fitted. This applies to the ladders / steps themselves as
well as to the corresponding holding devices.
− is in the operative state required (e.g. folding ladder in the
operating position).
− can be accessed and used without any restrictions (e.g.
the equipment must be free of oil / grease, snow / ice, dirt
and grit).
− Wait until the crane comes to a standstill.
− Do not misuse control elements (such as, for example, con-
trol levers in the crane operator’s cab) as grab handles / hol-
ding devices.
− Keep the crane clean and dry.
− Keep shoes and gloves clean and dry.
− Carry out a visual inspection to check for damage and safe
use. If faults are detected, ladders, steps or holding devices
may no longer be used − replace immediately.
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− Never jump off the crane. Always use the designated ladders
/ steps to get off.
− When using the ladders / steps, always face / always have the
front of your body facing the ladder and always use the three
points of contact.
− Ensure the height is sufficient.
− Observe the signs attached to the ladders.
− Adhere to the max. load − 150 kg (330 lbs).
− Fit and use personal safety equipment if it is not ensured that
there will be three points of contact.
− The crane must be aligned horizontally. If the crane is in the
inclined position, the crane operator might need to take addi-
tional measures.
− Repairs and maintenance on ladders must be carried out by
an expert and in accordance with the manufacturer’s instruc-
tions.
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2
1a
91
92.1
11 92.2
1a
12
Z 81 990 Z 315 786
41
Z 83 980
14/43 082−1020−82201c_en
2.3.4 Getting onto and down from the Crane Using Folding
Ladders
2.3.4.1 General
(Z 81 990, Z 315 786, Z 83 980)
If the superstructure is flush with the crane chassis (0°/360° or

180°), the two folding ladders can be used to get into or out of the
cab.
The grab handles outside of and within the crane operator’s cab
must also be used so that there are constantly three points of
contact when using this ladder.
Detailed information on actually entering / exiting the crane ope-

rator’s cab can be found in section 4 under ”Entering / exiting the
cab”.
Alternatively, the integrated steps (see from page 23) can be

used for other superstructure positions.
The hinged handles (41) on the crane chassis can be used as an

alternative to the previously described grab handles in the cab
when the folding ladders are used for getting onto and down from
the crane chassis.
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2
1a
91
92.1
11 92.2
1a
12
Z 81 990 Z 315 786
16/43 082−1020−82201c_en
2.3.4.2 Placing the Folding Ladders in the Operating Position

(Z 81 990, Z 315 786)
The folding ladder to be used must first be placed in the operating

position before getting onto it. This may only be done from the
ground. Before swinging and folding, ensure that no people or
objects are in the area affected.
Risk of crushing in the area of the ladder hinges!

There is a risk of crushing for fingers and hands when grip-
ping the ladder in the hinge area and subsequently swin-
ging it round.
For this reason, never handle the ladder in the hinge area,
but at the free end.
Wear protective clothing.
Proceed as follows:
1. Lift the folding ladder (1a) out of the lock (12) on the free end
of the ladder.
2. Swing the ladder away from the crane by 90° until the top le-
velling arms fit into the guide rails (11).
3. Fold support (91) down / inward at a right angle and fold the
ladder toward the chassis so that support (91) is supported
at the tyres and plate (92.1) locks in place at guide pins (92.2)
as shown in figure (Z 315 786).
This ensures a stable ladder position and a suitable angle for
going 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 when the ladder is used.
Ensure that plate (92.1) is up against guide pins (92.2) as
well.
The ladder is then in the operating position and can be used.
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2
1a
91
92.1
11 92.2
1a
12
Z 81 990 Z 315 786
41
Z 83 980
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2.3.4.3 Using the Folding Ladder

(Z 81 990, Z 315 786, Z 83 980)
Observe the points listed below when using the ladder:

− Do not exceed max. payload of the ladder (here: 150 kg /
330 lbs).
− Face / front of body facing the ladder.
− There must be three points of contact. This means that either
2 hands and one foot or 2 feet and one hand must be in con-
tact with the ground, ladder / holding device or the crane at
the same time.
The grab handles outside of and within the crane operator’s
cab or the hinged handles (41) must also be used so that
there are always three points of contact when using this lad-
der.
− Hold on tight (using the levelling arms and ladder steps and
the existing grab handles).
− Objects which are carried when climbing a ladder should not
be heavy and should be easy to handle.
Tools must be carried in / fastened to a corresponding har-
ness to keep your hands free.
− Hold on with one hand when working on the ladder. Take ad-
ditional safety precautions if this is not possible (e.g. atta-
ching personal protective equipment at the designated at-
tachment eyelets).
− When working on the ladder, personnel must also be equip-
ped with suitable personal protective equipment and must at-
tach themselves to one of the attachment eyelets (66) desi-
gnated for this purpose.
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2
1a
92.1
11
12
Z 81 990 Z 315 137
20/43 082−1020−82201c_en
2.3.4.4 Placing the Folding Ladders in the Transport Position

(Z 81 990, Z 315 137)
Risk of crushing between the plate, ladder and frame of the

crane chassis!
There is a risk of crushing for fingers and hands when
handling the ladder.
Proceed with appropriate caution.
Wear protective clothing.
Before driving the crane, all folding ladders must be placed in the
transport position and secured in lock (12). To do so, proceed as
described under ”Placing the folding ladder in the operating posi-
tion” on page 17, but in the opposite sequence.
However, before the ladder is folded up and away from the chas-
sis, plate (92.1) must first be placed in the position shown in figure
(Z 315 137) manually.
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2
12
11
1b
Z 81 993
22/43 082−1020−82201c_en
2.3.5 Getting onto and down from the Crane Using Integra-
ted Steps
2.3.5.1 General
(Z 81 993)
Steps (1b), integrated in the frame of the chassis, are on each

side of the crane. They are for getting onto and down from the
crane chassis.
When stepping from the steps onto the crane chassis (and vice
versa), you must use grab handle (11) and stay bar (12) as well
as a safety precaution against falling. To do so, stay bar (12) must
first be placed in the ”high” operating position, as described be-
low.
2.3.5.2 Before Getting on /off
Observe the detailed information from page 11.
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2
12
12.3
12.2
12
12.1 12
12.1
Z 81 994
24/43 082−1020−82201c_en
2.3.5.3 Getting on and off

(Z 81 994)
You may only get on and off if stay bar (12) is in the ”high” opera-
ting position in accordance with regulations. Only then can it be
ensured that there are three points of contact, particularly when
getting from the steps onto the crane chassis.
1. First place stay bar (12) in the ”high” operating position. To

do so:
1.1 Place grab handle (12.1) in the horizontal position and

use the lateral handle to slide the stay bar upwards un-
til dowel pin (12.2) is pushed up against the rectangu-
lar tube (12.3).
082−1020−82201c_en 25/43
2
12.3
12.3
12.2 12.4
12
Z 83 409 Z 83 410
12.2
Z 81 998
26/43 082−1020−82201c_en
(Z 83 409, Z 83 410, Z 81 998)
(Z 83 409)
1.2 Turn the stay bar by approx. 45° − in the depicted posi-
tion − so that dowel pin (12.2) is flush with the corner
of the rectangular tube (12.3). There is sufficient space
in this area of the rectangular tube to retract the dowel
pin.
(Z 83 410)
1.3 In this dowel pin position, continue to slide the stay bar
up until the head of the cylinder screw or the nut (12.4)
is pushed up against the rectangular tube (12.3).
(Z 81 998)
1.4 Turn the stay bar by approx. 45° again − back to the in-
itial position − and lower the stay bar up to the stop.
Dowel pin (12.2) then locks in place in the designated
lock and fixes the stay bar in the ”high” operating posi-
tion.
Risk of falling when the stay bar is not locked in place!

Ensure that the stay bar is firmly locked in the high opera-
ting position. This is the only way to ensure that the stay bar
does not suddenly fall back into the transport position
when placed under load.
Risk of damage!
There is a risk of collision when slewing the superstructure
as long as one of the stay bars is in the ”high” operating posi-
tion.
For this reason, after getting on, place the stay bar back in
the low transport position from above. Before getting off, the
rod must first be placed back in the ”high” operating posi-
tion.
Follow the guidelines for using the folding ladders on page 19

when actually using the steps.
082−1020−82201c_en 27/43
2
1d
Z 81 999
”b”
”a”
Z 56 634
28/43 082−1020−82201c_en
2.3.6 Getting onto and down from the Crane Using Mobile
Multi−purpose Ladders
2.3.6.1 General
(Z 81 999, Z 56 634)
In addition to the firmly fitted ladders, there is a mobile multi−pur-

pose ladder (1d). It is used not just for getting onto and down from
the crane, but also particularly for carrying out assembly proce-
dures (e.g. fitting or folding the main boom extension).
It is stored in the transport position on the crane chassis and must

be secured against falling down using two lashing straps.
This ladder can be fitted and removed from the ground.
The weight of the ladder is approx. 8,5 kg (19 lbs).
This ladder can

− be unfolded and set up − in this case it is used as a stepladder
(Z 56 634, variant ”a”).
− or leaned against something as a sliding ladder − in this case
it is used as a leaning ladder (Z 56 634, variant ”b”).
082−1020−82201c_en 29/43
2
66
21
Z 83 979 Z 83 402
Z 83 981
30/43 082−1020−82201c_en
(Z 83 979, Z 83 402, Z 83 981)
Risk of falling when instructions are not followed!

In particular, follow the safety instructions listed below on
handling the multi−purpose ladder.
If the multi−purpose ladder is used as a leaning ladder, the at-

tachment hooks on the top ladder end must be hung correctly into
the corresponding grooves (see arrows) of the ladder bracket
(21, Z 83 979).
The ladder bracket design shown here is fitted to the main boom
extension as an example. However, the ladder bracket can also
consist of individual attachment devices (e.g. in the main boom
head area).
There are other ladder brackets, for example, under the cover be-
hind the cab (see sect. 36 ”Emergency actuation”) and at the
back on the superstructure frame (Z 83 981).
If three points of contact with the ladder are not ensured when
carrying out assembly work (for example, both hands are needed
to knock in a pin), personnel must also be equipped with suitable
personal protective equipment and must attach themselves at
one of the designated attachment eyelets (66).
There is also an attachment eyelet for attaching the personal

equipment hook on each depicted ladder bracket or in the imme-
diate vicinity if the bracket is designed as a single element. Detai-
led information on these attachment eyelets can be found on
page 41.
Figure (Z 83 402) shows the ladder, correctly attached to a ladder

bracket, and personnel additionally equipped with personal pro-
tective equipment and secured.
082−1020−82201c_en 31/43
2
32/43 082−1020−82201c_en
2.3.6.2 Placing the Multi−purpose Ladder in Position and

Setting it up
To do so, observe the following points:

− The ladder must be set up in the correct set−up position, e.g.
correct set−up angle for leaning ladders (inclination angle:
approx. 1:4), rungs or steps horizontal and stepladder fully
opened.
− Locking devices, if fitted, must be fully locked before use.
− The ladder must be standing on a level, horizontal and immo-
bile base.
− A leaning ladder must be leaned against a level, firm surface
and must be secured before use, e.g. by fixing it in place or
by using a suitable device for ensuring stability.
− The ladder may never be placed in a new position from
above.
− When placing the ladder in position, remember the risk of
collision, for example with pedestrians, vehicles or doors.
Lock doors (not, however, emergency exits) and windows in
the operating range, if possible.
− Determine all risks due to the electrical equipment in the ope-
rating range, e.g. high voltage overhead lines or other expo-
sed electrical equipment.
− The ladder must be set up on its base, not on its rungs or
steps.
− The ladder may not be set up slippery surfaces (e.g. ice,
smooth surfaces or clearly contaminated and dirty firm surfa-
ces), unless additional measures have been taken to prevent
the ladder from slipping or to clean the contaminated surfa-
ces sufficiently.
082−1020−82201c_en 33/43
2
34/43 082−1020−82201c_en
2.3.6.3 Using the Multi−purpose Ladder
Particularly when using the multi−purpose ladder (stepladder or

leaning ladder), follow the specifications listed below:
− Do not lean out too far. Users should keep their belt buckle
(navel) between the levelling arms and stand with both feet
on the same step / rung.
− Do not step away from a leaning ladder at great heights wi-
thout securing yourself additionally, for example, fastening or
using a suitable device for securing the stability.
− Do not use stepladders for climbing onto another level.
− Do not use the top three steps / rungs as a base.
− Do not use the top two steps / rungs of a stepladder without
platform and holding device for hands / knees as a base.
− Do not use the top four steps / rungs of a stepladder with fitted
sliding ladder as a base.
− Do not use the ladder outside if the weather conditions are
unfavourable, e.g. strong winds.
− Avoid excessive loading or stress to one side.
− Do not stay on the ladder too long without regular breaks (ti-
redness is a risk).
In addition, observe the general regulations as listed for folding

ladders on page 19.
082−1020−82201c_en 35/43
2
Z 84 389
36/43 082−1020−82201c_en
2.3.7 Surfaces Permitted for Walking and Standing on the

Crane Chassis
(Z 84 389)
Risk to life and limb due to falling!

Only step onto the permitted surfaces! Observe the speci-
fications listed!
The surfaces on the crane chassis permitted for walking and

standing are shaded in the figure opposite. They are designed to
be slip−resistant.
You may only step onto these surfaces.
In the standard design, you can also walk on the surface indica-
ted by cross−hatching.
Optionally, this area can also be fitted with a frame so that this sur-
face can be used for putting down chains. In this case, you may
no longer walk on this surface.
Observe the notes listed below when stepping onto these surfa-
ces:
− Keep the surfaces permitted for walking and standing free of
oil / grease, debris, snow / ice and obstacles.
Risk to life and limb / risk of injury due to stumbling over

obstacles!
Do not leave any tools or other accessories lying around.
Tools belong in the toolbox.
Move with particular care in areas with obstacles, e.g. hol-
ding devices.
− Only walk in the areas wearing clean shoes.

− Only walk in the areas with sufficient height.
− Only step onto the engine covering when the main boom has
been luffed up and the engine is cold.
− Do not stumble over mounting parts.
− The max. permitted point load for walking on these surfaces
is 1500 N.
082−1020−82201c_en 37/43
2
Z 84 389
38/43 082−1020−82201c_en
(Z 84 389)
It expressly prohibited to walk on (or load) these surfaces:

− roof of the driver’s cab
− supports of the air filter
− wood and chain box cover (optional) on the rear of the crane
chassis − do not get into the box interior either
− slanted surfaces in the area of the engine covering
− hydraulic Tank
− surface for setting down the hook block (between hydraulic
tank and driver’s cab) − do not climb into it or place any ob-
jects inside
− occupied surface for ”Frame for putting down chains” option.
Risk of stumbling!
If surfaces are to be walked on where there are ladders in
the transport position, the ladders must first be removed or
folded into the operating position.
082−1020−82201c_en 39/43
2
66
21
Z 83 979
40/43 082−1020−82201c_en
2.3.8 Attachment Eyelets for Personal Protective Equip-

ment
(Z 83 979)
There are attachment eyelets (66) at various points of the crane

− here shown as a component part of ladder bracket (21). They
serve as attachment points for the lock−on hook of suitable per-
sonal protective equipment.
These attachment eyelets are marked with a decal (67) for clear
identification.
Observe the country−specific regulations concerning design and

use of personal protective equipment.
Risk of accidents when personal protective equipment is

not used properly!
All persons using personal protective equipment must be
trained accordingly and competently with regard to selec-
tion, checks before use and correct application of their per-
Risk of overloading and breaking if the attachment eyelets

are used improperly!
All attachment eyelets (66) marked with the corresponding
decals (67) may only be used to attach the hook of the per-
Under no circumstances are they to be used to hang indivi-
dual crane component parts to an auxiliary crane.
The attached objects could fall down.
082−1020−82201c_en 41/43
2
42/43 082−1020−82201c_en
2.4 Headlights
Depending on the design of the crane, headlights can be fitted

at the following points on the superstructure:
− Cab, bottom, front
− Cab, top, front and rear
− Basic case of the main boom, can be adjusted electrically
from the cab
− Hanging light on the main boom head.
2.5 Emergency Exit
The front window of the superstructure can be opened wide to the

front. It is therefore suitable as an emergency exit. On the cab of
the crane chassis the passenger door can be used as an emer-
gency exit.
2.6 Signs
Please read and observe the corresponding documents ”CE_Si-

cherheitsbeschilderung_safety_signs” as well as ”ANSI_Sicher-
heitsbeschilderung_safety_signs” in part ”Various”.
Keep all signs complete and legible.
082−1020−82201c_en 43/43
Crane Operator’s Cab 4
082−1040−82201d_en 1/45
4
1
2 3
7
11
10
9
8
15
Z 82 793
2/45 082−1040−82201d_en
4 Crane Operator’s Cab
4.1 Operating Elements and Displays

(Z 82 793)
Item Element Designation Function

1 Colour display Camera surveillance 1)
2 Operating panel Operation load hook camera 1)
3 Socket Power supply 24V
4 Operating panel Radio / CD
5 Microphone Announcements made to per-
sons nearby 1)
6 Key switch Bridging the load limit device
(function only for crane control
software in accordance with
EN 13000) 2)
7 Seat Seat with fitted seat contact but-
ton as a release button for crane
movements
8 Pedal Speed adjustment of the engine
9 Foot switch Release button for crane move-
ments
10 Pedal Slew gear brake
11 Foot switch Horn
15 Warning light: Display of the state of the load
− Green limit device and of the load utili-
− yellow zation of the crane
− red (see section “Safety equipment”)
1) = Optional
2) = You can check whether the crane has been equipped
with control software in accordance with EN 13000 by
selecting the “System settings (user)” screen on the
crane control. In this case, a corresponding note can
be found there.
082−1040−82201d_en 3/45
4
24 25
21
40 20
39
38
28
29
32
30 33 34 35 36
31
Z 82 578
31.3 31.4
31.1 31.2
31
Z 82 017
4/45 082−1040−82201d_en
(Z 82 578, Z 82 017)

20 Actuation Mechanical door unlocking (press)
21 Multifunctional dis- Calling up engine and crane infor-
play mation
(for the exact des-
cription, see sec-
tion ”Engine”)
24 Locking knob Pivot / fix the monitor (item 25) −
up / down
25 Control panel of Operation: Electronic crane infor-
crane control mation system (crane control)
28 Actuation Open the front window (pull)
29 Ignition lock Ignition Switch
30 Ignition key Engine start/engine stop
31 Remote control for Unlock / lock the cab doors
opening and clo-
sing the chassis
and crane opera-
tor’s cab
31.1 Button Open the chassis cab
31.2 Button Close the chassis cab
31.3 Button Open the crane operator’s cab
31.4 Button Close the crane operator’s cab
082−1040−82201d_en 5/45
4
24 25
21
40 20
39
38
28
29
32
30 33 34 35 36
31
Z 82 578
6/45 082−1040−82201d_en
(Z 82 578)

32 Pushbutton Quick stop of the engine
33 Socket Cigarette lighter and power sup-
ply 24 V DC
34 Socket Power supply 24 V DC
35 Service socket Ethernet RJ45 CAT 5 – connec-
tion for crane control
36 Service socket USB connection for crane control
38 actuation mechanical unlocking of the
open cab door (pull)
39 Knob electric door opener
40 Door handle Open / close the cab door form
the inside
082−1040−82201d_en 7/45
4
43.1 43.2
43.3
43.4
43.5
43
44
45 46 47 48
49 50 52
Z 82 018
8/45 082−1040−82201d_en
(Z 82 018)
No. Element Designation Function

43 Control lever Control of the crane movements
(control lever assignments, use of
the control levers, see section 10)
43.1 Rocker switch Fine tuning of the movement
speed − selecting crane move-
ment
43.2 Hoist rotation in- Vibration display: Hoist 2 1) rota-
dicator ting
43.3 Pushbutton High speed hoist 2 1)
43.4 Pushbutton without function
43.5 Button Release switch system crane mo-
vements
44 Left arm console Arm console incl. storage com-
partment under the armrest;
the arm console can be adjusted
forwards / backwards by pulling
handle “A”
1) = Optional
Risk of accidents!
Control lever assignment:
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the cur-
rent function of the lever is before he commences a crane
movement.
Otherwise there is a risk of accidents if unintended crane
movements are initiated.
082−1040−82201d_en 9/45
4
43.1 43.2
43.3
43.4
43.5
43
44
45 46 47 48
49 50 52
Z 82 018
10/45 082−1040−82201d_en
(Z 82 018)
No. Element Designation Function

45 S 6140A Switch Switch on lighting equipment of
operating area:
fitted on the basic boom section,
left−hand side 1)
46 S 6145A Button Adjustment of 1st spotlight on the
basic boom section of the main
boom (item 45) 1)
47 S 6140B Switch Switch on lighting equipment of
operating area:
2nd spotlight on the basic boom
section of the main boom, left−
hand side 1)
48 S 6145B Button Adjustment of 2nd spotlight on the
basic boom section of the main
boom (item 47) 1)
49 S 8805 Switch Release / block the slew gear par-
king brake
50 S 8817 Switch Switchover slewing gear: open /
closed circuit
52 S 8460 Button Angle adjustment of the hydraulic
luffing main boom extension
(HAVHY) 1)
1) = Optional
082−1040−82201d_en 11/45
4
54 56 58 60
55 57 59 61
64 65
62 66
63 67
68 69 70 71 72
73 76
Z 82 579
12/45 082−1040−82201d_en
(Z 82 579)

54 H 8040A Indicator light Radio remote control active 1)
55 S 8040 Key switch Release radio remote control 1)
56 H 7925 Indicator light Load−moment−reducing move-

ment ”Raise luffing gear” bridged
57 S 7925 Key switch Bridging the load−moment−redu-
cing movement ”Raise luffing
gear”
58 H 7270 Indicator light ”Hoist limit switch” bridged
59 S 7270 Key switch Bridging the ”Hoist limit switch”
60 H 7926 Indicator light State of the key−operated push-
button item 61
61 S 7926 Key switch Activate the setup button (function
only for control software in accor-
dance with EN 13000, 2);
otherwise:
Bridge load limit device (instead
of item 6)
1) = Optional
2) = You can check whether the crane has been equipped
with control software in accordance with EN 13000 by
selecting the “System settings (user)” screen on the
crane control. In this case, a corresponding note can
be found there.
082−1040−82201d_en 13/45
4
54 56 58 60
55 57 59 61
64 65
62 66
63 67
68 69 70 71 72
73 76
Z 82 579
14/45 082−1040−82201d_en
(Z 82 579)

62 S 4316 Dual button Horizontally retract/extend support on
the chassis,
front left
the chassis,
rear left
64 S 4320 Dual button Vertically retract/extend support on
the chassis,
front left
the chassis,
front right
the chassis,
front right
the chassis,
rear right
68 S 4300 Button Release supports
the chassis,
rear left
the chassis,
rear right
71 S 4331 Dual button Vertically retract/extend all supports
on the chassis
72 S 9380 Button Raise / lower counterweight
73 S 1219 Dual button Engine START / STOP
76 H 1260 Indicator light Engine quick stop is activated
082−1040−82201d_en 15/45
4
81.1 81.2
81.3
81.4
81.5
89
81
82
Z 82 020
16/45 082−1040−82201d_en
(Z 82 020)

81 Control lever Control of the crane movements
(control lever assignments, use of
the control levers, see section 10)
81.1 Rocker switch Fine tuning (%) of movement speed
81.2 Hoist rotation Vibration display: Hoist 1 rotating
indicator
81.3 Pushbutton High speed hoist 1
81.4 Pushbutton High speed luffing gear
81.5 Button Release switch system crane move-
ments
82 Right arm con- Arm console incl. storage compart-
sole ment under the armrest;
the arm console can be adjusted for-
wards / backwards by pulling handle
“A”
89 S 9310 Rocker switch Tilt cab
Risk of accidents!
Control lever assignment:
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the cur-
rent function of the lever is before he commences a crane
movement.
082−1040−82201d_en 17/45
4
90 91 92 93 94 95 96 98 99
0 I
102 103 104 105 107

108 109 110
114
Z 82 580
18/45 082−1040−82201d_en
(Z 82 580)

90 Rotary switch Fan
91 Rotary switch Fan air distribution
92 Rotary switch Thermostat
93 Switch Fresh air / recirculated air
94 Switch Air conditioning on/off
95 S 6420 Button Rotaflare light
96 S 6640 Switch Dash board illumination
98 S 6540 Switch Hazard light
99 S 6240 Rocker switch Lighting equipment outrigger
pressed down area;
integrated on the crane chassis
in the covers
S 6240B Rocker switch Lighting equipment rear / side
pressed up area 1)
102 Timer Control of the engine−indepen-
dent heating
103 S 5251 Switch Wipers, front, 2 stages (intermit-
tent / continuous)
104 S 5261 Switch Windscreen washer system
105 S 5253 Switch Roof window wipers, 2 stages
(intermittent / continuous)
107 S 9333 Rocker switch Extend/retract platform (no. 124)
108 S 6130A/B Switch Lighting equipment operating
range; Crane operator’s cab, bot-
tom front
109 S 6131 Switch Lighting equipment operating
range; Crane operator’s cab, top
front 1)
110 S 6132 Switch Lighting equipment operating
range; Crane operator’s cab, top
rear 1)
114 S 7145 Switch Hanging light on the main boom
head 1)
1) = Optional
082−1040−82201d_en 19/45
4
120
30
31
121
31.3 31.4
31.1 31.2 122
126 123
125 124
Z 82 022
20/45 082−1040−82201d_en
4.2 Entering / Exiting the Cab

(Z 82 022)
Risk of falling!
− Use handles and folding ladder / 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).
Item Designation Function

120 Handles for entry / exit
121 Handle for entry / exit
122 Handle for entry / exit
123 Handrail to slide the cab door open / clo-
sed
124 Platform Cab entry / exit
125 Platform Step
126 Door lock Unlock / lock the cab door with
ignition key (item 30) if the re-
mote control is not used
To allow the platform (124) to be used across its full width,

the door of the crane operator’s cab must be closed.
082−1040−82201d_en 21/45
4
120
30
31
121
31.3 31.4
31.1 31.2 122
126 123
125 124 Z 82 022
20
1 2
21
3 25 22
8 4 23
5
7 6 24
Z 82 215
107
Z 315 353
22/45 082−1040−82201d_en
(Z 82 022, Z 82 215, Z 315 353)
Access to the cab

Depending on the position of the cab on the crane chassis, ac-
cess to the cab is via a foldable or fix−mounted ladder on the
crane chassis (see in section 2 the section ”Climbing onto and off
of the crane”).
Sliding out the platform (124) on the crane operator’s cab
To enter / leave the cab, the platform (124) should be slid out com-
pletely. To do so:
1. In the driver’s cab, switch on the ignition or start the engine.
2. Open outrigger controls (control station).
DANGER!
Risk of crushing due to any existing protruding edges.

The platform on the crane operator’s cab may only be
slid out if there is a clear view of it.
3. Slide the platform out completely. To do so, actuate button

(5) and direction button (22) at the outrigger controls, from
where there is a clear view of the platform.
4. Close the switch panel to outrigger controls and remove the
ignition key from the driver’s cab.
Alternatively, the platform can be slid in and out using rocker
switch (107) in the crane operator’s cab.
Opening the cab door from the outside

1. Unlocking the door:
Press function button (31.3) of the remote control (31).
alternatively:
Unlock the cab door with the ignition key (30) at the door lock
(126) at the front of the crane operator’s cab.
2. Slide open cab door at handle (123).
082−1040−82201d_en 23/45
4
120
30
31
121
31.3 31.4
31.1 31.2 122
126 123
125 124
Z 82 022
20
40
39
38
28
Z 82 581
24/45 082−1040−82201d_en
(Z 82 022, Z 82 581)
Entering / exiting the cab

− For safe entering / exiting, use handles (120, 121, 122).
− The cab door is automatically locked when completely open
to prevent accidental closing.
− It might be required to push the left−hand arm console back
to enter and exit comfortably (setting the arm console: see
segment 4.5.2, page 35).
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 designated hand grips to ensure
that your hands are not in a dangerous area.
1. If the cab door is locked while completely open:

Pull control (38).
2. Closing the door:
− from the outside: using handle (123)
− from the inside: using handle (40)
Opening the cab door from the inside

1. Unlocking the door:
Press key (39).
alternatively:
Press control (20).

2. Slide cab door open using handle (40).
082−1040−82201d_en 25/45
4
120
30
31
121
31.3 31.4
31.1 31.2 122
126 123
125 124
Z 82 022
89A
89B
Z 82 023
26/45 082−1040−82201d_en
(Z 82 022)
Exiting the cab in an emergency

Use the front window as an emergency exit (for opening the front
window, see 4.5.5.2).
Locking the cab door (from the outside)

Press the function button (31.4) of the remote control (31).
alternatively:
Lock the cab door with the ignition key (30) at the door lock (126)
at the front of the crane operator’s cab.
4.3 Tilting the Cab

(Z 82 023)
In order to be able to follow work with the crane more easily the
cab can be tilted backwards by means of hydraulic cylinders.
Press self−return rocker switch (89A) up − tilt the cab back.

Press self−return rocker switch (89B) down − tilt the cab forward.
There is a risk of crushing when tilting the cab.

Persons must stay clear of the hazardous area!
082−1040−82201d_en 27/45
4
0 I
II
P
29
Z 82 024
28/45 082−1040−82201d_en
4.4 Ignition−starter Switch (29)
(Z 82 024)
The key switch of the ignition lock is designed as a four−position

switch:
− Position ”P”: ”Off” position

The key can be removed, depending
on the design of the ignition switch.
− Position “0”: ”Off” position
Removable key.
− Position ”I”: Operating position
The ignition is switched on.
− Position ”II”: Engine start position
DANGER!
Risk of starting by unauthorised persons!

Remove the key, even when leaving the vehicle for a short
period of time.
DANGER!
Risk of accidents!
It is forbidden to shut off the motor when a load is attached.
NOTE:
The interior lighting of the crane operator’s cab and the hazard
light always functions, regardless of the position of the ignition
key.
Risk of batteries discharging!
Any electric consumers which are not required should be

switched off when the engine is switched off.
When the operator leaves the crane with electrical consu-
mers switched on (e.g. hazard lights), the electrical supply
must be ensured, if necessary through additional steps (e.g.
battery charger).
082−1040−82201d_en 29/45
4
130
130.1
130.7 130.2
130.6
130.5
130.4 130.3
Z 104 501
30/45 082−1040−82201d_en
4.5 Workplace Ergonomics
4.5.1 Adjusting the Crane Operator’s Seat

(Z 104 501)
The crane operator is protected against mechanical vibrations by

means of a hydraulically dampened seat (130).

130.1 Lumber vertebrae Turn the hand wheel for optimum
support fit to the backrest contours.
130.2 Backrest setting Pull the handle up completely and
bring the backrest into the desired
position by pressing the upper half
of your body appropriately.
130.3 Heating Thermostatically controlled seat
cushion and back heating. It is
switched on and off using the
switch.
130.4 Horizontal setting Pull the lever up completely and
move seat. Let the lever lock in
place again.
130.5 Weight setting Turn the hand wheel and set the
resilience support to the weight of
the driver.
The number on the screen must
be identical to the weight of the
driver.
130.6 Rear height and tilt Pull lever up and change seat
setting height / tilt by applying or removing
pressure in the rear area of the
seat cushion.
130.7 Front height and tilt Pull lever up and change seat
setting height / tilt by applying or removing
pressure in the front area of the
seat cushion.
Tips for sitting correctly
− Set the horizontal setting so that the pedals can be reached

comfortably and can be pushed down effortlessly.
− In order to sit in a relaxed manner, your back must recline

against the backrest from your bottom to your shoulder bla-
des.
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4
130
130.1
130.7 130.2
130.6
130.5
130.4 130.3
Z 104 501
32/45 082−1040−82201d_en
(Z 104 501)
For safety reasons, the seat may only be adjusted / set

when no crane movements have been initiated.
An incorrectly set seat a risk to your health.

Before starting work, set the seat so that is ideally suited to
you, especially when you change drivers.
If the following warnings are not heeded it can cause serious

injury:
− The seat may only be fitted and repaired by specialist per-
sonnel.
− Have defective components repaired or replaced imme-
diately.
− It is prohibited to make changes to the seat.
− Fixtures and locks must be checked regularly.
− Do not use damaged or faulty seats.
− Broken steel components may not be welded.
− Only use a slightly damp cloth without any strong clean
agents to clean the seat.
− The cover fabric may not be wet through.
− The seat is only suitable for a driver’s weight of no more
than 150 kg (330 lbs).
− Do not activate several operating elements at the same
time.
− All adjusting mechanisms must audibly lock in place.
The actuating levers must be operated the full actuating
path to prevent wear to the adjusting mechanism.
− Make sure that the seat (especially the shock−cushio-
ning seat) is not blocked by objects in the vehicle.
This can cause damage to the seat.
− If the seat heating is operated or connected incorrectly,
the heating can become overheated.
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4
”X”
81
”X”
A
43
Z 82 025
131
132
132
133 133
Z 104 677
134
Z 104 421
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4.5.2 Setting the Arm Console

(Z 82 025)
Setting in the longitudinal direction

The corresponding arm console can be slid forward or backward
by pulling handle “A”.
Setting height and tilt

The arm consoles can be fastened to the cab side panel at 3 diffe-
rent heights.
In order to set the height, the screws (see detail “X”) must be loo-
sened and the arm consoles must be fastened again.
The fixtures on the arm consoles are designed so that the tilt of
the arm consoles can be set at the same time.
In order to set only the tilt, the screws (see detail “X”) must be loo-
sened and then fastened again.
4.5.3 Sunshade
(Z 104 677, Z 104 421)
The crane operator’s cab is fitted with roll−down sunshades on

the roof window, rear window and side window. These can be lo-
wered down to the desired level as required to avoid being dazz-
led by the sun or the cab becoming too warm.
131 Shackle To open / close the window
shade of the roof window
132 String To release the locks on the win-
dow shades in the side windows
/ rear window
133 Shackles To close the window shades in
the side windows / rear window
134 Front window sunshade
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131
132
132
133 133
Z 104 677
134
Z 104 421
36/45 082−1040−82201d_en
(Z 104 677, Z 104 421)
Window shade on the roof window

The window shade on the roof window can be moved forward at
corresponding clip (131). To roll it up, the clip (131) must be tur-
ned slightly to the front / back in order to unlock the window shade
in the corresponding position.
Vertical window shades

The vertical window shades can be pulled down to the desired
position at the corresponding clip (133). Once the shade has
been pulled down to the required level, it stays in that position.
In order to roll up the window shades again, release the lock by
pulling string (132). The window shade is then rolled up fully.
Sunshade on the front window

The sunshade (134, Z 104 421) on the front window can be pivo-
ted around into different positions as required.
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4
136 136A
136B 137
136C 137A 137C
137B
Z 82 027
38/45 082−1040−82201d_en
4.5.4 Lighting equipment

(Z 82 027)
The two interior cab lights are in the head runner, at the top on
the right−hand side. There are three possible settings for the ligh-
ting equipment:
136 Lamp Lamp / ambient lighting
136A Ambient lighting ON
136B Middle position: Light OFF
136C Reading light ON
137 Lamp Lamp / ambient lighting
137A Reading light ON
137B Middle position: Light OFF
137C Ambient lighting ON
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138
Z 104 427
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4.5.5 Opening / Closing Windows
4.5.5.1 Rear Window

(Z 104 427)
The window in the rear cab wall is a sliding window.

138 Handle Opening / closing the rear win-
dow
When closed, the individual handle on the window element and

the fixed counterpart on the cab frame support must be locked
together.
Press the grip together to open the rear window (138). The lok-
king nose is lifted and the window element can be closed/ope-
ned.
Risk of crushing!
When closing, there is a risk of crushing between the win-
dow element and the door / cab frame.
For this reason, use the designated handle to ensure your
hand does not get into the dangerous area.
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4
20
40
39
38
28
Z 82 581
141 139 141

140
140
Z 104 423
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4.5.5.2 Front Window

(Z 82 581, Z 104 423)
Risk of crushing!
Between handles (141) and gas−operated positioners
(140) when opening and closing the front window.
Make sure that you hold handle (141) so that your hands
are not in the area at risk!

139 Front Window
140 Gas−operated po-
sitioner
141 Handle Opening / Closing front window
Opening the front window (139)

1. Unlocking the window :
To do so, pull control device (28).
Risk of breakage!
When then pressing it open, do not let go of the window until
it is completely open. This prevents the window from being
knocked hard in the final position.
2. Press the window element outwards lightly with your hand.
The window element is opened automatically by the two gas−

operated positioners (140).
Closing the front window (139)
Risk of crushing!
Between the window element and the cab frame support.
For this reason, ensure that no body parts or members
are in the area at risk!
In order to close it, the window element (139) must be folded

down with handles (141) against the holding pressure of the gas−
operated positioners (140) and lock in place.
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147
144 145 146

143
148
149
Z 82 582
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4.5.6 Racks
(Z 82 582)
There are a number of racks and storage areas in the cab where
things can be put down:
Item Designation / Function
143 Storage rack on the top of the instrument panel (with
netting)
144 Storage recess on the right−hand side of the cab
145 Ashtray
146 Storage compartment in the right− and left−hand arm
consoles (under the armrest)
147 Storage compartment in head runner
148 Storage area under the seat
149 Storage compartment under the seat of the crane
operator (behind the flap)
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Engine 5
5 Engine
5.1 General
The superstructure does not have its own drive motor. Super-
structure operation is carried out using the engine of the crane
chassis.
For this reason, detailed information on the engine can be found

in the corresponding section in the operating instructions of the
crane chassis. Observe this information, particularly the safety
instructions before commissioning the engine.
Before commissioning, you must refer to the operating instruc-

tions of the engine manufacturer. These can be found in the part
”Various”.
The following points are primarily limited to the specifications

which particularly affect crane operation.
5.2 Damage−prevention measures
DANGER !
Certain safety measures must be observed to prevent in-

jury to persons and damage to the engine, components or
cable sets.
You must observe the corresponding point in the operating
instructions of the crane chassis in this regard.
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Engine 5
5.3 Starting the Engine
5.3.1 Checks before Starting the Engine
1. Before starting, check (on the outside on the crane):

− the hydraulic oil level
− the engine oil level
− the coolant level
To proceed, please also refer to the corresponding sections in the

lubrication and maintenance instructions.
− the fuel supply on the multifunctional display (see from

page 43).
− check the supply of the reducing agent (only for engines
with exhaust gas aftertreatment system) in the crane con-
trol screen (see page 35).
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29
30
32
11
8
Z 82 049
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Engine 5
5.3.2 Starting Procedure
5.3.2.1 Safety Regulations during the Starting Procedure

(Z 82 049)
Risk of accidents!
The following must be observed when starting the en-
gine:
− The control levers must be in the neutral position.
Otherwise, it could cause jerky movement of the crane
even when starting the engine.
− By this point at the latest only authorised persons may
be in the crane’s danger zone (for example, persons atta-
ching/detaching loads, banksman, etc.).
The crane operator or appointed safety personnel must
monitor this.
− People which might be outside of the crane operator’s
field of vision in the crane’s collision or crushing area,
must be informed / warned that crane operation is begin-
ning.
The crane operator must activate the horn using foot
switch (11) every time before starting the engine or initia-
ting crane movements.
Risk of damage!
The following conditions must be adhered to when starting
the drive motor:
− The ambient temperatures must be within the permitted
temperature range for crane operation (see section ”Sa-
fety instructions” under ”Ambient conditions which
must be adhered to”).
− Consumables suitable for the ambient temperatures
must be used (e.g. engine oil, transmission oil, etc.) (see
the corresponding specifications in the lubrication and
maintenance instructions, section ”Consumables”).
− The vehicle batteries must be connected firmly.
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0 I
II
P
29
30
29
32
30
11
8
Z 82 038 Z 82 049
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Engine 5
5.3.2.2 Starting the Engine (Starting Operation)

(Z 82 038, Z 82 049)
Under no circumstances must you use a starter spray or an-

ything similar for jump starting. Otherwise it could lead to an
explosion in the intake manifold, which could cause injury.
Only start the engine in well ventilated areas. Exhaust gases

contain carbon monoxide and nitrogen oxide − both are poi-
sonous.
When operating the engine in enclosed spaces, suitable ex-
haust systems for exhaust gases and gases from crankcase
ventilation are required.
1. Ensure that the safety regulations in the section 5.3.2.1

(page 5) are adhered to.
2. For cranes with battery isolating switch (optional):

Connect the crane’s electrical system with the vehicle’s batte-
ries by activating the battery isolating switch in the chassis
cab (see the operating instructions of the crane chassis in
section ”Engine”).
3. Switch on the ignition.

To do so, insert ignition key (30) in ignition lock (29) and turn
clockwise up to the first stop (position ”I”).
The crane control display and the multifunctional display (see
page 43) are switched on and are ramped up.
4. Actuate the horn using foot switch (11).
Risk of accidents due to crane operation!

People must leave the danger zone at the latest after this
acoustic warning.
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29
30
32
11
8
Z 82 049
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Engine 5
(Z 82 049)
5. Place the pedal (8) for speed adjustment into the idling posi-
tion.
Alternatively, the engine speed can also be adjusted using
crane control. To do so, call up the ”Automotive driving”
screen (see page 41).
6. Turn ignition key (30) further up to the stop (position ”II”) and
hold in this position (max. 30 s) until the engine starts.
After power take off has been released (drive gearbox of the
crane chassis), the hydraulic pumps of the superstructure start
up.
If no enable is granted, the crane control issues the collective
fault message 9002 ”Error chassis drive train STOP”.
In very rare cases it can happen that the power take off is not ena-
bled because of a gear teeth position. In that case, turn off the
engine and repeat the starting procedure.
Release the ignition key as soon as the engine starts. Under

no circumstances must the starter must be actuated with the
engine running.
Instructions if there are starting problems:
− Before attempting to start the engine again, turn the key back
to the first stop.
− The starter may only be actuated twice for maximum 30 se-
conds. Wait at least 5 minutes before attempting another
start.
− If the engine’s starter will not turn at all or too slowly:
Charge batteries or jump start (see page 11).
− If the engine does not start, determine the cause of the fault
using the operating instructions of the engine manufacturer.
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73
Z 82 200
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Engine 5
5.3.2.3 Starting the Engine (with the Ignition Already Swit-

ched on)
(Z 82 200)
If the engine was switched off with dual button (73) with the igni-
tion switched on (see page 29), it can be started again using dual
button (73).
To do so, press the bottom of dual button (73) without actuating

the pedal for speed adjustment until the engine is running.
For the length of the start−up procedure and instructions on

start−up problems, observe the corresponding specifica-
tions on page 9.
Release dual button (73) as soon as the engine starts. Under

no circumstances must the starter must be actuated with the
engine running.
5.3.2.4 Starting at Low Temperatures
The environmental regulations valid on location must be adhered

to. Use fuel preheater and engine heating to prevent starting pro-
blems and white smoke.
At low engine speeds and average load, the formation of white

smoke is limited and the cold engine reaches its operating tempe-
rature more quickly than when warming up without load.
Do not let the engine run at idle speed longer than absolutely ne-
cessary.
5.3.3 Jump Starting with External Batteries
Detailed information on this can be found in the operating instruc-

tions of the crane chassis, section ”Engine”, under ”Jump starting
with external batteries”.
5.3.4 Battery Charging Device (Optional)
Detailed information on this can be found in the operating instruc-

tions of the crane chassis, section ”Engine”, under ”Battery char-
ger (optional)”.
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25
21
Z 83 420
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Engine 5
5.3.5 After starting the engine

(Z 83 420)
Certain checks must be carried out. This is done either on the

multifunctional display (21) or on the crane control display (25).
Detailed information on calling up information in the multifunctio-

nal display can be found from page 43.
5.3.5.1 Engine oil pressure
0 bar Check in the multifunctional display.

Do not rev up the engine if there is no engine oil pressure dis-
played. If, after 10 seconds. no engine oil pressure is dis-
played, switch off the engine and determine the cause of the
fault.
After reaching the operating temperature and speed, the oil pres-
sure is normally approx. 3 − 6 bar (43.5 − 87 psi). It may not fall
below the following values:
− 0.7 bar (10.2 psi) for speeds below 1000 rpm
− 2.5 bar (36.3 psi) for speeds above 1000 rpm.
If the pressure falls below these values, switch the engine off and
determine the cause.
It is indicated by the engine control unit if the minimum permitted

value is not reached (see ”Warnings and alarms” from page 49).
High oil pressure (above 6 bar / 87 psi) is normal when starting

a cold engine.
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Engine 5
5.3.5.2 Engine fault
If the engine control unit reports an engine fault, the depicted

symbol flashes in the multifunctional display (either as ”Warning”)
or alternately with ”STOP” symbol as ”Alarm”.
Detailed information on ”Warnings” or ”Alarms” can be found from

page 49.
In the event of alarms from the engine control unit (”STOP”

symbol), switch the engine off immediately and determine
the cause of the fault (to prevent damage to the engine).
Crane operation is only permitted again once the fault has
been rectified.
Risk of accidents!
If this is not possible due to an existing hazardous situa-
tion, it can lead to different engine running characteristics
(emergency program) or possible engine damage. Proceed
with appropriate caution.
5.3.5.3 Air filter state
If a fault message appears on the crane control display in the form

of the depicted symbols (see ”Fault message” screen in the sec-
tion ”Safety equipment”) relating to the air filter: Service the air fil-
ter (see the lubrication and maintenance instructions).
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Engine 5
5.3.5.4 Hydraulic oil temperature
0 Check in the multifunctional display.
The hydraulic oil temperature may not exceed a certain ”upper

operating temperature”.
This depends on the hydraulic oil used. For this reason, observe
the corresponding specifications in the table on page 57.
If the maximum permitted temperatures are exceeded, a corres-

ponding warning or alarm appears in the multifunction display.
If the hydraulic oil temperature is higher than the indicated value
and / or a warning or alarm goes off, let the diesel engine continue
running at low speed so that the hydraulic oil can be cooled again
by the oil cooler.
Danger of the hydraulic oil overheating!

Do not switch the engine off, but let it continue running at a
low speed without load.
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Engine 5
5.3.5.5 Filling level hydraulic oil

%
Check in the multifunctional display.
Detailed specifications on checking the hydraulic oil level and

topping up if required can be found in the respective points in the
Transport condition
The displayed percentage must be as follows when the crane is

in the transport condition (main boom telescoped in and set down
on the boom support device, struts / outrigger cylinders retracted:
Explorer 5800 Explorer 5600 Explorer 5500
Display max 100% 100% 100%
Display min 92% 87% 86%
Superstructure operation
During superstructure operation, the percentage must not drop

below the following value:
Explorer 5800 Explorer 5600 Explorer 5500
Display min 31% 33% 34%
If the percentage drops below the permissible value, a fault mes-

sage is given in the superstructure on the crane control screen
(collective fault E ...... ”Fault UW Others warning”).
A definite identification of the cause of the fault for this fault mes-
sage in the superstructure is only possible on the driver informa-
tion system in the driver’s cab (crane chassis).
When the fault message is displayed, stop crane operation and

top up hydraulic oil (max. approx. 30 − 40 l / 8 − 10 gal; the corres-
ponds to about 4% on the display). The fault message is then
switched off again.
If required, check for leaks. Check the oil level again for crane in
transport condition according to corresponding description in the
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Engine 5
5.3.5.6 Hydraulic filter state
If, when the hydraulic oil is warm from operation, a fault message
appears in the crane control screen in the form of the depicted
symbols (see ”Fault messages” screen in the section ”Safety
equipment”) relating to the hydraulic filter: Service the high−pres-
sure hydraulic filter (see the lubrication and maintenance instruc-
tions).
This only applies when the hydraulic oil is at operating tempera-

ture.
If temperatures are low, this fault message can appear even if
there is no fault.
5.3.5.7 Coolant temperature
0 Check in the multifunctional display.
The normal coolant temperature during operation is 80 − 113°C

(176 − 235°F).
It is indicated by the engine control unit if the maximum permitted

value is exceeded (see ”Warnings and alarms” from page 49).
If there is a warning: Monitor the coolant temperature, reduce the

load on the engine, check the coolant level.
Danger of the engine overheating!

Excessively high coolant temperatures can cause damage
to the engine.
If the corresponding alarm appears or if there is a loss of
coolant, the engine must be shut down immediately and the
cause of the fault must be determined.
Crane operation is only permitted again once the fault has
been rectified.
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Engine 5
5.3.5.8 Engine oil quantity
79.6 % Check in the multifunctional display.

5.3.5.9 Filling level of the fuel tank
% Check in the multifunctional display.
If 90 % of the fuel supply has been used, a corresponding war-

ning appears in the multifunction display.
5.3.5.10 Filling level of the AdBlue / DEF tank
Only for engines with exhaust gas aftertreatment SCR systems:

Check the filling level in the crane control display in the ”Engine
display” screen (see page 35).

For minimum filling level and the consequences of a low filling le-
vel, see section 5.6.1 ”Engine display screen” from p. 35.
It is prohibited by law to commission the engine without Ad-

blue / DEF and it causes damage to the SCR system.
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29
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32
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8
Z 82 049
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Engine 5
(Z 82 049)
At extreme sub−zero temperatures, do not subject the cold en-

gine to full load.
Before the engine may be operated at maximum load, the hy-

draulic oil must be brought to operating temperature (see
from page 55).
Switch off the engine immediately in case of:

− the oil pressure drops abnormally or exhibits major fluc-
tuations.
− the output and speed falls without the position of pedal
(8) being changed.
− very smoky exhaust.
− abnormally rising coolant and oil temperatures.
− sudden abnormal noises in the engine or turbocharger.
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29
30
32
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8
Z 82 049
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Engine 5
5.4 Engine during Operation
5.4.1 Setting the Required Engine Speed

(Z 82 049)
During engine operation ensure that there are no explosive

materials in the vicinity as electrical or mechanical engine
components can cause sparks.
It is dangerous to be in the area of a rotating engine. Body
parts, clothing or dropped tools could get caught in rotating
parts (e.g. fan) and cause injuries. Always cover rotating
parts and hot surfaces to prevent injuries.
The speed of the drive engine must be continuously adapted to

the current stresses to cover the hydraulic oil requirements du-
ring crane operation.
The engine’s speed can be adapted in two ways:
Automatically Manually
Setting ”Automotive driving” 1. Using pedal (8)
at crane control 2. Using the engine display
(see page 41) (see page 35)
Basically, the engine speed must be adapted automatically using

“Automotive driving”.
This ensures comfortable working as the engine speed does not
have to be additionally activated by the crane operator.
5.4.2 Checks during Operation
Risk of damage!
During operation, check / observe all displays / values which
are checked in ”After starting the engine” (from page 13) so
that the values remain within the permitted range.
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73
Z 82 200
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Engine 5
5.4.3 Engines with SCR System Exhaust Gas After−treat-

ment
The electronic system monitors the following in engines with ex-

haust gas aftertreatment (SCR − selective catalytic reduction):
− The display, filling level and quality of the reduction agent Ad-
Blue / DEF
− The efficiency factor of the catalytic converter in relation to
the permitted tolerance limits of nitrogen oxide emission
(NOx)
A corresponding fault message is shown in the crane control dis-

play when a fault occurs.
Detailed information for calling up the information can be found

in the section ”Safety equipment” under ”Fault messages
screen”.
Risk of accidents!
As soon as a fault is displayed, stop operation, identify and
rectify fault (or have it rectified).
You must reckon with operating restrictions for the engine.
Detailed information on engines with exhaust gas aftertreatment,

fault displays and operating restrictions can be found under the
corresponding points in the operating instructions of the crane
chassis, section ”Engine” and ”Driving”.
5.5 Switch off the engine

(with the Ignition Switched on)
(Z 82 200)
Proceed as follows if the engine is to be switched off, but crane

control is to remain in operation:
1. Press dual button (73) in the upper area until the engine is
switched off. Crane control remains active.
Risk of accidents!
You may not leave the cab in this state. When leaving the
cab, you must remove the ignition key and lock the cab.
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0 I
II
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29
30
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Engine 5

(End of Operation)
(Z 82 049, Z 82 038)
1. When operating with the engine speed set manually:

Place the pedal for speed adjustment (8) in the idle position.
Risk of damage when switching off an overheated engine.

Otherwise, there could be damage to the turbocharger and
continued boiling.
After operation at full engine output, high coolant and / or hy-
draulic oil temperature, let the engine run without load at idle
speed for several minutes so that the temperature can drop
back to the permitted range.
The power supply may not be switched off before the engine
comes to a standstill.
2. Turn the ignition key (30) anti−clockwise (in position ”P” or

“0”).
For further information on the ignition switch, see section ”Crane

operator’s cab” in the corresponding section.
3. Remove the ignition key, leave the cab and lock it.
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29
30
32 76
11
8
Z 82 049 Z 82 039
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Engine 5
5.5.3 Switching off the Engine in an Emergency
5.5.3.1 Standard design

(Z 82 049, Z 82 039)
The drive motor is shut down during crane operation using the
quick stop button (32) in the crane operator’s cab.
If the quick stop button (32) is activated, indicator light (76) in the
crane operator’s cab is illuminated.
The quick stop button (32) in the instrument panel locks in the ac-
tivated position and must be unlocked before starting the engine
again. To do this, twist the button slightly. The indicator light goes
out again.
5.5.3.2 Quick stop device with air shut−off valves (optional)
This device makes it possible to shut down the engine in an emer-

gency, for example, during suction of flammable gases. A air
shut−off valve is fitted in the air suction channel for this purpose.
It can be actuated using the quick stop button, among other
things, as in the standard design.
Risk of damage!
The air shut−off valve must be unlocked manually and the air
paths must be checked before the engine can be started
again.
Detailed information on this can be found under the correspon-

ding point in the operating instructions of the crane chassis, sec-
tion ”Engine”.
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Z 84 390
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Engine 5
5.6 Engine Display in the Crane Control Screen
5.6.1 ”Engine display” screen

(Z 84 390)
Press the key shown in the quick menu of crane control to call up
the ”Engine display” screen.
(1) − Displayed engine data
Display Meaning
Engine speed
Operating hours
Supply −reducing
agent (only for engi-
nes with SCR ex-
haust gas aftertreat-
ment system)
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Z 84 390
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Engine 5
(Z 84 390)
(2) − Indicator lights for faults in the engine / exhaust gas after-
treatment system area (only for engines with SCR ex-
haust gas aftertreatment system)
If there are faults in the SCR system or if the level of reducing

agent in the reducing agent container is too low, control sends a
warning via the indicator light. For some faults, the torque is also
decreased.
Response in case of faults in the SCR system

Time Warning Torque reduction
Fault detec- Continuously
ted illuminated
After 30 mi- Flashes slowly Torque is reduced by 1 % per minute to
nutes (1/2 Hz) 70 % of the maximum torque
Flashes quickly Torque is reduced to 0 %(low idle
After 4 hours
(2 Hz) speed) within 2−10 minutes
After the fault was remedied, the torque will be returned to its nor-
mal level.
If there is a new fault within40 operating hours after the first one
occurred, the indicator light will light up. After 30 minutes, the indi-
cator light flashes quickly and the torque is reduced to 0 % within
30 minutes (low idle speed).
If the torque has been reduced to 0 % (low idle speed), the

engine control unit does not detect that the SCR system is
functioning again. The system must be replaced by a service
technician to ensure normal speed can be resumed.
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5
Z 84 390
38/57 082−1050−82201h_en
Engine 5
(Z 84 390)
Response to low level of reducing agent

Reducing
agent filling Warning Torque reduction
level
Continuously
20 %
illuminated
Flashes slowly Torque is reduced by 1 % per minute to
10 %
(1/2 Hz) 70 % of the maximum torque
Flashes quickly Torque is reduced to 0 %(low idle
0%
(2 Hz) speed) within 2−10 minutes
Engine returns to normal torque when reducing agent is filled to

a level of at least 20 %.
If the torque has been reduced to 0 % (low idle speed), the

engine control unit does not detect that the SCR system is
functioning again. The system must be replaced by a service
technician to ensure normal speed can be resumed.
082−1050−82201h_en 39/57
5
Z 84 965
40/57 082−1050−82201h_en
Engine 5
5.6.2 In the ”Automotive driving” screen, manually set the

engine speed
(Z 84 965)
Activate the key shown in the engine display to call up the ”Auto-
motive driving” screen.
(1) − Activate/deactivate ”Automotive driving”
(2) − Set the engine speed
5.6.2.1 Activating / Deactivating ”Automotive Driving”
During ”Automotive driving”, the engine speed is automatically

adapted in accordance with steering of the control lever. This en-
sures comfortable working as the engine speed does not have to
be additionally activated by the crane operator.
Activating ”Automotive driving”

Press the displayed key to activate ”Automotive driving”. It is
highlighted in green.
Deactivating ”Automotive driving”

Press the displayed key again to switch off ”Automotive driving”.
In the deactivated state, the key background reverts to grey.
5.6.2.2 Manually Setting the Engine Speed

(Z 84 965)
When ”Automotive driving” is switched off, the engine speed can

be regulated between the minimum and maximum values by ac-
tuating the arrows or moving the displayed control.
The current speed is shown directly under the slide control
switch.
082−1050−82201h_en 41/57
5
25
2
3
21
Z 83 420 Z 83 428
”X” ”Y” ”Z”
Z 83 421
42/57 082−1050−82201h_en
Engine 5
5.7 Multifunction display
5.7.1 Fitting Location of the Multifunctional Display

(Z 83 420)
The multifunction display (21) is fitted in the dashboard.
5.7.2 Structure of the Multifunctional Display

(Z 83 428)

1 Analogue display Engine speed
2 Display Display of important information
for crane operation
3 Button Selection of different displays in
the screen
5.7.3 Display
(Z 83 421)
A display in the screen is structured as follows:

Section Display
”X” Symbol of the currently selected value
”Y” corresponding numerical value
”Z” corresponding measuring unit
79.6 % Example depiction: Engine oil level in %
The structure of the display deviates when ”Warnings” and

”Alarms” occur. Observe the detailed information from page 49.
082−1050−82201h_en 43/57
5
B 0 rpm
J 25 v
C 0 bar
K
D 79.6 %
”S”
3
E 0
L
F %
”S”
M 00
G 0
H %
N 00
Z 83 986
44/57 082−1050−82201h_en
Engine 5
(Z 83 986)
Displayed values
Press button (3) in the multifunctional display repeatedly to call
up the displays in the specified sequence one after the other.
Item Symbol displayed value / meaning

”S”
A − Start display; only appears for a few seconds after the igni-
tion is switched on and then automatically merges into dis-
play (B).
Here the software version is displayed, among other
things.
B Engine speed in rpm
C Engine oil pressure in bar
D Engine oil level in %
E Coolant temperature in °C
F Fuel level in %
G Hydraulic oil temperature in °C
H Filling level hydraulic oil in %
J Battery voltage in Volt
082−1050−82201h_en 45/57
5
B 0 rpm
J 25 v
C 0 bar
K
D 79.6 %
”S”
3
E 0
L
F %
”S”
M 00
G 0
H %
N 00
Z 83 986
46/57 082−1050−82201h_en
Engine 5
(Z 83 986)
Item Symbol displayed value / meaning

”S”
K Fault memory for warning(s) which are active and have
been acknowledged.
If there are several warnings, they are displayed one after
the other by pressing button (3).
If there is no warning, this display is skipped.
This fault memory is deleted after the ignition is switched
off. If the ignition is switched on again, fault warnings which
still exist are then shown on the display directly and can be
written in the fault memory again by acknowledging them
and can then be called up again in (K).
The ”S” symbol (of the fault source) and / or the ”War-
ning triangle with frame” symbol (for warnings from
the engine control unit) flash in one−second cycles.
L Fault memory for alarms − the same is valid as for K.
The alarm symbol (”Warning triangle”) and the ”S” sym-
bol (of the fault source) and / or ”STOP” (for fault mes-
sages from the engine control unit) flash alternately in
one−second cycles.
M Saved engine faults in the engine control unit (number)
The fault messages can be viewed by pressing the
key (3) longer than two seconds. Detailed knowledge
of the engine control unit is required to interpret them.
N saved drive fault (quantity)
Display (B) ”Engine speed” is shown again once the last screen (N) has
been reached and button (3) has been pressed again.
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”S”
Z 83 423
48/57 082−1050−82201h_en
Engine 5
5.7.4 Warnings and alarms
5.7.4.1 Warnings
(Z 83 423)
Risk of damage!
If warnings or alarms occur, the operating safety of the crane
is at risk.
Display of warnings
If there are warnings, a warning message appears flashing on the

display instead of the currently displayed value:
− If there are warnings from the engine control unit, the dis-
played symbol appears; in addition, a fault message is dis-
played in the crane control screen (collective fault, E .... fault
chassis drive train warning).
Risk of damage.
If a warning occurs from the engine control
unit, the operating safety of the drive motor is
at risk.
Rectify the fault or have it rectified as soon as
possible.
− For all other warnings, the ”S” symbol of the source of the war-
ning appears (shown as an example: hydraulic oil tempera-
ture).
Rectify the fault or have it rectified as soon as possible.
Acknowledging the warning
Acknowledging means that the displayed warning is removed

from the current display and is written in the corresponding fault
memory.
The value which was displayed before the warning appeared is
shown on the display again − as long as there are no other further
warnings which have not yet been acknowledged.
Calling up the saved warnings
Detailed information on this subject can be found on page 47.
082−1050−82201h_en 49/57
5
”S”
Z 83 424
50/57 082−1050−82201h_en
Engine 5
5.7.4.2 Alarms
(Z 83 424)
Risk of damage!
If warnings or alarms occur, the operating safety of the crane
is at risk.
Display of alarms
If there are alarms, an alarm message appears flashing on the

display instead of the currently displayed value:
− If there are alarms from the engine control unit, the two dis-
played symbols appear alternately; in addition, a fault mes-
sage is displayed in the crane control screen (collective fault,
E .... fault chassis drive train STOP).
Risk of damage.
If an alarm occurs from the engine control unit,
the operating safety of the drive motor is at risk.
Switch off the engine, rectify the fault or have it
rectified.
− For any other alarm messages, the displayed alarm symbol
and the ”S” symbol of the respective fault source appear alter-
nately (shown as an example: hydraulic oil temperature).
Switch off the engine and rectify the fault immediately (or
have it rectified).
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5
”X”
”S”
Z 83 425
52/57 082−1050−82201h_en
Engine 5
Acknowledging the alarm

(Z 83 425)
Acknowledging means that the displayed alarm is removed from

the current display and is written in the corresponding fault me-
mory.
The value which was displayed before the alarm appeared is
shown on the display again − as long as there are no other further
alarms which have not yet been acknowledged.
However, the alarm symbol ”Warning triangle” and the ”S” sym-
bol, which belongs to the values of the current display, then flash
alternately in the symbol area (X).
On the right, next to the ”Warning triangle” alarm symbol, there
is a vertical line to indicate that the alarm is not assigned to the
current display, but to another physical value.
Calling up the saved alarms
Detailed information on this subject can be found on page 47.
5.7.4.3 Threshold values
The threshold values for warnings and alarms which are genera-
ted directly by the multifunctional display can be found in the table
below.
Symbol Value Limit value Result

Fuel filling level < 10 % Warning
Hydraulic oil tem- > 90 °C (194 °F) Warning

perature > 100 °C (212 °F) Alarm
082−1050−82201h_en 53/57
5
54/57 082−1050−82201h_en
Engine 5
5.8 Warming up the hydraulic system
The system must first warm up if the hydraulic oil temperature is

below the corresponding ”lower operating temperature”. To do
so, start the engine and increase the speed slowly from idling to
1200 min−1/rpm.
The hydraulic system must warm up for at least 10 minutes when

commissioning at ”starting ambient temperature”.
The hydraulic pumps may only be placed under load when the
”lower operating temperature” has been reached.
First drive all crane movements repeatedly without load.
The display of the operating temperature can be found in the sec-

tion ”Multifunctional display”, from page 43.
In the event of unusual noises, the crane must be shut down im-
mediately.
If this is not observed, safe crane operation is not ensured

and the hydraulic components can be damaged.
The hydraulic oil used must be suitable for the respective working
temperature.
The relevant temperature specifications for all authorised hy-

draulic oils can be found in the table below.
Detailed information on hydraulic oil can be found in the lubrica-

tion and maintenance instructions under ”Consumables and ca-
pacities”.
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5
56/57 082−1050−82201h_en
Engine 5
Authorised hydraulic oils (A) (B) (C) (D)

°C 5F °C 5F °C 5F °C 5F
Fuchs Renolin Xtreme Temp 46 Plus −16 3.2 −12 10.4 +95 203 +35 (+45) 95 (113)
Fuchs Renolin Xtreme Temp 32 Plus −23 −9.4 −19 −2.2 +85 185 +30 (+40) 86 (104)
Shell Tellus STX 46 ** Tellus S3 V 46 −18 −0.4 −14 6.8 +91 196 +30 (+40) 86 (104)
−11.
Shell Tellus STX 32 ** Tellus S3 V 32 −24 −20 −4 +79 174 +20 (+30) 68 (86)
2
Shell Tellus STX 68 ** Tellus S3 V 68 −11 12.2 −6 21.2 +99 210 +45 (+50) 113 (122)
Spirax S1 ATF
Shell Donax TM −20 −4 −15 5 +88 190 +35 (+50) 95 (122)
TASA
Spirax S2 ATF
Shell Donax TA −25 −13 −19 −2.2 +87 189 +35 (+50) 95 (122)
AX
Spirax S4 ATF
Shell Donax TX −28 −18 −22 −7.6 +88 190 +35 (+50) 95 (122)
HDX
Shell Tellus Arctic 32 Tellus S4 VX
−36 −33 −31 −24 +10 (+15) 50 (59)
** 32 +70 158
Aeroshell
Aeroshell Fluid 4 ** −60 −76 −53 −63 −10 (−5) 14 (23)
Fluid 41 +50 122
(A) Starting ambient temperature = oil temperature

The lowest ambient temperature at which it is permitted to start the vehicle
(the engine) under certain conditions. The consumable can be cooled
down to this temperature.
(B) Lower operating temperature = oil temperature
Lower temperature of the consumable from which the crane (engine,
pumps) may be placed under load.
(C) Upper operating temperature = oil temperature
Upper temperature of the consumable up to which the crane (engine,
pumps) may be used.
(D) Upper ambient temperature
Upper ambient temperature at which the crane (engine, pumps) can be
operated while adhering to the upper operating temperature.
The upper ambient temperature may rise briefly up to (+xx°) if the upper
operating temperature is not exceeded.
The specifications are extreme values related to the type of oil.
** particularly specified consumables. All specifications refer to

these lubricants.
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Supporting the Crane on Outriggers from theCrane Operator’s Cab (Optional) 7
082−1070−82201a_en 1/7
7
2/7 082−1070−82201a_en
7 Supporting the Crane on Outriggers from theCrane

Operator’s Cab (Optional)
7.1 General Instructions and Warnings
In order to support the crane on outriggers from the

crane operator’s cab, the risk and safety instructions and
the procedure details from section 12, part 2 must be ob-
served.
The outriggers must generally be set using the operating ele-

ments in the outrigger controls on the sides on the chassis (see
section 12, part 2).
However, it is possible to operate the outriggers from the crane
operator’s cab for later levelling.
Danger!
There is a risk of crushing between the components of
the outriggers and the ground and/or any other construc-
tional limits.
The supports may only be moved if the crane operator
has a direct view of the relevant support or has a direct
view of the relevant support using mirrors.
Check all mirror positions before operating the outrig-
gers.
If required, banksmen must support the crane operator.
Danger!
There is a risk of crushing between the tyres and the
base if the crane is lowered onto the tyres by retracting
the outriggers.
Before lowering, make sure that this area is completely
free of people.
Danger!
There is a risk of overturning if the crane is operated wi-
thout it being horizontally aligned.
Always align the crane horizontally before raising loads.
082−1070−82201a_en 3/7
7
64 65
62 66
63 67
68 69 70 71
ALL
ALL
73
Z 82 584
4/7 082−1070−82201a_en
7.2 Control elements
(Z 82 584)
The outriggers are activated using the following keys:

the chassis,
front left
the chassis,
rear left
the chassis,
front left
the chassis,
front right
the chassis,
front right
the chassis,
rear right
68 S 4300 Button Release supports
the chassis,
rear left
the chassis,
rear right
71 S 4331 Dual button Vertically retract/extend all supports
on the chassis
73 S 1219 Dual button Engine START / STOP
082−1070−82201a_en 5/7
7
64 65
62 66
63 67
68 69 70 71
ALL
ALL
73
Z 82 584
Z 82 202
6/7 082−1070−82201a_en
7.3 Procedure
Requirements
− Engine running. Crane control is set according to the assem-
bly state of the crane.
− Crane is supported on outriggers.
1. If the outriggers are to be retracted or extended horizontally:

Fit the pins for securing the support struts as described for
this case in the operating instructions of the chassis in the
section ”Outriggers”.
(Z 82 584)
2. Activate the outriggers’ hydraulic cylinders using the control
elements described in segment 7.2 (page 5).
In order to carry out a movement, the ”Enable outriggers”
button (68) and the button of the desired movement must be
actuated in the desired direction of movement simulta-
neously.
For safety reasons, only one support can be retracted or exten-

ded horizontally at once.
(Z 82 202)
The levelling display of crane control in the ”Outrigger support
area / tilt display” is used for levelling.
(For the ”Outrigger support area / tilt display” screen, see the cor-
responding section in section 10 ”Safety equipment”.)
3. If the outriggers have been retracted or extended horizon-
tally: Fit the pins for securing the support struts as described
for this case in the operating instructions of the chassis in the
section ”Outriggers”.
Danger!
There is a risk of overturning when raising loads if the
pins for securing the support struts are not fitted in the
locking position.
Fit the pins for securing the support struts as described
for this case in the operating instructions of the chassis
in the section ”Outriggers”.
082−1070−82201a_en 7/7
Slewing the Superstructure 8
082−1080−82201c_en 1/29
8
Z 53 468 Z 53 459
2/29 082−1080−82201c_en
8 Slewing the Superstructure
8.1 General
8.1.1 General Instructions on Risks
DANGER!
Risk of overturning when slewing with a crane that is not

supported on outriggers in accordance with regulations
(Z 53 468).
(Z 53 459)
After the crane has been supported on outriggers and the
counterweight has been fitted, check the existing outrigger
support area BEFORE the superstructure may be slewed.
Take the details in the load capacity tables into considera-

tion. When the outrigger support area is reduced, only fit
the maximum permitted counterweight listed in the capa-
city table.
It is only permitted to slew the superstructure in the over-

hang range for which load capacity values are still indica-
ted in the tables.
082−1080−82201c_en 3/29
8
4/29 082−1080−82201c_en
RISK OF ACCIDENTS!
There are the following risks when slewing the super-

structure:
− Risk of crushing in the area of the disconnecting point
between the superstructure and the chassis.
− Risk of crushing between the rear end of the superstruc-
ture (counterweight) and obstacles in the vicinity.
It is therefore PROHIBITED at all times for anyone to be
in the slewing area!
Never slew over people.
Do not jump from the slewing crane.
RISK OF ACCIDENTS !
It is prohibited to slew the superstructure if the counter-

weight has not been raised to its final position.
In this case, crane controls stops the slewing movement.

However, if crane control is overridden after a malfunction,
the risk still exists.
Determine and rectify the cause of the fault immediately.
Check regularly to ensure that the raised counterweight

has not lowered itself on its own (for example, due to ex-
treme temperature shifts after the machine has stood still
for a longer period of time or due to leaks). In such a case,
completely raise the counterweight again.
Risk of accidents!
For machines which are equipped with a dolly or dolly pre-
paration, the slew gear brake must not be blocked in the
open state when driving the crane function and the ball
valve of the luffing gear must be open. In this case, there is
a corresponding description in this section and in the ope-
rating instructions of the crane chassis in section 6 ’Dri-
ving’.
082−1080−82201c_en 5/29
8
6/29 082−1080−82201c_en
8.1.2 System Description
Drive
The slew gear which is for rotating the superstructure is driven by
a hydraulic engine.
Depending on whether the slew gear is activated hydraulically,
there are different operating modes of the slewing circuit (open,
closed slewing circuit).
The slewing movement is initiated by the control lever in the
crane operator’s cab (observe control lever assignment!). The
speed of the movements can be regulated at the control levers
(see section 10).
Retaining brake / slew gear parking brake

The slew gear has a holding brake that is closed via spring force.
To turn the superstructure the holding brake has to be opened hy-
draulically.
Service Brake
The hydraulic oil drainage of the slew gear motor is throttled by
a foot pedal in the crane operator’s cab.
In the open slew gear circuit, the slewing movement is braked by
activating the service brake’s pedal.
Preparation for Dolly (Optional)

In order to achieve low axle loads, the main boom can be set
down on a dolly during driving.
So that the crane can then be steered, the retaining brake / slew
gear parking brake must be blocked mechanically in the open po-
sition.
A special design is required for the slew gear brake to do so.
082−1080−82201c_en 7/29
8
25
49 50
10
Z 82 583
8/29 082−1080−82201c_en
The initiation and braking of the slewing movement, slewing

speed regulation when using the control levers and the particula-
rities of a crane with dolly preparation are described below.
8.1.3 Operating Modes of the Slewing Circuit
(Z 82 583)
Depending on the preferred method of operation, the slew gear

can be operated optionally in the closed or in the open circuit.
The operating mode is selected with switch (50).
Only the position of the switch indicates to which operating mode

the slewing circuit has been switched.
8.1.3.1 Closed Circuit
Switch (50) is not actuated in the closed circuit (indicator light in

the switch is not illuminated).
In a closed circuit, the speed of the slewing movement depends

directly on the movement of the corresponding control lever. The-
refore, it is possible
− to specifically decrease the slewing speed by taking the con-
trol lever back or even
− to directly stop the slewing movement by taking the control
lever back into the neutral position.
082−1080−82201c_en 9/29
8
25
49 50
10
Z 82 583
10/29 082−1080−82201c_en
8.1.3.2 Open Circuit
(Z 82 583)
Switch (50) is actuated / pressed down in the open circuit (indica-

tor light in the switch is illuminated).
In the open circuit, the slewing movement is not stopped abruptly

if the corresponding control lever has been brought back into the
neutral position. The movement slowly runs its course and comes
to a stop during freewheeling.
It is also possible to place the boom head in a vertical position
over the load without any problems.
The pedal (10) of the slew gear brake must be pressed down with
regard to the desired braking effect for targeted braking of the sle-
wing movement.
In this type of open circuit it is possible to counter the effects of

a side wind, for example, by countersteering the control lever.
082−1080−82201c_en 11/29
8
Z 200 294 Z 82 261
12/29 082−1080−82201c_en
8.1.4 Slewing Angle / Slewing Direction
Crane configuration
(Z 200 294 schematic drawing)
The slewing angle indicates the position of the superstructure to

the crane chassis.
The positive slewing direction is clockwise(Z 200 294).
In the example shown (principle depiction), the superstructure is
in the 0*° position, i.e. the superstructure (main boom) is to the
rear contrary to the forward direction.
In order to slew the superstructure to the 90*° position, for exam-
ple, it would have to be rotated a quarter turn to the right (clock-
wise).
Display of the ”crane operation” screen
(Z 82 261)
0° Display consists of the current slewing angle and two semi−circu-

lar arrows. The arrow tips indicate the corresponding slewing an-
gle.
The colours of the semi−circular arrows indicate if slewing is pos-
sible or blocked.
Symbol Colour Meaning
Green Slewing to the left possible
red Slewing to the left blocked
Green Slewing to the right possible
red Slewing to the right blocked
082−1080−82201c_en 13/29
8
Z 82 089
14/29 082−1080−82201c_en
8.2 Initiating a Slewing Movement

(Z 82 089)
Starting situation
− Crane assembled with the corresponding outrigger support

area and counterweight and supported on outriggers hori-
zontally.
− Engine running. All parameters selected at crane control in
accordance with the actual crane configuration, which must
correspond with specifications in the relevant capacity table.
Procedure
1. Check which mode has been selected for the assignment of

the control levers. The current mode (here: 1) is displayed in
the uppermost line of the ”Crane operation” screen
(Z 82 089).
You will find detailed information on the selection and range of the
different modes in section 10 ”Safety equipment”.
Risk of accidents!
It is the crane operator’s responsibility to check the current
control lever assignment before initiating a crane move-
ment.
2. Raise main boom so that it cannot get caught by other crane

components (see section 13 “Luffing”).
082−1080−82201c_en 15/29
8
25
49 50
10
Z 82 583
16/29 082−1080−82201c_en
(Z 82 583)
It makes a difference whether the slew gear is in “Open circuit”

or “Closed circuit” for what you do next.
3. Press switch (49) to release the slew gear parking brake

lock. The indicator light in the switch lights up.
Risk of accidents!
Note the differences between operating in “Open circuit”
and “Closed circuit”.
Slew gear in the ”Open circuit”

The slew gear parking brake is released.
Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewhee-
ling. This can cause accidental slewing movements or in-
dependent after−running of the superstructure due to wind
or oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (10).
Slew gear in the “Closed circuit”

The slew gear parking brake is only actually released
when the slewing movement is initiated in the next step.
082−1080−82201c_en 17/29
8
81
43
Z 82 259
25
49 50
10
Z 82 583
18/29 082−1080−82201c_en
(Z 82 259, Z 82 583)
4. Initiate the slewing movement by activating one of the but-

tons of the “release switch system” and carefully steering the
control lever (43) / (81) in the corresponding direction.
Risk of accidents!
Observe the current assignment of the control levers.
Risk of accidents!
Observe the warning instructions and other instructions
on the release switch system in section 10 subsection ”Re-
lease switch system for crane movements”.
RISK OF ACCIDENTS!
Only by adapting the acceleration and/or speeds of all
crane movements can you prevent the load or the hook
block swinging out when the relevant movement is swit-
ched off, causing risk of crushing or crashing.
The control lever automatically returns to the neutral position

when it is released. The crane movement that was initiated is
stopped.
Control levers (43) / (81) may not be switched directly to the

opposite movement, but must first rest in the neutral posi-
tion. A counter movement may be initiated only after move-
ment has ceased.
RISK OF DAMAGE!
Never initiate a slewing movement using the control levers
without first releasing the slew gear brake (switch (49,
Z 82 583) actuated).
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
082−1080−82201c_en 19/29
8
25
49 50
10
Z 82 583
81
43
Z 82 259
20/29 082−1080−82201c_en
8.3 Braking the Slewing Movement

(Z 82 583, Z 82 259)
The slew gear has two braking systems:

− Slew gear parking brake
Static retaining brake, spring−loaded, for stopping / locking
the slew gear. This brake is actuated using switch (49).
− Service brake
The hydraulic oil drainage of the slew gear motor is throttled
using the foot pedal (10) in the crane operator’s cab.
Slewing the superstructure is generally prevented using the slew

gear parking brake.
If switch (49) has not been actuated (indicator light in the switch
is not illuminated), the slew gear parking brake is locked. Slewing
is not possible.
If switch (49) is actuated (indicator light in the switch is illumina-
ted), the slew gear parking brake is not locked. Slewing is possi-
ble by moving the control lever (43) / (81) if the dynamic brake is
not activated using pedal (10).
Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewhee-
ling. This can cause accidental slewing movements or in-
dependent after−running of the superstructure due to wind
or oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (10).
082−1080−82201c_en 21/29
8
81
43
Z 82 259
25
49 50
10
Z 82 583
22/29 082−1080−82201c_en
(Z 82 259, Z 82 583)
In order to brake slewing movements, bring control lever (43) /

(81) slowly into the neutral position.
− in the closed circuit the slewing movement is directly brought
to a halt due to the fixed oil pillar.
If the control lever is in the neutral position and the movement
has run its course, the slew gear parking brake is automati-
cally closed.
− in the open circuit the slewing movement gradually runs out.
It must be brought to a standstill − if desired − using pedal (10)
or counterbalanced with control lever (43) / (81). Then lock
the slew gear parking brake using switch (49).
The effect of the dynamic brake (activated using pedal “10”) is

identical for the open and closed circuits.
Risk of accidents!
Operate the slew gear and slew brake with care. Select low
slewing speeds. Brake carefully!
This applies particularly to operation with main boom ex-
tension or under special local conditions.
When the slew gear brake is released, the superstructure

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

breaks or at the end of work, the slew gear parking brake
must be locked. Press switch (49). The indicator light in the
switch must not light up.
082−1080−82201c_en 23/29
8
81
43
Z 82 259
24/29 082−1080−82201c_en
8.4 Regulating the Slewing Speed

(Z 82 259)
Speed of movement
The slew gear is electrically pilot controlled.
The slewing speed depends on the engine speed and the move-
ment of the corresponding control lever (43) / (81).
Fine tuning of the movement speed
In order to be able to control the movement more sensitively, the

max. movement speed can be set with the control lever fully stee-
red (within the technical limits).
See section 10 ”Safety equipment” in segment ”Fine tuning of the
movement speed”.
Make sure you have a low slewing speed (lower range) in the
following cases:
− when working with loads > 30% of the load capacity
− completely extended main boom
− fitted fly jib
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Z 82 262
26/29 082−1080−82201c_en
8.5 Preparation for Dolly (Optional)

(Z 82 262)
If the crane is prepared for driving with dolly (optional), the brake
of the slew gear mechanism can be locked in the open state. The
brake may not be blocked for crane operation. The lever (3) on
the brake of the slew gear mechanism (1) must be in the down-
ward position. Additionally, actuating lever (3) must be secured
with the padlock (2).
DANGER!
Death or serious injury can be caused by the crane being
operated when not fully functional.
Before crane operation, check that lever (3) is in the down-
ward position.
Also observe the corresponding warning signs on the slew
gear and in both cabs (see section 2.6 ”Decals” as well).
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Z 82 570 Z 82 571
28/29 082−1080−82201c_en
8.6 Monitoring the Right−hand Side of the Superstructure
8.6.1 General
To observe the area on the right of the superstructure during sle-

wing.
8.6.2 Monitoring Using A Mirror (Optional)
(Z 82 570)
There is a mirror on the right−hand side of the superstructure

frame. It must be set up before crane operation.
Depending on the position of the main boom, the view to the mir-
ror can be obstructed by the main boom or the luffing cylinder.
DANGER!
Risk of crushing when slewing the superstructure.
A banksman must be used when slewing the superstruc-
ture in main boom positions in which the view to the mirror
is obstructed.
8.6.3 Monitoring Using the Camera (Optional)
(Z 82 571)
See the corresponding section in section 11 ”Working instruc-

tions”.
082−1080−82201c_en 29/29
Counterweight 9
9 Counterweight
9.1 General
When planning a load case, the required counterweight combi-

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

required counterweight combination is actually fitted and
that the load limit device is set accordingly. This is because
the control system does not monitor it!
DANGER!
Only when all components of the prescribed counterweight
combination are fitted correctly, i. e. to the counterweight
lift cylinders at the superstructure frame, is crane opera-
tion permitted in accordance with the corresponding load
capacity table!
Only counterweight combinations listed in this section
may be fitted! There is risk of damage and accidents if other
counterweight combinations are used.
In order to ensure faultless fitting, only counterweight ele-
ments may be fitted which are marked with the construc-
tion number of the individual crane!
All counterweight plates and saddle weights are marked with fol-
lowings specifications:
− Identification number XXX XXX XX + index x
− Serial number, consecutive, starting with 0 (for initial sample)
− Nominal weight in xxxxx kg / xxxxx lbs
− Manufacturer abbreviation or logo.
In addition, there is a sign with the crane’s construction number.
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2
1
Z 84 337 Z 84 338
Z 84 339
2/53 082−1090−82212a_en
Counterweight 9
9.2 Counterweight Combinations
The individual elements for all permitted counterweight combina-

tions are listed below from which the respective counterweight
combination must be assembled.
9.2.1 Counterweight Combination 0 t (0 kip)
For the 0 t (0 kip) counterweight combination, no counterweight

elements and no hoist 2 is required.
9.2.2 Counterweight Combination 5.1 t (11.2 kip)

(Z 84 337)
(1) − Counterweight plate, 5075 kg (11.2 kip)

(Z 84 338)


(Z 84 339)

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Z 84 340
Z 84 341
4/53 082−1090−82212a_en
Counterweight 9

(Z 84 340)


(Z 84 341)

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Z 84 342
Z 84 343
6/53 082−1090−82212a_en
Counterweight 9

(Z 84 342)

(3) − Counterweight plate, 11155 kg (24.6 kip), x 2

(Z 84 343)

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Z 84 344
1
Z 84 345
8/53 082−1090−82212a_en
Counterweight 9
9.2.9 Counterweight Combination 46 t (101.4 kip)

(Z 84 344)


(Z 84 345)

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6
5
6
1 2 3 3 4
Z 83 448
10/53 082−1090−82212a_en
Counterweight 9

(Z 83 448)

(6) − Saddle weight, 9300 kg (20.5 kip), x 2
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1
3
Z 83 977
Z 83 978
12/53 082−1090−82212a_en
Counterweight 9
9.3 Fitting the Counterweight
9.3.1 Anti−fall Protection Using a Safety Mast (Optional)

(Z 83 977 schematic diagram, Z 83 978)
The assembly assistant can use the safety mast by attaching

himself to it using suitable personal protective equipment after
getting onto the counterweight stack, thereby securing himself
against falling. Proceed as follows:
1. Step onto the counterweight stack as shown in figure

(Z 83 978).
2. On the top counterweight plate, move carefully in the direc-

tion of the mast’s fitting location (hole ∅ 104 mm/4.1 in in the
rear area of the plate).
Risk of falling!
It is essential that you move slowly and carefully!
It is essential that you keep a safe distance from the outer
edges!
3. Using the crane, raise the safety mast in the fitting position
area.
The safety mast weighs approx. 37 kg (82 lbs).
4. Fit the safety mast in the corresponding hole of the top coun-
terweight plate.
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9
1
3
Z 83 977
14/53 082−1090−82212a_en
Counterweight 9
(Z 83 977 schematic diagram)
5. Attach the safety device hook of the personal protective

equipment to the safety eyelets of the safety mast.
If required, the steps (2) and handles (3) on the safety mast (1)
can be used to reach the attachment eyelets.
This secures the assembly assistant against falling down and

while in this secured position, he can help with fitting the saddle
weights.
After fitting the saddle weights, remove the safety mast and set
down on the ground with the crane.
Risk of damage!
If the crane is slewed with the safety mast fitted, it can cause
collisions, e.g. with the superstructure.
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9
6
5
6
1 2 3 3 4
Z 83 448
16/53 082−1090−82212a_en
Counterweight 9
9.3.2 General
(Z 83 448)
Risk of crushing!
When fitting and removing individual counterweight ele-
ments, there is a risk of crushing between the individual co-
unterweight elements, between the counterweight and the
superstructure frame as well as between the counter-
weight and the crane chassis (counterweight support).
To prevent this risk, you must observe the specifications in
section 1 ”Safety instructions” under ”When assembling
and dismantling crane components”.
In particular, maintain a sufficient safety clearance!
The counterweight elements are set down on the crane
chassis with the help of an additionally trained person,
who, as an exception, is on the crane with the crane opera-
tor during this procedure. This person must leave the crane
and the area at risk immediately after the setting down pro-
cedure has been completed!
The crane operator must be in constant visual contact with
this person and must make sure that there is no−one in the
hazardous area! Before the superstructure is slewed, the
crane operator must have made sure that this person has
left the crane and/or the endangered area!
When turning, there is a risk of crushing between the coun-
terweight and obstacles in the vicinity.
Walking or standing beneath suspended loads or in areas
where equipment could fall is prohibited.
Fitting the counterweight is described using the largest possible

counterweight combination of 70.2 t (154.8 kip) as an example.
As a general rule, all counterweight combinations can be fitted

using your own crane.
The fitting procedure consists of two processes which follow

each other:
− Setting down the counterweight combination on the crane
chassis (see section 9.3.3, from page 19)
− Fitting the counterweight combination on the superstructure
frame (see section 9.3.4, from page 31).
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18/53 082−1090−82212a_en
Counterweight 9
9.3.3 Setting Down the Counterweight Combination on the

Crane Chassis
1. Support the crane on outriggers and align. Select the sup-

port width in accordance with the following operation of the
crane.
To fit, remove and modify the counterweight combination,

the crane must be supported on outriggers! Observe sec-
tion12 of the operating instructions of the crane chassis.
Risk of overturning!
When the support width is reduced, the maximum counter-
weight which may be fitted is limited.
Observe the corresponding details in the load capacity ta-
bles!
If a larger counterweight is fitted, there is a risk of tipping
backward during slewing!
2. Drive up counterweight element(s) on the low−loader up to

the crane.
3. Set the load limit device to the current load case.

The counterweight combination 0 t / 0 kip must be set at
crane control to fit the counterweight elements.
Detailed instructions on setting the load limit device to the current

crane configuration can be found in section 10 ”Safety equip-
ment” under the ”Selection of the operating mode” screen.
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9
11
11
33
33 3
Z 84 346 Z 83 957
Z 58 804
20/53 082−1090−82212a_en
Counterweight 9
(Z 84 346 , Z 83 957, Z 58 804, schematic diagram)
Risk of accidents!
You must take the safety instructions listed in the following
into consideration when attaching the counterweight ele-
ments!
All counterweight elements must be attached in the prescribed

attachment points! None of the attachment points may be loaded
over the max. permitted values!
This means for counterweight plate 5600 kg (12.3 kip) and the
two saddle weights (not shown) that each one may only be loa-
ded with the dead weight of the individual element.
The following applies to the other counterweight plates:

− Attachment hooks (11) on counterweight plate (1):
max. 15 t (33 kip) per hook (in accordance with the corres-
ponding marking on the hook).
− Attachment bollards in accordance with the specifications
of maximum permissible load indicated on each bollard:
− on counterweight plate (2): max. 4 t (8.8 kip) per bollard
− on counterweight plates (3) and (4): max. 6 t (13.3 kip)
per bollard (e.g ”33” for plate ”3”)
Only use lifting tackle which is suitable for the counterweight ele-
ments to be raised and is sufficiently dimensioned!
It is especially important that only flat lifting slings made of plastic
are used for hanging for the cast bollards!
Make sure that the attached counterweight element is not croo-

ked and does not swing out!
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21 1
Z 84 347
22/53 082−1090−82212a_en
Counterweight 9
(Z 84 347)
4. Using your own crane, attach counterweight plate (1) with
four falls to the corresponding draw bar attachment hooks −
as shown − and position it over the counterweight support of
the crane chassis .
Risk of damage for the hydraulic tank!

When approaching the position over the counterweight sup-
port, you must prevent the counterweight from swinging out,
so that it cannot hit the hydraulic tank (21) under any circum-
stances, which could damage it.
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9
58 803 Z 84 348
2 17b
17a 1 18
Z 83 478
24/53 082−1090−82212a_en
Counterweight 9
(Z 58 803, schematic diagrams Z 83 478)
A trained assembly assistant must get on the crane chas-

sis to align and remove the counterweight elements.
There is risk of crushing between the counterweight plate
and the crane chassis and between the individual counter-
weight elements! Proceed with appropriate caution. Main-
tain a sufficient safety clearance! Persons should therefore
remain in the area between the lowered counterweight and
cab of the crane chassis!
5. Set counterweight plate (1) down on the counterweight sup-

port of the crane chassis.
The correct position of the counterweight plate is ensured
due to the stops (17a, b) and retraction of the corresponding
counterweight plate grooves into centring (18) and other
centrings (not depicted).
The depiction in figure (Z 83 478) also shows counterweight

plate (2) already set down on counterweight plate (1).
(Z 84 348)
6. One after the other, attach the necessary counterweight pla-
tes to your own crane using 4 falls and lower onto the coun-
terweight plate(s) which have already been set down so that
the draw bars of counterweight plate (1) are within the cor-
responding grooves of the counterweight plate to be fitted.
Make sure that the counterweight plates are correctly fitted!
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5
4
3
3
2
1
Z 83 453
5
4
3
3
2
1
Z 83 976
26/53 082−1090−82212a_en
Counterweight 9
(Z 83 453)
The counterweight combination 51.6 t (113.8 kip) has been set

down on the counterweight support once all the counterweight
plates are stacked on top of each other as shown in (Z 83 453).
Make sure that the counterweight plates are correctly fitted.
(Z 83 976)
The attachment hooks of counterweight plate (1) are designed so

that the counterweight stack can be attached to them and raised
completely up to this maximum counterweight combination 51.6 t
(113.8 kip).
To do so, a suitable 4−strand suspension tackle must be used.
Its capacity must be designed so that it is not overloaded even
when only taking the load with 3 strands.
Risk of accidents!
For this load case, you must observe the specifications of
the corresponding capacity table 0 t (e.g. with regard to the
achievable radius, rope load, required number of falls,
etc.).
You may only attach to the attachment hooks of counter-

weight plate (1) as illustrated.
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Z 83 978
5 6
1 2 3 3 4
Z 83 454
28/53 082−1090−82212a_en
Counterweight 9
(Z 83 978, Z 83 454)
Counterweight plate (4) is designed so that saddle weights can

be attached on the sides.
An assembly assistant must get onto the counterweight stack to

support assembly of these counterweights (Z 83 978).
Risk of falling!
It is essential that you move slowly and carefully!
It is essential that you keep a safe distance from the outer
edges!
Use additional anti−fall protection (e.g. safety mast (optio-
nal), see page 13.
7. Attach one of the two saddle weights 9.3 t / 70.5 kip (6) using
your own crane.
This is done at the cast−iron bollards with two falls.
8. Attach the saddle weight with two attachment lugs to the

cast−iron recesses on counterweight plate (4).
9. Attach the second saddle weight (6) analogously on the

other side. This is shown in the figure opposite.
If these two saddle weights are attached, the process of setting

down the largest possible counterweight combination 70.2 t
(154.8 kip) onto the counterweight support is complete.
Risk of accidents! Risk of crushing!

After completing the raising procedure, the assembly assi-
stant must leave the crane and the area at risk.
Only then can the fitting procedure be continued as descri-
bed on the following pages!
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30/53 082−1090−82212a_en
Counterweight 9
9.3.4 Fitting the Counterweight Combination to the Super-

structure Frame
When fitting the counterweight combination, ensure that the

counterweight lift cylinders are always retracted correctly
(completely) during slewing.
Requirements
− desired counterweight combination set down as described in

the example in section 9.3.3 ”Setting down the counterweight
combination on the crane chassis” from page 19.
− the crane operator has made sure that no−one is on the su-
perstructure or in the endangered area.

If this is not taken into consideration, there is a risk of crus-
hing for anyone present as soon as a slewing movement is
initiated in the following procedure.
− the ”Slew” movement play an important part in fitting the co-

unterweight. You must therefore follow the detailed informa-
tion on this subject in the section 8 ”Slewing”.
The fitting procedure can either be automatic (see from page 33)
or manual (see from page 41).
Standard procedure is automatic fitting.
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Z 315 153 Z 83 455
Z 83 456
32/53 082−1090−82212a_en
Counterweight 9
9.3.4.1 Automatic Fitting
(Z 315 153)
the control levers. The current mode (here: 1) is displayed by
the corresponding symbol in the top line of the IC−1 display.
(Z 83 455)
2. Turn the superstructure until a position of approx. 10° has
been achieved.
(Z 83 456)
3. Call up the ”Counterweight display” screen.
Press the depicted key in the ”Quick menu” screen to do so.
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9
2.1
2.2
3.1
1
3.2
7 4
6
5
Z 83 460
34/53 082−1090−82212a_en
Counterweight 9
”Counterweight display” screen

(Z 83 460)
Item Symbol
Display: symbolic depiction of the fitted counter-
1
weight
Status display: ”Monitoring by control active” / button:
2.1
switch to ”Monitoring by control bridged”
Status display: ”Monitoring by control bridged” / but-
2.2
ton: switch to ”Monitoring by control active”
Status display: ”Counterweight fitting − manual ope-
3.1 ration” / button: switch to ”Counterweight fitting − au-
tomatic operation”
Status display: ”Counterweight fitting − automatic
3.2 operation” / button: switch to ”Counterweight fitting −
manual operation”
Note:
After switching the ignition on / off, symbol (3.1) al-
ways appears. If only the displayed screen is chan-
ged (without switching the ignition on / off), the re-
spective selected configuration remains.
Display of the condition of the counterweight cylin-
4 ders using percentages relating to extension state
and arrow symbols
Cylinders completely retracted
Cylinders retracting
Cylinders extending
Cylinders completely extended
Slewing angle display: only shows the angle range of

5
0°/360° +/− approx. 5° which is crucial for fitting.
Vertical bar: shows the current position of the super-
6
structure (here: 0°)
Current hydraulic pressure in the counterweight cy-
7
linders
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Z 83 466
36/53 082−1090−82212a_en
Counterweight 9
(Z 83 466)
4. Select ”Automatic operation”. After switching the ignition on/
off, manual operation is preselected when the ”Counter-
weight display” screen is opened. A new selection must be
made.
Press the corresponding button to do so. It changes in ap-
pearance as illustrated.
Automatic mode can only be selected when the counterweight lift

cylinders are retracted as far as possible.
5. Slew the superstructure in the direction of the 4°−position −

to do so, you must slew to the left.
To do so, press one of the keys of the release switch system
and carefully steer the corresponding control lever at the
same time.
During the entire fitting procedure, the control lever must
now be held in this direction.
The current slewing angle can be tracked within the angle

range of 0°/360° +/− approx. 5° in the depicted slewing angle
display.
The counterweight lift cylinders can only be retracted into the
counterweight stack with a superstructure position within the
angle window (approx. 4°) with a green background.
In automatic operation the slew gear works in closed circuit (see

section 8). This setting cannot be changed.
To ensure sufficient sensitivity, the engine speed is regulated by
the control system.
The only things the crane operator must actively do are de-
termine the slewing direction by moving the control lever
correspondingly and hold the control lever in this position.
The remaining procedure is then automatic and can be ob-
served in the control screen.
The automatic process can be interrupted at any time by re-

leasing the control lever and can be reinstated by actuating
the controls again.
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38/53 082−1090−82212a_en
Counterweight 9
When the control lever is actuated the following steps are carried
out automatically:
− slew the superstructure to the 4° position.
− extend the counterweight lift cylinders into the counterweight
stack.
− slew the superstructure to 0° with the lowered counterweight
lift cylinders within the counterweight stack.
− raise the counterweight stack into the end position.
6. When the movement is switched off and the engine speed

has been reduced, release the control lever, i.e. place in the
neutral position.
The actual automatic fitting procedure is concluded.
However, before a crane movement may be initiated, first the fol-

lowing tasks must be completed additionally:
− Check that the counterweight combination has been comple-
tely raised.
− Check that the counterweight combination is located central
to the superstructure frame.
Risk of accidents!
The raising procedure must be repeated again if BOTH
conditions are not fulfilled!
Check regularly to ensure that the raised counterweight

has not lowered itself on its own (for example, due to ex-
treme temperature shifts after the machine has stood still
for a longer period of time or due to leaks). In such a case,
completely raise the counterweight again.
− Set the load limit device to the changed crane configuration

with regard to the fitted counterweight.
Detailed information on setting the operating mode can be
found in section 10 ”Safety equipment”.
− Check the crane levelling.
Detailed information on this can be found in the operating in-
structions of the crane chassis, section 12 ”Outriggers”.
Risk of accidents!
Crane movements may only be carried out once all these
tasks have been completed.
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72A
72
72B
Z 83 466 Z 83 457
40/53 082−1090−82212a_en
Counterweight 9
9.3.4.2 Manual Fitting
At first, proceed as already described under points 1. − 3., page

33 for automatic fitting.
(Z 83 466)
1. Select ”Manual operation”:
1.1 After switching the ignition on/off, manual operation is

already preselected when the ”Counterweight display”
screen is opened. The corresponding symbol appears
as illustrated.
1.2 If ”Automatic operation” was set, a new selection must

be made. Press the corresponding button to do so. It
changes in appearance as illustrated.
2. Slew the superstructure until the 4°−position has been achie-

ved − you must slew to the left to do so.
The current slewing angle can be tracked within the angle

range of 0°/360° +/− approx. 5° in the depicted slewing angle
display.
The counterweight lift cylinders can only be retracted into the
counterweight stack with a superstructure position within the
angle window (approx. 4°) with a green background.
(Z 83 457)
3. Extend counterweight lift cylinders.
To do so, press luminous pushbutton (72) in the lower half
(72B) and keep it in this position.
In the condition display of the counterweight lift cylinders, the

”Downward arrow” is shown to indicate ’Counterweight lift cy-
linders extending’. The percentage (here: 90%) is changed
successively from 0% (completely retracted) up to approx.
100% (completely extended).
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72A
72
72B
Z 83 458 Z 83 457
42/53 082−1090−82212a_en
Counterweight 9
(Z 83 458, schematic diagram)
If the counterweight lift cylinders are completely extended into

the counterweight stack, the mushroom−shaped ends (1) of the
piston rods are at the side next to the appropriately designed re-
ceptacles (2) of the draw bars of the counterweight base plate.
The percentage display (here: 100%) does not change any more.
The arrow between the two cylinder symbols is shown with a hori-
zontal line at the bottom. The counterweight lift cylinders are
completely extended.
(Z 83 457)
4. End the movement ”Extend counterweight lift cylinders”. To
this end release the luminous pushbutton (72).
Slewing of the superstructure is enabled. The depicted slewing

symbol is shown in black/red. Slewing is only possible in the di-
rection of the black arrow.
Subsequently, slewing takes place within the counterweight

stack.
5. Slew the superstructure from the current 4° −position in di-
rection 0°/360° to the left. The slewing speed is automatically
reduced.
Observe the angle display. As soon as position 0°/360° has

been achieved, stop slewing movement. The angle display
indicates 0°.
During this slewing procedure, the mushroom−shaped ends
of the piston rods of the counterweight lift cylinder are retrac-
ted into the correspondingly designed receptacles of the
draw bars of the counterweight plate.
Only in this 0°/360° ±0.1° position is it permitted to raise the

counterweight combination.
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72A
72
72B
Z 83 479 Z 83 457
44/53 082−1090−82212a_en
Counterweight 9
(Z 83 479, Z 83 457)
6. Retract counterweight lift cylinders in order to raise the coun-
terweight combination. To do so, press luminous pushbutton
(72) in the top half (72a) and hold in this position.
The ”Upward arrow” is shown in the condition display of the

counterweight lift cylinders.
The percentage at the counterweight cylinders’ symbols
(here: 90%) is reduced successively.
p= 0 bar The pressure display indicates the pressure in the counter-

weight lift cylinders and changes depending on the mass of
the attached counterweight combination (here: for example,
0 bar / 0 psi).
7. Press luminous pushbutton (72) until raising is switched off.

Engine speed is reduced.
Authorisation for slewing is given as soon as the counter-

weight combination is raised to a sufficient height over the
crane chassis, but before the top end position has been re-
ached. However, raising must be completed as described
above!
In the condition display of the counterweight lift cylinders, the

”Upward arrow” with the top horizontal line is shown to indi-
cate ’Counterweight lift cylinders retracted in the highest
possible position’. The percentages (here: 10%) do not
change any longer.
The percentages cannot go back to 0% as the retraction move-

ment of the counterweight lift cylinders is limited due to the driving
of the upper rim of the draw bars (or the highest counterweight
plate) against the bottom rim of the superstructure frame.
This completes the actual manual fitting of the counterweight

combination to the superstructure frame.
However, before a crane movement may be initiated, first all

tasks must be additionally carried out as after automatic fitting.
The corresponding specifications on page 39 must be observed.
Risk of accidents!
Crane movements may only be carried out once all these
tasks have been completed.
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9
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Counterweight 9
9.4 Removing the Counterweight
As with the fitting procedure, the following basic requirements

must be satisfied:
− Support the crane on outriggers / align
− Set the load limit device (0 t / 0 lbs tables).
The equipment is removed as it is fitted, in the reverse order.
9.5 Behaviour in Case of a Fault / Bridging Control
When fitting the counterweight − as well as in manual operation

− all crane movements are monitored by control. Control only
enables movements (e.g. slewing, lowering / raising counter-
weight lift cylinders) which would not cause any damage at this
point.
In exceptional cases − e.g. in the case of faults or defects −

crane control can be bridged . Monitoring the fitting procedure
for the counterweight is then completely suspended.
Risk of damage!
When overridden, the controls do not monitor any more!
Only the crane operator decides which movements are
safe and may therefore be carried out.
This is why the crane operator may override only if he is ac-
quainted with the counterweight assembly in accordance
with the operating manual and he is aware of the existing
dangers.
If it becomes necessary − in an exceptional case − for auxi-
liary personnel to step onto the crane again to rectify faults,
there is RISK OF CRUSHING.
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9
Z 83 466 Z 700 046
Z 83 459
48/53 082−1090−82212a_en
Counterweight 9
(Z 83 466, Z 700 046, Z 83 459)
1. Press the depicted key in the ”Counterweight display” to

bridge. Screen (Z 700 046) is displayed which expressly
warns the crane operator of existing dangers.
Press the depicted key if bridging is not to be carried out after

all. Bridging is interrupted; the original screen reappears un-
changed.
Press the depicted key if existing dangers are to be con-

sciously risked.
Only then will overriding actually be activated.
The bridged state is shown in two places.

The originally activated key in the ”Counterweight display”
screen changes in appearance into a red warning symbol.
In addition, the depicted warning symbol is shown in the

crane display area.
This ensures that the bridged state is always displayed even
when the ”Counterweight display” screen has been exited
(the ”bridged” state remains).
2. Press the displayed key again in order to cancel overriding.
The symbol changes back to the state ”not overridden”.
The depicted warning symbol in the crane display area di-
sappears.
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9
3470
Z 83 461
6330
Z 83 462
50/53 082−1090−82212a_en
Counterweight 9
9.6 Dimensions
9.6.1 Slewing Radius and Width

(Z 83 461, Z 83 462)
Slewing ra-
Width
Type of counterweight Figure dius (approx.)
m ft mm ft
Standard Counterweight Z 83 461 3470 11.4
Standard counterweight + 5 16.4
Z 83 462 6330 20.8
saddle weights
082−1090−82212a_en 51/53
9
6
6 5
1734
2990
2200
5 1 2 3 3 4
1675
3480
890
6
4
220
2200
5
3480
373
4
3
2270
230
3
2990
3
2
2270
197
2
2990
1336
1135
2222
1
60
Z 84 349
52/53 082−1090−82212a_en
Counterweight 9
9.6.2 Transport Dimensions and Weights of the Counter-

weight Elements
(Z 84 349)
Weight Width Depth Height

Item
kg kip mm ft mm ft mm ft
Counterweight plate 60 0.2
1 5075 11.2 2990 9.8 2222 7.3
1135 3.7
2 Counterweight plate 8000 17.6 2990 9.8 2270 7.4 197 0.6
6 Saddle weight 9300 20.5 1734 5.7 1675 5.5 890 2.9
082−1090−82212a_en 53/53
Safety Equipment 10
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Z 82 592
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Safety Equipment 10
10 Safety Equipment
10.1 IC−1 Crane Control

(Z 82 592)
The crane control IC−1 (Intelligent Control System) combines se-

veral devices which provide the crane driver with essential infor-
mation for operating the crane within the parameters specified by
the manufacturer:
− Overload cut−off device (load limit device LLD)
− Telescoping information system
− Display of numerous crane functions, for example, support
pressure, tilt, crane configuration, capacities, etc.
− Warning (visual and acoustic) of prohibited conditions.
− Display of system diagnostics.
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 device is no substitute for the judgement and
experience of the crane operator or application of recogni-
sed safe working procedures for crane operation.
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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Safety Equipment 10
It is essential for the operating safety of the crane that the

IC−1 crane control functions in its original condition.
Necessary updates must be obtained from the customer
service department of the crane manufacturer.
10.1.1 Overload Cut−off Using the Load Limit Device (LLD)
10.1.1.1 Normal Operation
10.1.1.1.1 Function
To protect the crane from overload, the crane control system has
a load limiting device.
If the load limit device has triggered, the following crane move-
ments will be switched off:
− Luffing up
− Luffing down
− raise hoist
− Telescoping out
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 over-
ridden.
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Safety Equipment 10
The load limit device should only be triggered in an emer-

gency. Under no circumstances may it be used as a stan-
dard operating tool!
This means that the crane operator must be satisfied be-
fore raising the load, that the load to be lifted does not ex-
ceed the capacity of the crane. 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 must only be moved within

those ranges for which capacities are specified.
Detailed information on the status display of the load limit device

can be found in section 10.1.5.1.4, page 67.
Before raising a load, 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
configuration is achieved) after the ignition/engine is swit-
ched 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!
This is achieved by selecting the operating mode (detailed
description in section 10.1.6.6 from page 93).
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!
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Safety Equipment 10
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
− during dismantling, if loads are unscrewed / burnt off af-
ter attachment, then hang freely 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 appropriate acceleration / speed
of all crane movements.
Also watch the continuous load utilisation display with ad-
vanced warning at 90% of the permissible load utilisation
prior to shutdown.
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Safety Equipment 10
10.1.1.1.2 Displays, Warnings and Interventions of the Control

System
A distinction must be made thereby between the versions
”EN 13000” (see starting on p. 13) and ”Not EN 13000” (see star-
ting on p. 19).
You can check whether the crane has been equipped with control
software in accordance with EN 13000 by selecting the “System
settings (user)” screen (segment 10.1.6.2, page 87) at crane con-
trol. In this case, a corresponding note can be found there.
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1 8
LMB C
LMB
Z 82 043
15
Z 82 138
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Safety Equipment 10
10.1.1.1.2.1 Design “EN 13000”

(Z 82 043, Z 82 138)
(X) (Y)
Load utilisation Warning Warning Warning (Z)
”Crane Operation” Screen buzzer light siren
(15)
Normal range
(below 90%)
Load utilisation display (C) green illumina- unlimited
ted in
green
Advanced war-
ning range Warning symbol at item (8)
(90% − 100%) Sound illumina-
+
interrupted in unlimited
Load utilisation display (C) yellow ted yellow
Overload range
Warning symbol at item (8)
(from 100%)
+ illumina- Sound
Continu-
Overload display (C) red ted in interrup- stopped
ous tone red ted
”LLD” (red) at item (1)
The overload data is recorded.
All acoustic warning signals listed here can be acknowledged / switched off in the crane
operator’s cab after 5 seconds (see section 10.1.5.1.6, page 77).
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
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Z 82 044
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Safety Equipment 10
Configuring
(Z 82 044)
If a crane movement (for example, luffing up) is carried out out-

side of the capacity table to achieve the planned operating posi-
tion, the ”Configure” symbol which is highlighted in the figure will
appear.
In addition, the load utilisation display of the load limit device is

shown in red (with 3 stars).
No capacities are enabled in configuration operation.

The raising of loads is not permitted!
The crane may only be configured in an erected state (ou-
triggers, counterweight etc.) for which there are load capa-
city tables!
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10
1
LMB C
LMB
Z 86 530
15
Z 82 138
16/215 082−1100−82201e_en
Safety Equipment 10
Displays, Warnings and Interventions of the ControlSystem

(Configuring)
(Z 86 530, Z 82 138)
(X) (Y)
(15)
Normal range Load utilisation display (C) red
with configuration symbol (***)
Display of ”Maximum load” and illumina- unlimited
”Crane status” with configuration ted in
symbols green
Overload range
+
Load utilisation display (C) red
with configuration symbol (***) illumina- Sound
Continu-
ted in interrup- stopped
“Maximum load” indication with ous tone red ted
configuration symbols
The overload data is recorded.
Legend:
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10
1 8
LMB C
LMB
Z 82 043
15
Z 82 138
18/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.1.2.2 Design ”Non−EN 13000”

(Z 82 043, Z 82 138)
(X) (Y)
Warning Warning Warning
Load utilisation buzzer light siren (Z)
”Crane Operation” Screen (15) (optio-
nal)
Normal range
(below 90%)
Load utilisation display (C) green illumina- unlimited
ted in
green
Advanced war-
ning range Warning symbol at item (8)
(90% − 100%) + Sound illumina- Sound
interrupted in interrup- unlimited
Load utilisation display (C) yellow ted yellow ted
Overload range
(from 100%)
+ illumina-
Overload display (C) red Continu- Continu-
ted in stopped
ous tone red ous tone
The overload data is recorded with the overload recorder (optional)
activated.
Legend:
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10
Z 82 044
20/215 082−1100−82201e_en
Safety Equipment 10
Configuring
(Z 82 044)
If a crane movement (for example, luffing up) is carried out out-

side of the capacity table to achieve the planned operating posi-
tion, the ”Configure” symbol which is highlighted in the figure will
appear.
In addition, the load utilisation display of the load limit device is

shown in red (with 3 stars).
No capacities are enabled in configuration operation.

The raising of loads is not permitted!
The crane may only be configured in an assembly state (ou-
triggers, counterweight etc.) for which there are capacity
tables.
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10
1
LMB C
LMB
Z 82 045
15
Z 82 138
22/215 082−1100−82201e_en
Safety Equipment 10
Displays, Warnings and Interventions of the ControlSystem

(Configuring)
(Z 82 045, Z 82 138)
(X) (Y)
nal)
Normal range Load utilisation display (C) red
with configuration symbol (***)
Display of ”Maximum load” and illumina- unlimited
”Crane status” with configuration ted in
symbols green
Overload range
+
Load utilisation display (C) red
with configuration symbol (***) illumina-
Continu- Continu-
ted in stopped
“Maximum load” indication with ous tone red ous tone
configuration symbols
The overload data is recorded with the overload recorder (optional)
activated.
Legend:
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10
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Safety Equipment 10
10.1.1.2 Bridging the Load Limit Device
After the crane movements have been switched off by the load
limit device, overriding this safety apparatus is permissible only
for special operative states and in emergency situations.
Bridging may only be initiated if the control levers are in the

neutral position and/or the initiated crane movement is
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!
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10
56 58 60
57 59 61
Z 82 576
26/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.1 Bridging with the key−operated pushbutton ”Setup”

(Z 82 576)
Bridging with the key−operated pushbutton ”Setup” can only be

done with the ”EN 13000” version.
settings (user)” screen on the crane control. In this case, a corres-
ponding note can be found there.
To override, press the key−operated pushbutton “Setup” (61). 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.
By pressing the key−operated pushbutton ”Setup” no move-

ments are permitted which could lead to component failure or sta-
bility loss.
Cancelling bridging is done:
− by pressing the key−operated pushbutton ”Setup” (61) 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.
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10
1 8
LMB C
LMB
Z 82 266
15
56 58 60
57 59 61
Z 82 138 Z 82 576
28/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.1.1 Displays, Warnings and Interventions of the Control

System
(Z 82 266, Z 82 138, Z 82 576)
(X) (Y)
(15)
Normal range Warning symbol at item (8)
(below 90%) (flashing)
+
Load utilisation display (C) green Continu- illumina- reduced
ted in
LLD (black) at item (1) ous tone to 15%
green
Indicator light (60)
Advanced war- Warning symbol at item (8)
ning range (flashing)
(90% − 100%) +
Load utilisation display (C) yellow Continu- illumina- reduced
ted in
LLD (black) at item (1) ous tone to 15%
yellow
All data is recorded when bridging with the key−operated ”Setup” pushbutton (61).
Legend:
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10
1 8
LMB C
LMB
Z 82 043
15
56 58 60
57 59 61
Z 82 138 Z 82 576
30/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 043, Z 82 138, Z 82 576)
(X) (Y)
(15)
Overload range Warning symbol at item (8)
(100% − 110%) (flashing)
+
Overload display (C) red Continu- flashes reduced
LLD (black) at item (1) ous tone in yellow to 15%
Overload range Warning symbol at item (8)
(from 110%) (flashing)
+
Overload display (C) red illumina- Sound
Continu-
ted in interrup- stopped
LLD (black) at item (1) ous tone
red ted
All data is recorded when bridging with the key−operated ”Setup” pushbutton (61).
Legend:
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10
56 58 60
57 59 61
Z 82 576
32/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.2 Overriding shutdown of the ”Luff up” movement
10.1.1.2.2.1 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 82 576)
The key−operated pushbutton (57) 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 (57) must be

turned clockwise and held in this position.
DANGER!
Risk of tilting! Risk of breakage!

There is no monitoring of the crane if a load is raised with
the load limit device overridden.
It is prohibited to lock the key−operated pushbutton me-
chanically!
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34/215 082−1100−82201e_en
Safety Equipment 10
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!
This movement is not to be used to lift the load under any

circumstances!
If the ”luff up” movement is switched off due to the permis-
sible minimum radius being reached, then this cannot be
overridden, to prevent the crane from tipping over back-
wards.
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10
15
22
Z 82 906 Z 82 138
56 58 60
57 59 61
Z 82 576
36/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.2.2 Displays, Warnings and Interventions of the Control

System
(Z 82 906, Z 82 138, Z 82 576)
You must differentiate between the ”EN 13000” and “Non EN

13000” designs.
(X) (Y)
(15)
over all load uti- Warning symbol ”LLD shut−
lisation ranges down (luffing up) overrid-
den” under item (22)
+ Continu-
unlimited
Indicator light (56) ous tone
”EN 13000” design: All data is recorded when overriding with the key−operated pushbut-
ton “Override raise luffing gear”..
Legend:
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Safety Equipment 10
10.1.1.2.3 Bridging the Shut−down of All Movements
Risk of accidents!
The load limit device may only be overridden as an excep-
tion, for example, for repairs, when fitting a rope or for simi-
lar 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 over-
ridden to increase the load moment.
It is prohibited to raise a load with the load limit device over-
ridden.

ting on p. 47).
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”a”
”b”
3
6
”c”
Z 82 053 Z 82 051
40/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.3.1 Design “EN 13000”

(Z 82 053, Z 82 051)
Box (6) with the key−operated pushbutton for bridging the load
limit device is at the back.
Proceed in accordance with the following steps in order to over-

ride:
1. Step onto the step next to the crane operator’s cab with the
required key.
2. Attach yourself to the top of the crane operator’s cab to the

handle between the two mounting plates using personal pro-
tective equipment (e.g. safety harness).
Hold onto the handles with your left hand and carry out tasks
using your right hand.
3. Open the box (6). Proceed as follows:
(Z 82 051 “a”)
3.1 Press position lock (1) in the direction of the rear cab
wall to unlock the cover of the box.
(Z 82 051 “b”)
3.2 Fold cover (2) back completely and insert key (4) in the
key−operated pushbutton (3).
(Z 82 051 “c”)
3.3 Turn key (4) clockwise up to the stop and then let it re-
turn to its original position.
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”a”
”b”
3
”c”
Z 82 051
42/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 051)
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 the crane movements ”luff down, luff up, raise
hoist, telescope out” will all be limited to a max. of 15% of the
permissible speed for the load case concerned.
Cancelling bridging is done:
− by pressing key−operated pushbutton (3) again (Z 82 051

”b”)
− automatically after 30 minutes
− with engine stop.
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10
1 8
LMB C
LMB
Z 82 267
15
Z 82 138 Z 82 053
44/215 082−1100−82201e_en
Safety Equipment 10
Displays, Warnings and Interventions of the Control System

(Z 82 267, Z 82 138, Z 82 053)
(X) (Y)
(15)
over all load uti- Warning symbol at item (8)
lisation ranges (flashing)
+
Overload display (C) red Continu- flashing Continu-
ous tone red ous tone
LLD (black) at item (1)
The warning buzzer can be acknowledged/switched off in the crane operator’s cab after 5
seconds
(see section 10.1.5.1.6, page 77). The warning siren cannot be switched off.
All data is recorded during crane operation with crane control overridden.
Legend:
(Z) − Speed at which crane movements are executed:
Movements which reduce the load moment: unlimited
Crane Movements Luffing gear down, luffing gear up,
raise hoist, telescope out reduced to 15 %
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.
Box (6) on the outside of the rear cab wall must be closed again.
Proceed as described on page 41 in the opposite sequence.
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”a”
”b”
3
56 58 60
57 59 61
4
”c”
Z 82 576 Z 82 051
46/215 082−1100−82201e_en
Safety Equipment 10
10.1.1.2.3.2 Design ”Non−EN 13000”

(Z 82 576, Z 82 051)
The load limit device can be overridden using the key−operated

pushbutton (61).
To do so, the key in the key−operated pushbutton (61) 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.
DANGER!
Risk of tilting! Risk of breakage! There is no monitoring of

the crane if a load is raised with the load limit device over-
ridden.
It is prohibited to lock the key−operated pushbutton me-
chanically!
There is a key−operated pushbutton (4) at the back of the cab

(see ”EN 13000” design, section 10.1.1.2.3.1 , page 41), but it is
not activated.
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10
1 8
LMB C
LMB
Z 82 267
15
56 58 60
57 59 61
Z 82 138 Z 82 576
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Safety Equipment 10
Displays, Warnings and Interventions of the Control System

(Z 82 267, Z 82 138, Z 82 576)
(X) (Y)
nal)
over all load uti- Warning symbol at item (8)
lisation ranges (flashing)
+
Overload display (C) red illumina-
Continu- Continu-
ted in unlimited
Indicator light (60) ous tone ous tone
red (*)
LLD (black) at item (1)
(*) = Depending on special national regulations, the red lamp in the war-
ning light (15) could possibly also flash in this status.
The overload data is recorded with the overload recorder (optional) activated.
Legend:
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81
25 43
Z 82 586 Z 82 259
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Safety Equipment 10
10.1.2 Operating Controls and Display Elements

(Z 82 586, Z 82 259)
(25) Crane control’s control panel

(IC−1 display)
This computer has a colour screen. Several profiles
are available for setting the screen (colour)
(see section 10.1.6.3, page 89).
The brightness of the screen display can be set indi-
vidually.
All keys in the screen display are activated by tap-
ping the symbol (touch screen) directly with the fin-
ger.
(see section 10.1.3, page 55).
Risk of damage!
Make sure no adhesive is applied to the display screen!
Mounting stick−on labels would destroy the monitor (touch
screen)!
You will get the best results when cleaning the monitor by using
a clean, damp, non−abrasive cloth and any commercially−availa-
ble window cleaning agent without ammonia. The window clea-
ning agent should be applied to the cloth first instead of directly
onto the surface of the monitor.
(43), Left− and right−hand control levers

(81) − Control of the crane movements
− Operation of the release switch system for crane
movements
− Speed setting for crane movements
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1
2 8
9
3 10
4
11
12
13
5
6
7
Z 82 128
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Safety Equipment 10
10.1.2.1 Control Panel of Crane Control (Structure)
(Z 82 128)

(1) Touch−sensitive Operation of Crane Control
screen (touch-
screen)
(2) On / off key For any restart of the IC−1 which
may be required:
Switch off the ignition, press the
button for at least 3 s. Switch the
ignition on again.
(3) Key brightness ”+” (manual)
(4) Key brightness ”−” (manual)
(5) Lamp temperature warning
If the temperature of crane control’s control
panel is below −305 C (−225 F) or higher than
+625 C (1445 F), the LED is illuminated in red
and the computer is not ready for operation.
The temperature in the cab must then be ad-
justed using the heating system or air condi-
tioning until the control panel of crane control
is within the described temperature limits.
(6) Lamp hard drive access
(7) Lamp Operating status
(8) to Not assigned
Key
(13)
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Z 82 129 Z 82 130
”A” ”B”
Z 82 131
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Safety Equipment 10
10.1.3 Operating Crane Control (IC−1)

In this system, the functions are carried out by ”tapping on” but-
tons (keys) in crane control’s control panel (touchscreen).
(Z 82 129, Z 82 130)
Tapping on a key / active button (example: Z 82 129) changes the
display to another screen. There is a symbol on the key / active
button indicating the function (example: change to ”Selection of
the operating mode” screen; Z 82 131).
There is a ”top line” in the individual screens in which the name
of the corresponding screen can be found (example: ”Main
menu”; Z 82 130).
In most screens, there is a key / button with the ”Exit symbol”. The
screen can be exited by pressing this key / button. If settings were
changed in a screen, the changed settings are not saved.
Settings can be changed in screens in which there is a ”Save

symbol”. If settings were changed, the changed settings are sa-
ved.
(Z 82 131)
When a key / active button is tapped on (example: 1; Z 82 131
”A”), as shown on the left, a list of selection options is opened in
the selected area (pull−down menu; example: Z 82 131 ”B”). A
value must then be selected from the selection list. If the set value
is not to be modified, then the previous value must be selected
again from the selection list.
Operation at an ambient temperature over 50 °C (122 °F)
To prevent the display malfunctioning, the crane operator’s cab

must be cooled with the air conditioning before and during crane
operation if ambient temperatures are above 50°C (122°F). You
must avoid direct sunlight on the display.
An appropriate cooling−down stage should be prescribed if ne-
cessary for the period before work begins.
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Z 82 132 Z 82 133
Z 82 134 Z 82 130
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Safety Equipment 10
10.1.4 System Start / Switching the System off
Automatic system start
(Z 82 132, Z 82 133)
The crane control system of the superstructure is automatically

started when the ignition is switched on (Z 82 132).
If crane control is ready for operation, the ”Selection of the opera-
ting mode” screen (Z 82 133) is displayed.
A detailed description of the ”Selection of the operating mode”
screen can be found in section 10.1.6.6, from page 93.
(Z 82 133)
If the assembly or operative states are unchanged, the ”Selection

of the operating mode” screen can be exited using the ”Exit” key.
If the assembly or operative state has been changed, the speci-

fications in the ”Operating mode selection” screen must be chan-
ged accordingly.
In this case, the ”Selection of the operating” mode screen must
be exited using the ”Save” key so that the changes are transmit-
ted to control.
(Z 82 134)
In both cases, the ”Crane operation” screen appears (Z 82 134).

A detailed description on the ”Crane operation” screen can be
found in section 10.1.6.6, from page 61.
Central screens ”Crane operation” and ”Main menu”

(Z 82 134, Z 82 130)
As a starting point for using superstructure crane control, mainly

the ”Crane operation” screen (Z 83 134; see section 10.1.6.6,
from page 61) and the ”Main menu” screen (Z 82 130; see sec-
tion 10.1.5.2, from page 79) are used.
The required functions can be selected from these screens by

calling up the corresponding screens. The description of the
screens used is found in section 10.1.6, from page 83.
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10
1
2 8
9
3 10
4
11
12
13
5
6
7
Z 80 529 Z 82 128
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Safety Equipment 10
Switching off (Power Control)

(Z 80 529, Z 82 128)
After switching off the ignition, the display changes to the ”Power
Control” screen. The time to computer switch−off is shown here.
If the ignition is switched on again within this time, crane control
is ready for operation again. The ”Selection of the operating
mode” screen appears again. The computer’s switch−off time
can be set in the ”System settings (expanded)” screen (presetting
15 min).
For a potentially required restart of the IC−1:
Switch off the ignition. Press button (2) for at least 3 s. Switch the
ignition on again.
Calibration
If your touchscreen responds incorrectly, the display must be cali-

brated.
In this case, please consult our service department.
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10
A
B C
D
E
Z 82 055
60/215 082−1100−82201e_en
Safety Equipment 10
10.1.5 Central Screens
10.1.5.1 ”Crane Operation” Screen

(Z 82 055)
The ”Crane operation” screen appears after confirming or exiting

the ”Selection of the operating mode” screen.
The parameters which are relevant during crane operation are
displayed in this screen.
Danger!
Risk of accidents due to incorrectly set crane control.
The crane could overturn or parts of the crane could break
during crane operation with crane control set incorrectly.
If deviations between the values set in the ”Crane opera-
tion” screen and the actual assembly state are determined,
set the operating mode correctly (see section 10.1.6.6,
from page 93).
The ”Crane operation” screen can be divided into six areas (”A”
to ”F”).
These are described in the sections below.
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1 2 3 4 5 7 8 9
Z 82 056
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Safety Equipment 10
10.1.5.1.1 Section (A): Display of the Current Configuration In-

formation
(Z 82 056)
(1) − Abbreviations of the crane configuration
Abbreviation Crane configuration
HA Main boom
HA−0 Main boom, special case 0° (to the rear)
HAV Main boom extension
HAV−VA Main boom extension, hinged, with fixed
part (adapter)
HAVHY Hydraulic main boom extension
HAVHY−VA Main boom extension, hinged hydraulically,
with fixed part (adapter)
MS Assembly jib
(2) − Counterweight
(3) − Support base area
(4) − Reeving number
(5) − Selected length code no. (LC)
(7) − Current tilt
(see also 10.1.6.21 “Outrigger support area” screen on
page 167)
(8) − The assignment of the control levers
(see section 10.1.6.8.3, “the assignment of the control le-
vers (6 modes)” page 137)
(9) − Time
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1 2 3 4 5
Z 82 059
Z 82 060
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Safety Equipment 10
10.1.5.1.2 Section (B): Display of Load and Radius

(Z 82 059)
(1) − Net load

The actual load is tared by pressing the ”Net” key (see
section 10.1.7, page 177).
(2) − Maximum load (for the set crane configuration)
During configuring, the depicted configuring symbol is
displayed instead of a maximum load. It is then prohibited
to raise loads (see section 10.1.1.1, page 5 under ”Nor-
mal operation”.
(3) − Current total load (gross load)
This includes load, hook block, all lifting tackle and, if ap-
plicable, additional device attached.
(4) − In the actual radius section, the range which is still availa-
ble and/or shut−downs are indicated by colours
(white = OK, yellow = advanced warning, red = shut-
down).
(5) − Maximum radius for selected operating mode or selected
length code with current load
10.1.5.1.3 Section (C): Load Utilisation Display

(Z 82 060)
Continuously changing display of the current load utilisation as

a ”bar display” with percentage or overload display.
Detailed information can be found in the description of the load

limit device in section 10.1.1.1.2, from page 11.
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10
1 2 3 4 5 6 7 8
25
24
9
D 10
11
12
23
26
22
13
21
14
27 15
16
28
29
30
31 20 19 18 17 Z 86 531
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Safety Equipment 10
10.1.5.1.4 Section (D): Display of Status Information on the

Crane Condition
(Z 86 531)
Item Symbol Explanation

1 Display: Load limit device
LLD Load limit device is switched off and is not overridden.
LMI The load limit device is overridden.
At the same time, the STOP symbol appears at po-
sition (8).
2 Display: Hoist Limit Switches
HLS Hoist limit switch is triggered and not overridden.
HLS Hoist limit switch has been overridden.
3 Display: Support pressure / outrigger support area
STB Minimum support pressure has not been reached (< 1 t) or an
invalid outrigger support area has been activated if there is ou-
trigger support area recognition (optional, see part 2, sec-
tion 12 ”Outriggers”).
At the same time, the STOP symbol appears at po-
sition (8).
4 Display: Lower limit switch 1
SES1 Lower limit switch 1 (hoist 1) is triggered and not overridden.
5 Display: Control overridden in subsections
Counterweight control overridden
(see part 1, section 9 ”Counterweight”).
6 Display: Lower limit switch 2
SES2 Lower limit switch 2 (hoist 2, optional) is triggered and not
overridden.
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1 2 3 4 5 6 7 8
25
24
9
D 10
11
12
23
26
22
13
21
14
27 15
16
28
29
30
31 20 19 18 17 Z 86 531
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Safety Equipment 10
(Z 86 531)

7 Display: Current wind speed
8 Display: Warning symbols

Advanced warning range: 90%−99% of the permitted crane
utilisation has been achieved.
The load limit device has shut down.
OR
The load limit device is overridden.
9 Display: Operating range limit (optional)
Working range limit active
(see section 10.1.6.7, page 115)
10 Display: Radio remote control (optional) active
See part 1, section 34; Operation at crane control’s control pa-
nel no longer possible
11 Display: The emergency hydraulic lowering or emergency
operation function has been activated
(see part 1, section 36 ”Emergency actuation” / section 37
”Emergency operation”).
12 Display: High speed
see section 10.4.2, page 195
13 Display: HATZ diesel engine in operation
For the main boom extension (can be luffed hydraulically) (op-
tional) (see part 1, section 18)
14 Display: Head angle
Angle of the main boom to the horizontal
15 Display: Main boom length
16 Display: Foot angle

Angle of the main boom to the horizontal
17 Display: Current slewing angle
See part 1, section 8 “Slewing”
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10
1 2 3 4 5 6 7 8
25
24
9
D 10
11
12
23
26
22
13
21
14
27 15
16
28
29
30
31 20 19 18 17 Z 86 531
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Safety Equipment 10
(Z 86 531)

18 Display: Slew gear operation in an open circuit
See part 1, section 8 ”Slewing”
19 Display: Basic symbol of the selected crane configuration
Depending on the selected crane configuration, one of the ad-
ditional symbols, items (26), (27) or (30), can also appear.
Crane configuration ”Main boom operation” if none of the addi-
tional symbols appear
20 Display: current load radius
21 Display: max. / min. limit radius achieved

LLD shuts down.
22 Display: min. / max. main boom angle reached

Load limit device will shut down.
The switch off of the crane’s ”luff up” movement due to the load
limiting device has been overridden.
23 Display: Current head height (optional)
24 Display: Difference of the hook height to the set zero point

green frame: valid value
red frame: invalid value
Values displayed as invalid are made valid again by driving

back (telescoping or luffing) to the original range.
25 Key: Set hook height to zero
26 Display: Additional symbol ”Assembly jib” (MS)

appears for the crane configuration ”Assembly jib” in addition
to basic symbol (19)
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1 2 3 4 5 6 7 8
25
24
9
D 10
11
12
23
26
22
13
21
14
27 15
16
28
29
30
31 20 19 18 17 Z 86 531
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Safety Equipment 10
(Z 82 061)

27 Display: Additional symbol ”Main boom extension”
appears for the crane configuration ”Main boom extension” in
addition to basic symbol (19)
Depending on the set operating angle (0°, 20°, 40°), a mat-
ching symbol is shown.
28 Display: Bending angle of the main boom extension (can
be luffed hydraulically) to the main boom
(only for the main boom extension which can be luffed hydrau-
lically)
29 Display: Head angle of the main boom extension (can be
luffed hydraulically) to the horizontal
(only for the main boom extension which can be luffed hydrau-
lically)
30 Display: Additional symbol ”Main boom extension (can be
luffed hydraulically)”
appears for the crane configuration ”Main boom extension (can
be luffed hydraulically)” in addition to basic symbol (20)
in addition, items (28) and (30) appear
31 Display: minimum / maximum bending angle (0° / 40°)
achieved
LLD shuts down.
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Z 82 062
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Safety Equipment 10
10.1.5.1.5 Section (E): Function−dependent Screens (Here:

Quick Menu)
(Z 82 062)
The area ”E” is assigned various contents / screen, depending on

the function carried out.
The ”Quick menu” screen is displayed after confirming / exiting
the ”Selection of the operating mode” screen once crane control
has been switched on.
”Quick menu” screen
Call up the “Select operating mode” screen (see

section 10.1.6.6, from page 93)
Call up the “Telescoping display” screen

(see part 1, section 12 “Telescoping”)
Call up the ”Operating range limit” screen

Call up the ”Configure counterweight” screen (see

part 1, section 9 ”Counterweight indication”)
Calling up the outrigger support area / tilt display

screen (see chapter 10.1.6.21, page 167)
Call up the screen ”Engine display” (see section 5

”Engine”)
Call up the ”Main boom extension (can be luffed

hydraulically)” screen (optional)
(see part 1 , section 18 ”Main boom extension
(can be luffed hydraulically)” )
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E
F
Z 82 063 Z 82 135
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Safety Equipment 10
10.1.5.1.6 Section (F): Base Line

(Z 82 063, Z 82 135)
Key: Exit
Depending on which content / screen is displayed
in area ”E”, the following screen appears after
exiting:
The “Quick menu” screen will be displayed: ”Main
menu” appears (see section 10.1.5.2, page 79).
A screen other than the ”Quick menu” screen is
displayed (e.g. ”Telescoping display” screen):
”Quick menu” screen appears in area ”E”.
If settings were changed, the changed settings
are not saved.
Key: Fault messages
The crane’s control system indicates errors.

Calling up the “Fault messages” screen
(see section 10.1.6.18, from page 163)
Key: Warning buzzer

After the warning buzzer sounds, it can be ack-
nowledged by pressing the loudspeaker symbol,
and is switched off in doing so. The loudspeaker
symbol disappears after acknowledgement.
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Z 82 064
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Safety Equipment 10
10.1.5.2 ”Main Menu” Screen

(Z 82 064)
You can call up the “Main menu” screen by activating the dis-
played key below the “Quick menu” screen.
System settings
Call up the “System settings (user)” screen, (see

Call up the “Colour profile settings” screen (see

section 10.1.6.3, page 89)
Call up the “System settings (expanded)” screen

Crane operation
Call up the ”Crane operation” screen (see sec-

tion 10.1.6.5, from page 91)
Call up the “Selection of the operating mode”

screen (see section 10.1.6.6, from page 93)
Call up the screen ”Operating range limit” (see

Call up the ”Control lever assignment” screen

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Z 82 065
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Safety Equipment 10
(Z 82 065)
Service
Call up the screen ”Parameter” (see sec-

tion 10.1.6.9, from page139)
Call up the “Datalogger” screen (see section

10.1.6.10, page 143)
Call up the “Operating hour meter” screen (see

section 10.1.6.11 , page 151)
Activation / Deactivation of ”Emergency hydraulic

lowering” (optional, see section 36)or ”Emergency
operation” (optional, see section 37)
Diagnosis
Call up the ”Show function” screen (see sec-

tion 10.1.6.13, page 153)
Call up the diagnostics screen ”I/O” (see sec-

tion 10.1.6.14, page 155)
Call up the diagnostics screen ”CAN” (see sec-

tion 10.1.6.15, page 157)
Call up the diagnostics screen ”LoadSensing”

Call up the diagnostics screen of the control lever

”Joystick” (see section 10.1.6.17, page 161)

Calling up the “Fault messages” screen (see sec-
Functions which are not enabled although available as an option

are displayed in grey.
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10
Z 82 130 Z 82 136
Z 82 137
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Safety Equipment 10
10.1.6 Submenus
(Z 82 130, Z 82 136, schematic diagrams)
The submenus which can be called up from the ”Main menu”

(Z 82 130, schematic diagram) or from the ”Quick menu”
(Z 82 136, schematic diagram) are described below.
The sequence is based at first on the arrangement of the symbols
in the ”Main menu” screen (Z 82 130, from top left to bottom
right).
If the function can be called up from the ”Main menu” as well as
from the ”Quick menu”, then the position of the corresponding
key is also shown in the ”Quick menu”.
Subsequently the buttons from the ”Quick menu” that only exist
there (Z 82 136, schematic diagram) are described (see from
page 165).
10.1.6.1 Submenus − Basic Structure

(Z 82 137)
The submenus can be divided into three areas (”A” to ”C”).
Section ”A”
There is a ”top line” in the individual screens in which the name

of the corresponding screen can be found.
Section ”B”
The function−dependent content of the corresponding screen is

found here.
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Z 82 137
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Safety Equipment 10
(Z 82 137)
Area ”C”
The keys / buttons listed below are often used in submenus:

Key: Exit
The screen can be exited by pressing this key /
button. If settings were changed in a screen, the
changed settings are not saved.
Key: Fault messages

Calling up the “Fault messages” screen (see sec-
Key: Saving
If changes or entries are made in a screen which
are to be transmitted to control, the screen must
be exited by confirming this key / button.
Load utilisation display

If crane movements can also be driven for testing
purposes while a screen is visible, the load utili-
sation display of the load limit device is also
shown.
The crane operator is therefore continually infor-
med of the current load utilisation of the crane.
There can be other keys / buttons in area ”C”. These keys / but-
tons are specific to the function of the corresponding screen.
They are therefore described under the corresponding screen.
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Z 80 953
Z 82 066
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Safety Equipment 10
10.1.6.2 Calling up the “System Settings (User)” Screen

(Z 80 953, Z 82 066)
Activate the depicted key to call up the “System settings (user)”

screen.
Information
Type of crane
Tables Load capacity table set
75 corresponds to EN 13000
85 corresponds to 85 %
MTC version Display of the current software version
MTC firmware Display of the current MTC firmware ver-
sion
Construction Display of the construction number of the
number crane
EN 13000 Display of conformity with regard to.
EN 13000
Active: Software in accordance
with EN13000
not active: Software not in accor-
dance with EN 13000
HMI version Display of the current version of the user
interface
ENV MTC Display of the current MTC environment
version
Settings
Language Selection of the language setting
Units Selection of the unit display
You can select between ”Metric” and
”Feet”.
Date Setting option for the date
Time Setting option for the time
The keys / buttons which are or can be at the bottom of the screen
are described in section 10.1.6.1 (from page 85).
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Z 80 955 Z 82 099
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Safety Equipment 10
10.1.6.3 “Colour Profile Settings“ Screen

(Z 80 955, Z 82 099)
Activate the displayed key to call up the ”Colour profile settings”

screen.
This screen makes it possible to set the different colour profiles:
Standard (setting ex works)
Night
Day
Select the corresponding key to set the start and end time. A
number pad for entering the times appears.
If “Automatic switch−over to night profile” has been selected, the

profile is changed automatically at the set time. A screen which
is displayed using the night profile, will only appear the next time
that the screen changes.
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Z 80 957 Z 82 170
Z 82 067
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Safety Equipment 10
10.1.6.4 “System Settings (Expanded)” Screen

(Z 80 957, Z 82 170)
Activate the displayed key to call up the “System settings (expan-

ded)” screen.
View software version of the input / output boxes /

software update
Press the depicted key to call up the ”Software” screen.

Normally, the software levels of the input and output boxes cor-
respond with each other. The ”Update” key is shown greyed out.
An automatic software update might be required after repairs to

crane control. In this case, the ”Update” key can be selected.
Update Press the displayed key to do so.
Access only for customer services
These buttons are used for service work. A PIN is required to use
them.
10.1.6.5 ”Crane Operation” Screen

(Z 82 067)
Press the displayed key to call up the ”Crane operation” screen

(right−hand side with ”Quick menu” screen).
See section 10.1.5.1, page 61.
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Z 82 587
Z 82 068
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Safety Equipment 10
10.1.6.6 ”Selection of Operating Mode” Screen

(Z 82 133, Z 82 068)
This screen appears:

− after every restart, as soon as the IC−1 has run through the
starting procedure
− if the displayed key is actuated in the ”Main menu” screen or
”Crane operation” screen (in the quick menu).
The individual parameters which are relevant for operating mo-
des / crane configuration are listed as symbols in this screen. The
meaning of the symbols can be found in the following table:
Abbreviations of the crane configuration
(see 10.1.5.1.1, page 63)
Length of the fly jib (optional)
Angling of the fly jib (optional)
Counterweight combination
Support width
Numberof the reeved rope strands
Key “tabular view”

(see 10.1.6.6.1, page 101)
Key “Radio remote control” (for radio remote con-

trol (optional) (see section 34))
In addition, the keys / buttons which appear at the bottom of the

screen are described in section 10.1.6.1 (from page 85).
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10
H
Z 82 070
H
Z 82 071
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Safety Equipment 10
(Z 82 070)
Risk of accidents!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane! This responsibility lies with the crane operator
alone! It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation!
The screen can be exited by pressing the displayed key (H) if the
details shown in the top line (F) or in the selection area (G) corres-
pond with the actual state of the crane when the screen appears.
Then the “Crane operation” screen will appear (see 10.1.5.1,
from page 61).
(Z 82 071)
Exiting the screen using the (H) key discards the settings that
were just carried out and the previous configuration will remain
set.
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Z 82 072
96/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 072)
If the specifications shown are not consistent with the crane sta-
tus, the operating mode must be reset . Proceed as follows for
setting/changing the parameters:
Starting at the first parameter “Abbreviations of the crane confi-

guration”, using the depicted arrow button, open the correspon-
ding pull−down menu and select the crane configuration in accor-
dance with the desired equipment (for example, ”HA” for main
boom operation).
The corresponding abbreviations are on all capacity tables and

operating range diagrams. The meaning of all abbreviations can
be found in section 10.1.5.1.1, page 63.
Depending on the number of corresponding selection elements,

these pull−down menus are opened with or without scroll bars.
An element in the list must then always be selected in the pull−
down menu so that the pull−down menu can be closed.
This must even be done if you decide to keep the original selec-
tion after opening the pull−down menu.
The selection of the crane configuration determines the content

of all other parameters. Proceed in the same manner for all other
parameters that must be changed.
Selection elements which only contain one parameter can not be

changed. Its text is shown in grey.
If, when a parameter is changed, another one is also automati-
cally modified by the system (for example, a fictive outrigger
support area of 1.2 m), this value is displayed in red font. Values
in ”red” must be confirmed by the user; this means the key must
be actuated again.
If then afterwards a symbol appears with a red background
(here: outriggers), this configuration cannot be set due to the
current state of the crane.
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Z 82 073
Z 82 074
98/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 073)
If all areas in selection area (G) are filled in correctly in accor-

dance with the actual configuration of the crane, you exit the
screen for assuming the newly set values by activating the depic-
ted key (K).
The set configuration is transmitted to control.
The operating mode must not be changed when under load.
(Z 82 074)
After completing the transmission, the ”Crane operation” screen

appears. The parameter values just selected appear there in the
left−hand area of the top line.
Risk of accidents!
If these values are not consistent with the actual crane sta-
tus, crane operation is not permissible!
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10
Z 82 075
2
3
12
11
10 4
9 8 7 6 5
Z 86 532
100/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.6.1 ”Table View” Screen

(Z 82 075)
The ”Table view” screen within the ”Selection of the operating

mode” screen is called up by activating the displayed key.
(Z 86 532)
The following details can be found in the load capacity tables sto-
red in the system:
(1) Pinned lifting capacities
RISK OF OVERTURNING! RISK OF BREAKAGE!

The capacities indicated in the capacity tables correspond
100 % with the permitted maximum load of the individual
crane configuration. If these limit values are exceeded,
there is a risk of the crane overturning and/or crane compo-
nents and auxiliary equipment breaking!
(2) Number of the length code (LC)

(3) Main boom length
(4) Scroll bar
(5) ID no. of the capacity table
(6) for luffing boom extensions, the current angle step is
additionally shown (for example, 10°).
Then the remaining angle steps can be called up one
after the other by pressing this button.
(7) Key to call up the “Search configuration mode for load

case” screen (see 10.1.6.6.1.2 , page 109)
(8) Key to call up the ”Length code LK” screen (see

10.1.6.6.1.3 , page 113)
(9) Key to call up the unpinned load bearing capacity
(only available for main boom operating mode “HA”)
See part 1, section 12 “Telescoping”, section “Load
bearing capacity in unpinned state”.
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2
3
12
11
10 4
9 8 7 6 5
Z 86 532
102/215 082−1100−82201e_en
Safety Equipment 10
(Z 86 532)
(10) Horizontal capacities
The capacity table starts with values at 2° main boom
angle to the horizontal.
(11) Minimum reeving
(12) Radius
Please refer to the capacity tables which you receive with the
crane − either on paper or as a CD−ROM − for more specifica-
tions on capacities.
Observe the following pages.
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A
C
D
E
F
G
H
I K
L
M
N
O
Z 82 730
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Safety Equipment 10
10.1.6.6.1.1 Capacity Table on Paper or CD−ROM

(Z 82 730)
The following example shows where which specifications can be

found in the capacity table.
The adjacent capacity table is only a specimen. Only the ca-

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

(B) Lifting capacities on the main boom, all telescopic sec-
tions bolted
(C) Abbreviation of the crane configuration (here: ”HA” for
main boom operation)
The meaning of all abbreviations can be found in sec-

tion 10.1.5.1.1, page 63.
(D) Permissible slewing area: 0° − 360°

(E) Outrigger length (here: 8.86 m / 29.1 ft)
(F) Outrigger width (here: 8.4 m / 27.6 ft)
(G) Counterweight (here: 70.2 t / 154.8 kip)
(H) Main boom length (here: 17.4 m / 57.1 ft)
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A
C
D
E
F
G
H
I K
L
M
N
O
Z 82 730
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Safety Equipment 10
(Z 82 730)
(I) Load radius up to the centre of the slew ring (here: 4.0 m
/ 13.1 ft)
(K) Lifting capacity (pinned), (here: 128.0 t / 282.2 kip)
(L) Horizontal load capacity (here: 11.9 t / 26.2 kip)
The capacity table starts with values at 2° main boom
angle to the horizontal.
(M) Reeving number of the hoist rope (here 14 falls)
(N) Length code no. (LK) of the extension sequence (here:
2)
(O) Extension state of the telescopic sections
Tele 1: 45 %
Tele 2: 0%
Tele 3: 0%
Tele 4: 0%
Tele 5: 0%
Tele 6: 0%
(P) Restrictions / notes on danger (here: none)
(Q) ID no. / page no. of the capacity table
Characteristics:
− Depending on the application of the capacity table, the indivi-
dual elements (for example, ”Slewing range”) can be arran-
ged differently to how it is shown in the example on the left.
− Some load capacity tables feature the term “Load capacity
class”. This value can be used for the comparison of indivi-
dual crane types.
Arranging the capacity values

The columns of the capacity values in the capacity table are sor-
ted by ascending length codes (LK).
The columns of the capacity values on the crane control’s opera-
ting unit are sorted by ascending main boom lengths.
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Z 82 078
Z 82 174
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Safety Equipment 10
10.1.6.6.1.2 ”Search Configuration for Load Case” Screen

(Z 82 078)
The ”Search configuration for load case” screen is called up wit-

hin the ”Table view” screen by activating the displayed key.
(Z 82 174)
If the load and the load radius are known, possible configurations
for raising the load can be displayed.
Proceed as follows:
1. tap entry field below ”Load (t/kip)”. A number pad appears

where the desired load can be entered − within the limits spe-
cified in the head of the number pad. If the entry is outside
the permissible range, it will be shown in red.
By pressing this key, the cursor is moved one position to the
left and the character that was there is removed.
2. Select the load.
3. Either discard or accept the entry by pressing the correspon-

ding key:
Key Action
discard entry
accept entry and return to start screen.
4. Select radius. Proceed analogue to the procedure described

for the load.
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HAV−VA (23.4 / 0.0) / 41.10 / 5.54
Z 82 142 Z 82 104
110/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 142)
5. If both fields for load and radius are filled with the desired en-
tries, start Search by activating the displayed key.
All configurations found are entered into the corresponding field

(Z 82 104, lower marked range).
The entire selection is opened by pressing the arrow key.
The desired configuration can be selected by tipping on it and is

thereby carried over to the “Selection of the operating mode”
screen as a suggestion.
(Z 82 104)
An entry such as (e.g. Z 82 104)

HAV−VA (23.4 / 0.0) / 41.10 / 5.54 means:
− Abbreviations of the crane configuration with fly jib
”HAV−VA”: Main boom extension, hinged, with fixed part
(adapter)
The meaning of all abbreviations can be found in sec-

tion 10.1.5.1.1, page 63.
− the details in brackets are only relevant when working with

additional equipment:
Value in brak- Example given Meaning
kets
Length 1 23.4 m (76.8 ft) Length of the fly jib
Angle 0.0° Angling of the fly jib
− Counterweight combination: 41.1 t (90.6 kip)
− Support width: 5.54 m (18.2 ft)
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Z 82 081
112/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.6.1.3 ”Length Code LC” Screen

(Z 82 081)
The ”Length code LK” screen can be called up within the ”Table
view” screen by activating the ”LK” key.
The possible extension states of the main boom with details of
the length code (LK), main boom length, extension state of the
individual telescopic sections and possible capacities are listed
here in relation to the currently set configuration.
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Z 82 082
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Safety Equipment 10
10.1.6.7 ”Operating Range Limit” Screen

(Z 82 082)
Activate the depicted key to call up the “Operating range limit”

screen.
This is where operating area limits can be observed, defined and
activated/deactivated.
If the initiated movement approaches a fixed limit, the movement

is slowed down until it comes to a stop.
The set limits are always adhered to. The crane operator can the-
refore switch the operating range limits briefly off and on again
without losing any data.
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 crane operation.
Make sure that you deactivate the activated limits as soon as

work in a limited operating range has been 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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A B C
D E F G
Z 82 083 Z 82 084
116/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 083)
(A) − The operating range defined by the active operating

range limits is shown as a green area. The black square
(1) shows the current position of the main boom head.
(B) − Actual and max. permitted height of the main boom head
depicted in a bar diagram
(C) − Current values for load and radius (see also section
10.1.5.1.2 / page 65)
(D) − Slewing angle limit (see section 10.1.6.7.2 / page 123)
(E) − Radius limit (see section 10.1.6.7.3 / page 125)
(F) − Operating range limit by virtual wall (see section
10.1.6.7.4 / page 127)
(G) − Height limit (see section 10.1.6.7.5 / page 129)

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A B C
D E F G
Z 82 083
118/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.7.1 Procedure for Defining, Activating and

Deactivating Operating Range Limits
(Z 82 083)
When selecting the ”Operating range limits” screen, the entire

field (A) is displayed green if no operating range limits have been
activated.
Procedure
1. Defining an operating range limit.

Move to the crane position for defining the operating range
limit. Teach slewing angle, radius, wall point and/or max.
height. Move to second crane position and teach when re-
quired by the definition of the operating range limit. The key
for teaching is described in the corresponding section of the
respective operating range limit.
Caution!
Risk of damage if the operating range limits are set too close
to the danger zone / projecting edge.
Make sure that the selected teach points ensure sufficient di-
stance to the danger zone even in extreme situations (e.g.
when the hook block swings out after the crane movement
has been switched off).
2. Place the crane in a permitted position.
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A B C
D E F G
Z 82 084 Z 82 083
Z 82 085
120/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 084, Z 82 083)
3. Activating / deactivating an operating range limit.

Activate the operating range limit with the corresponding key
to do so (Z 82 084).
The key for activating / deactivating is described in the cor-
responding section of the respective operating range limit.
The background colour of the key changes depending on
whether the operating range limit has been activated or
deactivated.
Symbol Back- Meaning
ground co-
lour
Operating range limit deacti-
vated
grey
(here: ”Slewing angle limit” ex-
ample)
Operating range limit acti-
vate
Green
(here: ”Slewing angle limit” ex-
ample)
4. Exit the screen using the displayed key. Changed settings

are saved.
5. After setting the limits, first check in a ”test run” that the shut-
down actually occurs at the intended points.
Display in the ”Crane operation” screen
(Z 82 085)
If one of the limits (for example, slewing angle limit) is active, the
depicted symbol appears in the ”Crane operation” screen. This
symbol is for information purposes only and cannot be activated.
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A B C
D E F G
Z 82 083
122/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.7.2 Slewing Angle Limit, Field (D)

(Z 82 083)
− Activating / deactivating the slewing angle limit

(for visual differentiation between the two states ”Acti-
vated” / ”Deactivated”, see section 10.1.6.7 / on page
121)
− Teaching the left−hand slewing angle

Move to the desired left−hand limit point and press this
key to do so. The angle setting above the key is over-
written by the current slewing angle.
− Teaching the right−hand slewing angle:

To do so, move to the right−hand limit point and press
this key. The angle setting above the key is overwritten
by the current slewing angle.
Observe the description of the procedure for defining, activating

and deactivating the operating range limit in section 10.1.6.7.1
(page 119).
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A B C
D E F G
Z 82 083
124/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.7.3 Radius Limit, Field (E)

(Z 82 083)
− Activating / deactivating the max. radius limit

(for the visual difference between the two states ”Acti-
121)
− Teach the max. radius
− Activate / deactivate the min. radius limit
− Teach the min. radius

(page 119).
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10
A
F
Y+ P1
X− X+
Y−
P2
Z 82 159
126/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.7.4 Limitation by a Virtual Wall, Field (F)

(Z 82 159)
− Activating / deactivating the limit by a virtual wall

(for the visual difference between the two states ”Ac-
tivated” / ”Deactivated”, see section 10.1.6.7 / on
page 121)
− Teaching the first wall point (P1)

Approach the desired wall point with the hook block
and confirm this with this key. On the display, field (A),
a red dot appears (P1).
The co−ordinates for this point (here: “10.00” as a va-
lue for the x−axis, “+5.00” as a value for the y−axis)
are displayed.
− Teaching the second wall point (P2)

Approach the desired wall point with the hook block
and confirm this with this key. On the display, field (A),
a blue dot appears (P2).
The co−ordinates for this point (here: “+5.00” as a va-
lue for the x−axis, “+10.00” as a value for the y−axis)
are displayed.
The second wall point must be at least 8 m (26.3 ft)
from the first wall point. Otherwise the range is high-
lighted in red with the co−ordinate information.
When activating the limit, the two taught points are automatically
connected in field (A) with a line. The resulting permitted opera-
ting range is displayed as a green area.

(page 119).
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10
A
F
Y+ P1
X− X+
Y−
P2
Z 82 159
A B C
D E F G
Z 82 083
128/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 159)
− Switching over the permitted operating range

If the other side of the wall is to be defined as the per-
mitted operating range, press this key; its appea-
rance changes, i.e. it has a green background.

(page 119).
10.1.6.7.5 Height Limit, Field (G)

(Z 82 083)
− Activating / deactivating the height limit

(for the visual difference between the two states ”Acti-
121)
− Teaching the max. height

(page 119).
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Z 80 985
Z 82 270
130/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.8 ”Control Lever Assignment” Screen

(Z 80 985, Z 82 270)
Press the key displayed in the ”Main menu” screen to call up the
”Control lever assignment” screen.
10.1.6.8.1 Structure of the ”Control Lever Assignment” Screen

(Z 82 270)
Item Symbol Function / explanation

1 Display: Current assignment of the con-
trol levers
”Slew gear”
superstructure slews to the left
superstructure slews to the right
”Telescoping main boom”
telescope in/out to LK entered
telescope to LK1 (completely retracted)
The specifications listed here refer to auto-

matic telescoping. For information on con-
trol lever movement when telescoping ma-
nually, see section 12 ’Telescoping’, seg-
ment ”Control levers in the crane opera-
tor’s cab”.
”Luffing gear (main boom)”
main boom luffs up
main boom luffs down
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Z 82 270
132/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 270)
Item Symbol Function / explanation

1 Continued:
”Hoists” (here: example hoist 1)
hoist unreels
hoist reels in
2 Keys / display: Selection assignment of

the control levers
(Modes 1 − 6; for the description of the
modes, see section 10.1.6.8.3, from
page 137)
Mode can be selected
Mode is selected. Control lever assign-

ment can be identified by symbols under
(1).
Mode cannot be selected.
Only the modes can be selected for which

the crane has the corresponding technical
equipment (for example, without hoist 2,
only modes 1, 4 and 6 can be selected).
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Z 82 270 Z 82 089
134/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.8.2 Display / Change to the Control Lever Assignment

(Z 82 270)
For item (1), the symbol of the current crane movement is depic-
ted on the axes of the two coordinate axes.
The corresponding mode is displayed ”green” under (2) at the

corresponding key (here: ”Mode 1”).
Press the key of the desired mode (e.g. mode 4) under (2) to
change the control lever assignment.
This key / display is shown ”green”.
The symbolic display of the control lever assignment (1) is chan-

ged accordingly and indicates the changed control lever assign-
ment.
Risk of accidents!
If the assignment of the control levers is changed, a check
must be carried out to ensure the crane movements are car-
ried out properly with the new assignment.
ment.
Also observe the further details on items (1) and (2) in section
10.1.6.8.1 Structure of the ”Control lever assignment” screen
(from page 131).
Display of the control lever assignment in the ”Crane opera-

tion” screen
(Z 82 089)
The mode number of the current assignment of the control levers

is displayed in the top line of the IC−1 display (Z 82 089).
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10
v h v h
43.3 81
43.1 81.1 81.3
43.2 43.4
43 81.2 81.4
43.5
81.5
Z 82 090
Z 82 270
136/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.8.3 Control Lever Assignments (6 Modes)

(Z 82 090, Z 82 270)
There are six different options for standard control lever assign-
ment (modes 1 − 6).
Control lever, left (43) Control lever, right
Mode (81)
Legend:
Control lever: horizontal steering direction (h)
Control lever: vertical steering direction (v)
Slewing
Telescoping main boom
Luffing
Hoist 1
Hoist 2
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Z 80 988
Z 82 091
138/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.9 ”Parameters” Screen

(Z 80 988, Z 82 091)
Press the displayed key to call up the ”Parameters” screen.
This screen can be used to set different profiles for three crane
operators relating to the progressive activation of certain crane
movements.
The bottom figure shows the following example:
Crane operator ”1” active
Movement Control
Slewing linear
Luff main
linear
boom
Hoist 1 linear
Hoist 2 linear
As crane movements can also be driven for testing purposes, the

depicted load utilisation display of the load limit device is also
shown in the top part of the screen.
The crane operator is therefore continually informed of the cur-
rent load utilisation of the crane.
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Z 82 091
140/215 082−1100−82201e_en
Safety Equipment 10
Change profile
(Z 82 091)
1. Activate symbol of the desired crane operator − it gets a

green background (here: crane operator ”1”).
2. Change the progressiveness to be modified of control until

the desires depiction appears.
Display Control
progressive
Moderately pro-
gressive
linear
3. Press the displayed key to save the change.
Exit the screen without changing the profile

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Z 82 731
3
Z 82 588
142/215 082−1100−82201e_en
Safety Equipment 10
10.1.6.10 ”Datalogger” Screen (Optional)
10.1.6.10.1 Call−up and Display
(Z 82 731)
Activate the depicted key in order to call up the “Datalogger”

screen.
(Z 82 588)
The datalogger saves relevant events of crane control. The last

100 events are shown.
The information listed below is displayed:
− Change of operating mode (date and time of the change, set
operating mode)
− Events which have occurred during operation (further details
in the events table further below)
Item Function / designation
(1) Current operating mode
(2) Event table
(3) Key ”Copy and download datalogger” (optional)
(see 10.1.6.10.2 , page 149)
The most recent event is listed last in the events table.
The so−called ”Current operating mode” (1) is displayed above

the actual events table. This is the operating mode that was set
when the event (2) occurred which can currently be seen at the
top rim of the events table.
Risk of accidents!
If a fault message concerning the datalogger is displayed,
the fault must be rectified immediately.
To do so, please consult the crane manufacturer’s custo-
mer service team.
082−1100−82201e_en 143/215
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3
Z 82 588
144/215 082−1100−82201e_en
Safety Equipment 10
(Z 82 588)
Legend − Event table
Date Date the event occurred

Time Specifying the time of the event
LMB−Stop 0= Enabled
1= Not enabled
UE_RT_EU 0= Configuration key 110%
(EN 13000) not activated
1= Configuration key 110%
(EN 13000) activated
UE_LMB 0= Bridging key LLD not activated
(EN 13000: key−operated pushbut-
ton on rear cab wall; Non−
EN 13000: key−operated pushbut-
ton in dashboard)
1= Bridging key LLD activated
(EN 13000: key−operated pushbut-
ton on rear cab wall; Non−
EN 13000: key−operated pushbut-
ton in dashboard)
UE_HES 0= Bridging key HLS (hoist limit
switch) not actuated
1= Bridging key HLS (hoist limit
switch) actuated
UE−AUF 0= Bridging key UP (luff up) not actua-

ted
1= Bridging key UP (luff up) actuated
Tele−manual 0= Tele automatic active
1= Tele manual active
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3
Z 82 588
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Safety Equipment 10
(Z 82 588)
Legend: Events table − continued

LK Selected length code
LK−rel The relevant length code for the
load calculation
LK−err Length code achieved
Einscherung Hoist rope reeving
Auslastung Current crane load
MAX Maximum lifting capacity
Last Current load
Radius Current radius

Radius−REL Radius relevant to load calculation
HA−Winkel Current main boom angle
HA−Kopfwinkel Current main boom head angle
HAV−Winkel Current angle of the main boom
extension (MBE)
HA_Laenge Current main boom length
SVE−Laenge Current extension length of the te-
lescoping cylinder
SVE−Zustand Current LPU−state
Drehwinkel Current superstructure slewing an-
gle
HA−Hoehe Current main boom height
ABB 0= Operating range limits not activa-

ted
1= Operating range limits activated
FFS 0= Radio remote control not activated

1= Radio remote control activated
082−1100−82201e_en 147/215
10
1
2
3 Z 82 588
36
Z 82 589 Z 82 590
Z 82 591
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(Z 82 588)
Legend: Events table − continued

Anst−HW1 Control value hoist movement
HW 1 (−200 to 200)
Anst−HW2 Control value hoist movement
HW 2 (−200 to 200)
Anst−DW Control value slewing gear move-
ment (−200 to 200)
Anst−WW Control value luffing gear move-
ment (−200 to 200)
Anst−Tele Control value telescoping move-
ment (−200 to 200)
HMI−Maskenin- Number of the screen displayed
dex during the event
10.1.6.10.2 Copy and download datalogger file (optional)
(Z 82 588, Z 82 589, Z 82 590, Z 82 591)
1. Insert USB stick in USB connection (36, Z 82 589).
2. Call up ”Datalogger” screen.

If the crane is prepared for copying the datalogger file, the
corresponding key is in the footer (3, Z 82 588)
3. Press the depicted key in the ”Datalogger” screen.

During the download, the ”Info”: ”Kopiere ausgewählte Datei
auf den USB−Stick.” (”Copy selected file onto USB stick.”)
screen appears. (Z 82 590).
The ”Info” screen disappears again after successful down-
load.
If there is a fault during download, the ”Info”: ”Es ist ein Fehler auf-
getreten! (”A fault has occurred!) Die Datei wurde nicht kopiert.”
(The file has not been copied.”) screen appears. (Z 82 591).
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Z 80 991
Z 82 166
Z 80 993
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Safety Equipment 10
10.1.6.11 ”Operating Hour Meter” Screen

(Z 80 991, Z 82 166)
Activate the depicted key to call up the “Operating hour meter”

screen.
Display of operating hours for slew gear
Display of operating hours for luffing gear
Display of operating hours for tele unit
Display of operating hours for hoist 1
Display of the operating hours for hoist 2 (optio-

nal)
10.1.6.12 Activate / Deactivate the ”Emergency hydraulic lowe-

ring” / ”Emergency operation” functions (options)
(Z 80 993)
Actuate the buttons shown, to activate or deactivate the ”Emer-

gency hydraulic lowering” and ”Emergency operation” functions.
All specifications on this option can be found in section 36 ”Emer-

gency actuation” and section 37 ”Emergency operation”.
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Z 80 994
Z 82 168
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Safety Equipment 10
10.1.6.13 “Function Display” Screen

(Z 80 994, Z 82 168)
Activate the displayed key to call up the “Function display”

screen.
If there are malfunctions, all input and output parameters requi-

red for a movement can be displayed in this screen to carry out
a comparison of the setpoint and actual values.
The crane movement is selected using the function buttons on

the left−hand side of the screen.
Slew superstructure display
Hoist 1 display
Hoist 2 display (optional)
Telescoping display
Luffing gear display
Configure counterweight display
The selected function button receives a green background colour

(here: ”Slew superstructure”).
The key / button for “Dismantling the main boom” is an exception
and is describe on the following pages.
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Z 82 893
Z 80 997
Z 82 092
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Key / button ”Dismantling the main boom”
(Z 82 893)
If the crane is equipped with equipment for fast dismantling of the

main boom, there is another key / button at the bottom of the
screen when the ”Telescoping” crane movement has been selec-
ted.
The meaning and use of this button is described in Section 31
”Dismantling the main boom”.
10.1.6.14 “I/O−Display”Screen
(Z 80 997, Z 82 092)
Activate the depicted key to call up the “I/O−display” screen for

diagnosis of the individual inputs and outputs of the control unit.
The required element is selected using the function keys shown

on the left.
In the example shown in the illustration, this is “A0701”.
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Z 80 998
Z 82 169
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Safety Equipment 10
10.1.6.15 ”Can Status”Screen

(Z 80 998, Z 82 169)
Press the displayed key to call up the “Can Status” screen for dia-
gnosis of the status of the individual bus participants of the CAN
buses.
The desired bus (CAN 1, CAN 2, CAN 3 or CAN 4) is selected

using the function keys shown on the left.
In the example shown in figure (Z 82 169), this is “CAN 1”.
Status display Meaning

Operational Colour ”green”, ok
Colour ”red”,
not available participant not
available
All CAN participants which are not active in the bus are marked
with a red dot. This can have two causes:
− Participants such as the radio remote control are not active
as the crane is not equipped with the corresponding equip-
ment; therefore there is no fault.
− Participants are not active due to a fault. In this case, please
consult our customer service team.
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Z 80 999
2
7 3
6 5 4
Z 82 176
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Safety Equipment 10
10.1.6.16 ”LoadSensing” Screen

(Z 80 999, Z 82 176)
Press the displayed key to call up the ”LoadSensing” screen for

diagnostics of the load sensing system.
The depiction for pump P1 appears:

(1) − Symbols of the crane movements, which can be assigned
to the pump, here: telescoping, luffing, hoist 1, hoist 2
(optional), counterweight
(2) − Load pressure
(3) − Pump pressure
(4) − Difference pressure
(5) − Switch on / off “LoadSensing” key
(6) − “LoadSensing” symbol switched off
(7) − Symbolic depiction of the sliders (”z”)
By activating the displayed key, ”Load sensing” can be switched

on or off.
If “LoadSensing” is switched off, the depicted key (5) is displayed

red.
The displayed symbol (6) appears with ”Load sensing” switched

off.
By switching off ”Load sensing”, the ”Load sensing” elements can

be switched off during troubleshooting, for example, eliminating
them as potential fault sources.

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Z 80 530
Z 82 177
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10.1.6.17 ”Joystick” Screen

(Z 80 530, Z 82 177)
Press the displayed key to call up the ”joystick” screen for diagno-
sis of the control lever.
The function can be checked by moving the control lever.
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Z 80 531
Z 82 178
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10.1.6.18 ”Fault Messages” Screen

(Z 80 531, Z 82 178)
Warning information and tips shown when faults occur
If there is a fault in crane control, a corresponding message ap-

pears in every screen with fault display.
To deal with faults, please see the warning information and tips
on this subject under 10.1.8.2 ”Error messages are displayed on
a visual display computer”, page 181.
Calling up the ”Fault messages” screen
Press the ”Fault display” key in the currently displayed screen to

call up a list of existing faults (Z 82 178).
The fault display in the ”Main menu” screen is shown as an exam-
ple in figure (Z 80 531).
The contents of the ”Error messages” screen
The faults with fault codes and descriptive text are listed here.
If a fault’s descriptive text is too long to be displayed in its entirety,

an auxiliary window can be called up by tapping on the corres-
ponding line. Then the entire text is displayed.
Acknowledging fault messages
The displayed fault messages are ”acknowledged” with this key,

i.e. it is confirmed that the crane operator has registered them.
If the ”Fault messages” screen is exited without the fault messa-

ges being ”acknowledged”, they will still be displayed as new fault
messages in the other screens.
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Z 82 093 Z 82 094
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The following provides a description of the keys that can only be

actuated on the ”Quick menu” screen.
10.1.6.19 ”Telescoping display” screen

(Z 82 093)
Activate the depicted key in order to call up the “Telescoping dis-

play”.
Detailed information on this subject can be found in section 12
”Telescoping”.
10.1.6.20 ”Configure Counterweight” Screen

(Z 82 094)
Press the key shown to call up the ”Counterweight display”

screen.

”Counterweight”.
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1
2
Z 82 095 Z 82 593
Z 82 087
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Safety Equipment 10
10.1.6.21 ”Support Base Area” Screen

(Z 82 095, Z 82 593, Z 82 087)
Press the key shown to call up the ”Outrigger support area”

screen.
The information listed below is shown for each support:

(1) − current support force
(2) − current support width (optional outrigger support area
display)
The information listed below is displayed for the crane:

(3) − current tilt
The screen is exited using the displayed key in the ”Crane opera-
tion” screen.
The ”Crane operation” screen with the partial screen ”Quick
menu” will appear.
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1
2
Z 82 593 Z 82 097
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10.1.6.21.1 Support Force Display

(Z 82 593, Z 82 097)
The current support forces (1) are registered by pressure con-

tacts in the vertical support cylinders.
RISK OF ACCIDENTS!
In order to support on outriggers, observe the procedure
described in part 2, section 12 ”Outriggers”!
If the vertical support cylinders − contrary to the prescribed
procedure − are extended fully up to the stop, the support
forces displayed will be inaccurate.
If the crane is operated properly in accordance with the regula-

tions of the lifting capacity tables, the maximum occurring support
forces are:
front: 95 t (209.4 kip)
rear: 105 t (231.5kip)
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.
The current and maximum occurring forces (1) are displayed as

a numerical value and as a display bar in the ”Outrigger support
area / tilt display” screen for each of the 4 supports.
A symbolic crane is displayed between the 4 support pressure
displays (1) so that it is possible to assign the respective support
force value to the corresponding support: The front supports are
displayed at the top, the rear supports are displayed at the bot-
tom.
The display bars are depicted in red for support forces from ap-
prox. 90% of the permitted maximum value.
If a support force of 1 t (2.2 kip) is not reached, ”STB” appear in
the ”Crane operation” screen. In addition, the warning buzzer
goes off.
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1
2
Z 82 593 Z 82 097
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10.1.6.21.2 Support Base Area Display (Optional)

If the crane is equipped with an outrigger support area display,
there is a length measuring device at each support to register the
support position of each support.
The support position displayed at the outrigger controls (2;

rear right, rear left, front left, front right) designates the position
of each support.
What is displayed and what this means is described below in the

corresponding segment.
If one or several supports are not assembled in accordance with

one of the support variants described in part 2, section 12 ”Outrig-
gers”, ”STB” appears in red in the ”Crane operation” screen. In
addition, the warning buzzer goes off.
DANGER!
Risk of overturning due to incorrect support position.
The displays are for information purposes only. There is
no shut−down if the crane is assembled with incorrect
supports.
When supporting the crane, ensure the supports are in
the correct position.
Current support width (2)

(Z 82 593, Z 82 097)
If a numerical value is displayed, it is an extended position in

8.40 accordance with one of the support variants described in part
2, section 12 ”Outriggers”.
If dashes are displayed, the support is not in an extended po-
sition in accordance with one of the support variants descri-
−−− bed in part 2, section 12 ”Outriggers”.
In this case, place the support in an extended position which
is in accordance with one of the described support variants.
If three question marks are shown, there is a fault in the
??? length measuring device.
In this case, check the length measuring device.
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1
2
Z 82 593 Z 82 098
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10.1.6.21.3 Tilt display

(Z 82 593, Z 82 098)
Before each operation of the crane, the crane must be supported

on outriggers and horizontally aligned. Observe the correspon-
ding information in the operating manual of the crane chassis,
section 12 ”Outriggers”.
Operation of the crane is only permitted when the crane is
aligned horizontally!
Align the supported crane so that the maximum deviation
is less than 0.1° after aligning it (levelling).
The current tilt is permanently displayed on the ”Crane operation”

screen (Z 82 098) by means of the symbol shown.
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Z 82 097 Z 82 072
Z 82 160
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10.1.6.21.4 Outrigger Support Area Monitoring (optional)

(Z 82 097, Z 82 072)
If the crane is configured with a monitor for the outrigger support,

the statements made in 10.1.6.21.2 (page 171) apply.
If, however, the support variant set in the ”Operating mode selec-
tion” screen does not correspond with the actual assembly state
of the supports, crane control responds as listed below:
− Crane control is shut down.
− ”STB” appears in red in the ”Crane operation” screen.
− The warning buzzer goes off.
Continued operation is only possible once the assembly state of

the supports corresponds with the support variant set in the ”Se-
lection of the operating mode” screen.
Danger!
Risk of accidents due to the supports being assembled in-
correctly!
Only the extension position of the support is monitored du-
ring outrigger support area surveillance. It does not moni-
tor whether the pins to be fitted in the supports are fitted
correctly and are secured against falling out.
Support the crane as described in part 2, section 12 ”Ou-
triggers”.
10.1.6.22 ”Engine display” screen

(Z 82 160)
Press the displayed key to call up the ”Engine display” screen.

”Engine”.
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Z 86 537
B1 B2
Z 82 100
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Safety Equipment 10
10.1.6.23 The ”HAVHY” screen (hydraulically luffable main

boom extension, optional)
(Z 86 537)
Press the key shown to call up the ”HAVHY” screen.

”HAVHY”.
10.1.7 Load Monitoring Equipment

(Z 82 100)
It is possible to check the weight of the raised load (net load)

using the computer of the load limit device.
The load monitoring assembly may not be used to calculate

the load, but is used to check the weights of loads that have
been previously calculated in order to calculate better the
load hoist and to avoid potentially hazardous situations!
Before raising the load, the maximum load for the operative state
must be determined. It is displayed in relation to the selected ope-
rating mode on the screen in the ”MAX (t/kip)” display (B2).
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B1 B2
Z 82 100
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(Z 82 100)
Load monitoring
1. If the hook block is suspended freely (without load, with load

handling devices), press the key of the net display ”NET (t/
kip)” (B1). The load handling equipment is tared and set at
0.0 t (0.0 kip) net load.
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 then shows the net load (actual load on the
hook without the load handling devices).
Apart from the load weight, the gross load consists of the weight
of the hook block and all load handling devices. The net load is
the actual load on the hook block without the load handling devi-
ces. Display errors are possible due to external factors, such as
wind acting on the crane and the load, for example.
10.1.8 Procedure in the Event of Faults
10.1.8.1 Fault−free Operation

If operation is free of malfunctions, the currently set menus and
screens will be shown on the crane control system’s visual dis-
play computer. The crane can be moved with the aid of the control
lever.
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Z 80 531
Z 82 178
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10.1.8.2 Error messages are displayed on a visual display

computer
(Z 80 531, Z 82 178)
If a fault occurs in the crane’s control system, in each screen

which displays faults, a button with a corresponding symbol will
appear. The fault display in the ”Main menu” screen is shown as
an example in figure (Z 80 531).
The fault must be identified without delay. Depending on the fault
concerned, the crane operator must judge whether it is possible
to continue working with the crane or whether the fault must first
be fixed.
Risk of accidents!
Death or serious injury may result if work continues with
the crane, after safety−relevant faults occur or faults
whose effect on the crane or its operation are not clear.
− Immediately cease to operate the crane if safety−rele-
vant or unclear faults occur.
− If necessary, contact the crane manufacturer’s custo-
mer service department.
− Have the fault remedied by suitably qualified personnel
(e.g. customer service).
If personnel who are not qualified try to rectify faults, it
can cause serious injury to people and / or damage to
objects.
Different symbols appear, depending on the fault status:

Display Explanation
There are new (not yet acknowledged) faults or
faults no longer exist or both at the same time.
The symbol flashes.
There are old, already ”acknowledged” fault mes-

sages.
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To identify the fault in the currently displayed screen, press the

”Show error” button to call up the ”Error messages” screen (see
10.1.6.18, page 163).
If errors occur which cannot be remedied before continuing to

work with the crane, please see 10.1.8.3 ”What to do for safety−
relevant faults whose cause cannot be directly remedied”, page
183.
10.1.8.3 What to do for safety−relevant faults whose cause

cannot be directly remedied
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 device (de-
pendent on the control lever function configuration). If it is not
possible to telescope in, 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 department!
The faults must be rectified before crane operation can be conti-
nued.
Risk of accidents!
Death or serious injury may result if work continues with
the crane, after safety−relevant faults occur or faults
whose effect on the crane or its operation are not clear.
− Immediately cease to operate the crane if safety−rele-
vant or unclear faults occur.
− If necessary, contact the crane manufacturer’s custo-
mer service department.
− Have the fault remedied by suitably qualified personnel
(e.g. customer service).
If personnel who are not qualified try to rectify faults, it
can cause serious injury to people and / or damage to
objects.
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10.1.8.4 Screen failure − The screen’s display is black

The function of the load limit device is ensured.
What is to be done?
1. Set down the load.
2. Have the service department search for the fault and rectify
it.
Risk of accidents!
No crane operation is permissible when the display fails!
The error must be eliminated before crane operation is per-
mitted to resume!
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Z 82 143
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Safety Equipment 10
10.1.8.5 Connection Problems − Crane Control’s

Control Panel to Crane Control
Behaviour in case of failure

(Z 82 143)
If there is no connection between crane control’s control panel

and the other components of crane control, this message ap-
pears: ”No connection to control! Continue without connection to
diagnosis”.
In this case, please consult the service department of the crane

manufacturer.
10.1.8.6 Total Failure of Crane Control

If crane control has failed, but the engine and the hydraulic sy-
stem are intact, the load can be set down with the optional electric
emergency control (see section 36 “Emergency activation”) and
the crane can be placed in a safe state.
Danger!
There is no monitoring by the limit switches during emer-
gency operation with the “electric emergency control”. The
load limit device and operating range limits are also inope-
rative.
on electric emergency control in section 36 “Emergency
control”.
The faults must be rectified before crane operation can be
continued.
10.2 Maintenance, Repairs and Disposal

The operating unit of crane control is maintenance−free.
The unit may only be repaired by the manufacturer. Disposal

must be in accordance with the national environmental regula-
tions.
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v h v h
43.3 81
43.1 81.1 81.3
43.2 43.4
43 81.2 81.4
43.5
81.5
Z 82 090
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10.3 Release Switch System for Crane Movements
10.3.1 General
This is to prevent accidental crane movements being initiated
when entering and exiting the crane operator’s cab.
switch system.
The crane operator must only assume the designated operating
position if the corresponding control lever is in the “neutral posi-
tion” and must only leave it once the initiated crane movement
has been completed.
10.3.2 Assignment of the Release Buttons

(Z 82 090)
There are release buttons at the following points:

− In both control levers: (43.5) and (81.5)
− Foot switch (9)
− Seat contact button in the crane operator’s seat
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10.3.3 Activating the Release Buttons

The release buttons must only be activated (hand and foot but-
tons pressed and released, sitting down on / getting up from the
crane operator’s seat) if the control levers are in the “neutral posi-
tion” and / or the initiated working movement has been comple-
ted.
The release buttons can be activated alternately during a crane
movement.
RISK OF ACCIDENTS!
Activating / releasing the release buttons with a deflected
control lever, without the release button being previously
activated, or if some other release button is activated, will
lead to the corresponding crane movement being braked.
Only initiate a crane movement when the release switch
has been activated.
When a crane movement is being executed, only let go of
one release button if another one has been activated.
Only let go of the release buttons, or get up from the crane
operator’s seat, if the working movement has been comple-
ted.
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v h v h
43.3 81
43.1 81.1 81.3
43.2 43.4
43 81.2 81.4
43.5
81.5
Z 82 090
Z 82 108
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10.4 Speed
10.4.1 Fine tuning of the movement speed

(Z 82 090, Z 82 108)
In order to finely tune the speed of different movements, first

press one of the self−return rocker switches (43.1) / (81.1) briefly.
The ”Percentage setting” screen appears on the right−hand side
of the IC−1 display for 5 seconds.
As long as the ”Percentage setting” screen is displayed, a dis-

played percentage value, and therefore the speed, can be chan-
ged as follows:
− Select the crane movement to be changed using rocker
switch (43.1) on the left−hand control lever. The crane move-
ment value that can be changed has a yellow background.
− Modify the speed by percentage using rocker switch (81.1) on
the right−hand control lever. The value is reduced or increa-
sed depending on whether the rocker switch is actuated to
the left or the right. The minimum value that can be set is 20%.
If there is no adjustment to the percentage values, the ”Percen-

tage setting” screen disappears again after 5 seconds.
The speeds of the following movements can be set:
Slewing the superstructure
Reeling in and unreeling hoist 1
Luffing down the main boom
Reeling in and unreeling hoist 2 (optional)
Risk of accidents!
There is a risk of accidents if crane movements are carried
out inappropriately quickly.
Observe a moderate speed of movement.
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v h v h
43.3 81
43.1 81.1 81.3
43.2 43.4
43 81.2 81.4
43.5
81.5
Z 82 090
Z 82 109
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Safety Equipment 10
10.4.2 High speed

(Z 82 090, Z 82 109)
The luffing gear and the hoists are electrically pilot−controlled.

The speed of the controlled movement depends on the engine
speed and the steering of the corresponding control lever.
A high speed mode can be activated to raise the main boom (luf-
fing up) and to reel in and unreel the hoist. To do so, press the
corresponding pushbutton on control levers (43) / (81). The ”Per-
centage setting” screen appears on the right−hand side of the
IC−1 display for 5 seconds.
The high speed mode remains activated until the corresponding
pushbutton is pressed again.
Assignment of the pushbuttons
(43.3) Activate high speed mode for hoist 2 (optional)
(81.3) Activate high speed mode for hoist 1
(81.4) Activate high speed mode for luffing gear
The high−speed mode cannot be activated for the movements

“Luffing gear down”, “Slewing the superstructure” and “Telesco-
ping the main boom”.
If the high speed mode is activated for one of the movements li-
sted, the ”Percentage settings” screen is shown for 5 seconds.
The depicted arrow symbol is displayed there for each activated
high speed mode.
In addition, the depicted arrow symbol is displayed in area ”D” du-
ring the entire activation time in area “D”.
Risk of accidents!
Performance of crane movements in high speed mode if
only permitted if the load utilisation situation allows it.
Please observe the relevant instructions in the section in
which the crane movement is described.
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Switching to high speed mode is not permitted in the follo-

wing cases:
− when working with loads > 30% of the capacity
− with a fly jib fitted
− 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 be-
fore shutdown by the load limit device (at latest up to the
advanced warning).
Risk of tilting due to dynamics!
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Z 82 101
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10.5 Limit Switches
10.5.1 Hoist Limit Switches
10.5.1.1 Function
(Z 82 101)
Hoist limit switches are safety devices that limit the upward move-
ment of hoist ropes and/or 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 must 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 checked
that it functions properly.
If a hoist limit switch is activated (and not overridden), the warning

”HES” appears in red in the ”Crane operation” screen. The war-
ning buzzer goes off.
The following crane movements are shut down:

− Raise hoists
− Extend telescopic sections
− Lower luffing gear and raise luffing gear
Then either lower the hoist or telescope in to end this prohibited

condition.
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10
56 58 60
57 59 61
Z 82 576
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Safety Equipment 10
10.5.1.2 Bridging the Hoist Limit Switches

(Z 82 576)
Key−operated pushbutton (59) is used to override the hoist limit

switches ”Raise hoists”. Indicator light (58) lights up when key
switch (59) is pressed.
DANGER!
Risk of tilting! Risk of breakage!

There is no monitoring of the crane if a load is raised
with the load limit device overridden.
− It is prohibited to lock the key−operated pushbutton
mechanically!
− Bridging may only be initiated if the control levers are
in the neutral position and/or the initiated crane move-
ment has been completed.
− The limit switches may only be overridden in exceptio-
nal cases, for example when configuring the crane (fit-
ting or changing equipment components, fitting ropes,
etc.).
− Operation of the crane with limit switches overridden is
prohibited. RISK OF ACCIDENTS!
ting on p. 205).
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56 58 60
57 59 61
Z 82 576 Z 82 101
Z 82 102
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Safety Equipment 10
10.5.1.2.1 ”EN 13000” Version

(Z 82 576, Z 82 101, Z 82 102)
As described, when the hoist limit switches are triggered and not
overridden, the warning ”HES” appears in red in the ”Crane ope-
ration” screen.
The hoist limit switches ”Raise hoists” are overridden by turning

key switch (59) clockwise.
When key switch (59) (hoist limit switch overridden) is activated,

”HES” is displayed in black.
The following must be observed when overriding (”EN 13000”

version):
− It is only possible to override the hoist limit switches once they
have been triggered.
− The speed of the hoist movement ”Raise hoists” is reduced
to 15 %.
− If the hoist limit switch is relieved in the following crane opera-
tion, the overriding of the hoist limit switch is cancelled.
− If the hoist limit switch is triggered again, key switch (59) must
first be switched back to the neutral position to override again.
Then the hoist limit switch can be overridden again as descri-
bed above.
− For configuration movements with the main boom in a hori-
zontal position or tilted downwards, the hoist limit switch can
be permanently overridden without switching the key switch
back to the neutral position.
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56 58 60
57 59 61
Z 82 576 Z 82 101
Z 82 102
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Safety Equipment 10
10.5.1.2.2 ”Non−EN 13000” Version

(Z 82 576, Z 82 101, Z 82 102)
As described, when the hoist limit switches are triggered and not
overridden, the warning ”HES” appears in red in the ”Crane ope-
ration” screen.
The hoist limit switches ”Raise hoists” are overridden by turning

key switch (59) clockwise.
When key switch (59) (hoist limit switch overridden) is activated,

”HES” is displayed in black.
This means the hoist limit switches are overridden, regardless of
whether they are triggered or not.
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Z 82 103
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Safety Equipment 10
10.5.2 Lower Limit Switches
10.5.2.1 Function
(Z 82 103)
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. There is one lower limit switch for hoist 1
(SES1) and one for hoist 2 (SES2).
If a lower limit switch is triggered (and not overridden), ”SES2” or

”SES2” appears in red in the ”Crane operation” screen. The war-
ning buzzer goes off. ”Lower hoist” is switched off. Only ”Raise
hoist” is possible.
10.5.2.2 Bridging the Lower Limit Switches
DANGER!
Risk of accidents!
Operation of the crane with limit switches overridden is
prohibited.
− The lower limit switches may only be overridden in ex-
ceptional situations, e.g. when configuring the crane
(fitting or changing equipment parts, fitting ropes, etc.).
− In this exceptional case, please consult our customer
service team!
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10
61 62
62
62.3
62.2
62.1
62.2
Z 315 280 Z 315 325
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Safety Equipment 10
10.6 Electric Safety Chain
10.6.1 Fitting the Anemometer and the Hazard Light
Anemometer
(Z 315 280, Z 315 325)
DANGER!
If the crane is operated at prohibited high wind speeds, it
will be at risk of overturning!
If an anemometer rotor is not fitted to the top section of the
main boom / boom system, adherence to the permitted
wind speeds cannot be monitored in the display of crane
control.
In this case, adherence to the permitted wind speed must
be monitored in a different manner (for example external
wind measuring equipment at the height of the tip section
of the main boom / boom system).
1. Attach the anemometer receptacle (62.1) to the correspon-

ding bracket on the main boom head and fasten with fixing
nut (62.2). Make sure that the grooves of the thread of the
anemometer receptacle (62.1) and fixing nut (62.2) are flush
in one line (for the subsequent fitting of the anemometer ca-
ble).
2. Fit the anemometer cable in the grooves and slide anemo-

meter (62) onto anemometer receptacle (62.1).
3. Tighten the fixing nut (62.2).
4. Fix the anemometer (62) firmly onto the receptacle (62.1) by

screwing in the thumb screws (62.3) − only one is shown.
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”A”
61
61.1 61.2
”B”
61.2
Z 171 349
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Safety Equipment 10
Hazard light (optional)

Use of the hazard light

The hazard light must always be used if there is a risk of collision
with other obstacles in the air. For example, this can be the case
when the slewing ranges of several cranes overlap.
For this reason, the hazard light must be fitted at the highest pre-
scribed point of the boom system at night and also by day if there
are bad visual conditions.
National regulations are valid for designating aviation obstacles.
Assembly
Fit hazard light (61) to the main boom head.
Fix the retainer of the hazard light (61) to the corresponding hol-
ding device on the left−hand side of the main boom head.
Operating position for crane operation

The hazard light must be able to swing freely, i.e. the locking de-
vice (61.2) must be actuated by turning the handle so that the
stop pin is pulled in (depiction ”A”).
Transport condition
In the transport configuration (depiction ”B”) for driving the crane,
hazard light (61) must be fixed in a position which is tilted to the
back using locking bolt (61.2).
In this position, all exterior dimensions noted in the official crane
documents are exceeded.
For this reason, the hazard light must be removed for driving on
public roads.
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”X0550”
C1
A1 A F
Z 82 111
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Safety Equipment 10
10.6.2 Connecting the Distributor Box on the Main Boom

Head
(Z 82 111)
Assign the sockets as follows for main boom operation:

X550
Socket Assignment
A Anemometer rotor (62) plug
Alternatively:
Bridging plug (A1)
F Plug of the hazard light (61, optional)
(hazard light in the operating position)
Alternatively:
Protective cap
C CANBUS terminating plug (C1)
Plug each plug into the corresponding socket and turn the union
nut clockwise until it locks in place.
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”L” ”R”
3
1
Z 82 268 Z 171 362
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Safety Equipment 10
10.6.3 Hoist limit switch on the main boom head
10.6.3.1 Crane Operation on the Main Boom
(Z 82 268)
During crane operation with the main boom, the hoist limit switch
must be in the functional state.
Figure (Z 82 268 figure ”R”) represents the hoist limit switch in the
functional state, i.e. the restrainer (see arrow in Z 82 268 figure
”L”) is not fitted.
To deactivate the bridging of the hoist limit switch, the equipment

wire must be pulled down 1 and then to the side 2 and out of
the way. Then the restrainer (see arrow in Z 82 268 figure ”L”) can
be removed. 3 .
The shift weight of the hoist limit switch must hang freely while
loads are being raised. The hoist rope is fed through the opening
of the shift weight (see section 17).
DANGER!
There is a risk of collision between the hook block and the
head of the main boom during hoist operation due to the ho-
ist limit switch being without function.
The hoist limit switch fitted to the main boom head must
be in a functioning state.
10.6.3.2 Instructions on the Shift Weight of the

Hoist Limit Switch in the Transport Condition
(Z 171 362)
Risk of damage!
Risk of damage due to freely swinging hoist limit switch shift
weight.
If the hoist limit switch shift weight is not fitted in the trans-
port condition over the hoist rope (see section 17 ”Ree-
ving”), it must be placed in the transport position (similar to
figure Z 171 362).
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Working Instructions 11
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2
3
Z 315 317
2/53 082−1110−82201b_en
11 Working Instructions
11.1 Wind Forces on the Crane

It is essential that you observe the permitted maximum wind
speeds.
11.1.1 Measuring the Wind Speed
The crane can be optionally fitted with an air speed indicator

(anemometer) in order to check the wind speed.
If an anemometer rotor is not fitted to the top section of the
main boom / boom system, adherence to the permitted
wind speeds cannot be monitored in the display of crane
control.
If required, adherence to the permitted wind speeds must
be monitored in another way (for example, external wind
measuring equipment at the height of the top section of the
main boom/boom system).
The wind meter consists of two elements:

− The rotor (1), which must be fitted to the head of the main
boom or the fly jib.
Detailed information on fitting can be found:
− concerning the main boom head – in section 10 ”Safety
equipment” under ”Safety chain”
− concerning the fly jib – in the corresponding sections.
If rotor (1) is fitted, the transport dimensions listed in the offi-

cial crane documents are exceeded!
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Z 82 212
4/53 082−1110−82201b_en
(Z 82 212 Principle drawing)

− the display on the IC−1 screen with the corresponding sym-
bol.
The rotational movement of the rotor caused by the wind is
converted into an electrical signal which is displayed on the
IC−1 display in the crane operator’s cab. The crane operator
can read off the wind speed here in m/s (mph).
Before commencing work or erecting the equipment it must

be ensured that the anemometer is fully functional. This is
the case if the displayed value changes when the rotor is ro-
tated.
If there is no wind, this must be simulated by manual rotation
of the rotor.
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11.1.2 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 capa-
city 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
over 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
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Also observe the information in the ”Instructions on crane opera-

tion” which are with the capacity tables.
Set 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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11.1.3 Wind Forces on the Crane
For the wind speeds accounted for in the lifting capacity tables
a wind surface of 1.0 m2/t (4.88 ft2/kip) load − however, at least
2 m2 (21.5 ft2) − and a wind resistance correction value cw of 1.2
are used for making calculations.
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.
Danger!
The crane could become damaged or even overturn if, due
to winds, there are extraordinary lateral forces in relation
to the weight of the raised load.
If required, please consult the crane manufacturer concer-
ning loads with a larger area exposed to wind.
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11.2 Crane Operation
Before starting the engine or initiating crane movements,

the crane operator must sound the horn every time to warn
persons who are in the vicinity of the crane.
The crane may be put into operation only if:

∗ the cab of the crane chassis is closed.
(except when driving the crane with load from the chassis ca-
bin).
∗ the control panels of the outriggers are locked.
Four movements can be carried out simultaneously and indepen-
dently of one other.
Before each load case, the corresponding limit switches must be

checked to make sure that they are functioning correctly.
Before raising a load, the corresponding configuration must be

entered in the operating mode preselection screen of crane con-
trol.
The procedures for operating the crane with additional equip-

ment are contained in the individual sections (e.g. Fly jib).
It is prohibited to raise a load on the main boom and on the fly jib
simultaneously.
Two−hook operation is not secured by the load limit de-
vice and can lead to overloads and overturning of the
crane.
It is not permitted to raise a load on the main boom with the fly jib
in operating position (loaded or unloaded).
If the main boom is extended to its final operating length and pin-
ned, the Locking and Pinning Unit must be fully retracted.
The designation number for the length code then has a green
background in the telescoping display.
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Z 53 410
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Some lifting capacity tables require that a permissible minimum

radius must be complied with. The corresponding crane move-
ments will then be switched off.
This minimum radius must not be undercut.

Risk of falling backwards!
There is one capacity table that only allows operation of the crane
with the superstructure in the 0° position, i.e. the superstructure
to the rear. In this case:
∗ Slew superstructure to a position of 0° +/− 2°.
∗ Select operating mode ”HA−0”.
Non−compliance with this will result in a RISK OF OVER-

TURNING!
Unless otherwise specified in the capacity tables, the number of

reevings must not be lower than 2 rope strands.
If, however, single−strand reeving is required, the lifting capaci-
ties specified in the table must be reduced by 20%. This also ap-
plies when the lifting capacity is less than the maximum permitted
cable tension per strand of 6.1 t (13.5 kip).
The cut−off weight of the hoist limit switch must be installed over
a still or the slowest running cable.

If the main boom is in the high position and is completely te-
lescoped in, the crane movements must be carried out with
appropriate care and at slow speeds. By doing this you pre-
vent swinging movements of the hook block (1) in particular,
which could collide with the luffing cylinder (2).
Risk of damage!
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The weight of the hook blocks and lifting tackle must be subtrac-
ted from the values in the capacity tables.
With regard to ”Hook block weights” and ”Minimum loads”

observe the ”Instructions on operating the crane”, which are
supplied with the capacity tables.
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 capacity tables.
If no notes with regard to the support base area have been made
in the load capacity tables, the crane must be operated while sup-
ported on outriggers and with the supports fully extended (exten-
ded up to the corresponding marking).
For the reduced outrigger support areas, the maximum counter-

weight that can be fitted is the one listed in the corresponding
load capacity table.
If, contrary to these specifications, larger counterweights

are fitted, the superstructure must not be slewed!
RISK OF OVERTURNING!
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Operate the slewing gear and slewing brake with care. Select a
low slewing speed! Brake carefully!
This is particularly important during operation with the fly jib or un-
der special local 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 be avoided only by appropriate acceleration/
speed of all crane movements.
In order to safeguard immediate response to changing ambient

conditions, it is prohibited to switch off the drive of the crane and/
or to leave the crane operator’s cab when a load is attached.
An exception is only permitted in emergencies. To prevent

dangerous situations, the drive source (diesel engine) can
be switched off using the quick stop switch in the crane
operator’s cab as a last resort. First – where possible – mo-
vements that have been started should be completed using
the control levers.
The configured crane without load may only be left without the su-
pervision of a trained crane operator if certain conditions are met
(see operating instructions of the crane chassis, section 14 ”Par-
king”).
switch system.
The crane operator must only assume the prescribed operating
position if the corresponding control lever is in the ”neutral posi-
tion” and he must only quit it once the initiated working movement
has been completed.
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11.3 Operation Planning / Monitoring Safety Measures
Before commencing work, i.e. before taking up a load, the condi-

tions described below must be fulfilled.
11.3.1 General
For every planned operation, the crane operator/operation plan-

ner must provide a suitable crane with sufficient capacity, lifting
height and working radius.
A valid load capacity table must be present and enabled in the

crane controls for the intended configuration of the crane.
The load weight must be known. The crane must not be used as
a device to weigh loads.
When the load is being carried, keep it as close 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 tables are valid if all instruc-
tions in the ”Notes on crane operation” – provided along with the
capacity tables – are complied with. This includes among other
things:
− Crane is set on horizontally level ground ( 0.5%).
− The ground must have sufficient bearing capacity for the re-
sulting ground pressures.
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Interpolation of capacities
The capacities stated in the capacity tables are stored in the

crane control. The crane control automatically calculates values
even for differing boom positions. This is called interpolation of
intermediate values.
Such an interpolation can be performed:

− between load radii
For operational planning, these intermediate values can be de-

termined using suitable software (Cranimation). This software
should be used only by trained personnel.
11.3.2 Condition of the Crane
− correctly supported on outriggers and aligned in the hori-

zontal.
− all four support struts extended to the support base area
specified in the corresponding capacity table.
− all four vertical support cylinders are extended so that all ax-
les are relieved of loads i.e. 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.
− suspension system of the crane chassis switched to ”Raise
axles” or ”Hold axles”.
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11.3.3 Ambient conditions
− The ground must have sufficient load−bearing capacity to

take the maximum occurring support pressures. If necessary,
increase the support area by stacking suitable materials un-
der the support plates.
Details on the maximum occurring support pressures and calcu-

lation of the required ground contact surface can be found in sec-
tion 12 ”Outriggers” of the operating instructions of the crane
chassis.
− No live power lines 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 small a working radius as possible.
− If there is bad visibility or darkness directly in front of the crane
operator’s cab, illuminate the outriggers and the winches
using spot lights which are on the machine (rear outside ligh-
ting, front outside lighting, side outside lighting) (see section
4 ’Crane operator’s cab’ of the superstructure operating in-
structions and section 4 ’Driver’s cab’ of the chassis opera-
ting instructions).
Other surrounding areas (load, load path, slewing range, dri-
ving path, and similar) must be lit using suitable means, inde-
pendently of the crane. The responsibility for this lies with 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 ”11.1 Wind forces on the Crane” (from
page 3).
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− Lateral deformation of telescopic booms through solar radia-

tion:
Because of continuous one−sided solar radiation, tempera-

ture differences arise between the left and right sides of the
boom. This results in a difference between the lengths of the
right and left sides. 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 approxima-
tely 1 m / 3.3 ft.
When using the maximum loads, visual inspection is requi-

red to ensure that there is no lateral deformation when unloa-
ded.
Danger:
Risk of accidents from overloading components.
Turn the crane to ensure that both boom sides have
approximately the same temperature.
− If the crane is to be driven in the configured state or with a

load, the road surface must have sufficient load−bearing ca-
pacity and it must be level.
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11.4 Cameras on the crane (option)

11.4.1 General / Warnings
Four cameras can be used in this crane type as an option. The
pictures of all four cameras can be viewed simultaneously on a
monitor in the crane operator’s cab.
DANGER!
Risk of crushing/collision due to incorrect interpretation
of the displayed pictures.
If there are any doubts about the actual space situations
in the places in the work environment being monitored
by the cameras, a banksman must be summoned to help.
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1
2
4
5
Z 82 269
Z 83 278
30/53 082−1110−82201b_en
11.4.2 Components of the camera system (optional)

(Z 82 269, Z 82 278)
The camera system of your crane consists of the following com-

ponents:
Item Explanation
1 Monitor, camera monitoring (optional)
(see section 11.4.3, page 33)
2 Operating panel, hook camera (optional)
(see section 11.4.4, page 39)
3 Camera, superstructure, right page (optional)
For observation of the area to the right of the superstruc-
ture during slewing (see section 8 ”Slewing of the super-
structure”)
4 Camera, hoist 1 (optional)
For monitoring of the hoist rope’s reeling behaviour (see
section 14 ”Hoist 1”)
5 Camera, hoist 2 (optional)
− For monitoring of the hoist rope’s reeling behaviour
(see section 15 ”Hoist 2”)
− With optional hoist 2:
For observation of the rear area during slewing (see
section 8 ”Slewing of the superstructure”)
6 Hook camera on the pendulum bracket (optional)
For observation of the load on the hook and of the imme-
diate surroundings (see section 11.4.4, page 39)
An optional hanging light for lighting of the load from
above is available (see arrow in Z 82 278) at the main
boom head (see section 11.4.4.6, page 47)
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1 2
3 4
Z 82 277
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11.4.3 Monitor, camera monitoring (optional)
11.4.3.1 General
The monitor may only be used in excellent condition in ac-

cordance with the operating instructions. The user is perso-
nally responsible for the correct use of the product.
Thanks to the connected camera, the crane operator is able to

view the operating range without direct eye contact.
Preset priorities of the individual cameras
Priority Display on the Camera

screen
1 upper left Hoist 1
2 upper right Hoist 2 (optional)
3 lower left Hook camera
4 lower right Camera, right side of su-
perstructure
If a camera is not available/in operation, the next picture comes

in accordance with the priority determination.
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1 2 3 4 5 6 7 8
Z 82 275
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11.4.3.2 Operating Controls and Display Elements

(Z 82 275)
1 Mode key
The mode switch is used to switch between different display modes (single
frame, split screen, display split into thirds and quarters and timer mode).
2 Single picture mode
This button used to switch between the four cameras in single picture mode.
The split picture mode can be used to switched between the camera displays
1/2, 2/3, 3/4, 4/1, 1/3 and the camera displays 2/4. The key has a Play/Pause
function in timer mode. This button has no function when the picture is split
into thirds or quarters.
3 Day/night switch over
4 ”Minus”
5 ”Plus” selection list
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1 2 3 4 5 6 7 8
Z 82 275
36/53 082−1110−82201b_en
(Z 82 275)
6 Call up and changeover of the menu to the sequence:
Brightness Brightness − 0(MIN) ... 60(MAX)
Contrast Contrast − 0(MIN) ... 60(MAX)
Colour Colour saturation − 0(MIN) ... 60(MAX)
standard Reset to factory settings
Language Language – English, French, German, Spanish, Portuguese,
Italian, Polish
Mirroring The camera picture is mirrored. You return to the main menu via
the ”Input” menu point. The ”Finish” menu point ends the menu.
Video PAL, NTSC, Auto
Poc Not assigned
Timer OFF/ON – timer mode is activated
Timer setup Camera selection which is shown in timer mode and setting of
the display duration (OFF/ON 5−30 sec.)
Finish End the menu
7 Monitor on/off
8 Indicator lights
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1
2
6.1
6.2
8
6.3
7 6.4
6.5
6
Z 82 280
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11.4.4 Hook camera (overall system; optional)
11.4.4.1 General
(Z 82 280)
The hook camera provides the crane operator with a view from
above of the load and the immediate surroundings.
The video signal of the hook camera (6) that is suspended on the
main boom head is transmitted by cable to the video transmitter
(7); from here via radio signal to the video receiver (8); from here
via cable to the control unit (2) and then onto the display (1) in the
crane operator’s cab.
The operating panel is described in the section 11.4.4.5, page 45.
Documents of Motec, the manufacturer, can be found in the ”Mi-

scellaneous” part.
11.4.4.2 Important Information / Warning Information
For operation of the hook camera
The devices (hook camera and accessory components) may

only be put into operation when the user is aware of the risks
and hazards arising from the use of the device.
Risk of accidents!
Before each use of the camera system, check the system
for visible defects and make sure it functions properly. Mo-
nitor the system for defects during the entire operation pe-
riod.
Do not put a camera system into use or continue to use it
if defects have been found which may impair its safety.
Always resolve defects which may impair safety before re-
suming use of the camera system.
The camera system may not be operated without drop pro-
tection (safety chain)!
Risk of accidents!
The camera system may not be operated without drop pro-
tection (safety chain 6.4)!
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1
2
6.1
6.2
8
6.3
7 6.4
6.5
6
Z 82 280
40/53 082−1110−82201b_en
(Z 82 280)
For driving of the crane
If the crane is driven with the main boom set down and the hook
camera fitted to the main boom head at the same time, the crane
operator’s view will be obstructed.
DANGER!
Risk to life and limb when the view is obstructed!
Death or serious injuries can result if the crane is driven
despite the obstructed view.
Remove the hook camera for driving the crane.
block reeved at the same time, the hook block can collide with the
hook camera.
CAUTION!
Risk of damage to the hook camera due to collision!
Remove the hook camera for driving the crane.
11.4.4.3 Operation of the hook camera

Once the ignition, the operating unit (2) and the display (1) in the
crane operator’s cab is switched on, the hook camera system be-
comes active. The hook (hook block) can be monitored from the
display (1), after making an appropriate selection.
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1
2
6.1
6.2
8
6.3
7 6.4
6.5
6
Z 82 280
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11.4.4.4 Assembling/dismantling of the hook camera at the

main boom head
(Z 82 280)
Assembling of the hook camera at the main boom head
1. Insert the hook camera (6) with the shaft of the pendulum
bracket (6.1) in the bracket (6.2).
2. Secure with the cotter pin (6.3), which is attached to the sa-
fety chain (6.5).
3. Attach the carabiner hooks (6.5) of the safety chain (6.4) in

the bore at the main boom head’s holding plate.
4. Connect the hook camera to the electrical system.

To do so, connect the cable between the hook camera (6)
and the video sender (7).
Disassembly is performed analogously in the reverse direction.
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Z 82 287
44/53 082−1110−82201b_en
11.4.4.5 Operating panel, hook camera (optional)
The operating panel may only be used in excellent condition

in accordance with the operating instructions. The user is
personally responsible for the correct use.
(Z 82 287)
The operation of the hook camera is done using the shown ope-
rating panel.
Operating elements
Element Display Function

Switching on or off
Brightness Switching the screen brightness on or off
Auto Focus Function button in combination with other buttons.

AF OFF
Switching the auto focus on or off
Focus Manual focussing of the motor zoom camera in the ”AF OFF” state
Focus Manual focussing of the motor zoom camera in the ”AF OFF” state
Camera xx Switching between camera 1 and camera 2

No second camera is connected during the installation at this
crane, the screen is blue (no video signal present).
Zoom Zoom out
Zoom Zoom in
LED Green System switched on

red The hook camera is defective or the connection to the camera has
been interrupted
In this case, check the cabling.
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6.2
6.3
6.4
6.5
9
Z 82 289
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11.4.4.6 Hanging light on the main boom head.

(Z 82 289)
Assembling / dismantling of the hanging light at the main

boom head
1. Plug in the hanging light (9) on the bracket (6.2).
2. Secure with the cotter pin (6.3), which is attached to the sa-
fety chain (6.5).
3. Attach the carabiner hooks (6.5) of the safety chain (6.4) in

the bore at the main boom head’s holding plate.
4. Connect the hanging light to the electrical system.
Disassembly is performed analogously in the reverse direction.
Operation
Risk of accidents!
The hanging light may not be operated without drop protec-
tion (safety chain 6.4)!
The switch for switching on and off is in the crane operator’s cab.
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For driving of the crane
If the crane is driven with the main boom set down and the han-
ging light fitted to the main boom head at the same time, the crane
operator’s view will be obstructed.
DANGER!
Risk to life and limb when the view is obstructed!
Death or serious injuries can result if the crane is driven
despite the view being obstructed.
Remove the hanging light for driving the crane.
block reeved at the same time, the hook block and the hanging
light can collide.
CAUTION!
Risk of damage to the hanging light due to collision!
Remove the hanging light for driving the crane.
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11.5 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 (metric) kip 2.2046
kip t (metric) 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
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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
ml floz 0.0338
floz ml 29.6
oC oF toF= 1.8 (toC) + 32
oF oC toC= (toF−32) / 1.8
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Z 82 148
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Telescoping 12
12 Telescoping
12.1 General
(Z 82 148)
Section content
− Telescoping procedure, incl. assembly and functioning princi-
ple of the main boom as required for comprehension of the
telescoping procedure.
− Capacities with the main boom in the unpinned state, telesco-
ping under load: Explanation of the correlation between the
state of the main boom (pinned, unpinned in the intermediate
position) and permitted or achievable loads (see section
12.5; page 99).
− Main boom 70 m / 229.7 ft (6 extendable telescopes)
(Z 82 148)
− Main boom state for driving the crane in the transport position
(see section 12.6; page 109)
Definition telescoping
”Telescoping” means retracting or extending the main boom.
Risk of crushing at bearing points
DANGER!
Risk of crushing during telescoping!

Death or serious injuries can result if someone is in the
area of telescopic section bearing points during telesco-
ping in or out (for example, for maintenance work).
Persons must not be within the danger zone.
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Z 82 148
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Telescoping 12
12.2 Assembly, Function of the Main Boom
12.2.1 Components of the Main Boom

(Z 82 148)
(0) − Basic case

(1) − Telescopic section 1
12.2.2 Extension States of the Main Boom

All telescopic sections can be pinned at 0% / 45% / 90% and
100% of their possible extension lengths. There are length codes
for all extension states used in the capacity tables (”LK”).
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7
3
5
11
2
4
Z 82 221
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Telescoping 12
12.2.3 Telescoping System’s Mode of Operation

The telescopic sections are telescoped in and out using the follo-
wing elements:
− A telescoping cylinder with its cylinder rod fastened to the
rear of the basic case.
− A Locking and Pinning Unit ”LPU” which is attached to the cy-
linder barrel of the telescoping cylinder and is actuated hy-
draulically. The LPU is moved along in the lengthways direc-
tion of the main boom as soon as the telescoping cylinder is
driven.
12.2.4 Locking and Pinning Unit (LPU)
12.2.4.1 Function of the LPU

(Z 82 221)
(2) − Pins for locking between the telescopic section to be mo-
ved and the Locking and Pinning Unit (LPU)
(3) − Pins for locking between the telescopic sections
(4) − Telescopic section to be moved
(5) − Gripper on LPU
(7) − Next largest telescopic section (is not moved)
(11) − Locking and Pinning Unit (LPU)
The Locking and Pinning Unit (11) is fitted to the cylinder barrel
of the telescoping cylinder. This means that the LPU is moved in
the lengthways direction of the main boom as well as soon as the
telescoping cylinder is telescoped out.
A hydraulically moved shifting gate controls the pins for the lok-
king and pinning movement:
− Lock / unlock:
Two horizontally arranged pins (2) on the side of the LPU are
for mechanical locking between the Locking and Pinning
Unit and the individual telescopic section.
− Pin / unpin:
Two horizontally arranged pins (3) on the side of the LPU are
for locking between the respective telescopic section and the
next largest telescopic section.
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”I” ”II” ”III”
Z 82 222
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Telescoping 12
States of the Locking and Pinning Unit (LPU)

(Z 82 222)
Three states of the LPU are of importance to the functionality:
− Unsecured and pinned (I)
− Secured and pinned (II)
− Secured and unpinned (III)
The arrows in the pictures show the extension state (retract/ex-

tend) of the affected pin.
Unsecured and pinned

(Z 82 222 ”I”)
If the individual telescopic sections are connected to each other
with pins, the locking and pinning unit is in the ”Unsecured and
pinned” state. When this is done, the telescoping cylinder can be
moved ”empty”; that is, without locked telescopic section.
Secured and pinned

(Z 82 222 ”II”)
The LPU is in the ”Lock and pin” state when changing between
the two states ”Unsecured and pinned” and ”Secured and unpin-
ned”. In this state, the telescopic section to be moved is locked
to the LPU and to the next largest telescopic section.
Secured and unpinned

(Z 82 222 ”III”)
When telescoping the main boom, the LPU is in the state ”Secu-
red and unpinned”. In this state, the largest telescopic section to
be moved is locked to the telescoping cylinder via the LPU.
The Locking and Pinning Unit is designed in such a way that the
state ”Unlocked and unpinned” can never occur.
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Telescoping 12
12.2.4.2 Supply of the LPU with Hydraulic Oil
12.2.4.2.1 Automatic supply
The LPU is supplied with hydraulic oil through the telescoping cy-
linder with an internal oil conduit. A hydraulic tank is needed to
do this.
If the pressure in the tank falls below the desired value, the loa-
ding procedure is normally automatically started.
The automatic loading procedure is not carried out if:
− The pressure in the accumulator is higher than the desired

pressure.
− The telescopic cylinder is retracted.
− the LPU is in the state ”locked / unpinned” and the telesco-
pic cylinder is not telescoped (unpinned loads)
− the LPU is in the state ”unlocked / pinned”, the telescopic
cylinder is not telescoped and the entire telescoping drive
is telescoped out less than 1.5 m (4.9 ft)
− The LPU is in the approach position, fine position or fol-
low−up position during the locking or pinning procedure.
Automatic supply
If there is a malfunction of the pressure sensor, a corresponding

fault message will appear.
In this case, the hydraulic accumulator pressure must be chek-

ked (see ”Display of the hydraulic accumulator pressure”).
If the pressure is too low, the hydraulic accumulator can be reloa-
ded manually (see ”Manual loading of the hydraulic accumula-
tor”).
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Z 82 152
Z 86 520 Z 82 154
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Telescoping 12
12.2.4.2.2 Hydraulic accumulator pressure display
(Z 82 152, Z 86 520, Z 82 154)
The pressure display is shown in the ”Manual telescoping”

screen (Z 82 152).
1. Call up the ”Telescoping display” screen (Z 86 520).

See also section 12.4.2.2.1, from page 29.
2. Select the ”Manual telescoping” screen in the ”Telescoping

display” screen. Press the displayed button to do so.
The ”Manual telescoping” screen (Z 82 154) appears. (With
regard to the ”Manual telescoping” screen, see section
12.4.3.2.1, page 55.)
The hydraulic accumulator pressure state is indicated at the point

shown in figure (Z 82 152).
Meaning of the colours of the key:

Colour Meaning
Green Pressure in the normal range
red Pressure outside the normal range
yellow during the loading procedure (max. 15 s)
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Z 82 154 Z 82 063
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Telescoping 12
12.2.4.2.3 Manual loading of the hydraulic accumulator
(Z 82 154)
If the automatic supply of the Locking and Pinning Unit (LPU) with
hydraulic oil does not work, the ”LPU hydraulic supply” button is
shown with a red background colour in the ”Manually telesco-
ping” screen. The pressure of the hydraulic accumulator has to
be manually applied to the target range.
1. Call up the ”Manual telescoping” screen

see section 12.4.3 ”Manual telescoping” screen, page 53.
2. ”Hydraulic supply of the LPU” button (red background) ac-
tuated.
An arrow is depicted in the hydraulic accumulator symbol during

loading.
If the pressure is higher than the desired pressure, the loading

procedure cannot be started manually with the pressure sensor
intact.
The key must have a green background again once the loading
procedure has been completed.
12.2.4.2.4 Exit screen
(Z 82 063)
Activate the displayed key to quit the screen again.
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”II” 3
”I”
A A
2
Z 82 223 Z 82 224
3
”III” 5
B B
Z 82 226
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Telescoping 12
12.2.5 Correlation of the Components
In order to achieve an extension state, the telescopic sections to

be moved must be telescoped one after the other.
Starting situation
(Z 82 223 ”I”)
Before each telescoping procedure, all telescopic sections must
be pinned and unlocked.
This means that the rear area of each telescopic section is locked
to the next largest telescopic section by two pins.
Telescoping out
(Z 82 223 ”I”)
When telescoping out, you start with the smallest telescopic sec-
tion to be telescoped.
The Locking and Pinning Unit (LPU) is moved to the rear end of
the telescopic section to be moved.
(Z 82 224 ”II”)
The horizontal pins (2) lock the Locking and Pinning Unit to the
individual telescopic section. This is described as ”Locking” (A).
After the ”Locking” movement (A) has been carried out, the LPU
is in the ”Lock and pin” state.
The telescopic section to be moved is still pinned to the next lar-

gest telescopic section.
The pins (3) must be relieved so that the unpinning procedure

described in the following can be carried out. To do so, the tele-
scoping cylinder telescoped out slightly.
(Z 82 226 ”III”)
”Unpinning” (B) follows. In this case, the grippers (5) draw both
pins (3) inwards to lock the corresponding telescopic section with
the next largest section. After the movement ”Unpin” (B) has
been carried out, the LPU is in the state ”Locked and unpinned”.
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3
”III” ”II” 5
C C
Z 82 227 Z 82 225
”I”
2
Z 82 228
18/113 082−1120−82201c_en
Telescoping 12
(Z 82 227 ”III”)
The telescopic section to be moved is only locked to the LPU. The

telescopic section can be telescoped in this state.
(Z 82 225 ”II”)
The telescopic section must be pinned again to set down the tele-
scopic section locked to the LPU at the new pinning point. The
grippers (5) of both pins (3) now enable this to be locked again
between this and the next largest telescopic section (= ”Pin” (C)).
After the ”Pinning” movement (C) has been carried out, the LPU
is in the ”Secured and pinned” state.
The telescopic section is locked to the LPU and pinned to the next
largest telescopic section.
(Z 82 228 ”I”)
Then both horizontal locking pins (2) are retracted so that there
is no longer a connection between the Locking and Pinning Unit
and the telescopic section (= ”Unlocking” (D)). After the ”Unlock”
(D) movement has been carried out, the LPU is in the state ”Un-
locked and pinned”.
In order to telescope out the next telescopic section, the telesco-

ping cylinder must be moved back with ”empty” Locking and Pin-
ning Unit.
If the main boom has been extended or retracted to its final ope-
rating length and pinned, the telescoping cylinder must be com-
pletely retracted. The values of the capacity tables are enabled
only once the telescoping cylinder has been completely retrac-
ted.
Telescoping in
Telescoping in works inversely to telescoping out which means
that you start with the largest telescopic section to be telescoped.
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81
43
Z 82 259
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Telescoping 12
12.3 Operating Elements / Auxiliary Equipment
12.3.1 Control Levers in the Crane Operator’s Cab
(Z 82 259)
By activating the control lever (43) or (81) (depending on the set
control lever assignment) the telescoping cylinder is retracted or
extended during telescoping. For further information about the
possible control lever assignments, for change of the control le-
ver assignment, etc (see section 10 about this).
The telescoping cylinder with the firmly fitted locking and pinning
unit can be retracted and extended empty or with an attached te-
lescopic section (locked).
Deflection of the control le- Automatic Telescoping Manual tele-
ver (refer to section 12.4.2, scoping (re-
starting at page 25); fer to sec-
(43) (81) tion 12.4.3,
(modes 1, 3, (mode 6) starting at
4) page 53);
to the front to the right activate after input of the Telescoping
length code (LK); depen- out
ding on the current state,
telescoping in or out is
carried out
to the rear to the left telescoping in without se- Telescoping
lection of a LK (LK 1 is au- in
tomatically selected)
The crane is equipped with a release switch system to prevent

accidental activation of crane movements.
A crane movement can only be carried out if one of the release
buttons of the release switch system is pressed. Observe the
segment ”Release switch system for crane movements” in sec-
tion 10 ”Safety equipment”.
12.3.2 Input and Monitoring Screens on Crane Control
There are input and monitoring screens for telescoping.

Depending on the procedure, different screens are used for tele-
scoping (”Automatic” or ”Manual”). The screens are explained
with the corresponding descriptions of the procedures.
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Telescoping 12
12.4 Telescoping the Main Boom
12.4.1 General
Introduction
This segment describes telescoping the main boom without load

from one pinned state to another pinned state.
If loads are to be raised in the unpinned state, see section 12.5

(page 99).
Telescoping with fitted additional equipment:

Any special characteristics which must be taken into considera-
tion are described in the section which deals with the correspon-
ding additional equipment.
Automatic telescoping
As long as there is no fault, telescoping must always be carried

out in automatic mode.
The description of automatic telescoping can be found in sec-

tion 12.4.2 (from page 25).
Manual telescoping
If there are mechanical or electrical faults, telescoping can be

carried out manually.
The description of manual telescoping is in section 12.4.3 (from

page 53).
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81
43
Z 82 157 Z 82 259
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Telescoping 12
12.4.2 Automatic telescoping
12.4.2.1 General
Introduction
As long as there is no fault, telescoping must always be carried

out in automatic mode. Automatic telescoping is carried out with
the help of the telescoping information system of crane control.
The telescoping information system is an aid to operation. It is not

a replacement in any way for the judgement and experience of
the crane operator as well as recognised safe operating procedu-
res for the operation of cranes!
Using the operating aid does not relieve the crane operator of his
responsibility for safe operation of the crane.
DANGER!
Risk of accidents due to incorrect operation

Death or serious injuries can result if the crane tips over or
is damaged due to incorrect inputs at the crane control.
The crane operator must be aware of his responsibility for
the safe operation of the crane.
The crane operator must ensure that all the issued speci-
fications and instructions at the crane control and in the
operation manual are understood and observed.
Telescoping the main boom a new final length
(Z 82 157, Z 82 259)
The crane control makes it possible for the telescoping procedure

to run automatically after entry of the desired final length at the
control panel of the crane control and activation of the correspon-
ding control lever (43) / (81).
This also applies if the new main boom length is shorter than the
current length.
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81
43
Z 82 259 Z 82 158
Z 82 572
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Telescoping 12
Telescoping the main boom in
(Z 82 259, Z 82 158)
The main boom can be telescoped in two ways by automatic tele-

scoping:
− Steer control lever (43) / (81) in the retracting direction:
”LK 1” (all telescopic sections 0%) is automatically selec-
ted.
− At the control panel of crane control, select ”LK 1” and
create the corresponding extension state as described in
the segment ”Telescoping the main boom to new final
length”.
Telescoping Procedure
(Z 82 572)
The telescoping speed varies throughout the procedure. Just be-

fore the pinning position is reached, the telescoping speed is re-
duced, so that the telescopic sections can be pinned.
The crane control prescribes the extension / retraction sequence

of the telescopic sections to achieve the selected length code. In
the ”Telescoping display” screen, the extension states of the tele-
scopic sections are shown in colour as a bar display (see also
segment 12.4.2.2.1, from page 29).
If there is a fault during telescoping, the fault symbol depicted ap-
pears on the control panel of the crane control.
For more detailed information on calling up fault messages, see

section 10 ”Safety equipment”.
After eliminating the error, work can only be continued, once the
error message has been acknowledged.
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Z 82 062
Z 86 520
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Telescoping 12

(Automatic Telescoping)
12.4.2.2.1 ”Telescoping display” screen
12.4.2.2.1.1 Call up the ”Telescoping display” screen.

(Z 82 062, Z 86 520)
1. In the ”Quick menu” screen, select the ”Telescoping display”

screen (Z 82 062). Press the button shown to do so.
The ”telescoping display” screen will appear instead of the ”Quick

menu” screen.
Submenus can be selected in this screen and information on the

state of the telescoping system can be obtained.
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5 4
Z 82 161
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Telescoping 12
12.4.2.2.1.2 Structure of the ”Telescoping display” screen

(Z 82 161)
Item Symbol Colour Explanation
1 Extension lengths of the telescopic section as a bar display and
in percentages
blue The telescopic section has been extended for the selected length
code
grey The telescopic section has been retracted and must be extended
black The telescopic section must be retracted and possibly extended
again, according to the selected length code
yellow The telescopic section extends or retracts with the locking and pin-
ning unit
white The telescopic section has been retracted.
If the main boom is in the state for driving the crane (see
section 12.6, page 109), a crane symbol is shown instead of
the bar display.
2 Combined display:
− Position display of the LPU as a bar display and in percen-
tages
− Telescoping speed display of main boom / telescoping cy-
linder
Just before the pinning position is reached, the telescoping speed is
reduced, so that the telescopic sections can be pinned.
3 Calling up the ”Manual telescoping” screen (see ”Manual tele-
scoping” screen 12.4.3.2.1, page 55)
The ”Manual telescoping” screen is not required for automatic tele-
scoping. The ”Manual telescoping” screen can be called up during
automatic telescoping to observe the procedures carried out at the
telescoping cylinder and LPU.
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5 4
Z 82 161
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Telescoping 12
(Z 82 161)
4 Display of the current driving state of the telescoping cylinder
Forward at reduced speed
Reverse at reduced speed
Forward at high speed
Reverse at high speed
5 Call up ”Length code (LK) selection” screen
See section 12.4.2.2.2, page 35
grey The selected length code has not been achieved.
Green The selected length code has been achieved.
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Z 86 520
Z 86 521
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Telescoping 12
12.4.2.2.2 The “Select length code” screen
12.4.2.2.2.1 Call up the ”Length code (LK) selection” screen

(Z 86 520, Z 86 521)
1. Press the key shown in the ”Telescoping display” screen

LK (Z 86 520). (For further information on the ”Telescoping dis-
play” screen, see 12.4.2.2.1, page 29)
The digit shown on the button is the number of the current selec-
ted length code (LK).
The ”Length code selection” screen (Z 86 521) appears instead

of the ”Crane operation” screen.
All length codes (including corresponding main boom length, ex-

tension state of the individual telescopic sections and possible
maximum load capacities) which are permitted and can be activa-
ted for the selected operating mode are displayed in the ”Length
code (LK) selection” screen.
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1 2 3 4 5 6 7
Z 86 522
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Telescoping 12
12.4.2.2.2.2 Structure of the ”Length Code (LK) selection” screen

(Z 86 522)

1 Number of the length code (LK−N.)
2 Main boom length
3 Extension state of the telescopic sec-
tions 1 to 6 (from left to right)
white 0% extended
blue 45% extended
grey 90 % extended
black 100 % extended
4 Max. lifting capacity in high position

5 Radius in high position
6 Max. lifting capacity in low position
7 Radius in low position
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12 11 10
Z 86 523
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Telescoping 12
(Z 86 523)

8 Selected length code
The desired length code is selected and
receives a coloured background when
pressed (the entire line is touch−sensi-
tive).
9 Can be scrolled for leafing through
length code:
− line by line: Touch the triangular mar-
king at the bottom and top at the end
of the bar.
− through the entire table: Sliding over
the progress bar
10 Leave the screen with save. the set-
tings are saved.
The ”Telescoping display” screen appears
again. (For further information on the ”Te-
lescoping display” screen, see 12.4.2.2.1,
page 29)
11 Selection of the screen to choose the
length code for lubrication of the main
boom (only for operating mode HA −
main boom)
Detailed information on this can be found
in the lubrication and maintenance in-
structions, “Main boom, rope, equipment”
section.
12 Length code selection for the position
of the locking and pinning unit to drive
the crane (only for operating mode HA
− main boom). For more about this, see
12.6 Putting the main boom into trans-
port condition, page 109.
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15 14 13
Z 86 524
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Telescoping 12
(Z 86 524)

13 Selection of the ”Selection of length
code (LK) in accordance with capa-
city (pinned−unpinned)” screen; only
for operating mode ”HA − main
boom”. See segment 12.4.2.2.3, page
43.
14 Error button (appears in case an error
is displayed. For more about this, see
section 10 ”Safety equipment”)
15 Exit the screen without save. The set-
tings are not saved.
The ”Telescoping display” screen ap-
pears again. (For further information on
the ”Telescoping display” screen, see
12.4.2.2.1, page 29)
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Z 86 521
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Telescoping 12
12.4.2.2.3 ”Length Code (LK) selection in accordance with

capacities (pinned−unpinned)” screen
12.4.2.2.3.1 Structure of screen call up ”Length Code (LK) selec-

tion” acc. to capacities (pinned−unpinned)”
(Z 86 521)
Press the button shown in the ”Length code (LK) selection”

screen. (For further information on the ”Length code selection”
screen, see the 12.4.2.2.2 ”Length code (LK) selection” screen,
page 35).
The ”Length code (LK) selection in accordance with (pinned−un-

pinned)” screen appears instead of the ”Length code (LK) selec-
tion” screen.
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1 1
6 5 3 2 6 4 2
Z 86 525
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Telescoping 12
12.4.2.2.3.2 Structure of the ”Length Code (LK) selection in ac-

cordance with capacities (pinned−unpinned)” screen
(Z 86 525)

1 Selected length code
The desired length code is selected and
receives a coloured background when
pressed (the entire column is touch−sen-
sitive).
2 Leave the screen with save.
the settings are saved.
3 Change to the unpinned load capaci-

ties
only for operating mode ”HA − main
boom”
4 Change to the pinned load capacities
only for operating mode ”HA − main
boom”
5 for luffing boom extensions, the cur-
rent angle step will be shown
(e.g. 40).
Then the remaining angle steps can be
called up one after the other by pressing
this button.
6 Exit the screen without save.
The settings are not saved.
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Z 82 089
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Telescoping 12
12.4.2.3 Procedure for Automatic Telescoping

(Z 82 089)
Requirements
− Crane assembled, supported on outriggers and aligned in ac-
cordance with regulations.
− Crane engine is running.
− Crane control:
− Set the correct configuration in the ”Selection of the opera-
ting mode” screen.
− Control lever assignment selected for which telescoping is
possible.
(Z 82 089)
The current assignment of the control levers (here: 1) is displayed
by the corresponding symbol in the top line of the IC−1 display.
DANGER!
Risk of accidents!
Death or serious injuries can result if unintended crane mo-
vements are carried out.
Check which control lever assignment has been currently
selected.
For detailed information on the control lever assignment and

other settings in crane control, see section 10 ”Safety equip-
ment”.
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12
”a” ”b” ”c”
”d”
”e”
Z 82 573
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Telescoping 12
(Z 82 573)
1. Enter length code (LK):
1.1 Actuate the marked button (picture ”b”) in the ”Crane
operation” screen (picture ”a”) with the partial ”Quick
menu” screen. The ”Telescoping display” screen ap-
pears (picture ”c”).
1.2 Actuate the button for selection of the ”Length code
(LK) selection” screen (picture ”c”) in the ”Telescoping
display” screen. The ”Length code (LK) selection”
screen appears (picture ”d”).
1.3 Press the desired length code (the whole line is touch
sensitive) (picture ”d”) in the ”Length code (LK) selec-
tion” screen. The selected length code receives a co-
loured background.
1.4 Leave the screen with save (picture ”e”).
Alternatively, you can switch to the ”Length code (LK) selection

in accordance with load capacity (pinned−unpinned)” screen and
select a corresponding length code (LK) there.
For further information on selecting the length code (LK), see

segment 12.4.2.2.2 from page 35.
Pay attention to the following during the performance of the follo-

wing work step:
DANGER!
Risk of accidents!
Death or serious injuries can result if unintended crane mo-
vements are carried out.
Check which control lever assignment has been currently
selected.
Note the warning information and other specifications for
the release switch (see section 10 ”Safety equipment” for
more about this).
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81
43
Z 82 259 Z 86 527
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Telescoping 12
(Z 82 259, Z 86 527)
DANGER!
Risk of crushing and collision!

Death or serious injuries can result if the load or the hook
block swings out when the respective crane movement is
switched off.
Only carry out crane movements with suitable acceleration
or speed.

stopped.
2. Start telescoping by pressing one of the ”Release switch sy-

stem” buttons and carefully moving control lever (43) / (81),
which has been assigned the telescoping movement, in the
direction for extension.
As soon as the desired final length is reached, the colour of
the ”LK” key switches from grey to green.
The hook height changes when telescoping.

It must be ensured that the hoist limit switch is not triggered when
extending. For this reason, the hoist (the hook) must also be lo-
wered when telescoping out (see hoist 1, section 14 and hoist 2,
section 15).
Telescoping in
(Z 82 259)
1st option:
The main boom is automatically fully telescoped in by pressing

one of the buttons of the ”Release switch system” and carefully
pulling the corresponding control lever (43) / (81) back in the di-
rection of telescoping in. ”LK 1” is then activated.
2nd option:
Procedure for telescoping as previously described in this section
with input of the length code ”LK 1”.
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Z 82 154
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Telescoping 12
12.4.3 Manual telescoping
12.4.3.1 General
Mechanical faults
If there are mechanical faults, telescoping can be carried out ma-
nually.
Crane control is fully functional in this case.
The procedure for manual telescoping is described in segment
12.4.3.3 (from page 71).
Electrical faults
If there are electrical faults, the load limit device (LLD) must also
be overridden during manual telescoping.
Observe the description, notes and warning information in seg-
ment ”12.4.3.4 Overriding the load limit device” (page 93).
Display on crane control

(Z 82 154)
The information required (position and state of the LPU) and the
operating controls for manual telescoping are in the ”Manual tele-
scoping” screen.
The description of the input and monitoring screens on crane
control for manual telescoping are in segment 12.4.3.2 (from
page 55).
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Z 82 154 Z 82 093
Z 82 239 Z 82 240
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Telescoping 12

(Manual Telescoping)
12.4.3.2.1 ”Manual Telescoping” Screen
Purpose of the ”Manual telescoping” screen

(Z 82 154)
Status messages and keys for manual operation of the Locking

and Pinning Unit (LPU) are shown in the ”Manual telescoping”
(Z 82 154) screen.
The ”Manual telescoping” screen can also be called up during au-
tomatic telescoping to observe the procedures carried out at the
telescoping cylinder and LPU.
Call up the ”Manual telescoping” screen.

(Z 82 093, Z 82 239, Z 82 240)
1. Activate the marked key in the ”Crane operation” screen in

the ”Quick menu” area (Z 82 093).
Instead of the ”Quick menu”, the ”Telescoping display”
screen (Z 82 239) appears.
2. Press the marked key in the ”Telescoping display” screen
(Z 82 239).
Instead of the ”Telescoping display” screen, the ”Manual Te-
lescoping” screen appears (Z 82 240).
When the ”Manual Telescoping” screen opens, the hand symbol

is crossed out.
This means that the automatic mode is active.
The function keys for operating the Locking and Pinning Unit
(LPU) are displayed greyed out.
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Z 82 063 Z 82 236
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Telescoping 12
Exiting the ”Manual telescoping”screen

(Z 82 063, Z 82 236)
The ”Manual telescoping” screen can be exited directly by pres-

sing the ”Exit” key in two cases:
− No change has been made to the screen.
− Telescoping was carried out manually and there are no elec-
trical faults.
If there is an electrical fault, the ”teaching” procedure must be car-

ried out after manual telescoping to exit the ”Manual telescoping”
screen. This means that the telescoping system must be infor-
med concerning the extension state of each telescopic section.
In this regard, see section 12.4.3.3.2 from page 89.
If the ”teaching” procedure must be carried out, the ”Exit” button
in the area (F) of the ”Crane operation” screen is displayed
”greyed out” and cannot be actuated.
After exiting, the ”Crane operation” screen appears again with

the partial ”Telescoping display” screen (Z 82 236).
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1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
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Telescoping 12
Structure of the ”Manual telescoping” screen

(Z 82 175)
(1) − LPU position

Depending on the measuring unit set in the ”System”
screen, the position value is displayed in m (”metric”)
or in ft (”feet”).
(2) − LPU speed
Depending on the measuring unit set in the ”System”
screen, the speed value is displayed in mm/s (”me-
tric”) or in ft/min (”feet”).
(3) − Number of the telescopic section identified by the crane
control system.
It means that crane control has not identified any telesco-
pic section when ”0” is displayed.
(4) − Approach position ”Locking position” (symbol has a
green background when the position is reached)
(5) − Follow−up position ”Locking position” (symbol has a
green background when the position is reached)
If the ”locking” approach and follow−up position has been re-

ached (symbols (4) and (5) has a green background), the affec-
ted telescopic section is in the ”locking” fine position.
(6) − Display of the pinning state of the LPU

Symbol Meaning
”Pinning” basic symbol
pinned
unpinned
(7) − Display of the locking state of the LPU

Symbol Meaning
”Locking” basic symbol
locked
unlocked
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1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
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Telescoping 12
(Z 82 175)
(8) − Status Sensor System of the LPU

Status State of the LPU
Symbol
code
1 unlocked and pinned
12 State change lock and pinned
2 locked and pinned
23 locked and state change pin-

ning
3 locked and unpinned
5 ”Locking/pinning unknown”
state
(9) − Hydraulic supply of the LPU (see section 12.2.4.2, from
page 11)
(10) − Pin
(11) − Unpin
(12) − Preselection lock/unlock
(13) − Lock
(14) − Unlock
(15) − Calling up a visual depiction of the current state of the

LPU (see section 12.4.3.2.2, from page 63)
(16) − Calling up the ”Teaching” screen (setting and saving the

position of the telescopic sections). See section
12.4.3.2.3, page 65.
After teaching, the ”Manual telescoping” screen ap-

pears.
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1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12 Z 82 175 Z 82 254
Z 82 255 Z 82 256
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Telescoping 12
(Z 82 175)
(17) − Switch−over between automatic and manual telescoping

operation:
Automatic telescoping operation active
Manual telescoping operation active.
The ”Teaching” screen appears after this key has

been selected if ”teaching” must first be carried out
after manual telescoping. See 12.4.3.2.3 (page 65).
After ”teaching”, automatic telescoping operation is
active.
12.4.3.2.2 ”Visual Depiction of the LPU States”Screen
(Z 82 175, Z 82 254, Z 82 255, Z 82 256)
By pressing the displayed key, visual depictions of the LPU states

currently shown in the ”Manual telescoping” screen are called up.
Figure Status code in Meaning
accordance
with (9) ”Ma-
nual telesco-
ping”
(Z 82 254) 1 unlocked and pinned
(Z 82 254) 12 State change lock and pinned
(Z 82 255) 2 locked and pinned
(Z 82 255) 23 locked and state change pin-
ning
(Z 82 256) 3 locked and unpinned
5 ”Locking/pinning unknown”
state
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Z 82 237
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Telescoping 12
12.4.3.2.3 ”Teaching” Screen
(Z 82 237)
The displayed key in the ”Manual Telescoping” screen must be

activated for ”teaching”, i.e. in order to inform the telescoping sy-
stem which extension state each telescopic section is in.
This key is displayed active and can be selected only when requi-
red by circumstances. Otherwise it becomes inactive, i.e. is
shown ”greyed out”.
If, after manual telescoping, ”teaching” must first be carried out

to exit the ”Manual telescoping” screen, the ”Teaching” screen
appears also after selecting the key for switching from manual te-
lescoping to automatic telescoping.
Structure of the ”Teaching” screen:

(1) Telescopic section numbers and corresponding input fields
The displayed value changes by activating the input
field.
All input fields assigned to the individual telescopic sec-
tions T1 to T6 are filled in with a star when the screen is
selected. Subsequently, the current extension states for
all telescopic sections must be selected manually. The
following options are available for selection:
”0”, ”45”, ”90” and ”100” for pinned states and ”LPU” if
the telescopic section is unpinned and locked to the
LPU.
(2) Saving the set extension state: the settings are saved.
(3) Entering the length code
If the extension state corresponds with an existing length code
(LK):
Call up the ”Selection length code (LK) teaching” screen, see
section 12.4.3.2.4, from page 67 for setting the length code
(LK).
Select the corresponding length code (LK) in the ”Length code
(LK) selection − teaching” screen and exit the screen with
”Save”.
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Z 82 574
1 2 3 4 5 6 7
10
13 12 11
Z 82 238
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Telescoping 12
12.4.3.2.4 ”Length Code (LK) Selection − Teaching”Screen
(Z 82 574)
Activate the key displayed on the left in the ”Teaching” screen to

LK select the length code (LK) for the desired main boom length.
The ”Length code (LK) selection − teaching” screen appears.
(Z 82 238)
All length codes (including corresponding main boom length, ex-
tension state of the individual telescopic sections and possible
maximum load capacities) which are permitted and can be activa-
ted for the selected operating mode are displayed in the ”Length
code (LK) selection” screen.
(1) − Length code number (LK no.)
(2) − Main boom length
(3) − Extension state of the telescopic sections 1 to 6 (from left
to right)
0% extended 90 % extended
45% extended 100 % extended
(4) − Max. capacity in high position

(5) − Radius in high position
(6) − Max. capacity in low position
(7) − Radius in low position
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1 2 3 4 5 6 7
10
13 12 11
Z 82 238
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Telescoping 12
(Z 82 238)
(9) − Selected length code

The desired length code is selected and receives a
coloured background when pressed (the entire line is
touch−sensitive).
(10) − Scroll bar for scrolling through the length codes:
> line by line: Touch the triangular marking at the
bottom and top at the end of the
bar.
> through the Sliding over the progress bar
entire table
(11) − Exit the screen with save; the settings are saved.
The ”Teaching” screen appears again (12.4.3.2.3,
page 65).
(12) − Fault button (see section 10 ”Safety equipment”)
(13) − Exiting the screen without saving; the settings are not sa-
ved.
The ”Teaching” screen appears again (12.4.3.2.3,
page 65).
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Z 82 089
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Telescoping 12
12.4.3.3 Manual Telescoping Procedure
12.4.3.3.1 Moving the Telescopic Sections or the LPU
Requirements
− Crane assembled, supported on outriggers and aligned in ac-
cordance with regulations.
− Crane engine is running.
− Crane control:
− Set the correct configuration in the ”Selection of the opera-
ting mode” screen.
− Control lever assignment selected for which telescoping is
possible.
(Z 82 089)
The current assignment of the control levers (here: 1) is displayed
by the corresponding symbol in the top line of the IC−1 display.
DANGER!
Risk of accidents!
ment.
For detailed information on the control lever assignment and

other settings in crane control, see section 10 ”Safety equip-
ment”.
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Z 82 154 Z 82 241
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Telescoping 12
Procedure
(Z 82 154)
1. Call up”Manual telescoping” screen. For this see section

”12.4.3.2.1 ”Manual telescoping” screen” from page 55.
(Z 82 241)
2. Activate manual telescoping operation.

To do so, activate the marked key in the ”Manual Telesco-
ping” screen.
The function keys for operating the Locking and Pinning Unit
(LPU) are no longer displayed greyed out.
Crane control is now in manual telescoping operation.
Procedure continued on next page.
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12
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 253
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Telescoping 12
(Z 82 253)
For clarification, the further procedure is shown using an exam-

ple:
Telescopic section 1 (T1) is to be driven out of the 100% pinning
hole (P4) into the 0% pinning hole (P1) (telescoped in).
The telescoping cylinder (110) must be completely retracted at
the start.
Telescoping of several telescopic sections:

If several telescopic sections are to be moved, you must always
start with the smallest telescopic section to be moved when ex-
tending the main boom.
When telescoping in, you must always start with the largest tele-
scopic section to be moved.
During the following procedure, telescoping the hydraulic cylin-

der – in accordance with the prescribed steps – must be interrup-
ted or resumed using the corresponding control lever.
When telescoping, one of the release switch system buttons
must be pressed at the same time as the corresponding control
lever is moved.
If there is an electrical fault, the load limit device (LLD) must also
be overridden. For more about this, see segment ”12.4.3.4 Over-
riding the load limit device (LLD) (in case of electrical errors)”
(page 93).
Procedure continued on next page.
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12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12 Z 82 175
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 253
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 257
76/113 082−1120−82201c_en
Telescoping 12
(Z 82 175, Z 82 253)
3. Check under (6) and (7) using the displayed symbols, whe-
1 ther the LPU (111) is in the state ”unlocked and pinned” (the
digit ”1” must appear under item (8)). For a description of the
LPU states, see section 12.4.3.2.1, from page 55 under item
(8).
The telescoping cylinder (110) can be moved in this state

using the control lever to which the telescoping movement
is assigned without a telescopic section being moved.
This can be seen at (2): A speed greater than 0 mm/s (ft/min)
must be displayed without a telescopic section moving.
(Z 82 257)
4. Telescope the telescoping cylinder (110) up to just before the

locking position.
In our example (telescopic section 1: 100% telescoping out),

the telescoping system must be telescoped out about 9.725
m (31.906 ft) in order to secure LPU (111) to telescopic sec-
tion 1 (T1) (Z 82 257).
The definitive extension length is displayed under (1).
The position of the pinning holes and the corresponding ex-

tension lengths of the telescoping system are described in
section 12.4.3.5 ”Locking and pinning positions of the tele-
scopic drive” (from page 97).
As soon as crane control detects a telescopic section or when a

telescopic section has been left, it is shown on display (3).
In our example, display (3) changes from ”IC 0” to ”IC 1” when te-
lescopic section 1 is detected.
5. To lock the LPU (111) press the ”Preselect” (12) and ”Lock”
(13) buttons successively.
The keys are displayed red after they are pressed.
Observe the correct sequence when pressing the keys: First

press ”Preselect”, then press ”Lock”. The locking proce-
dure is then automatically actuated when the fine position is
approached.
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12
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 257
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12 Z 82 175
78/113 082−1120−82201c_en
Telescoping 12
(Z 82 257, Z 82 175)
If an electrical fault is present, it may be that the ”Preselect lock/

unlock” function is unavailable. Instead of this the fine position
must be approached manually before performing the locking pro-
cedure in the 7. Work step.
6. Continue to telescope the telescoping cylinder (110) slowly.

When the fine position has been reached (symbols ”4” and
”5” shown against a green background) if the ”Preselect lock/
unlock” function is operational the locking procedure is trig-
gered automatically.
7. If as described above an electrical fault is present, the fine

position ”Lock” (symbols ”4” and ”5” shown against a green
background) must be approached manually and the ”Lock”
button (13) actuated.
The ”Lock” (13) and ”Unlock” (14) buttons may be actuated

only in the fine position ”Lock” (symbols ”4” and ”5” shown
against a green background).
The locking procedure is completed as soon as the ”locked and

2 pinned” state (the digit ”2” must appear under item 8) is displayed
for the LPU.
Even though the locking procedure is completed, the ”Preselect”

(12) and ”Lock” (13) buttons are still displayed against a red back-
ground. This means that the hydraulic valve is still activated for
the locking movement to be carried out.
8. Place the hydraulic valve in the neutral position to control the

locking movement.
To do this, press the ”Preselect” (12) and ”Lock” (13) buttons
again.
The buttons are then displayed in grey once again.
082−1120−82201c_en 79/113
12
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 257
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12 Z 82 175
80/113 082−1120−82201c_en
Telescoping 12
(Z 82 257, Z 82 175)
9. The telescoping cylinder must be extended by approx. 5 mm

(0.2 in) to relieve the pins of the pinning between the telesco-
pic sections.
10. Activate key (11) for unpinning.

The key is displayed red after it has been pressed.
The unpinning procedure is completed once the state ’locked and

3 unpinned’ (the digit ”3” must appear under item 8) is displayed for
the LPU.
In this state, telescopic section 1 is locked to the LPU and can be
telescoped in as follows
Even though the unpinning procedure has been completed, the

key ”Unpin” (11) is still displayed with a red background. This
means that the hydraulic valve is still activated for the unpinning
movement to be carried out.
unpinning movement.
To do so, press the key ”Unpin” (11) again.
The key is shown in grey again.
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12
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 82 257
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 86 514
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12 Z 82 175
82/113 082−1120−82201c_en
Telescoping 12
(Z 82 257, Z 86 514, Z 82 175)
12. Telescopic section 1 secured at the LPU (111; Z 82 257) can

be telescoped in by activating the control lever in the telesco-
ping in direction.
In our example, telescopic section 1 must be completely re-

tracted (Z 86 514).
The telescoping system must be telescoped out approx.
0.035 m (0.115 ft) in order to pin telescopic section 1 (T1) to
the 0% pinning hole (P1) (Z 86 514). The current extension
length is displayed under (1).
The position of the pinning holes and the corresponding ex-

tension lengths of the telescoping system are described in
section 12.4.3.5 ”Locking and pinning positions of the tele-
scopic drive” (page 97).
13. Just before reaching the pinning hole:

Press key (”Pin”, 10).
The key is displayed red after it has been pressed.
14. Slowly telescope in the telescoping cylinder (110) until the

secured telescopic section (here: telescopic section T1) is
pinned to the next larger telescopic section (here: telescopic
section T0).
The pinning procedure is completed once the ”locked and pin-

2 ned” state (the digit ”2” must appear under item 8) is displayed for
the LPU.
Even though the pinning procedure has been completed, the key
”Pin” (10) is still displayed with a red background. This means that
the hydraulic valve is still activated for the pinning movement to
be carried out.
pinning movement.
To do so, press the key ”Pin” (10) again.
082−1120−82201c_en 83/113
12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 86 514
84/113 082−1120−82201c_en
Telescoping 12
(Z 82 175, Z 86 514)
16. In order to unlock the LPU, press the ”Preselect” (12) and
”Unlock” (14) buttons successively.
The keys are displayed red after they are pressed.
Observe the correct sequence when pressing the keys: First

press the ”Preselect” button, then press the ”Unlock” but-
ton. Now, the unlocking procedure is triggered automatically
by driving to the fine position.
If an electrical fault is present, it may be that the ”Preselect lock/

unlock” function is unavailable. Instead of this the fine position
must be approached manually before performing the unlocking
procedure in the 18. Work step.
17. Continue to telescope the telescoping cylinder (110) slowly.

When the fine position has been reached (symbols ”4” and
”5” shown against a green background) if the ”Preselect lock/
unlock” function is operational the unlocking procedure is
triggered automatically.
18. If as described above an electrical fault is present, the fine

position ”Lock” (symbols ”4” and ”5” shown against a green
background) must be approached manually and the ”Un-
lock” button (14) actuated.
The ”Lock” (13) and ”Unlock” (14) buttons may be actuated

only in the fine position ”Lock” (symbols ”4” and ”5” shown
against a green background).
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12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
T1 P4 P3 T0 P2 P1
100% 90% 45% 0%
110 111
Z 86 514
86/113 082−1120−82201c_en
Telescoping 12
(Z 82 175, Z 86 514)
The unlocking procedure is completed once the state ’unlocked
1 and pinned’ (the digit ”1” must appear under item 8) is displayed
for the LPU.
Even though the unlocking procedure is completed, the ”Prese-
lect” (12) and ”Unlock” (14) buttons are still displayed against a
red background. This means that the hydraulic valve is still activa-
ted for the unlocking movement to be carried out.
unlocking movement.
In order to do this press the ”preselection”” (12) and ”unlock”
(14) buttons again.
In our example telescopic section 1 is pinned at the pinning hole

0% (P1) on telescopic section 0 (basic case). The LPU state is
”unlocked and pinned”. The telescoping cylinder can therefore
be moved ”empty”, i.e. without a locked telescopic section.
The procedure described in this section can now be repeated for
the next telescopic section to be moved.
Observe the notes on the subject ”Exiting the ’Manual telesco-
ping’ screen” in segment 12.4.3.2.1 (page 55) to exit the ”Manual
telescoping” screen.
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12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
Z 82 242
88/113 082−1120−82201c_en
Telescoping 12
12.4.3.3.2 Teaching the Extension State of the Telescopic Sec-

tions
(Z 82 175, Z 82 242)
Depending on the fault / malfunction and the activities carried out

on the telescoping system during manual telescoping, it might
not be possible to exit the ”Manual telescoping” screen directly.
In this case, the telescoping system must be informed with regard
to the extension state of each telescopic section.
This procedure is referred to as ”teaching”. During ”teaching”, the

positions of the telescopic sections are ”set” and saved.
If ”teaching” is required, key (16) for calling up the ”Teaching”

screen is displayed active and can be selected. Otherwise it be-
comes inactive, i.e. is shown ”greyed out”.
Risk of accidents!
During the ”teaching” process, only exactly those values
which correspond to the actual state may be transferred to
the control system. The crane operator is solely responsi-
ble for this!
Proceed as follows:
1. Activate the depicted key in the corresponding ”Manual tele-

scoping” screen (Z 82 175).
At first, all of the keys assigned to individual telescopic sections

are only filled in with a star. In the sequence, the current exten-
sion state must be selected for all telescopic sections. The follo-
wing options are available for selection:
”0”, ”45”, ”90” and ”100” for pinned states and ”LPU” if the telesco-
pic section is unpinned and locked to the LPU.
2. If the longitudinal code (LK) for the extension state to be

taught is known, the procedure can be continued with step
6.
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12
Z 82 242
Z 82 243
90/113 082−1120−82201c_en
Telescoping 12
(Z 82 242)
3. If the length code (LK) is not known, a telescopic section is

locked to the ”LPU” or if there is no LK for the current exten-
sion state, the extension state must be selected individually
for each individual telescopic section.
To do so:
Activate key next to T1 until the corresponding value ap-
pears.
In our example: ”0”, i.e. telescopic section 1 is extended 0%).
4. Repeat the procedure described for telescopic section 1 ac-

cordingly for the remaining telescopic sections.
5. Continue procedure with step 7.
(Z 82 243, Z 82 242)
6. Enter length code (LK) directly:
6.1 Press ”LK” key.
6.2 Select the line of the length code which corresponds

with the actual extension state of the telescopic sec-
tions (Z 82 243, right−hand side of the figure).
6.3 Exit the screen with the displayed ”Save” key

(Z 82 243, right−hand side of the figure).
The ”Teaching” screen (Z 82 242) reappears and all
sections on the individual telescopic sections are filled
in.
7. Make sure the defined state corresponds to the actual exten-

sion state for all telescopes.
In our example, ”0” has been entered for all telescopic sec-
tions.
If incorrect values have been ”taught”, there is a risk of
overturning.
Check the set values carefully.
8. Exit the ”Teaching” screen (Z 82 243, left−hand side of the

figure).
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12
92/113 082−1120−82201c_en
Telescoping 12
12.4.3.4 Bridging the Load Limit Device (LLD)

(for Electric Faults)
General
If there is an electrical fault, the load limit device (LLD) must be
overridden during manual telescoping for telescoping the tele-
scoping cylinder in and out.
When overriding the LLD, you must differentiate between the

”EN 13000” and ”Non−EN 13000” versions.
When doing this, refer to the corresponding descriptions in sec-
tion 10 ”Safety equipment” under ”Overriding the load limit de-
vice”.
You must remember in particular that bridging continues for a cer-
tain period of time in the ”EN13000” version. For the ”Non−EN
13000” version, the bridging button must be pressed again every
time each telescoping movement is carried out.
Danger!
There is an increased risk of accidents, overturning and
damage!
When the load limit device (LLD) is overridden, neither
the state of the crane nor the telescoping state is monito-
red by the LLD.
The crane operator is responsible for any damage or ac-
cidents that might be caused by this situation.
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12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
94/113 082−1120−82201c_en
Telescoping 12
Coming off the inner guide rails

(Z 82 175)
When the load limit device (LLD) is overridden, the telesco-

pic drive can be extended so far that it comes off the inner
guide rails.
For this reason, there is a table with the approximate locking
and pinning positions of the LPU under subpoint 12.4.3.5
”Locking and pinning positions of the telescopic drive” on
page 97.
The table values correspond with the LPU position (1) in the
”Manual telescoping” screen.
If the corresponding locking and pinning position is not
found, probably several electronic sensors are defective at
once. In this case or when the telescopic drive has come off
the inner sliding rails please contact our customer services
department.
If the telescopic drive has come off the inner guiding slides, tele-
scoping is no longer possible. The telescopic drive can be exten-
ded but will always stick at the same place when being extended.
082−1120−82201c_en 95/113
12
1 2 3 4 5
6
7
8
17 9
16 10
15 11
14 13 12
Z 82 175
96/113 082−1120−82201c_en
Telescoping 12
12.4.3.5 Locking and Pinning Positions of the Telescopic

Drive
(Z 82 175)
The locking and pinning positions are required during manual te-
lescoping.
To be able to recognise beyond doubt by the detail (1, LPU posi-
tion) at which pinning hole the LPU is at for each telescopic sec-
tion (display of the telescopic section under ”3”), observe the fol-
lowing table.
The indicated extension lengths may be exceeded at the

most by approx. 0.05 m (approx. 0.164 ft) during manual tele-
scoping so that the telescopic drive cannot come off the in-
ner guide rails.
Locking and pinning position

Telescopic Pinning LPU posi- LPU posi-
section hole (%) tion (m) tion (ft)
0 0,035 0.115
45 4,750 15.584
1
90 8,565 28.100
100 9,725 31.906
0 0,215 0.705
45 4,480 14.698
2
90 8,745 28.691
100 9,905 32.497
0 0,395 1.296
45 4,660 15.289
3
90 8,925 29.281
100 10,085 33.087
0 0,575 1.886
45 4,840 15.879
4
90 9,105 29.872
100 10,235 33.579
0 0,755 2.477
45 5,020 16.470
5
90 9,285 30.463
100 10,255 33.645
0 0,935 3.068
45 5,200 17.060
6
90 9,465 31.053
100 10,210 33.497
082−1120−82201c_en 97/113
12
98/113 082−1120−82201c_en
Telescoping 12
12.5 Capacities in the Unpinned State
12.5.1 General
Requirement
The capacity tables supplied apply only to extension conditions

where all telescopic sections are pinned to each other.
There are also load bearing capacities for the main boom when
unpinned.
− To lift loads in intermediate positions of the main boom, for
which there is no length code (LK). For this, see ”12.5.4 Lifting
loads in unpinned intermediate positions”, page 107.
− If the main boom is to be telescoped with a load attached. See
”12.5.5Telescoping with a load attached”, page 107.
The main boom is extended to an length for which there is no

length code (LK).
Unpinned capacities are only for main boom operation.
In this case, the lowest extended telescopic section is not pinned

to the next telescopic section, but is connected to the telescopic
cylinder via the LPU.
Limit of the load which can be attached
When attaching loads to the unpinned main boom, the capacity

of the telescoping cylinder and the deflection of the main boom
additionally limit the loads which can be attached.
There is a description in segment 12.5.2 (page 103) of how the un-

pinned capacities table can be displayed at the crane control’s
control panel.
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12
100/113 082−1120−82201c_en
Telescoping 12
Display of the permitted capacities in crane control
The load limit device automatically carries out a comparison bet-

ween the pinned and unpinned capacities.
The lower of the two load bearing capacities compared is the ma-
ximum permissible load. This maximum permissible load will be
shown in the ”Crane operation” screen.
An example of this is described in segment 12.5.3 (page 105).
Applying the capacity in the unpinned state of the main

boom
− Unpinned capacities, for which the main boom length re-
mains unchanged, so−called ”Capacities in intermediate
positions”. Refer to section 12.5.4.
− Unpinned capacities, for which the main boom length is chan-
ged under load, so−called ”Capacities that can be telesco-
ped”. Refer to section 12.5.5.
082−1120−82201c_en 101/113
12
Z 82 244
Z 86 528
Z 86 529
102/113 082−1120−82201c_en
Telescoping 12
12.5.2 Display of the ”Unpinned Load Capacities” Table

at the Crane Control’s Operating Unit
(Z 82 244, Z 86 528, Z 86 529)
1. Activate the displayed key in the Quick menu (Z 82 244, left−

hand side). The ”Operating mode preselection” screen then
appears (Z 82 244, right side).
2. Activate the displayed key in this screen.

The ”Table View” screen then appears (Z 86 528).
The pinned capacities (marked area) for the set operating
mode appear there.
The button shown to the left is shown in the screen’s footer.
3. Activate the displayed key.

The unpinned capacities (marked area) for the set operating
mode appear.
The main boom symbol is changed as shown (without
double arrow) (Z 86 529).
The symbols on the buttons are very similar. They only differ by
the presence or absence of the double arrow.
082−1120−82201c_en 103/113
12
B C
Z 82 247
B D
Z 82 248
Z 82 249
104/113 082−1120−82201c_en
Telescoping 12
12.5.3 Example: Permitted capacity / display in the ”Crane

operation” screen
The adjacent capacity table is only a sample. Only the capa-

city tables which are supplied with the crane may be used for
crane operation.
Pinned capacity
(Z 82 247)
For a main boom length (A) of 21.2 m / 69.6 ft (with LK 12) and
a radius (B) of 4 m (13.1 ft), the corresponding pinned load capa-
city (C) would be 68.8 t / 151.7 kip (Z 82 247) in this case.
Unpinned capacity
(Z 82 248)
For a main boom length (A) of 21.2 m / 69.6 ft (with LK 12) and
a radius (B) of 4 m (13.1 ft), the corresponding unpinned capacity
(D) would be 39.2 t (86.4 kip).
Permitted capacity / display in the ”Crane operation” screen

(Z 82 249)
As described, the load limit device automatically compares the
pinned and unpinned capacities.
The lower of the two load bearing capacities compared is the ma-
ximum permissible load.
In the ”Crane operation” screen, this value for the load bearing
capacity is shown as the maximum permissible load (here: MAX
(t) 39.2 t / 86.4 kip).
082−1120−82201c_en 105/113
12
Z 82 249
106/113 082−1120−82201c_en
Telescoping 12
12.5.4 Lifting loads in unpinned intermediate positions

(Z 82 249)
The main boom is extended to the required length before atta-

ching the load.
The main boom length remains unchanged when the load is atta-
ched.
The capacity values ”MAX (t)” permitted by crane control when

unpinned can be raised.
12.5.5 Telescoping with a suspended load

The load bearing capacity values permitted by the crane control
system when unpinned ”MAX (t)” will also be approved by the
crane control system during a telescoping procedure.
However, the capacities that are actually achievable during tele-

scoping under load are only given as approximate values due to
the large number of variable external influences.
The capacities which can be telescoped (on request) are achie-

ved under the following conditions:
− Sliding surfaces well lubricated
− Normal ambient temperature
− During telescoping, the main boom angle may not be chan-
ged using the luffing cylinder.
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12
108/113 082−1120−82201c_en
Telescoping 12
12.6 Put the main boom into transport condition

To move the crane into the transport position, all telescopic sec-
tions must be completely retracted and pinned and the Locking
and Pinning Unit (LPU) must be secured at the position specified
for the transport condition. If the procedure described in this sec-
tion is observed, then this is ensured.
CAUTION!
If the telescopic sections of the main boom are not pinned in

the intended position, either the main boom will protrude too
far to the front over the crane contour or the telescopic sec-
tions can slip out in an uncontrolled fashion while driving.
In both cases there is a risk of collision.
Bring the main boom into the transport position using the
procedure described in this segment.
If the telescopic sections are not the position intended for driving,
the specified axle loads will not be correct.
The transport condition of the main boom is also the starting con-
dition when fitting the main boom extension (see section 18).
Prerequisites:
The main boom is telescoped in and placed on the crane chassis
in transport position (current length code LK1).
082−1120−82201c_en 109/113
12
Z 82 139
Z 82 232 Z 82 153
110/113 082−1120−82201c_en
Telescoping 12
(Z 82 139, Z 82 232, Z 82 153)
1. Set the ”HA” crane configuration at the crane control’s con-

trol panel in the ”Selection of the operating mode” screen
(Z 82 139).
If a deviating setting is made for the crane configuration, then the

button for selection of the length code to establish the driving con-
figuration will not be shown in the ”Length code (LK) selection”
screen which is used in one of the following work steps.
2. Leave the screen with ”Save”.

The ”Crane operation” screen appears with the partial
”Quickmenu” screen (Z 82 232).
3. Select the ”Telescoping display” screen in the ”Quickmenu”

screen. Press the displayed button to do so.
The ”Telescoping display” screen appears (Z 82 153).
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12
Z 82 233 Z 82 235
Z 82 234
112/113 082−1120−82201c_en
Telescoping 12
(Z 82 233, Z 82 234)
4. Select the ”Length code (LK) selection” screen in the ”Tele-

scoping display” screen. Press the displayed button to do so.
The ”Length code (LK) selection” screen appears
(Z 82 234).
(Z 82 234, Z 82 235)
5. Select the length code to establish the driving configuration

of the main boom for driving the crane in the ”Length code
(LK) selection” screen. Press the displayed button to do so.
The ”Telescoping display” (Z 82 233) appears again with se-
lected ”LK0”. The ”LK0” is shown in grey.
(Z 82 235)
In the next work step, the control lever must be actuated until a
symbolic crane appears in the top half of the ”Telescoping dis-
play” screen. The ”LK0” is then shown in green.
6. Move the control lever which is on the telescoping movement

to the ”Telescope out” direction.
The locking and pinning unit (LPU) will be corresponding mo-
ved and secured.
Only when a symbolic crane is shown in the top half of the ”Tele-
scoping display” screen are the telescopic sections of the main
boom, including the LPU, in the transport condition for driving the
crane.
082−1120−82201c_en 113/113
Luffing 13
082−1130−82201c_en 1/15
13
56 58 60
57 59 61
Z 53 469 Z 82 576
Z 82 264
2/15 082−1130−82201c_en
Luffing 13
13 Luffing
13.1 Luffing Operation
13.1.1 General Safety Instructions
The main boom is raised and lowered (luffing) by extending and

retracting the luffing cylinder. (Z 53 469 schematic diagram).
It is prohibited to raise a load from the ground using the luf-

fing gear! This can only be done using the hoist!
(Z 82 576, Z 82 264)
If a prohibited overload condition has occurred, the load−mo-

ment−reducing movement ”Raise luffing gear” is also shut down
by the load limit device. It can then be driven after the key−opera-
ted pushbutton (57) has been pressed and held in order to bring
any free−hanging loads back out of the overload range into the
normal operating range. The arrow shown in figure (Z 82 264)
appears to display the bridged state (red = activated, not bridged,
black = bridged).
These load−moment−reducing movements may be ena-

bled only if they do not cause a dangerous situation. Take
this into consideration before pressing the key−operated
pushbutton.
If the load is still touching the ground and raising the hoist
was switched off, the load is too heavy. The ”Raise main
boom” movement may then not be enabled!
The movement ”Raise luffing gear” may not be used under

any circumstances to raise the load!
082−1130−82201c_en 3/15
13
Z 82 264
4/15 082−1130−82201c_en
Luffing 13
(Z 82 264)
Risk of falling backwards!
In some cases, it is not permitted to enable load−moment−

reducing movements.
Example: the permitted minimum radius is 3 m (9.8 ft) and
“Luffing up” is switched off. A corresponding symbol ap-
pears in the ”Crane operation” screen (Z 82 264).
In this case, you may not perform an override and the load−
moment−reducing movement “Luffing up” may not be con-
tinued as the crane could tilt over backwards if it has a lar-
ger counterweight.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the
hook) must be lowered (see section 14).
082−1130−82201c_en 5/15
13
220
Z 82 263
81
43
Z 82 089 Z 82 259
6/15 082−1130−82201c_en
Luffing 13
13.1.2 Procedure for Luffing
(Z 82 263)
Starting situation

zontally.
− Optional ball valve (220) for blocking the bottom of the luffing
cylinder in the open position (position for crane operation,
see also section 13.4, page 15).
Procedure
(Z 82 089)

the control levers. The current mode (here: 1) is
displayed in the uppermost line of the ”Crane operation”
screen (Z 82 089).
Risk of accidents!
ment.
(Z 82 259)
2. Initiate luffing movement by activating one of the keys of the

“release switch system” and carefully steering control lever
(43) / (81) in the corresponding direction.
Risk of accidents!
082−1130−82201c_en 7/15
13
81
43
Z 82 259
8/15 082−1130−82201c_en
Luffing 13
(Z 82 259)
Risk of accidents!
RISK OF ACCIDENTS!

stopped.

ment has ceased.
082−1130−82201c_en 9/15
13
81
43
Z 82 259
10/15 082−1130−82201c_en
Luffing 13
13.2 Regulating the Luffing Speed

(Z 82 259)
The luffing gear is electrically pre−controlled. The luffing speed

depends on the engine speed and the steering of the correspon-
ding control lever (43) / (81).
13.2.1 High speed mode ”Raise main boom”
A high−speed mode can be selected to raise the main boom (luf-

fing up).
See section 10 ”Safety equipment” in segment ”High−speed
mode” in this regard.

wing cases:
− with a fly jib fitted
− 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
shutdown by the load limit device (at latest up to the advan-
ced warning).
Risk of tilting due to dynamics!
13.2.2 Fine tuning “Lowering main boom”
In addition, speed fine tuning is possible for lowering the main

boom (luffing down).
movement speed”.
082−1130−82201c_en 11/15
13
Z 82 889
12/15 082−1130−82201c_en
Luffing 13
13.3 Setting down the Main Boom in the Support Device

for the Boom
When setting down the main boom in the support device for the
boom, the alignment of the superstructure and the luffing angle
of the main boom must be selected so that no components of the
chassis (e. g. hydraulic tank of the chassis) are damaged.
For this crane type, this is supported by a movement limit.

The slew gear and luffing gear are shut down before anything can
be damaged. The superstructure position must then be corrected
accordingly before the main boom can be lowered any further.
The setting down procedure is carried out at a superstructure an-

gle of 180°.
(Z 82 889)
The slew display in the ”Crane operation” screen indicates in
which direction slewing is possible if there is a shut−down.
See the section ”Slewing angle / slewing direction” in the section
”Slewing the superstructure”.
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13
220
Z 82 263
14/15 082−1130−82201c_en
Luffing 13
13.4 Dolly Preparation / Preparation for Dismantling

the Main Boom (Options)
(Z 82 263)
If the crane is prepared for driving with dolly (optional) or for dis-
mantling the main boom (optional), there is a stop valve (220) to
block the oil supply of the luffing cylinder at the bottom.
Ball valve (220) must be open for crane operation, i.e. the oil sup-
ply of the luffing cylinder at the bottom must be ensured.
DANGER!
Death or serious injury can be caused by the crane being
operated when not fully functional.
Check that ball valve (220) is open before crane operation.
Observe the corresponding warning signs in both cabs
(see the section ”Decals” in section 2 ”Structure of the
Crane” as well).
082−1130−82201c_en 15/15
Hoist 1 14
082−1140−82201a_en 1/9
14
Z 22 437
2/9 082−1140−82201a_en
Hoist 1 14
14 Hoist 1
14.1 Hoist operation
14.1.1 General Safety Instructions
(Z 22 437)
Loads are raised or lowered by reeling or unreeling the hoist rope

on to or out from the hoist rope drum (Z 22 437).
Risk of accidents!
Loads may only be taken up using the hoist!
Observe the reeling behaviour of the hoist (see section 14.3,

page 9).
14.1.2 Procedure for reeling the hoist rope in and out
Starting situation

zontally.
082−1140−82201a_en 3/9
14
81
43
Z 82 089 Z 82 259
4/9 082−1140−82201a_en
Hoist 1 14
Procedure
(Z 82 089)

the control levers. The current mode (here: 1) is
displayed in the uppermost line of the ”Crane operation”
screen (Z 82 089).
Risk of accidents!
ment.
(Z 82 259)
2. Initiate hoist movement by activating one of the keys of the

”release switch system” and carefully steering control lever
(43) / (81) in the corresponding direction.
Risk of accidents!
Risk of accidents!
RISK OF ACCIDENTS!
082−1140−82201a_en 5/9
14
81
43
Z 82 273
6/9 082−1140−82201a_en
Hoist 1 14
(Z 82 273)

stopped.

ment has ceased.
You will feel definite vibration on the hoist rotation indicator (arrow
in Z 82 273) of control lever (81) as soon as hoist 1 rotates.
The movement ”raise load” is automatically shut down when :

* the load limit device has shut down.
* the hook block has triggered the hoist limit switch.
It is possible to lower the load.
The movement ”lower load” is automatically shut down, when the

lower limit switch for hoist 1 has tripped.
It is possible to raise the load.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the
hook) must be lowered.
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14
81
43
Z 82 259
Z 82 284
8/9 082−1140−82201a_en
Hoist 1 14
14.2 Regulating the hoist speed

(Z 82 259)
The hoist is pilot controlled electrically. The hoist speed depends

on the engine speed and the steering of the corresponding con-
trol lever (43) / (81).
14.2.1 High speed
A high−speed mode can be added for the hoist.

See section 10 ”Safety equipment” in segment ”High−speed
mode” in this regard.

wing cases:
− for single−rope operation of the main boom extension.
14.2.2 Fine tuning
In addition, speed fine tuning is possible for the hoist.

movement speed”.
14.3 Camera monitoring of the hoist (optional)

(Z 82 284)
A camera (4) is attached to hoist 1 to monitor of the hoist rope’s

reeling behaviour. The camera is permanently installed.
The display (1) is in the crane operator’s cab.
When the ignition is switched on, the camera pictures appear on

display (1) if it is turned on.
For detailed specifications on operating the camera and dis-

play, see the section ”Cameras on the crane” in section 11
”Working instructions”.
082−1140−82201a_en 9/9
Hoist 2 15
082−1150−82201b_en 1/33
15
785
1655
925
Z 84 321 Z 84 322
2/33 082−1150−82201b_en
Hoist 2 15
15 Hoist 2 (optional)
15.1 Transport Dimensions and Weights

(Z 84 321, Z 84 322)
Width Height Depth Weight

mm ft mm ft mm ft kg lbs
925 3.0 785 2.6 1655 5.4 1650 3640
All specifications are approximate values.
15.2 Fitting and Removing Hoist 2
15.2.1 General
Hoist 2 can be fitted and removed in two different ways:

− using an auxiliary crane (see from page 5)
− using a forklift truck (see from page 17)
− using your own crane with special accessories (optional); see
from page 19.
Equipment may only be fitted and removed by trained and

qualified personnel.
Risk of falling!
All assembly work/work at height must be carried out using
suitable auxiliary equipment (ladders, hoist platforms,
scaffolding, auxiliary crane, personal protective equip-
ment).
Detailed information on this subject can be found in sec-
tion 2 ”Structure of the mobile crane” under ”Getting on
and down from the crane”, in particular ”Getting on and
down using the mobile multi−purpose ladder” and ”Attach-
ment eyelets for personal protective equipment”.
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15
4/33 082−1150−82201b_en
Hoist 2 15
15.2.2 When Fitting and Removing Hoist 2with the Auxiliary

Crane
15.2.2.1 Fitting
1. Support the crane correctly on outriggers and align. Select

the outrigger support area in accordance with the subse-
quent crane operation.
Please observe the corresponding description in the opera-
ting instructions of the crane chassis.
We recommend first fitting hoist 2 and then the counterweight.

This makes it easier to knock in the connecting pins for mounting
hoist 2.
In general, it is also possible to attach hoist 2 with the counter-
weight fitted.
Exception: In the two largest counterweight combinations 51.6 t
(113.8 kip) and 70.2 t (154.8 kip), first the top counterweight
plate (5) must be removed in order to obtain sufficient space to
retract hoist 2 from below into the attachment point.
2. There must be a trained assembly helper on the crane in the

assembly area when fitting hoist 2.
082−1150−82201b_en 5/33
15
33
34
Z 84 320 Z 86 494
Z 86 495
6/33 082−1150−82201b_en
Hoist 2 15
(Z 84 320)
3. Release rope shackle (33) from the transport position on ho-
ist 2 and fit it (see section 17 ”Reevings” under ”Reeving/un-
reeving the hoist rope”).
(Z 84 320)
4. Check that the 4 pins (34) are fitted and secured in the fork
heads of hoist 2 as illustrated.
They are used at a later point during the fitting procedure to
fix in place the assembly position of hoist 2.
In the following, hoist 2 may not swing out or hang crookedly

during raising!
Risk of accidents!
There is risk of crushing between hoist 2 and the super-
structure frame! Proceed with appropriate caution. Main-
tain a sufficient safety clearance!
(Z 86 494)
5. Attach the auxiliary crane to the two middle lifting lugs of ho-
ist 2 as illustrated.
Hoist 2 weighs approx. 1650 kg (3640 lbs).
(Z 86 495)
6. Raise and position hoist 2 so that the pins in the fork heads
of hoist 2 are aligned with the corresponding hook jaws on
the superstructure frame as illustrated.
082−1150−82201b_en 7/33
15
Z 84 305
Z 86 496
8/33 082−1150−82201b_en
Hoist 2 15
(Z 84 305, Z 86 496)
7. Using the auxiliary crane, raise hoist 2 until the pins in the
fork heads of hoist 2 are retracted into the hook jaws on the
superstructure frame − as illustrated.
(Z 84 305, Z 86 496)
8. Pin hoist 2 on both sides using pins (9) − as illustrated − and
secure each pin with forelocks.
Risk of falling!
Additional suitable auxiliary equipment (e.g. lifting plat-
form) must be used to safely carry out this work at height.
9. Release the auxiliary crane.
082−1150−82201b_en 9/33
15
Z 84 324
10/33 082−1150−82201b_en
Hoist 2 15

10. Position the superstructure to the crane chassis so that there
is sufficient access on the crane chassis to create the hy-
draulic and electric connections on the superstructure.
It is only ever permitted to create and release hydraulic con-

nections in the depressurised state, i.e. the engine may not
be running.
11. Connect hoist 2 hydraulically and electrically.

To do so, unscrew the protective caps from the correspon-
ding coupling sleeves / sockets and fully fit quick release
coupling plugs of the corresponding hydraulic hoses or plug
in the connecting cable plugs.
The coupling sleeves and plugs are each marked with plates.
Connect the individual connections with identical markings.
Observe the list on the next page for the connection markings.
082−1150−82201b_en 11/33
15
2 3
4
1
6 7
8 17
18
Z 84 307
6 7
9 17 / 18 8
Z 84 323
12/33 082−1150−82201b_en
Hoist 2 15
(Z 84 307, Z 84 323)
K(*) Connection function

Mobile control panel for driving the hydraulic cylinders
1
of the configuration aid hoist 2 (XS560.1)
2 Distribution box hoist 2 (X8200)
3 Camera hoist 2 (X7134)
4 Can bus hoist 2
Control pressure for releasing the brake (DN 8, nominal

6
diameter approx. 8 mm / 0.31 in)
Lower hoist 2 (DN 32, nominal diameter about 32 mm /
7
1.25 in)
Raise hoist 2 (DN 32, nominal diameter about 32 mm /
8
1.25 in)
Leak oil (DN 20, nominal diameter approx. 20 mm /
9
0.8 in)
Retract hydraulic cylinders of the configuration aid
17
(DN 8, nominal diameter approx. 8 mm / 0.31 in)
Extend hydraulic cylinders of the configuration aid
18
(DN 8, nominal diameter approx. 8 mm / 0.31 in)
K(*) − connection marking
Make sure in each case that the hydraulic connections have

been made correctly, i.e. that the couplings open properly.
Risk of accidents!
Connections (7)/(8) and (17)/(18) have identical couplings
and can therefore be easily confused. For this reason, first
carry out a function test after connecting. It must be possi-
ble to carry out all movements as intended.
082−1150−82201b_en 13/33
15
1 2 3
Z 84 315
3 1
2 4
Z 84 316
14/33 082−1150−82201b_en
Hoist 2 15
(Z 84 315, Z 84 316)
12. If the crane is equipped with the superstructure central lubri-
cating system, connect hoist 2. To do so:
12.1 Remove the return line plug (3) from the depicted col-
lecting plate of coupling (2) of the supply line and close
it with protective cap (1).
12.2 Remove the protective cap and then fit lubricant line
plug (4) from hoist 2 to coupling (2) of the supply line
as illustrated.
Risk of damage!
The return line plug (3) must be closed with the correspon-
ding protective cap so that no dirt can get into the lubrication
system.
In the same way, after dismantling hoist 2 and disconnecting
the lubricant line of hoist 2, it must be closed with a protec-
tive cap and the return line must be reconnected to the sup-
ply line coupling.

After making the connections, the assembly assistant
must exit the crane and the endangered area.
You must observe the corresponding specifications in sec-

tion 17 ”Reevings” under ”Hoist ropes” for fitting / reeving
the hoist rope.
15.2.2.2 Dismantling
Hoist 2 is removed in the same way as it is fitted, only in the re-

verse order.
In particular observe the safety instructions required for fit-

ting the equipment.
082−1150−82201b_en 15/33
15
1
Z 86 493
16/33 082−1150−82201b_en
Hoist 2 15
15.2.3 When Fitting and Removing Hoist 2 with the Forklift

Truck
(Z 86 493)
In principle, fitting and removing is carried out with a forklift truck

as described for the use of an auxiliary crane starting on p. 5.
However, also observe the following special features.

− Superstructure is rotated so that the forklift truck can safely
reach the assembly area.
− The ground at the assembly area must be suitable for the for-
klift truck to be positioned safely.
− Forklift truck with sufficient capacity.
Danger due to falling loads!

When raising/lowering hoist 2 with a forklift truck, ensure
that hoist 2 is lying fully on the forks of the forklift truck.
Only the four forklift pockets (1) may be used to pick up ho-
ist 2.
082−1150−82201b_en 17/33
15
Z 84 325
Z 84 326
18/33 082−1150−82201b_en
Hoist 2 15
15.2.4 When Fitting and Removing Hoist 2 with Your Own

Crane
15.2.4.1 General
(Z 84 325)
In order to fit and dismantle hoist 2 using your own crane, the ba-
sic crane and hoist 2 (1) must be equipped accordingly in terms
of hydraulics and configuration frame (5) is required.
Among other things, hoist 2 is then equipped with two erection
cylinders (2) which are used to place it in the fitting position.
15.2.4.2 Fitting
(Z 84 326)
1. In the section ”Fitting with auxiliary crane”, observe the

points 1. − 4. (from page 5) and in particular, the correspon-
ding instructions on risks.
(Z 84 326)
2. Set counterweight combination 13.1 t (28.9 kip) down on the
counterweight support of the crane chassis (as for fitting the
counterweight).
Observe the corresponding description in section 9 “Coun-
terweight”.
082−1150−82201b_en 19/33
15
Z 86 497
20/33 082−1150−82201b_en
Hoist 2 15
In the following, hoist 2 may neither swing out nor hang

crooked.
(Z 86 497)
3. Using your own crane, attach hoist 2 (1) to the two middle lif-
ting lugs and set down on configuration frame (5) so that the
piston rods ends of the two erection cylinders (2) are aligned
with the corresponding receptacles on the configuration
frame.
(Z 86 497)
4. On both sides, remove pins (3) from the transport position on
the configuration frame and pin and secure to the correspon-
ding shackles of the configuration frame as illustrated.
Hoist 2 and the configuration frame are connected with each
other. They form an assembly unit from this point.
082−1150−82201b_en 21/33
15
7
8 8
Z 86 498
9
8
Z 84 329
22/33 082−1150−82201b_en
Hoist 2 15
(Z 86 498)
5. Attach the assembly unit to the lifting lugs of the hoist on both
sides − however, not to the middle ones at this point, but to
the rear ones.
This results in a slightly tilted assembly unit position, which
makes the following fitting procedure easier.
The assembly unit weighs approx. 1770 kg (3902 lbs).
(Z 86 498)
6. Raise the assembly unit and position it in the area of the draw
bars of the counterweight combination which has been set
down − as illustrated.
(Z 86 498)
7. Retract the assembly unit with spigots (6) and shackles (7)
at the corresponding counterparts on the draw bars (8).
(Z 86 498, Z 84 329)
8. Remove pins (9) from the transport position on hoist 2
(Z 86 498) and pin and secure as shown in (Z 84 329).
The assembly unit is then pinned to the draw bars (8) on both
sides.
9. Release lifting tackle from the assembly unit.
082−1150−82201b_en 23/33
15
18 1
19
Z 84 350 Z 84 331
Z 84 330
24/33 082−1150−82201b_en
Hoist 2 15
10. At first, only create the hydraulic connection for both erection
cylinders on hoist 2 (connections “17” and “18”).
To do so, follow the corresponding description in section ”Fit-
ting ... with an auxiliary crane” from point 10., page 11.
(Z 84 350, Z 84 331)
11. Plug the mobile control panel into socket (1) on the collecting
plate.
(Z 84 330)
12. Slew the superstructure so that the main boom is to the rear.
The pins in the fork heads of hoist 2 are flush with the hook
jaws on the superstructure frame.
082−1150−82201b_en 25/33
15
18
9
19
Z 84 332 Z 84 350
Z 84 333
26/33 082−1150−82201b_en
Hoist 2 15
(Z 84 332, Z 84 350)
13. Extend erection cylinder (2) until the 4 pins in the fork heads
of hoist 2 are all retracted up to the stop into the correspon-
ding hook jaws on the superstructure frame.
To do so, switch selector switch (18) on the mobile control pa-
nel to position ”1” while the engine is running and press rok-
ker switch (19) up until this state has been reached.
(Z 84 332, Z 84 333)
14. Pin hoist 2 to the superstructure frame.
To do so, remove pins (9, Z 84 332) from the shackles − the
connection between hoist 2 and the configuration frame is
released − and pin and secure as shown in (Z 84 333).
For a detailed description of pinning and securing these

pins, you must observe the corresponding description on
page 9.
Risk of falling!
082−1150−82201b_en 27/33
15
18
19
Z 84 334 Z 84 350
Z 84 335
28/33 082−1150−82201b_en
Hoist 2 15
(Z 84 334, Z 84 350)
15. Fully retract erection cylinder (2).
To do so, switch selector switch (18) on the mobile control pa-
nel to position ”1” and press rocker switch (19) down until this
state has been reached.
16. Connect all the hydraulic and electric lines of hoist 2.

To do so, follow the corresponding description in section ”Fit-
ting ... with an auxiliary crane” from point 10., page 11.
17. If the crane is equipped with the superstructure central lubri-

cating system, connect hoist 2.
Observe the corresponding description on page 15.

The assembly assistant must leave the area at risk before
the superstructure is slewed in the following procedure
(e.g. by getting down from the crane).
If the assembly assistant remains on the crane outside of
the slewing range, he must stay in constant contact with
the crane operator.
(Z 84 335)
18. Once the crane operator has ensured that there is no longer
anyone in the area at risk, slew the superstructure to dis-
mantle the configuration frame using your own crane.
To do so, attach the configuration frame (5) to the crane:
− either to lifting lugs (2) with 4−strand lifting chains (as illu-
strated)
− or to attachment holders (1) with flat lifting slings.
The configuration frame weighs approx. 120 kg (265 lbs).
082−1150−82201b_en 29/33
15
Z 84 336
30/33 082−1150−82201b_en
Hoist 2 15
(Z 84 336)
19. Slightly tension the lifting tackle so that the crane takes the
weight of the attached configuration frame.
(Z 84 336)
20. Unlock and pull out pins (9) on both sides and pin and secure
in the top shackles (transport position).
21. Raise the configuration frame and set it down.
22. Either dismantle the remaining counterweight combination

as well or fit to the superstructure frame, possibly after adap-
ting the fitted counterweight combination.
Risk of accidents!
The fitted counterweight must correspond with the speci-
fications in the capacity table for the planned load case.
15.2.4.3 Dismantling
Hoist 2 is removed in the same way as it is fitted, only in the re-

verse order.
In particular observe the safety instructions required for fit-

ting the equipment.
15.3 Hoist operation
Detailed instructions on raising or lowering loads with the hoist

can be found in section 14 ”Hoist 1” under ”Hoist operation”.
15.4 Regulating the hoist speed
Detailed specifications for regulating the hoist speed can be

found in section 14 ”Hoist 1” under the corresponding point.
082−1150−82201b_en 31/33
15
Z 86 499 Z 84 313
4
5
Z 84 314
32/33 082−1150−82201b_en
Hoist 2 15
15.5 Camera monitoring of the hoist (optional)

(Z 86 499, Z 84 313, Z 84 314)
A hoist camera (5) can be fitted to hoist 2 to monitor the hoist ro-
pe’s reeling behaviour. This camera is simply fitted by screwing
it in place with star−knob screw (6) − as shown in (Z 86 499).
Plug the plug on the collecting plate into connection (3) to con-
nect the camera electrically.
As soon as the ignition is switched on, camera images are shown

in screen (1) in the crane operator’s cab.
For detailed specifications on operating the camera and dis-

play, observe section 11 ”Working instructions” and the cor-
responding manufacturer’s documents in the part ”Va-
rious”.
As long as hoist 2 is not fitted, camera hoist 2 (5) can be fitted at

the back on the superstructure frame − next to camera (4) for ho-
ist 1 − as shown in (Z 84 314). This makes it possible to monitor
the rearward crane surroundings.
082−1150−82201b_en 33/33
Heating and Ventilation 16
082−1160−82201a_en 1/19
16
2/19 082−1160−82201a_en
16 Heating and Ventilation
16.1 Cab heater arrangement, engine−independent
16.1.1 Operating / Safety Instructions
DANGER!
Risk of fire and explosion!

The heater assembly may not be used if combustible va-
pour or dust could develop (for example, at filling stations
or near fuel, coal dust, wood dust, grain storage facilities
and similar).
Risk of poisoning!
Do not operate the heating device in enclosed rooms, e.g.
a garage or a parking garage.
Danger of burning!
Switch off the heater assembly and let all hot components
cool down before working on the heater assembly or in its
vicinity. Remove the electrical fuse!
CAUTION!
Only a contractual partner authorised by the manufacturer

may repair the heater assembly.
Repairs by unauthorised third parties and / or using non ori-
ginal spare parts are dangerous and are therefore prohibi-
ted.
The original installation condition of the heater unit and cor-

responding components must not be altered.
This is especially applicable for electric wiring, fuel supply,
combustion and flue gas evacuation.
Defective fuses may only be replaced with fuses of the same

number of amps.
082−1160−82201a_en 3/19
16
Z 82 570
4/19 082−1160−82201a_en
CAUTION!
The run on of the heating device should not be interrupted

prematurely, except in case of an emergency.
If emergency stop is essential during an operation, switch
off the heating device using the operating element or pull out
the fuse or disconnect the heating device from the battery.
You must carry out a test run with the heater assembly be-
fore the heating period. If thick smoke develops, remaining
for an extended period of time, or if there are unusual noises
from the burner or a definite stench of burning, the heating
must be switched off and put out of operation by removing
the fuse. The equipment should only be restarted once it has
been tested by an authorised service outlet.
During electric welding work on the vehicle, the + pole must

be disconnected from the battery and connected to ground
to protect the control unit.
Switch the heating device on for approximately 10 minutes ap-

proximately once a month, even outside the regular heating pe-
riods. This prevents the water pump and burner motor from sei-
zing up.
Fuel: The heater assembly is connected to its own fuel tank. The
fuel tank is located to the right of the slew ring (Z 82 570, 1).
After a long operational break, check the fuel system for leak
tightness; rectify any leakage immediately.
082−1160−82201a_en 5/19
16
90 91 92 93 94
0 I
102
Z 104 570
6/19 082−1160−82201a_en
16.1.2 Operating Elements in the Crane Operator’s Cab

(Z 104 570)
The temperature in the crane operator’s cab can be regulated via

a rotary switch (92).
A fan can also be installed via the rotary switch (90). The air ex-
change in the cab can be accelerated accordingly by using the
fan.
Using luminous switch (93), you can select between fresh air and
recirculation mode:
− Luminous switch (93) not activated; the indicator light in the
switch is not illuminated: fresh air operation.
− Luminous switch (93) activated; the indicator light in the
switch is illuminated: recirculation operation.
− The fan’s air distribution in the cab is monitored using a rotary
switch (91).
In the cab there are several vent nozzles (12). 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.
082−1160−82201a_en 7/19
16
90 91 92 93 94
0 I
102
Z 104 570
1 2 3 4
8 5
7 6
Z 104 995
8/19 082−1160−82201a_en
16.1.3 Operating Control of the Heater Timer
(Z 104 570)
The heating device is controlled by the timer (102).
Components of the timer

(Z 104 995)
Display:
(1) − Program strip
(2) − Menu strip
(3) − Display strip
(4) − Status display
Function keys:
(5) − Control key forwards
(6) − OK key
(7) − Activation key
(8) − Control key backward
NOTE:
Do not switch off and on more than twice in a row.

Further information on operating the engine−independent cab
heater arrangement can be found in the ”Various” section of
these operating instructions.
082−1160−82201a_en 9/19
16
90 91 92 93 94
0 I
102
Z 104 570
10/19 082−1160−82201a_en
16.2 Air Conditioning

(Z 104 570)
The air conditioning system only works when the engine is run-
ning and the fan is switched on. Proceed as follows in order to
operate the air conditioning system:
1. Set switch (90) to the desired fan level.
2. Turn switch (94) to ”I”.
The air conditioning system works continually at maximum

power. The actual cooling power is then determined by the selec-
tion of the fan setting.
In order achieve maximum cooling in the cab:

− Set fan to highest setting using switch (90).
− Turn switch (92) fully to the left (anticlockwise) up to the stop.
− Open the air vents completely.
− Activate the luminous switch (93) for recirculation mode.
− Close the windows and doors of the cab.
Instructions on operating the air conditioning unit
If the cooling power of the air conditioning system decreases noti-

ceably even though the switch settings have not changed, it is
possible that the evaporator has iced up.
In this case, switch the air conditioning unit off for approx. 3 minu-
tes with the evaporator fan still running. The ice on the evaporator
will melt.
On damp and cool days the air conditioning unit can dehumidify
the cab air. Cooling is compensated by the heating. This then
achieves a more pleasant cab climate and prevents the windows
from misting up.
Do not direct cold air coming out of the air vents directly onto un-
protected parts of your body.
The air conditioning unit must be switched on at least once

a month for a short period of time (compressor lubrication).
082−1160−82201a_en 11/19
16
2 A
1 B
C
3
Z 59 555
B
1.2
Z 59 556
12/19 082−1160−82201a_en
16.3 Petrol Gas Heating (Engine−independent), Optional

(Z 59 555, Z 59 556)
16.3.1 Important Information

DANGER!
− Check before each commissioning whether the wall

chimney for exhaust gas ventilation is unblocked. Do
not fail to remove or open the cover cap from the wall
chimney!
− The cover cap for the wall chimney is always to be moun-
ted and/or closed when the heating system is not in ope-
ration. This is particularly important when washing the
crane.
− Have the exhaust gas ventilation checked by a specialist
after each deflagration (backfire) .
− The heating unit may not be operated when filling up or
in a garage.
− Any spray cans or gas cartridges in the crane may not
be subjected to the heating air flow.
− The following is to be observed in cases of gas system
leaks and/or gas odour:
∗ Close the gas bottle at once
∗ extinguish all open flames
∗ do not smoke
∗ Switch Off the auxiliary heater
∗ open windows
∗ do not actuate any electrical switches
∗ have the entire installation checked by service per-
sonnel
∗ at a suitable specialist workshop.
082−1160−82201a_en 13/19
16
2 A
1 B
C
3
Z 59 555
B
1.2
Z 59 556
14/19 082−1160−82201a_en
16.3.2 Heating
(Z 59 555, Z 59 556)
Switch on the heating as follows:

1. If necessary, remove the flue cover.
2. Open the bottle valve and quick release valve in the gas line.
3. Set desired room temperature using the control knob.
Operating part with sliding switch
Set switch (3) to ”Heating” (position ”A”) and switch (2) to the desi-
red output (”FULL, large flame” or ”1/2, small flame”). If ambient
temperatures are low, let the heating start up at ”FULL”.
Control element with combination rotary switch
Set rotary switch (1.2) to desired heating stage ”A” (”FULL, large
flame” or ”1/2, small flame”). If ambient temperatures are low, let
the heating start up at ”FULL”.
16.3.3 Ventilation
Switch on the fan as follows:
Operating part with sliding switch
− Set switch (3) to ”Ventilation” (position ”C”).

− Set switch (2) to desired air output (”FULL” or ”1/2”).
Control element with combination rotary switch
− Set rotary switch (1.2) to the desired air output (C).
082−1160−82201a_en 15/19
16
2 A
1 B
C
3
Z 59 555
B
1.2
Z 59 556
16/19 082−1160−82201a_en
16.3.4 Shutting off

(Z 59 555, Z 59 556)
− Set sliding switch (3) or rotary switch (1.2) to the middle (B).
NOTE:
If the heating system is switched off after a heating phase, then

the blower can continue to run afterwards to utilise any residual
warmth.
− During prolonged down times, put the chimney cover in place

and close the valve on the gas tank.
16.3.5 Notes on heating operation

(Z 59 555, Z 59 556)
If switch (3) or rotary switch (1.2) is set to ”Heating” (position ”A”)

or ”Ventilation” (position ”C”), the green indicator lamp must be
illuminated. The fan is in operation.
If the indicator lamp does not light up, the fuse in the electronic
control unit should be replaced (see the lubrication and mainte-
nance instructions in ”Heating systems”).
If the heating is switched off following a heating phase, the green

light means that the fan is still running to use up the residual
warmth. The ignition−starter switch may therefore only be swit-
ched off once the fan comes to a standstill.
If the red indicator lamp remains continously on, this may indica-
tea shortage of gas, air in the gas line, a severely clogged fan im-
peller or a defect in a fuse link among other things.
The fault is unlocked/deactivated by switching the heating off and
on again.
If the red indicator lamp flashes there is insufficient operating vol-

tage for the heating.
082−1160−82201a_en 17/19
16
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
18/19 082−1160−82201a_en
CAUTION!
Make sure that the flue for exhaust emission is always free
of any contamination (slush, leaves, etc.).
Always put on the cover cap of the wall chimney when the
heater is not in operation.
This cover cap must be removed before each time the appa-
ratus is put into operation.
The heating unit may not be operated when filling up or in a
garage.
The positive terminal is to be disconnected from the battery
and to be grounded during electric welding work on the
crane chassis or on the superstructure for the protection of
the heating system control units.
In addition, observe the operating instructions ”Trumatic E

2400” from the heating unit’s manufacturer when operating
and servicing the heating system.
082−1160−82201a_en 19/19
Reevings 17
082−1170−82201d_en 1/69
17
FK
Z 83 480
2/69 082−1170−82201d_en
Reevings 17
17 Reevings
17.1 General
The safety of the crane is at risk due to incorrect reeving.
Every configuration is assigned a corresponding reeving

number that is shown in the capacity tables supplied. Work
only in accordance with the reeving numbers listed there.
The corresponding reeving number must be set on the load
limit device.
Unless otherwise specified in the capacity tables, the num-

ber of reevings must not be lower than 2 rope strands.
If, however, single−strand reeving is required, the lifting ca-
pacities specified in the table must be reduced by 20%. This
is also valid, when the lifting capacity lies below the maxi-
mum permissible rope pull per line.
The concrete numerical value can be found in the ”Instruc-
tions on crane operation” supplied with the capacity tables.
Risk of damage for the rope safety bracket / hoist rope.

An even number of falls must be reeved for a boom angle be-
low 10°.
(Z 83 480)
Twisting problems can occur when fitting a new hoist rope
which has never been placed under load. For this reason, we
recommend that a spin stabiliser is used (1) in this case.
082−1170−82201d_en 3/69
17
FK
Z 83 480
“a” “b”
ca. 1250
ca. 1500
Z 55 732
4/69 082−1170−82201d_en
Reevings 17
(Z 83 480, Z 55 732)
If a spin stabilizer (1) is fitted at the rope attachment point of

the main boom head, the length of the chain of the hoist limit
switch’s shift weight (up to bottom edge of the hoist limit
switch) must be AT LEAST approx. 1500 mm (4.9 ft) (see “a”
in figure Z 55 732). Only then is it ensured that the switch−off
of ”Raise hoist” is carried out by the hoist limit switch within
a sufficient distance of the lowest point of the main boom
head. Otherwise, there is a risk of damage.
If no spin stabilizer is fitted to the rope attachment point of

the main boom head, the length of the chain of the hoist limit
switch’s shift weight (to the bottom edge of the hoist limit
switch) must be AT LEAST about 1250 mm (4.1 ft) (see ”b” in
figure Z 55 732).
In order to achieve maximum hoist heights, a longer chain
could be used once it is shortened. However, the measure-
ment of about 1250 mm (4.1 ft) may never be undercut. Risk
of damage!
082−1170−82201d_en 5/69
17
3
2
Z 52 210
6/69 082−1170−82201d_en
Reevings 17
17.2 Load Handling Equipment

If a load is to be raised with the crane, so−called load handling

equipment are required to raise the said load. These are:
− Carrying equipment
Carrying equipment is permanently connected to the crane.
This includes:
− Hoist ropes (1); see section 17.2.1 from page 9
− Hook blocks (3); see section 17.2.2 from page 33.
− Load−handling devices
Load−handling devices are equipment, for example lifting be-
ams, that are not part of the crane. They are connected to the
carrying equipment and take up the load.
Their selection and safe operation lies within the responsibi-
lity of the crane operator.
− Load handling equipment
Load handling equipment is equipment which does not be-
long to the crane, such as sling ropes, for example. They con-
nect the carrying equipment with the load or the carrying
equipment with the load handling devices.
Their selection and safe operation lies within the responsibi-
lity of the crane operator.
To ensure safe utilization of the load handling equipment, the

corresponding national regulations, such as, for example,
the accident prevention regulation „load handling devices in
lifting operations (GUV−V9a)“ must be observed.
082−1170−82201d_en 7/69
17
8/69 082−1170−82201d_en
Reevings 17
17.2.1 Hoist Ropes
17.2.1.1 General
Information on how to handle ropes safely and correctly is contai-

ned in section 11 of the lubrication and maintenance instructions
for the superstructure.
Risk of accidents!
When reeving, there is a risk of becoming caught and ent-
angled in the head sheaves and deflection sheaves as well
as in the hook blocks.
Proceed with appropriate caution and make sure that sa-
fety guards are fitted, for example, infeed guards.
Risk of overloading and accidents!

If a rope must 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 operating safety of the crane in
the normally permitted capacity range is no longer guaran-
teed.
The length of the ropes of hoist 1 and hoist 2 is approx. 345 m

(1132 ft) each.
082−1170−82201d_en 9/69
17
21
22
24 23
Z 83 481
10/69 082−1170−82201d_en
Reevings 17
17.2.1.2 Rope End Connections
Risk of accidents!
If the rope connection is not made correctly as described
below, the hook block / load could fall!
Rope end connection with press fitting

(Z 83 481)
The hoist rope is equipped with press fitting on hoist 1 and on ho-
ist 2 (optional).
This rope end connection consists of the following elements:

(21) − Rope pocket
(22) − Press fitting on the end of the hoist rope
(23) − Fore lock
(24) − Locking bolts
082−1170−82201d_en 11/69
17
21
22
24 23
Z 83 481
12/69 082−1170−82201d_en
Reevings 17
(Z 83 481)
Proceed as follows to make the rope end connection as descri-

bed below:
1. Remove forelock (23), thereby unlocking locking bolt (24).
2. Pull locking bolt (24) out of rope pocket (21).
3. Fit hoist rope with press fitting (22) in rope pocket (21).
4. Fit locking bolt (24) back in rope pocket (21) and secure with
forelock (23).
The locking pin (24) prevents the press fitting (22) from becoming
detached from the rope pocket (21) when the hoist rope is not car-
rying a load (e.g. when the hook block lands heavily on the
ground).
Risk of accidents!
The hoist rope may subsequently be loaded only when the
press fitting (22) is locked by the locking pin (24). In the
design that is described and shown, the rope pocket (21)
may only be used for low−twisting / non−twisting ropes.
Before reeving a hoist rope with press fitting, all rope protec-
tion devices such as support rollers, pins or rods on the de-
flection sheaves or rope idlers to be reeved must be remo-
ved or opened.
If this is not done the hoist rope cannot be drawn through
with the press fitting or may cause damages.
082−1170−82201d_en 13/69
17
1
2
Z 41 377
1
1
5
4a 4b
4a
Z 53 479 Z 41 379
14/69 082−1170−82201d_en
Reevings 17
Rope end connection without press fitting

(Z 41 377, Z 53 479, Z 41 379)
The diagrams of the rope socket (1) and the rope clamp (3)
are schematic diagrams and do not correspond exactly with
the components supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.
The rope end is secured by clamping it in a tapered rope socket

(1) with the help of a wedge (2).
To attach the rope socket (1) the rope end is first pulled through
the tapered rope pocket, turned in a loop and fed out of the rope
pocket again. The rope wedge is then laid inside the loop. The
rope ends protruding from the rope pocket are then pulled out
further, pulling the wedge into the tapered pocket.
The ”dead” rope end (4a) must be protruding from the rope pok-
ket by about 8 times the rope diameter. It must be secured with
a suitably sized rope clamp (3) at a distance outside of the rope
socket of about 3 times the rope diameter, to prevent the wedge
loosening and falling out if the load is sudden taken off the rope.
From rope clamp (3), wire thread (5) ∅ 1.5 mm (0.06 in) must be
wound around the free rope end to prevent the rope being drawn
through.
(Z 41 379)
Risk of damage to the rope!
The rope clamp must be fitted in a way that does not connect
the ”live” (4b) and ”dead” rope line (4a) together.
082−1170−82201d_en 15/69
17
5b
Z 38 385 Z 38 386
16/69 082−1170−82201d_en
Reevings 17
(Z 38 385)
When assembling the rope socket make sure that the “live” rope
line (5b) runs into the pocket so that, when the end connection
is placed under load, the active line of the tensile force runs preci-
sely through the centre of the fixing bolt without a kink developing
in the cable.
(Z 38 386)
If assembled incorrectly, the end connection will position it-
self when placed under load so that the active line of the ten-
sile force runs through the fixing bolt, each time developing
a kink in the heavily loaded ”live” line of the cable at the out-
let of the rope pocket.
On the one hand, this will result in a reduction in the maxi-
mum tensile force which can be transferred via the end con-
nection, on the other hand the pressure, coupled with regu-
lar bending around a very small radius, will result in early fa-
tigue of the cable wires in this area, which means that the end
connection can fail after a limited period of time when expo-
sed to even small tensile forces.
082−1170−82201d_en 17/69
17
14
E1 E2
11
12
13
K
Z 52 200 Z 83 482
18/69 082−1170−82201d_en
Reevings 17
17.2.1.3 Reeving / Unreeving the Hoist Rope

(Z 52 200, principle illustrations Z 83 482)
Before reeving and before starting crane work, check the

status of all accessible ropes (including the end connec-
tions), winches and sheaves.
Reeving
As an example, the description is of reeving the rope of hoist 1

over run−in sheave (E1).
1. Position the hook block beneath the main boom head so that
it is stable.
Work may only be carried out on the hook block (reeving
and unreeving) if it is set down in a stable manner on firm
ground.
The Vario hook block (see page 43) may only be set down
on the ground with the pinned ballast weight. The hook
block is too unstable without the ballast weight.
2. Remove the rope guard pin (11) from the hook block and fold
out the metal rope protection plates (12).
3. Remove both rope guard pins (13) and rope guard pins (14)
from the main boom head.
In the opposite figure, the main boom head is shown with the op-
tional equipment load hook camera and 2nd run−in sheave (E2).
082−1170−82201d_en 19/69
17
32 E1
A
1e
Z 83 483 Z 83 988
20/69 082−1170−82201d_en
Reevings 17
4. Guide the hoist rope from the hoist drum to the ground and
there, pull it forwards up to in front of the main boom head.
While the crane operator is operating the hoist, the hoist

rope must be guided by an assistant in such a way that slack
rope cannot form.
Risk of accidents!
There is a risk of accidents due to slipping and stumbling
when stepping onto the main boom.
For this reason, it is prohibited to step onto the main boom.
(Z 83 483)
5. Move the auxiliary rod (1e) from the transport position and fit
the hoist rope on the main boom.
(Z 83 988)
6. Set up and attach the mobile multi−purpose ladder supplied
on the main boom head in accordance with regulations.
Detailed information on this subject can be found in section
2 ”Structure ...” under ”Getting on and off using the mobile
multi−purpose ladder”.
After getting on, secure yourself against falling using the cor-
responding attachment eyelets.
082−1170−82201d_en 21/69
17
32 E1
A
Z 83 988
22/69 082−1170−82201d_en
Reevings 17
(Z 83 988)
7. First feed the hoist rope under the rope shackle which is fitted
onto the 2nd telescopic section and then fit it in run−in
sheave (E1).
Regarding the rope shackle, you must differentiate between

whether the rope of hoist 1 (see this page) or of hoist 2 (see from
page 25) is fitted:
Rope of hoist 1
7.1 From the ladder, feed the hoist rope under rope
shackle (32) as illustrated.
This rope shackle is fitted onto the 2nd telescopic sec-
tion as standard.
Continue with point 8. on page 27.
082−1170−82201d_en 23/69
17
32 E1
A
Z 83 988
32
33
33
Z 84 302 Z 84 301
24/69 082−1170−82201d_en
Reevings 17
Rope of hoist 2
(Z 83 988, Z 84 301, Z 84 302)
If the rope of hoist 2 is to be reeved, the large rope shackle (33)

must be fitted − fitting position direction hoist − instead of rope
shackle (32).
Risk of falling!
Proceed as follows:
7.2 On both sides of the rope shackle (32), remove fore-

locks in points (A) and pull out pins.
7.3 Lift rope shackle (32).
Rope shackle (32) weighs approx. 15 kg (33 lbs).
7.4 Release rope shackle (33) from the transport position

on hoist 2 − to do so, loosen the four lashing straps.
7.5 Fit rope shackle (33) − in the opposite direction as the

previously fitted rope shackle (32).
Rope shackle (33) weighs approx. 25 kg (55 lbs).
7.6 Peg rope shackle (33) to the 2nd telescopic section

using the previously removed pins and secure each
one with forelocks.
With the rope shackle (33) fitted, the max. permitted trans-
port height of the crane of 4 m (13.1 ft) is exceeded.
082−1170−82201d_en 25/69
17
14
E1 E2
11
12
13
K
Z 52 200 Z 83 482
26/69 082−1170−82201d_en
Reevings 17
8. Guide the hoist rope over run−in sheave (E1) to the sheaves
(K) in the main boom head and reeve in accordance with the
corresponding reeving diagram (see from page 53).
9. Refit the rope guard pins (11) on the hook block and (13),
(14) on the main boom head and secure. To do so, first the
rope protection plates (12) must be folded in on the hook
block.
10. Fit the rope end with press fitting in the rope pocket. See sec-
tion 17.2.1.2 ”Rope end connections”, starting on page 11.
082−1170−82201d_en 27/69
17
FK
64
1
Z 83 480 Z 83 987
2 1
Fu
3
2
2a 2b
Z 52 214 Z 52 209
28/69 082−1170−82201d_en
Reevings 17
(Z 83 480)
11. Pin the rope pocket to the corresponding fixed point:
− with uneven number of rope strands fixing point on the
hook block (FU, Z 52 209)
− with an even number of falls, the fixed point is on the main
boom head (FK, Z 83 480).
In the corresponding figure, the rope pocket is not shown
on the fixed point, but the spin stabilizer.
Use a ladder if the fixed point on the main boom head can-
not be reached from the ground. To do so, the supplied
multi−purpose ladder can be used as a sliding ladder.
(Z 83 987, Z 52 214)
12. Release the shift weight of the hoist limit switch out of the
transport position, remove both spring cotter pins and pull
both halves (2a) and (2b) of the shift weight apart.
(Z 52 214, Z 52 209)
13. Guide the separated halves of the shift weight around the ho-
ist rope and secure again with spring cotter pins.
The condition shown in figure (Z 52 209) must be achieved.
The shift weight must be attached to the ”resting” rope. This

avoids wear of the hoist rope and shift weight.
The ”resting” rope is the rope line that goes to the fixing
point.
Make sure that the shift weight is hanging free. Only then is
it guaranteed to function properly.
Risk of accidents!
If the shift weight of the hoist limit switch is not – as descri-
bed – fitted on the hoist rope, the hoist stroke limitation
does not work.
The hook block could be pulled into the head of the main
boom. There is a risk of the hoist rope breaking, so that the
hook block / load fall.
082−1170−82201d_en 29/69
17
30/69 082−1170−82201d_en
Reevings 17
Unreeving
In principle, the procedure for unreeving corresponds to the pro-

cedure for reeving, but it is carried out in the reverse order.
In particular, pay attention to the following points:
− Overturning the hook block which has been set down
Work may only be carried out on the hook block (reeving
and unreeving) if it is set down in a stable manner on firm
ground.
The Vario hook block (optional, see page 43) may only be
set down with the pinned ballast weight.
− Sudden release of the hoist rope end from the hook block
Risk of accidents!
When unreeving, the hoist must be operated with great care
and the hoist rope reeled in slowly.
No−one may be in the area at risk around the hook block at
any time.
− Observe the winding pattern of the hoist rope when reeling

in the rope. Slack rope must not form.
082−1170−82201d_en 31/69
17
Z 50 696
32/69 082−1170−82201d_en
Reevings 17
17.2.2 Hook blocks

17.2.2.1 Definition
In DIN 15002, the hook block is defined as the ”multiple line sus-
pension of carrying equipment with a load hook”.
A single−line suspension would be referred to as hook suspen-

sion gear. As this differentiation is not relevant for the following
general contexts, only the description ”hook block” is used.
Only hook blocks may be used which have been obtained

from the crane manufacturer. To do so, observe the table on
page 35.
The use of other hook blocks is only permitted following
consultation with the crane manufacturer and the relevant
authorisation.
The indicated max. permitted capacity of the hook blocks
must never be exceeded.
082−1170−82201d_en 33/69
17
Z 50 696
34/69 082−1170−82201d_en
Reevings 17
Rope
Description Capacity (A) Hook type (B) Weight
j
t kip mm (D) (E) kg lbs
160−7/21−D 160 353 7 x − 32 V 1670 3682
125−5/21−D 125 276 5 x − 32 V 1130 2491
80−3/21−E 80 176 3 − x 20 V 850 1874
80−3/21−D 80 176 3 x − 20 V 830 1830
32−1/21−E 32 71 1 − x 10 V 630 1389
32−1/21−D 32 71 1 21 x − 10 V 620 1367
32−1/21−E
32 71 1 − x 8V 590 1301
Vario (*)
32−1/21−D
32 71 1 x − 8V 580 1279
Vario (*)
12.5−0/21−E 12,5 27 0 − x 5P 340 750
(A) − Number of sheaves

(B) − Hook size in accordance with DIN 15401 (single hooks)
or DIN 15402 (twin hooks)
(D) − Twin hook
(E) − Single hook
(*) − Explanations on Vario hook blocks from page 43
082−1170−82201d_en 35/69
17
Z 50 696
36/69 082−1170−82201d_en
Reevings 17
17.2.2.2 Markings
The following specifications must be permanently marked on the

hook block and must be easily recognisable:
− Warning marking
− Manufacturer or supplier
− Year of construction
− Type, if type designation exists
− Make or serial number
− Permitted load
− Rope diameter
− Drive group
− Dead weight.
In addition, comply with the respective information concer-

ning the permitted hook blocks in the ”Instructions on opera-
tion of the crane”, which are supplied together with the capa-
city tables.
082−1170−82201d_en 37/69
17
Z 42 980
38/69 082−1170−82201d_en
Reevings 17
17.2.2.3 Operation
When reeving, there is a danger of becoming entangled and

drawn in and a risk of crushing at rotating and mobile parts
of the hook blocks.
Proceed with appropriate caution and make sure that sa-
fety guards are fitted, for example, infeed guards.
In particular, pay attention to the following points:

− The personnel (persons 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 detaching the load, particular care

must be taken as a result of swinging loads or 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 items of recognition must be of a distinctive colour
and preferably all in the same design and must be worn/car-
ried exclusively by the person handling the load.
Before starting movements of the winches (raising or lowe-

ring), all persons must leave the danger zone in the proxi-
mity of the rope drums and sheaves.
The crane operator must maintain visual contact with the

operating personnel and must give a warning signal before
starting the drive motor and/or initiating crane movements.
082−1170−82201d_en 39/69
17
Z 42 975
Z 50 697 Z 42 976
40/69 082−1170−82201d_en
Reevings 17
(Z 50 697, Z 42 975, Z 42 976, principle illustrations)
− Touch the hook block only using the handrails provided. The
hands must be KEPT CLEAR of the following areas:
∗ between the sheaves, side plates and covers.
∗ in the area of the fixing points (sometimes of a folding de-
sign), the hook, the hook nut, the lifting beam or the protec-
ting cages.
− Make sure that items of clothing do not get caught in rotating
parts.
− Work on the hook block may only be carried out (i.e. reeving),
when it is set down in a stable position on firm ground.
Be aware that the hook block could still tip over. Proceed
− Only use the hook block for lifting in the vertical direction. Ob-
lique pull is not permitted.
− Place the hook block under load slowly and evenly.
No sudden loads! No one−sided loading!
− Always fit the load / load handling devices in the middle of the
hook (hook jaw), never at the top section.
− Never load only one side of the double hook.
Welding on the hook block is prohibited.
082−1170−82201d_en 41/69
17
Z 83 989 Z 83 990
42/69 082−1170−82201d_en
Reevings 17
17.2.2.4 Vario Hook Block

(Z 83 989, Z 83 990)
General
The Vario hook block is a 1−sheave hook block which consists of

2 main elements which can be separated:
− actual hook block (Z 83 989);
Weight: 197 kg (434 lbs)
− Weight frame (Z 83 990, depiction together with hook block);
Weight: 390 kg (860 lbs)
082−1170−82201d_en 43/69
17
2
”A”
”B”
Z 84 370 Z 83 991
44/69 082−1170−82201d_en
Reevings 17
Placing the Vario hook block in the operating state (assembly)

(Z 84 370, Z 83 991)
The Vario hook block must be used as an assembled unit in order

to be used during crane operation. The actual hook block on its
own would be too light.
The weight of the assembled unit is approx. 590 kg (1300 lbs).
Starting situation:
Weight frame (2) set down in the support on the rear of the crane
chassis (see page 47 − 49); Vario hook block fastened to the cou-
pling ring.
1. Release the Vario hook block from the transport position at

the front coupling ring of the crane chassis.
2. Position the Vario hook block (1) over the weight frame (2)
on the rear of the crane chassis.
Risk of crushing!
The crane operator must be supported by an assembly as-
sistant in order to align the hook block precisely when lo-
wering it into the weight frame. There is a risk of crushing
for the assembly assistant between the hook block and the
weight frame when retracting the hook block. For this re-
ason, proceed with appropriate caution when handling the
hook block.
There must be constant contact between the crane opera-
tor and the assembly assistant.
3. Lower the Vario hook block (1) into the weight frame (2).
4. Remove the two connecting pins (left− and right−hand sides)

and the corresponding locking elements from the state (de-
tail ”B”) and place them in the state (detail ”A”).
This pins the hook block to the weight frame and at the same
time, the weight frame is disconnected from the support.
5. Lift the assembled unit out of the support and use it for crane
operation.
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17
Z 83 992 Z 83 993
”A”
”B”
Z 83 991
46/69 082−1170−82201d_en
Reevings 17
Placing the Vario hook block in the transport condition (dis-

mantling)
(Z 83 992, Z 83 993, Z 83 991)
The pins and locking elements must be placed in the state shown
in (Z 83 991, detail ”B”) to separate the hook block and the weight
frame.
The actual hook block can be fastened to the front coupling ring
of the crane chassis and the weight frame can be stored in the
support (1) on the rear of the crane chassis when transporting
them when disconnected.
Proceed as described below to set the weight frame down in sup-

port (1) on the rear of the crane chassis:
(Z 83 993)
1. Position the assembled unit over the support at the rear.
Risk of crushing!
The crane operator must be supported by an assembly as-
sistant in order to align the unit precisely when lowering it
into the weight frame. There is a risk of crushing for the as-
sembly assistant between the hook block and the weight
frame when retracting the hook block. For this reason, pro-
ceed with appropriate caution when handling the hook
block.
There must be constant contact between the crane opera-
tor and the assembly assistant.
(Z 83 993)
2. Lower the unit into the support.
(Z 83 991)
3. Move the connecting pins on both sides from the state (detail
”A”) and place in the state (detail ”B”).
This pegs the weight frame to the support on one side at the
same time (see point 5. on page 49).
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17
Z 83 994
Z 83 995
48/69 082−1170−82201d_en
Reevings 17
(Z 83 994, Z 83 995)
(Z 83 994)
4. Lift the hook block out of the weight frame and fasten it to the
front coupling ring of the crane chassis.
(Z 83 995)
5. Ensure that the weight frame has been pinned to the sup-
port.
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17
B T
Z 83 998
B T
H
Z 83 999
50/69 082−1170−82201d_en
Reevings 17
17.2.2.5 Transport dimensions of the hook blocks
Standard hook blocks (Z 83 996)

Height ”H” Width ”B” Depth ”T”
Description
mm in mm in mm in
160−7/21−D 1813 71.5 682 27
125−5/21−D 1863 73.5 482 19
80−3/21−E 1717 68 363 14.5
680 27
80−3/21−D 1633 64.5 363 14.5
32−1/21−E 1513 60 420 16.5
32−1/21−D 1441 57 420 16.5
12.5−0/21−E 914 36 ∅ 350 mm / 13.8 in
Vario hook blocks (Z 83 999)

Height ”H” Width ”B” Depth ”T”
Description
mm in mm in mm in
only hook
165 6.5
32−1/21−E block
1389 55 750 29.5
Vario Hook block +
495 19.5
weight frame
only hook
165 6.5
32−1/21−D block
1348 53 750 29.5
Vario Hook block +
495 19.5
weight frame
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17
10 9
E1 E1
K5 K5
K4 K4
K3 K3
K2 K2
K1 K1
FK
9
7 7
5 9 3 5
3 1
1 6 8
4 10 4
8 6 FU
2 2
U5 U5
U4 U4
U3 U3
U2 U2
U1 U1
8 7
E1 E1
K5 K5
K4 K4
K3 K3
K2 K2
K1 K1
FK
7
3 5 7 5
1 8 1 3
6 6
4 4 FU
2
2
U5 U5
U4 U4
U3 U3
U2 U2
U1 U1
Z 83 489
52/69 082−1170−82201d_en
Reevings 17
The safety of the crane is impaired by incorrect reeving!

For this reason, the hoist rope may only be reeved in accor-
dance with the depicted reeving diagram.
Other reevings would disrupt the function of the load limit
device.
17.3.1 Reevings 10−, 9−, 8−, 7−falls

(Z 83 489)
Hook block type 125, 5−sheave
E − Run−in sheaves
K − Head sheaves
U − Hook block pulleys
FK − Outer fixed point on the sheave head
FU − Fixing point on the hook block
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17
7 6 5
E1 E1 E1
K5 K5 K5
K4 K4 K4
K3 K3 K3
K2 K2 K2
K1 K1 K1
FK
6 5
4 5
2 3 3
7 1 1
6
5 2 4 2 4
3
1
FU FU
U3 U3 U3
U2 U2 U2
U1 U1 U1
4 3
E1 E1
K5 K5
K4 K4
K3 K3
K2 K2
K1 K1
FK
3 1 3
4
1
2
2
FU
U3 U3
U2 U2
U1 U1
Z 83 490
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Reevings 17
17.3.2 Reeving 7−, 6−, 5−, 4−, 3−fold

(Z 83 490)
K − Head sheaves
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17
3 2
E1 E1
K5 K5
K4 K4
K3 K3
K2 K2
K1 K1
FK
1 3
2 1 2
FU
U1
1 U1
E1
K5
K4
K3
K2
K1
FH
Z 83 491
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Reevings 17
17.3.3 Reeving 3−, 2−, 1−fold

(Z 83 491)

Hook suspension gear type 12.5
K − Head sheaves
FH − Fixing point on the hook suspension gear
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17
2
3
3
63
Z 83 996
58/69 082−1170−82201d_en
Reevings 17

with Two Auxiliary Sheaves (HD Attachment, Optio-
nal)
Risk of accidents!
Only the original HD attachment of the crane manufacturer
for this crane type may be used!
For the use of other additional equipment the crane owner
carries sole responsibility.
17.4.1 Fitting and Removing the HD Attachment

(Z 83 996)
In the standard design there are 5 sheaves on the axle (2) of the
main boom.
It is possible to attach two additional sheaves (3, HD attachment)
for reevings above 10 falls.
The HD attachment (3) weighs approx. 105 kg (230 lbs).
1. One after the other on both sides, stand the main boom axle
(2) on its end, slide the HD attachment (3) on and peg with
bolt (1) as illustrated.
Secure the bolts (1) on both sides with locking pins.
2. Reeve the hoist rope. For possible reevings see page 67.
The hoist rope is not shown in figure (Z 83 996).
To reeve the hoist rope on the HD attachment (3) the three rope
locking pins (4) can be removed.
Immediately after fitting the hoist rope all 3 rope locking pins (4)
must be fitted again and locked.
082−1170−82201d_en 59/69
17
23
24
L: R:
63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 82 406 Z 104 165
60/69 082−1170−82201d_en
Reevings 17
(Z 82 406)
3. Fit the hoist limit switch shift weight (23) of the main boom
head hoist limit switch to the bracket attached to the right−
hand side of the main boom head and secure it against falling
out with locking spring (24).
(Z 104 165)
If the hoist limit switch shift weight of the hoist limit switch on the
main boom head is hung in the transport position, the switch must
be mechanically locked in the open state (bridged). Figure
(Z 104 165 figure ’R’) shows the hoist limit switch in the bridged
state. In order to bridge the hoist limit switch, the restrainer (63.2)
must first be fitted onto the actual hoist limit switch (63.1).
1 Then the jumper wire is pulled away to the side, 2 then rota-
ted in the longitudinal direction of the restrainer (63.2), 3 and fi-
nally relaxed. This procedure jams the restrainer (63.2) by the
jumper wire’s spring resistance.
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17
1
3 2
3
4
63
Z 83 996
L: R:
63.1 63.1
”X0550”
”B”
”B”
”A”
A 63.2
3
1
Z 84 000 Z 104 166
62/69 082−1170−82201d_en
Reevings 17
(Z 83 996, Z 84 000, Z 104 166)
(Z 83 996)
4. Attach hoist limit switch (63) in functional condition with the
appropriate shift weight on the HD attachment (3) to the left
side of the main boom head.
To do so, fit the hoist limit switch (27) onto the corresponding
bolt on the HD attachment − as illustrated − and secure with
forelock.
Risk of accidents! Risk of collision!

Due to functionless hoisting limiter.
The hoist limit switch (63) must be in a functional condition.
The restrainer (63.2) of the hoist limit switch (63) may not
be fitted.
Figure (Z 104 166 ”R”) shows the hoist limit switch in a
functional condition.
(Z 84 000)
5. Connect the hoist limit switch (27) electrically. To do so, use
the supplied adapter cable (length is approx. 1 m / 3.3 ft) to
create a connection between the hoist limit switch and distri-
bution box X0550 on the main boom head, connection ”A”
(air speed indicator).
Risk of accidents!
This means adherence to the permitted wind speeds can no
longer be monitored in the crane control screen. In this
case, suitable alternative measures must be taken.
Please observe the relevant specifications in section 11
“Working instructions” under “Measuring wind speeds”!
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Reevings 17
6. Fit the shift weight of the hoist limit switch to the hoist rope.

point.
The HD attachment is removed in the same way, in the reverse

order.
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17
E1
12
Z2
K5
K4
K3
K2
K1
Z1
FZ
11
10 9 12
7
1 8
3 6
4
5
2
U7
U6
U4 U5
U3 E1 14
U2
U1
Z2
K5
K4
K3
K2
K1
Z1
FZ
13
10 9 11 14
6
8 7 12
3 4 1
5
2
U7
U6
U4 U5
U3
U2
U1
Z 83 997
66/69 082−1170−82201d_en
Reevings 17
17.4.2 Reeving 14−, 12−fold

(Z 83 997)

dance with the depicted reeving diagram and the following
table.
device.
These two reevings are performed in ”US−/Texan−style reeving”.

This means that the rope sheaves are not reeved continuously
from one side to the other, but are partially skipped and subse-
quently reeved.
Observe the representation of the rope guidance in the illustra-
tion on the other side. A solid line indicates that the rope runs to
the front side of the next sheave, a dashed line that it runs to the
rear one.
K − Head sheaves
Z − Auxiliary sheaves on the sheave head (HD attachment)
Fz − Fixing point on the auxiliary sheave (HD attachment)
(v) − Front of the rope sheave
(h) − Back of the rope sheave
Num-
ber of
Guide of rope over the sheaves
strand
s
E1−K1(v)−U2(v)−Z1(h)−U1(v)−K2(v)−U3(v)−K3(h)−U4(v)−K4(h)−
14
U5(v)−K5(h)−U6(v)−Z2(h)−U7(v)−Fz
E1−K1(v)−U2(v)−Z1(h)−U1(v)−K2(v)−U3(h)−K3(h)−U5(v)−K5(h)−
12
U6(v)−Z2(h)−U7(v)−Fz
Fall (4) − from U1 to K2 − must be guided in front of fall 2 −

U2 to Z1 − in the depicted view of the reeving diagram.
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17
68/69 082−1170−82201d_en
Reevings 17
17.5 Reeving the Hoist Rope on Additional Equipment
You will find the relevant information in the section of the corres-
ponding additional equipment (e.g. section 41 ”Runner”).
082−1170−82201d_en 69/69
Main Boom Extension (Optional) 18
082−1180−82201c_en 1/221
18
11.4 m (37.4 ft) 23.4 m (76.8 ft)
”a” ”c”
21,0 m (68.9 ft) 33,0 m (108.3 ft)
”b” ”d”
Z 82 352
11.4 m (37.4 ft) 23.4 m (76.8 ft)
1
”a” ”c”
21,0 m (68.9 ft) 33,0 m (108.3 ft)
”b” ”d”
Z 82 934
2/221 082−1180−82201c_en
18 Main Boom Extension (Optional)
18.1 General
(Z 82 352, Z 82 934)
There are two alternative designs for the main boom extension
(MBE) for this type of crane:
(Z 82 352)
− Design with fixed operating angles to the main boom longitu-
dinal direction:
− 0° to the main boom longitudinal direction, firmly pinned
− 20° / 40° to the main boom longitudinal direction using ten-
sion plates
(Z 82 934)
− Design with hydraulically smooth operating angle adjustment
of 0° − 40° to the main boom longitudinal direction
Depending on the length of the fitted main boom extension, it can

be angled either directly at the main boom head or at the interme-
diate section.
There are only slight differences when folding over the MBE fitted
on the side from the transport into the operating position (and vice
versa) and / or when fitting and dismantling the MBE during sepa-
rate transportation. The relevant differences are described sepa-
rately in the operating procedures.
The main differences in both MBE variants are when setting the
operating angle.
Observe the description for setting the operating angle for both
variants.
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4/221 082−1180−82201c_en
18.2 Important Information
The main boom extension is marked with the construction

number of the crane. It may only be fitted on the crane with
this construction number.
Exceptions are only permitted if this is expressly stated in
the crane papers (for example, crane log book).
The main boom extension may only be fitted and removed

by qualified personnel who have been instructed accordin-
gly.
Check that there are no damages to the pipes on the lattice

mast components of the main boom extension. If you di-
scover damaged pipes during a visual inspection, it is pro-
hibited to continue work with the main boom extension.
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18
6/221 082−1180−82201c_en
Risk of breakage!
The components of the main boom extension must be
checked at least once a year by an expert (e.g. for Germany:
in accordance with the accident prevention regulations
”Load−handling equipment in hoist operation (GUV−
V 9a)”). Furthermore, they must be checked by an expert
between these intervals if required by the operating and
site conditions.
The inspection intervals are generally determined by the
operating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals
must be.
This inspection must be documented once it has been car-

ried out (for example, in the examination log book for the
crane).
The following checks must be carried out:

− Check for cracks
− Check of length
− Check for wear
− Check the paintwork
− Check for plastic deformation
Instructions for the performance of the inspections can be
found in the ”Lubrication and Maintenance Instructions”,
(part 3).
Risk of tilting! Risk of uncontrolled movement!

Before fitting the main boom extension (MBE) the crane
must be supported on outriggers in accordance with the
planned configuration (MBE, CWT etc.) and the counter-
weight fitted (see load tables).
The crane must be levelled horizontally (see section 12:
’Outriggers’ in the operating instructions for the chassis).
If the crane is not to be levelled horizontally during fitting,
there will be a specific note in the corresponding descrip-
tion.
Risk of uncontrolled movement of the MBE.

As a rule, the main boom must be horizontally aligned when
the main boom extension is fitted or folded over. Any ex-
ceptions to this rule are clearly listed.
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18
66
2−EXPLICIT
3−EXPLICIT
Z 55 536 Z 82 372
8/221 082−1180−82201c_en
- Supplied multi−purpose ladder:

(Z 55 536)
Depending on the height of the technician, some of the assembly

steps can be carried out from the ground.
The supplied multi−purpose ladder or lifting platform (or some-
thing similar) must be used for all assembly work that cannot be
carried out from the ground.
Risk of falling!
Only carry out any assembly work from a safe position. If
required, use the supplied ladder or a platform (or some-
thing similar).
It is not permitted to walk on the main boom or on any other
auxiliary equipment.
Transporting the multi−purpose ladder
The transport position of the multi−purpose ladder is described

in section 2.
Holding devices for attaching the ladder

(Z 82 372)
There are plates on the entire crane for safely attaching the lad-
der during the corresponding working procedures.
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 82 372)!
Some of the brackets for attaching the ladders can only be
used with a horizontal main boom.
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18
66
Z 82 371 Z 82 372
Z 65 146 Z 65 147
10/221 082−1180−82201c_en
- Auxiliary rod:
(Z 82 371)
The depicted auxiliary rod is required for fitting the hoist rope and
to carry out individual work steps when fitting the main boom ex-
tension in the transport position.
Further information, e.g. the transport position of the auxiliary
rod, is described in section 17 ’Reeving’.
- Attachment eyelets (66):

(Z 82 372, Z 65 146, Z 65 147)
There are attachment eyelets on the crane and the additional

equipment for attaching suitable personal protective equipment.
In this case, country−specific regulations on personal protective
equipment might have to be adhered to.
Risk of accidents!
The diameter of the attachment eyelets is 35 mm (1.4 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 82 372) 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!
Ladders must be attached and personnel must be secured
against falling using personal protective equipment for the
entire further assembly procedure for operation at heights.
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18
31 32
32
33
Z 82 943
2 3
Z 82 397
12/221 082−1180−82201c_en
- The main components of the main boom extension can be

combined in different lengths.
The combination of the main components of the main boom ex-

tension can be found in section 18.3.2 (page 19).
(Z 82 943)
- The main components are generally connected with each

other and with the main boom head using 4 fixing pins:
Each fixing pin must be secured against falling out with two
functioning locking springs (32).
Danger!
Risk of breakage due to interchanged or lost fixing pins.
Only use the corresponding original fixing pins for assem-
bly.
Each fixing pin must be secured with 2 functional locking
springs (32) to prevent it from falling out.
These fixing pins (31) and/or (33) must be well greased before
every pinning procedure.
If the MBE is angled, fixing pins (31) are only fitted at the bottom.
The force is transmitted at the top via the tension plates (design
with fixed operating angles) or via the adjusting cylinders (hy-
draulic luffing MBE (HAVHY)). Detailed specifications can be
found in the corresponding section.
(Z 82 397)
- When moving the crane or during crane operation on the

main boom, the basic boom MBE (2) or the basic boom MBE
(2) and the box top piece (3) can be folded to the side on the
main boom basic case.
The main boom extension can only be fitted and removed

using the auxiliary crane.
When driving the crane, the permitted axle loads must be ob-
served (see section 6 in the operating instructions of the
chassis).
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18
62
61 62
61
Z 315 280 Z 86 552
14/221 082−1180−82201c_en
- If the crane is equipped with a HD attachment (auxiliary shea-

ves at the side), this must be removed before the main boom
extension is fitted (see section ”Reeving”).
- For fitting and removing the main boom extension, the super-
structure should be turned so that the boom is positioned to
the front or the side (90°).
(Z 315 280, Z 86 552)

- Rotor (62) of the wind measuring device and hazard light
(61):
Before fitting the main boom extension (MBE) on the main
boom head, the optional hazard light (61) with bracket and /
or the rotor (62) of the wind measuring device with bracket (if
existing) must be removed so that they are not damaged
when assembling the main boom extension.
Later, when the main boom extension is fitted, the hazard
light (61) and the rotor (62) of the wind measuring device must
be fitted onto the head of the respective fitted main boom ex-
tension.
Danger
Risk of overturning during crane operation without a wind
measuring device or with a defective one.
Only raise loads with a fitted, faultlessly functioning wind
measuring device. This is the only way it can be determined
whether current wind speeds are within the capacity table
specifications.
There are two variants of the wind measuring device (62) and the
hazard light (61). For assembling and handling the hazard light
and the anemometer, observe the relevant specifications in the
section ”Safety equipment” in the ”Electrical safety chain” sec-
tion.
082−1180−82201c_en 15/221
18
16/221 082−1180−82201c_en
- In the design with fixed operating angles, the crane can be

operated with the main boom extension under 0°, 20° and 40°
to the main boom.
In the design with hydraulically smooth operating angle ad-
justment, the crane can be operated between 0° and 40° to
the main boom.
The MBE is angled either at the main boom head or at the in-
termediate section.
The folding procedure for the main boom extension from the
transport into the operating position (and back) is explained in
section 18.5.3, from page 35.
The fitting procedure of the main boom extension when transpor-

ted separately is described in section 18.6.3, from page 117.
The guidance of the hoist rope is described in section 18.7, from

page 161.
Notes on setting the MBE operating angle with fixed operating

angles (0°, 20°, 40°) can be found in section 18.8, from page 169.
Notes on setting the MBE operating angle with hydraulically

smooth operating angle adjustment (0° − 40°) (HAVHY) can be
found in section 18.9, from page 195.
082−1180−82201c_en 17/221
18
Z 82 956
2
”a”
3 2
”b”
2 1
”c”
3 2 1
”d”
Z 82 375
18/221 082−1180−82201c_en
18.3 Construction of the Main Boom Extension
18.3.1 Main Components of the Main Boom Extension
(Z 82 956)
Part Description
no.
1 Intermediate
section
2 Basic boom
MBE 1)
3 Box top piece
1)= Depending on whether it is an MBE with fixed operating

angles (0°, 20°, 40°) or an MBE with hydraulically smooth
operating angle adjustment (0° − 40°; HAVHY), there are 2
design variants for the basic boom main MBE.
18.3.2 Combination of the Main Components
(Z 82 375)
The main boom extension can be assembled to the following

lengths:
HAV Components Picture
Intermediate Basic boom Box top Z 82 375
section (1) MBE (2) piece (3)
11,4 m / x ”a”
37.4 ft
21 m / x x ”b”
68.9 ft
23.4 m / x x ”c”
76.8 ft
33 m / x x x “d”
108.3 ft
Figure (Z 82 375) shows the design with fixed operating angles,

but also applies to the hydraulic luffing MBE (HAVHY).
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18
Z 200 294
20/221 082−1180−82201c_en
18.4 Operation of the Crane with Main Boom Extension
18.4.1 Procedure
Initial situation:
− Crane supported on outriggers in accordance with the subse-
quent configuration in which loads are to be raised; axles rai-
sed
− Counterweight fitted in accordance with the subsequent con-
figuration in which loads are to be raised
Procedure
1. Position the hook block at a suitable point so that it can be

subsequently reeved on the main boom extension (MBE).
(Z 200 294)
2. Slew the superstructure in the in 0°− , 90°− or 270° position

for fitting the main boom extension.
3. Place the main boom in the horizontal position.
4. Fit the MBE on the main boom head at the front in the opera-
ting position:
11.4 m (37.4 ft) MBE / 21 m (68.9 ft) MBE in the transport po-
sition:
The folding procedure for the main boom extension from the
transport into the operating position (and back) is explained
in section 18.5.3, from page 35.
Transporting parts of the MBE separately:

Fitting the main boom extension with separate transportation
with the auxiliary crane is described under section 18.6.3,
from page 117 .
In addition to the specifications in the corresponding section on

fitting, rope guidance / reeving of the hoist rope is described in
section 18.7 (page 161), in particular for checks and troubleshoo-
ting.
In the MBE design with fixed operating angles (0°, 20°, 40°), the
operating angle is set during fitting on the main boom head.
082−1180−82201c_en 21/221
18
Z 200 294
22/221 082−1180−82201c_en
Danger!
There is a risk of accidents when assembly work is not
completed and due to falling parts.
Before carrying out the next work step, check that all requi-
red bolts/pins have been fitted and that there are no loose
objects (e.g. hammers) on the main boom or main boom ex-
tension.
Unless otherwise specified in the capacity tables, the num-

ber of reevings must not be lower than 2 rope strands.
If, however, single−strand reeving is required, the lifting ca-
pacities specified in the table must be reduced by 20%. This
is also valid, when the lifting capacity lies below the maxi-
mum permissible rope pull per line. Use of the high speed
range is than prohibited.
Check that the parameters entered at crane control corres-
pond with the current crane configuration (for example,
main boom length, fitted counterweight, etc.).
5. Set the operating mode in the ”Selection of the operating

mode” screen in crane control. See segment 18.4.2 on page
27.
6. Luff up the main boom in the high position.
(Z 200 294)
7. Relevel the crane chassis in the 0°− or 180° superstructure
position , i.e. check the horizontal position.
8. Telescope out the main boom.
The hydraulic luffing MBE (HAVHY) can only be telescoped out

at an operating angle of 0° between the main boom and MBE
(HAVHY) until the end length code is reached.
The capacity values in the capacity table are not enabled and dis-
played in the LLD until the end length code has been reached.
082−1180−82201c_en 23/221
18
24/221 082−1180−82201c_en
Under no circumstances may any additional load be atta-

ched when configuring during the telescoping process.
9. For the hydraulic luffing MBE (HAVHY):

Set the operating angle of the MBE.
10. Raise load
The crane is deconfigured the same way, but in the reverse se-
quence (then see the relevant section).
082−1180−82201c_en 25/221
18
11.4 m (37.4 ft) 23.4 m (76.8 ft)
”a” ”c”
21,0 m (68.9 ft) 33,0 m (108.3 ft)
”b” ”d”
Z 82 352
26/221 082−1180−82201c_en
18.4.2 Setting the Operating Mode in the ”Selection of the

Operating Mode” Screen in the IC−1
When setting the operating mode, the design of the MBE (fixed
operating angle or hydraulic luffing) must be taken into conside-
ration.
Figure (Z 82 352) shows the design of the MBE with fixed opera-
ting angles, but also applies to the hydraulic luffing MBE
(HAVHY).
1. Set the abbreviation of the crane configuration in accor-

dance with the following table:
Main boom extension Figure: Abbreviation of the crane configuration

Z 82 352 Design with fixed ope- hydraulic luffing MBE
rating angles
11.4 m (37.4 ft) ”a” HAV HAVHY
21 m (68.9 ft) ”b” HAV HAVHY
23.4 m (76.8 ft) ”c” HAV−VA HAVHY−VA
33 m (108.3 ft) ”d” HAV−VA HAVHY−VA
2. Select length of the fly jib (here: Length of the main boom ex-
tension).
Length Figure:
Z 82 352
11.4 m (37.4 ft) ”a”
21 m (68.9 ft) ”b”
23.4 m (76.8 ft) ”c”
33 m (108.3 ft) ”d”
3. Select angling of the fly jib (only for the design with fixed ope-
rating angles).
Angling Figure
0°
20° Z 82 352
40°
082−1180−82201c_en 27/221
18
28/221 082−1180−82201c_en
4. Select all other parameters in accordance with the actual as-

sembly state of the crane, which must correspond with the
specifications in the respective capacity table.
Details on operating mode selection can be found in section 10

”Safety equipment”.
18.4.3 Raising Loads with the MBE

11.4 m / 21 m (37.4 ft / 68.9 ft) Folded in the Transport Po-
sition
The capacity values in the table are reduced when raising

loads with the MBE 11.4 m / 21 m (37.4 ft / 68.9 ft) folded
alongside. See the ’instructions for operating the crane’,
contained in the supplied load table set.
082−1180−82201c_en 29/221
18
”a” ”c” 36 38
”b”
32, 33
27
2 3
24.2
”d” 24.1
”f”
11
15.3
”e”
34
15.2 12
Z 86 575
30/221 082−1180−82201c_en
18.5 Main Boom Extension Fitted to the Main Boom
18.5.1 General
As previously described, the main boom extension is available in
a design with fixed operating angles and with hydraulically
smooth operating angle adjustment. This is irrelevant for the spe-
cifications and instructions in this section ”Main boom extension
fitted on the main boom”. The figures in this section show the
main boom extension with fixed operating angles as an example.
18.5.2 Transport Instructions for the MBE in the Transport

Position
For driving the crane with the MBE folded into the transport posi-
tion, the following applies:
− When driving, observe the permitted axle loads.
(Z 86 575 “a”)
− The fixing pins (33) between basic boom MBE (2) and box top
piece (3) (if existing) must be pinned and secured. The fixing
pins (33) must be secured against falling out with two locking
springs (32).
(Z 86 575 “b”)
− The folding cylinder (27) must have ’gripped’ the basic boom
MBE.
(Z 86 575 “c”)
− For the main boom extension with fixed operating angles (0°,
20°, 40°):
The fixing pins (36), (38) of the basic boom MBE (2) for faste-
ning the tension plates must be fitted in the transport position
as shown and secured against falling out. The fixing pins are
on the right− and left−hand tension plate.
082−1180−82201c_en 31/221
18
”a” ”c” 36 38
”b”
32, 33
27
2 3
24.2
”d” 24.1
”f”
11
15.3
”e”
34
15.2 12
Z 86 575
32/221 082−1180−82201c_en
(Z 86 575 ”d” depicted without MBE)

− When the 21 m (68.9 ft) MBE is fitted in the transport posi-
tion, the box top piece must be pinned to bracket (24.1). The
pin (24.2) protrudes out of the top end of the holding device.
There is no holder (24.1) when the MBE 11.4 m (37.4 ft) is fitted
in the transport position.
(Z 86 575 ”d”, ”e”)

− The mobile part (15.2) of the rollway must be folded and pin-
ned with pins (15.3).
This means that locking plate (34) of basic boom MBE (2) is clam-
ped between the mobile part (15.2) of the rollway and the fixed
part of the rollway. This prevents the main boom extension (MBE)
from folding away during transport.
(Z 86 575 ”f”)
− The basic boom MBE (2) must be pinned at the side to the
bracket of pivot point (11).
− The shift weight of the MBE’s hoist limit switch must be remo-
ved from the hoist limit switch and stored in one of the storage
compartments.
Pins
All pins must be in a transport position which is secured against

falling out.
Hoist Limit Switches
The entire hoist limit switch and/or only the shift weight of the ho-
ist limit switch must be removed and stored in the storage box.
082−1180−82201c_en 33/221
18
Z 82 391
34/221 082−1180−82201c_en
18.5.3 Folding Procedure

As long as the MBE 11.4 m (37.4 ft) / 21 m (68.9 ft) is not requi-
red, the main boom extension can be carried alongside the main
boom − folded in the transport position and pinned.
When driving in this condition, the permitted axle loads and

other approval regulations must be observed.
18.5.3.1 General Instructions for Folding over the Equipment

The conditions listed below must be observed both when folding
the equipment from the transport into the operating position, 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.
(Z 82 391)
∗ Main boom in the transport position (travel position: fully tele-
scoped in, pinned and horizontal) (see section 12 Telesco-
ping information system ”Placing the main boom in the trans-
port condition”). View on display see (Z 82 391).
In order for the folding procedure to be carried out without any

problems, 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. This is why you
cannot tell if the stops are flush just by looking.
For this reason, the transport position (display: Z 82 391) must be
restored every time the MBE is folded from the transport into the
operating position (and vice versa) and/or additionally the tele
drive secured on the last telescopic section must be manually re-
tracted (see section 12 Telescoping information system ”Manual
telescoping”).
∗ The catches must be fitted (top and bottom of the main

boom).
∗ Main boom horizontally aligned
082−1180−82201c_en 35/221
18
27
2−EXPLICIT
3−EXPLICIT
Z 82 393 Z 55 536
36/221 082−1180−82201c_en
When the MBE is folded from the transport into the operating
position or vice versa the folding procedure must not be ob-
structed in any way.
(Z 82 393)
∗ A folding cylinder (27) fitted to the side of the main boom is
used for one part of the folding over procedure.
This folding cylinder can tension the steel components me-
chanically.
It could become more difficult to move pins which must be loo-
sened or fitted.
For this reason, it can be useful to retract or extend the folding
cylinder minimally in these cases.
(Z 55 536)
In the following, the method for repositioning the MBE from the
transport to the operating position and vice versa is shown.
Use the supplied multi−purpose ladder to carry out assem-

bly work on the MBE (Z 55 536). Walking on the MBE or on
the top of the main boom is prohibited.
082−1180−82201c_en 37/221
18
Z 82 392
2 3
Z 82 397
38/221 082−1180−82201c_en
18.5.3.2 Folding over the 11,4 m MBE (37.4 ft)
When folding and during pinning and unpinning there must

be no−one in the slewing range or beneath the MBE or in
areas at risk of falling equipment etc.
The prescribed sequence for the folding procedure must

be followed at all times.
(Z 82 392)
With 18.5.3.2.1 (from page 41) only the 11.4 m MBE (37.4 ft) is
fitted in the transport position on the main boom.
(Z 82 397)
With 18.5.3.2.2 (from page 81) the 21 m MBE (68.9 ft) is fitted in
the transport position. However, only the 11.4 m MBE (37.4 ft)
should be folded into the operating position. The box top piece
remains fitted on the basic case of the main boom in the transport
position.
082−1180−82201c_en 39/221
18
2
39
Z 82 895
2
B
Z 82 415
27
Z 82 393 Z 315 691
40/221 082−1180−82201c_en
18.5.3.2.1 MBE (11,4 m (37.4 ft)) Fitted in the Transport Position

from the Transport into the Operating Position
1. Observe all the instructions contained in section 18.5.3.1,
which contains general instructions for folding over the
equipment (from page 35).
Preparations
(Z 82 895)
2. Fasten the draw and guide rope (39) to the head of the basic
boom MBE (2).
The MBE can be pulled and braked using the draw and guide
rope (39).
Danger!
There is a risk of accidents due to the main boom extension
falling down and folding over unchecked and there are ad-
ditional risks during the fitting procedure.
Carry out the checks described in the following or place the
components in the configuration described.
(Z 82 415, Z 82 393, Z 315 691)
3. Carry out the following checks:

3.1 The main boom extension must be pinned in pivot
point ”B” (Z 82 415).
3.2 The folding cylinder (27) must have ’gripped’ the basic
boom main boom extension (2) (Z 82 393).
3.3 The head axle must be turned as illustrated (Z 315 691
schematic diagram).
082−1180−82201c_en 41/221
18
21.3
21.2
21.1
21
Z 104 207 Z 82 928
”a” ”b”
15.2
15.3 15.2 15.3
Z 82 394
27
Z 82 393
42/221 082−1180−82201c_en
(Z 104 207, Z 82 928)
4. Plug the mobile control panel (21) into the corresponding

electric connection (Z 82 928) on the front left of the basic
case of the main boom.
(Z 82 394)
5. Fold out mobile part (15.2, Z 82 394 ”a”) of the rollway.

To do so, release pin (15.3). Fold over mobile part of the roll-
way (15.2, Z 82 394 ”a”) and refit pin (15.3).
(Z 82 393)
After the mobile part (15.2) of the rollway has been folded out, the
main boom extension (2) is only kept from folding over by the fol-
ding cylinder (27).
082−1180−82201c_en 43/221
18
B
”a”
F/G
2 27
B
”b”
F/G
27
2
Z 82 398
21.3
21.2
21.1
21
Z 104 597 Z 104 207
44/221 082−1180−82201c_en
Actual folding procedure
Figure (Z 82 398) shows the initial state for the next steps.
6. Start the drive motor.
(Z 82 398, Z 104 597 schematic diagram)
You must ensure that the bottom head axle is rotated as shown
during the following folding over procedure of the MBE around
the centre of motion ’B’ (Z 104 597).
(Z 82 398, Z 104 207)

7. Extend the folding cylinder (27) carefully until the holes of the
fork ends are flush with the corresponding holes in the head
axis (F, G).
To carry out this step, position yourself so that you are not directly
under the MBE.
On the mobile control panel (21), press rocker switch (21.2) until
the position is reached (selector switch (21.3) in position “1”).
The MBE then rotates around pivotal point (B, Z 82 398).
When folding the lattice mast top section from the transport
into the operating position there are risks of crushing,
shearing or falling objects (e.g. forgotten tools ). There
must therefore be no−one in the endangered area during
the folding procedure. It is prohibited to walk between the
lattice mast top section and the main boom.
082−1180−82201c_en 45/221
18
31 32
F F/G
G 27
37
32
31 B
Z 104 212 Z 82 399
6.2 6 6.1 5
E2
”a” ”b”
Z 104 214 Z 82 405
46/221 082−1180−82201c_en
(Z 104 212)
8. Pin the MBE at the boom head axes in fixing points (F) and
(G) with fixing pins (31) and secure with locking springs (32).
(Z 82 399, Z 104 214)
For risk−free operation, the locking bolt (37, Z 82 399) must be

in the locked position at the back on the basic boom MBE during
one of the following work steps.
In figure (Z 104 214, figure ’a’, principle depiction), the locking
bolt is shown in the locked position.
9. If not already occurred: Fit locking bolt (37, Z 82 399) at the

back on the basic boom MBE in the lock position (Z 104 214,
figure ’a’, schematic diagram).
(Z 82 405)
10. Fit hoist rope (5) onto intake sheave (E2) on the main boom
head.
10.1 Remove forelock (6.1).
10.2 Pull out rope sheave (6.2) sideways.
10.3 Guide hoist rope (5) over intake sheave (E2).
10.4 Slide rope sheave (6.2) back in and secure against fal-
ling out with forelock (6.1).
10.5 Fold complete rope guard (6) upward and guide hoist
rope (5) sideways on the left−hand side of the main
boom head, as shown in figure (Z 82 405).
082−1180−82201c_en 47/221
18
13
B 13
73
12
Z 82 400 Z 82 403
48/221 082−1180−82201c_en
RISK OF ACCIDENTS!
During the subsequent unpinning procedure persons must
stay clear of the area beneath the main boom extension and
where items could fall.
If the MBE is not being held by the draw and guide rope, it
can swing away to the side when the equipment is unpin-
ned at point (B).
It is only permitted to unpin pin (12) if the MBE is pinned to

the main boom head (F) and (G) in the front.
(Z 82 400, Z 82 403)
11. Release connecting pin (12) of the MBE to the main boom’s
basic boom section in point (B) by pressing lever (13) up with
the actuating rod (73). Lever (13) is locked in the upper posi-
tion by sliding it to the side. Figure (Z 82 403) shows this
state.
082−1180−82201c_en 49/221
18
F/G
27
15
Z 82 402
21.3
21.2
21.1
21
Z 104 207
13
B 73
12
13
Z 82 404 Z 82 400
50/221 082−1180−82201c_en
(Z 82 402, Z 104 207)

12. Extend the folding cylinder (27) carefully until the main boom
extension has moved down from the rollway (15).
To do so, press the rocker switch (21.2) on the mobile control
panel until the final position has been reached. (The position
of the selector switch (21.3) is irrelevant for this procedure.)
The MBE then rotates around the slewing point (B).
(Z 82 404, Z 82 400)
13. Disable locking of lever (13): Lift the lever (13) to the side
using actuating rod (73).
082−1180−82201c_en 51/221
18
27.1
37
27 73
Z 82 401 Z 104 217
Z 155 157
32 31 H
I
31
32
Z 104 531
52/221 082−1180−82201c_en
Danger!
Risk of accidents due to the main boom extension moving
unchecked!
The main boom extension must be held with the draw and
guide rope when detaching the folding cylinder in the next
work step.
Due to the mechanical system fitted onto the basic boom MBE,
pin (12) remains open and the lever (13) remains in the top posi-
tion.
(Z 82 401)
14. Detach the folding cylinder (27) as follows:
Using actuating rod (73), lift safety lug (27.1) and pull the
MBE slightly forward with the draw and guide rope.
Folding cylinder (27) can be slightly retracted as an alternative to

pulling the MBE forward with the draw and guide rope.
Risk of injury!
When swinging the MBE in the following and during pin-
ning and unpinning, there must be no−one in the swinging
range or beneath the MBE or in areas where loads/equip-
ment could fall, etc.
15. Fold the MBE at the draw and guide rope in front of the main
boom (Z 155 157 principle depiction).
It must be ensured that locking pin (37) locks in place on the

mounting axle on the left (Z 104 217 schematic diagram).
16. Knock in one fixing pin (31) in point (I) and secure it against
falling out with 2 locking springs (32).
17. MBE with fixed operating angles (design with tension pla-
tes): Knock in one fixing pin (31) in point (H) and secure it
against falling out with 2 locking springs (32).
082−1180−82201c_en 53/221
18
F 31
H ”X0550”
C
I
G 31
C1
A1 A F
Z 82 944 Z 82 111
L: R:
23 63.1 63.1
”B”
24 ”A”
63.2 63.2
1 2
3
Z 82 896 Z 104 165
54/221 082−1180−82201c_en
(Z 82 944)
MBE with hydraulically smooth operating angle adjustment

(HAVHY):
It is sufficient if one of the upper fixing pins (31) is fitted in points
(H) or (F) so that the adjusting cylinders can be fitted on the main
boom head in a subsequent operating step.
(Z 82 111)
18. Connect plug of the basic boom MBE (2) cable harness with
connection (A) on distribution box ”X0550” on the left−hand
19. For the MBE with hydraulically smooth operating angle ad-
justment (HAVHY): Connect the plug of the basic boom MBE
CAN line to connection (C) on distribution box ”X0550” on the
left−hand side of the main boom head.
For MBE with fixed operating angles (design with tension plates):
Connection (C) remains fitted with the CAN BUS terminating plug
(C1).
For both MBE variants, connection (F) remains free and must be
closed using the dust cap.
(Z 82 896)
20. Fit the hoist limit switch shift weight (23) of the main boom
(Z 104 165)
082−1180−82201c_en 55/221
18
2
73
Z 82 407
56/221 082−1180−82201c_en
21. Set the current operating mode (with main boom extension)
in the ”Selection of the operating mode” screen in crane con-
trol. See segment 18.4.2 on page 27.
(Z 82 407)
22. Unreel hoist rope (5) approx. 3 m (10 ft) longer than the
length of the main boom extension.
Danger!
There is a risk of accidents if the hoist rope falls down when
carrying out the next work step.
Ensure the work step is carried out carefully.
23. Lay hoist rope (5) over the main boom extension using the
auxiliary rod (73). This is done by laying hoist rope (5) section
for section, starting from the main boom head, so that the
plates (arrows in figure) welded onto the upper chord prevent
the fitted sections from falling down.
082−1180−82201c_en 57/221
18
48 5
5
42 40
49
2
S2
63
64
Z 82 416 Z 86 554
58/221 082−1180−82201c_en
(Z 82 416)
24. Guide hoist rope (5) over the rear rope sheave (40) of the ba-
sic boom MBE (2), fit rope guard pin (42) and secure against
falling out.
(Z 86 554)
25. Guide the hoist rope over the two front rope sheaves of the
basic boom MBE, fit rope guard pins (48) and (49).
If the main boom extension with fixed operating angles (design

with tension plates) is to be fitted with an operating angle of 205
or 405, the operating angle must be set before reeving the hook
block.
tes):
Setting the operating angle if the MBE is to be operated at
an angle of 20° or 40° (see section 18.8 from page 169).
27. Reeve the hook block in (see section 17).
(Z 86 554)
With two−fold reeving, the rope socket of the hoist rope end must
be secured at point (S2, Z 86 554) on the basic boom MBE.
082−1180−82201c_en 59/221
18
48 5
”X0560”
49
S2 A F H
A1 H1
63
64
Z 86 554 Z 315 590
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
3
1
Z 104 166
60/221 082−1180−82201c_en
Remaining tasks
(Z 86 554, Z 315 590)

28. Mount hoist limit switch (63) in functional configuration and
connect to the electrical power supply.
28.1 On the right−hand side of the basic boom MBE, slide

the hoist limit switch (63) over the pins that have been
welded on and secure it against falling out using safety
forelocks.
28.2 Mount shift weight (64) above hoist rope (5) (see Sect.
17).
28.3 Connect the plug of the hoist limit switch (63) to the
connecting port (H).
(Z 86 554, Z 104 166)

The hoist limit switch (63) must be in the functioning state:
− The restrainer (63.2) of the hoist limit switch (63) may not
be fitted.
Figure (Z 104 166 ”R”) shows the hoist limit switch in
the functioning condition.
− The shift weight (64) of the hoist limit switch (63) must
hang freely. The hoist cable is in this case carried out
through the aperture of the shift weight.
082−1180−82201c_en 61/221
18
61
”X0560”
62 48 5
49 A F H
S2 A1 H1
63
64
Z 86 553 Z 315 590
21.3
21.2
21.1
21
Z 104 207
62/221 082−1180−82201c_en
(Z 86 553, Z 315 590)
29. Fit the hazard light (61, optional) and the rotor (62) of the
wind measuring device to the head of the basic boom MBE
and/or place it in the operating position and connect it to elec-
tric connections (F) and (A).
If the rotor of the wind measuring device is not fitted to the
top section of the main boom / boom system, it is not possi-
ble to monitor compliance with permitted wind speeds in
the crane control display.
If the crane’s assembly situation does not permit fitting the
wind measuring device rotor (e.g. due to the proximity of
the upper edge of the top section of the main boom / boom
system to a protruding edge), compliance with the permit-
ted wind speeds must be monitored in a different way (e.g.
external wind measuring device at the height of the top sec-
tion of the main boom / boom system).
If the rotor of the wind measuring device is not fitted, bridging

plug (A1) must be connected to electric connection (A).
tion.
Danger
Risk of accidents due to overloaded components!
In the next work step, conscientiously check that all pins
and locks are fitted securely.
30. Check that all pins and locking elements are fitted correctly.
(Z 104 207)
31. Remove the mobile control panel (21) on the main boom.
082−1180−82201c_en 63/221
18
27
28
Z 82 409
64/221 082−1180−82201c_en
(Z 82 409)
32. If required: Fold in folding cylinder (27) on the main boom and
lock with locking bolt (28).
Risk of accidents!
The framework of the MBE could collapse due to missing
pins or locks.
Before proceeding further, check that all pins and locks are
fitted firmly.
082−1180−82201c_en 65/221
18
61
62 48 5 42
2
49
S2
63
64
Z 86 553 Z 82 417
2
39
Z 82 418 Z 82 895
66/221 082−1180−82201c_en
18.5.3.2.1.2 Folding from the Operating into the Transport Posi-

tion
(Z 86 553)
1. Dismantle hazard light (61) and rotor (62) of the wind measu-
ring device incl. bracket. For the device designed with sepa-
rated brackets, fasten it to the transport receptacle on the
right−hand side of the superstructure. Remove hoist limit
switch (63) together with hoist limit switch shift weight (64)
and store in the storage department.
tion.
(Z 86 553, Z 82 417, Z 82 418)

2. Remove the hoist rope on the main boom extension:
2.1 Unreeve the hook block (see section 17 ”Reeving”).
2.2 Remove hoist rope (5) from the rope sheaves on the
head of the basic boom MBE (2): To do so, remove
rope guard pins (48) and (49) from the head of the ba-
sic boom MBE (2). Pull hoist rope (5) down from the
rope sheaves. Refit rope guard pins (48) and (49) and
secure them against falling out.
2.3 Peg rope guard pin (42) in the transport position and
secure it against falling out (see Z 82 417).
2.4 Pull hoist rope (5) back to the main boom head so that
it hangs down to the side (see Z 82 418).

tes): If the MBE was angled, fit the MBE on the main boom
head in the 0°−position (see section 18.8 from page 169).
(Z 82 895)
boom MBE (2).
rope (39).
082−1180−82201c_en 67/221
18
”a” ”b”
15.2
15.3 15.2 15.3
Z 82 394
27.1
28
27
27 73
Z 82 410 Z 82 411
21.3
21.2
21.1
21
Z 104 207 Z 82 928
68/221 082−1180−82201c_en
(Z 82 394)
5. If not already occurred: Fold out mobile part (15.2) of the roll-
way (Z 82 394 ”b”).
To do so, release pin (15.3), fold over the mobile part of the
rollway (15.2) and refit pin (15.3).
(Z 82 410, Z 82 411)
6. Place the folding cylinder (27) in the operating state:

6.1 If not already occurred: Fold folding cylinder (27) into
the operating position. If locking bolt (28) is locked, fol-
ding cylinders (27) are in the correct position. Figure
(Z 82 410) shows this state.
6.2 Align safety lug (27.1) of the folding cylinder (27) verti-
cally if it has twisted.
(Z 104 207, Z 82 928)
7. Plug the mobile control panel (21) into the corresponding

electric connection on the front left of the basic case of the
main boom.
082−1180−82201c_en 69/221
18
13
13
B 73 Z 82 404
12
”X0550”
Z 82 400
C1
A1 A F
Z 82 111
70/221 082−1180−82201c_en
(Z 82 400, Z 82 404, Z 82 111)
8. Prepare connecting pins (12) for locking (if not already occur-
red): To do so, lever (13) must be lifted to the side with actua-
ting rod (73) to disable the lock of lever (13).
A mechanical lock keeps the connecting pin (12) open. When

swinging the main boom extension into the holder on the basic
case of the main boom at a later point, pin (12) closes automati-
cally. Lever (13) moves down with a jerk when this is done.
9. Remove the plug of the MBE cable harness from connection

(A).
For the hydraulic luffing MBE (HAVHY), also remove the
MBE CAN plug from connection (C) and fit the CAN BUS ter-
minating plug (C1).
082−1180−82201c_en 71/221
18
L: R: 32 31 H
63.1 63.1
”B”
”B”
”A”
63.2 I
31
32
3
1
2 Z 104 166 Z 104 531
37
Z 104 217
72/221 082−1180−82201c_en
(Z 104 166)
10. Bring the hoist limit switch on the main boom head into the
functioning state:
To deactivate the bridging of the hoist limit switch, the equipment

wire must be pulled down 1 and then to the side 2 and out of
the way. The restrainer (63.2) can then be removed 3 .
Figure (Z 104 166 figure ’R’) shows the hoist limit switch in the
functional state.
For the following unpinning procedure at points (H) and (I)

(Z 104 531), make sure that the locking pins (37, Z 104 217)
are locked into the main boom on the bottom left.
11. Remove fixing pins (31) from points (H) and (I).
Risk of falling
For subsequent unlocking of the lock catch (37, Z 104 217):
Do not lean the ladder against the MBE.
Danger!
Risk of accidents due to the main boom extension moving
unchecked!
The main boom extension must be held with the draw and
guide rope when unlocking locking bolt (37) in the next
work step.
12. Unlock the locking bolt (37) by rotating it 180°.
082−1180−82201c_en 73/221
18
F/G
27
15
Z 82 402
27.1
21.3
21.2
21.1
27 21
Z 82 897 Z 104 207
74/221 082−1180−82201c_en
When folding over the lattice mast top section from the ope-
rating into the transport position there is a risk of crushing,
shearing or falling objects (e.g. forgotten tools). There
must therefore be no−one in the endangered area during
the folding procedure. It is prohibited to walk between the
lattice mast top section and the main boom.
(Z 82 402, Z 82 897)
13. Fold over the MBE at the draw and guide rope until the joint
piece (27.1) of the folding cylinder (27) locks in place.
(Z 82 402, Z 104 207, Z 82 897)
14. If the joint piece (27.1) does not lock in place:

Telescope the folding cylinder (27) out until the joint piece
(27.1) has ’gripped’ the basic boom MBE.
For this, on the mobile control panel (21), press rocker switch
(21.2) until the position is reached (selector switch (21.3) in posi-
tion “1”).
If necessary, the position of the MBE must be adjusted using the

pull and guide ropes or by adjusting the angle of the folding cylin-
der (27).
082−1180−82201c_en 75/221
18
21.3
21.2
F/G
27 21.1
37
21
B
Z 82 399 Z 104 207
B
13
12
73
Z 82 412 Z 82 898
B
”a”
F/G
2 27
B 31
32
”b”
F/G
27
2
Z 82 413
76/221 082−1180−82201c_en
(Z 82 399, Z 104 207, Z 82 412, Z 82 898, Z 82 413)
To carry out this step, position yourself so that you are not directly
under the MBE.
15. Using folding cylinder (27), pull the MBE sensitively along the
main boom until the pinning position on the centre of motion
(B) on the side has been reached.
tion “1”).
As soon as the holes of the shackles of the basic boom MBE are
lined up with the corresponding holes of the bracket, the connec-
ting pin (12) is pressed in with spring force.
If the pinning procedure malfunctions, the connecting pin (12)
must be put in the pinning position by pressing lever (13) up with
the actuating rod (73) before attempting pinning again.
Risk of crushing!
When pressing the connecting pin (12) into the correspon-
ding holding device’s holes, the lever (13) moves down with
a jerk.
Risk of accidents!
Before continuing the fitting procedure, you must check vi-
sually whether the connecting pin (12) has actually locked
in place at the lateral centre of motion (B).
16. Remove the fixing pins from the attachment points (F/G,
Z 82 413 ”b”) in the boom head axes and fit in the transport
receptacle (on the inner side of the basic boom MBE) and se-
cure.
If necessary: Telescope the folding cylinder (27) out minimally so

that the fixing pins (31) are relieved of load in points (F/G,
Z 82 413 ”b”).
082−1180−82201c_en 77/221
18
B
”a”
F/G
2 27
B 31
32
”b”
F/G
27
2
Z 82 413
21.3
21.2
21.1
21
Z 104 207 Z 82 928
”a” ”b”
15.2
15.3
15.2 15.3 2
15
34
Z 82 414
78/221 082−1180−82201c_en
(Z 82 413)
17. Pull the MBE with the folding cylinder (27) completely into the
transport position past the main boom (Z 82 413 ”a”).
(Z 104 207)
tion “1”).
(Z 82 414)
18. Fold back the mobile part (15.2) of the rollway.

To do so, release pin (15.3); Fold over the mobile part of the
rollway (15.2) and refit pin (15.3).
This means that the locking plate (34) of the basic boom MBE (2)
is clamped between the mobile part (15.2) of the rollway and the
fixed part of the rollway. This prevents the main boom extension
(MBE) from folding away during transport.
(Z 82 928)
19. Remove the mobile control panel (21) from the electric con-
nection (Z 82 928) on the front left of the basic case of the
main boom.
20. Remove the draw and guide rope.
082−1180−82201c_en 79/221
18
2 3
B
Z 82 419
2 27
39
Z 82 895 Z 82 393
24.2
Z 315 691 25 Z 82 899
80/221 082−1180−82201c_en
18.5.3.2.2 MBE (21 m (68.9 ft)) Fitted in the Transport Position

from the Transport into the Operating Position
Preparations
(Z 82 895)
boom MBE (2).
rope (39).
Danger!
There is a risk of accidents due to the main boom extension
falling down and folding over unchecked and there are ad-
ditional risks during the fitting procedure.
components in the configuration described.
(Z 82 419, Z 82 393, Z 315 691)

point ”B” (Z 82 392).
schematic diagram).
(Z 82 899)
Figure (Z 82 899) is shown without the main boom extension for
clarification.
4. Fasten the box top piece to the basic boom section of the
main boom (if not already done).
Pin pin (24.2) to actuating lever (25) on the box top piece.
082−1180−82201c_en 81/221
18
55
55.1
3 Z 82 425 Z 82 371
3 2
32, 33
27
2
Z 82 424 Z 82 393
”a” ”b”
15.2
15.3 15.2 15.3
Z 82 394
82/221 082−1180−82201c_en
5. Pull out pin (55) between the basic boom main boom exten-
sion (2) and box top piece (3) and place in the locked posi-
tion. To do so, pull on eyebolt (55.1) from below using auxi-
liary rod (Z 82 371) and when pulled, place it in the locked
position with a 90° turn.
(Z 82 424)
6. Remove fixing pins (33; 2x) between the basic boom MBE (2)
and the box top piece (3).
(Z 82 394)
7. Fold out mobile part (15.2, Z 82 394 ”a”) of the rollway.

To do so, release pin (15.3). Fold over mobile part of the roll-
way (15.2, Z 82 394 ”b”) and refit pin (15.3).
(Z 82 393)
After the mobile part (15.2) of the rollway has been folded out, the
main boom extension (2) is only kept from folding over by the fol-
ding cylinder (27).
082−1180−82201c_en 83/221
18
”a”
F/G
2 3 27 B
”b”
F/G
3
27 B
2 Z 82 421
55
55.1
3 Z 86 555 Z 82 371
84/221 082−1180−82201c_en
(Z 82 421)
8. Continue the procedure from work step 6. (page 45) to the

last work step from section 18.5.3.2.1.1 .
(Z 86 555 schematic diagram, Z 82 371)
9. Unlock pins (55) on the box top piece (3). To do so, use the
auxiliary rod (Z 82 371) to turn the eyebolt (55.1) back by
90°.
Pin (55) returns independently to the lock position due to
spring resistance.
This work step prepares the folding over procedure from the ope-
rating into the transport position.
082−1180−82201c_en 85/221
18
2 3
Z 82 397
24.2
3
32, 33
25
Z 82 424 Z 82 423
86/221 082−1180−82201c_en
18.5.3.2.2.2 Folding from the Operating into the Transport Posi-

tion
(Z 82 397)
1. Carry out all steps of segment 18.5.3.2.1.2 (page 67).
Figure (Z 82 397) shows the main boom extension when work

step 1. has been carried out.
(Z 82 424)
2. Fit fixing pins (33) between the basic boom MBE and the box
top piece (2x) and secure against falling out with two locking
springs (32) each.
(Z 82 423)

clarification.
3. Fasten the box top piece to the basic case of the main boom.
082−1180−82201c_en 87/221
18
2
39
Z 82 895
2 3
B
Z 82 419
2 3
32, 33
27
2
Z 82 393 Z 82 424
88/221 082−1180−82201c_en
18.5.3.3 Folding over the 21 m MBE (68.9 ft)
When folding and during pinning and unpinning there must

be no−one in the slewing range or beneath the MBE or in
areas at risk of falling equipment etc.
The sequence of the operating steps must be adhered to
during the folding procedure.
18.5.3.3.1 Folding over the MBE 21 m (68.9 ft) from the

Transport into the Operating Position

(Z 82 895)
boom MBE.
rope (39).
Danger!
components in the configuration described. Otherwise,
there is a risk that the main boom extension will fall down,
fold over unchecked or that there will be additional hazards
during the fitting procedure.
(Z 82 419, Z 82 393, Z 82 424)

point ”B” (Z 82 419).
3.3 The fixing pins (33) between basic boom MBE (2) and
box top piece (3) must be pinned. The fixing pins (33)
must be secured against falling out with two locking
springs (32) (Z 82 424).
082−1180−82201c_en 89/221
18
24.2
25
Z 315 691 Z 82 423
Z 82 427
90/221 082−1180−82201c_en
(Z 315 691)
schematic diagram).
(Z 82 423)

clarification.
4. Release the box top piece on the basic case of the main
boom.
To do so, pull pin (24.2) using actuating lever (25), releasing
the pinning between the box top piece and the basic case of
the main boom.
(Z 82 427)
5. Continue the procedure from work step 4. (page 43) to work

step 20. (page 55) from section 18.5.3.2.1.1 .

082−1180−82201c_en 91/221
18
2
52
”a” ”b”
Z 82 429 Z 104 214
3 55
55.1
39
Z 82 900 3 Z 82 431
33
32
32
33
Z 82 433
92/221 082−1180−82201c_en
(Z 82 429)
For risk−free operation, the locking bolt (52, Z 82 429) must be

in the lock position at the front on the basic boom MBE (2) during
one of the following work steps.
In figure (Z 104 214, figure ’a’, principle depiction), the locking
bolt is shown in the locked position.
(Z 82 429, Z 104 214 schematic diagram)
6. If not already occurred: Place locking pin (52, Z 82 429) in

the locked position at the front on the basic boom MBE (2)
(Z 104 214, figure ’a’, schematic diagram).
Fold up box top piece (3) into the operating position at the ba-
sic boom MBE (2).
(Z 82 900)
7. Fasten the draw and guide rope (39) to the head of the box
top piece.
rope (39).
(Z 82 431)
8. Pull out pin (55) between the basic boom MBE (2) and the
box top piece (3). To do so, pull ring bolt (55.1) from below,
releasing box top piece (3).
Danger!
If pin (55) has been released, the box top piece can fold over
unchecked.
The box top piece must be gripped and possibly held at the
draw and guide rope to prevent this.
(Z 82 433, Z 82 429)
9. Fold box top piece (3) around the two fixing pins (33, right−
hand side) (Z 82 433 schematic diagram) until locking bolt
(52, Z 82 429) locks in place at the front on the basic boom
MBE (2).
082−1180−82201c_en 93/221
18
K
”X0560”
3 33 A F H
32
52 A1 H1
2
Z 82 432 Z 315 590
94/221 082−1180−82201c_en
(Z 82 432)
10. Pin the box top piece in points (K) and (L) using fixing pins
(33) and secure.
Both fixing pins (33) are inserted at the top and/or bottom.
Both fixing pins are driven in deeper alternatively until the locking
springs (32) for securing the fixing pins can be inserted.
(Z 315 590)
11. Connect the cable harness plug of the box top piece with dis-
tribution box ”X0560” of the basic boom MBE in connection
(A).
12. Connect strapping plug (H1) with distribution box ”X0560” of
the basic boom MBE in connection (H).
082−1180−82201c_en 95/221
18
3
2
73
Z 82 434
3 2
73
Z 82 901
96/221 082−1180−82201c_en
(Z 82 434, Z 82 901)
Danger!
(Z 82 434, Z 82 901)
for section, starting from the main boom head, over the basic
boom MBE (2) and box top piece (3) so that the plates (ar-
rows in respective figure) welded onto the upper chord pre-
vent the fitted sections of hoist rope (5) from falling down.
082−1180−82201c_en 97/221
18
5 S3
5
42 40
54
53
S4 3
63
2
64
Z 82 416 Z 86 556
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
3
1
2 Z 104 166
98/221 082−1180−82201c_en
(Z 82 416)
falling out.
tes): Setting the operating angle if the MBE is to be operated
at an angle of 20° or 40° (see section 18.8 from page 169).
For the MBE with hydraulically smooth operating angle adjust-

ment, the operating angle is only set when the main boom is ex-
tended.
(Z 86 556)
18. Guide the hoist rope over the sheave of the box top piece (3),
fit rope guard pins (54; 2x) and reeve the hook block (see
section 17).
be fastened at the designated point, marked ’S4’, on box top
piece (3).
19. Fit hoist limit switch (63) in the functioning state and fit shift
weight (64) to the head of the box top piece via hoist rope (5).
(Z 82 436, Z 104 166)

be fitted.
082−1180−82201c_en 99/221
18
61
”X0561”
5 S3 54
62
54
53
S4 3
A F H
63 A1
64
Z 86 557 Z 315 702
100/221 082−1180−82201c_en
(Z 86 557)
20. Fit the hazard light (61) and the rotor (62) of the wind measu-
ring device onto the head of box top piece (3) and plug the
corresponding electrical connections into the electrical ter-
minal box (53).
(Z 315 702)
Danger
082−1180−82201c_en 101/221
18
61
42
5 S3 54
62
54
53
S4 3 2
63
64
Z 86 557 Z 82 417
Z 82 418
102/221 082−1180−82201c_en
18.5.3.3.2 Folding the 21 m MBE (68.9 ft) from the Operating

into the Transport Position
(Z 86 557)
1. Dismantle hazard light (61) and rotor (62) of the wind measu-
ring device incl. bracket. For the device designed with sepa-
rated brackets, fasten it to the transport receptacle on the
right−hand side of the superstructure. Remove hoist limit
switch (63) together with hoist limit switch shift weight (64)
and store in the storage department.
tion.
(Z 86 557, Z 82 417, Z 82 418)
2. Remove the hoist rope on the main boom extension:

2.1 Unreeve the hook block (see section 17 ”Reeving”).
2.2 Remove hoist rope (5) from the rope sheave on the
head of box top piece (3): To do so, remove rope guard
pins (54, 2x) from the head of box top piece (3). Pull ho-
ist rope (5) down from the rope sheave. Refit rope
guard pins (54, 2x) and secure against them falling out.
2.3 Pin rope guard pin (42) at the back on the basic boom
MBE (2) in the transport position and secure against
falling out (see Z 82 417).
2.4 Pull hoist rope (5) back to the main boom head so that
it hangs down to the side (see Z 82 418).

tes): If the MBE was angled: fit the MBE on the main boom
headin the 0°position (see section18.8 from page169 in the
reverse order).
082−1180−82201c_en 103/221
18
39
Z 82 900
104/221 082−1180−82201c_en
(Z 82 900)
4. Fasten the draw and guide rope (39) to the head of the box
top piece (3).
rope (39).
Fold up the box top piece on the basic boom MBE into the
transport position:
5. Remove the plug of the harness of the box top piece from the
head of the basic boom MBE.
082−1180−82201c_en 105/221
18
K 33
32
2
L
3
3 33
32 32
52 33
2
Z 82 432 Z 82 437
55
”a” ”b”
Z 104 214 3 Z 82 438
2 3
B
Z 82 419
106/221 082−1180−82201c_en
(Z 82 432)
6. Remove fixing pins (33, 2x) from the connection between the
basic boom MBE (2) and the box top piece (3) in points (K)
and (L) (left−hand side of the main boom extension) (33, 2x).
(Z 82 432, Z 82 437, Z 104 214)
(Z 82 438)
Danger!
If pin (55) does not lock in place when carrying out the next
work step, the box top piece (3) could fold back unchecked.
Check that pin (55) is locked in place.
7. Using the draw and guide rope, fold box top piece (3) around
the right−hand pins (33, 2x) until pin (55) locks in place on the
basic boom MBE due to the folding movement.
To start the movement, turn the locking bar (52) by 180° in
the release position. The locking pin is depicted in the re-
lease position in figure (Z 104 214 ”b”, schematic diagram).
Fold the basic boom MBE (2) with folded box top piece (3) in
the transport position:
8. Continue the procedure from work step 4. (page 67) to the

last work step from section 18.5.3.2.1.2 .

082−1180−82201c_en 107/221
18
24.2
25
Z 82 423
2 3
Z 82 397
108/221 082−1180−82201c_en
(Z 82 423)

clarification.
9. Fasten the box top piece to the basic case of the main boom.
(Z 82 397)
After the described steps have been carried out, the

21 m (68.9 ft) main boom extension is in the transport position on
the side of the main boom.
082−1180−82201c_en 109/221
18
2 3
3
Z 82 374
15.3
15.2
Z 82 450
110/221 082−1180−82201c_en
18.6 Transporting the Main Boom Extension Separately
18.6.1 Transport Instructions for Separate Transportation
Transportation of the Main Components

(Z 82 374)
The transport dimensions, transport weights and attachment

points of the main components (1), (2) and (3) are described in
segment 18.6.2 (page 113).
Pins
All pins must be in a transport position which is secured against

falling out.
Measures to be taken at the basic unit

(Z 82 450)
If the parts of the transport position are on the main boom, the mo-
bile part (15.2) of the rollway must be folded in and pinned with
pins (15.3).
082−1180−82201c_en 111/221
18
2 3
3
Z 82 374
112/221 082−1180−82201c_en
18.6.2 Transport Dimensions / Weights, Attachment Points
18.6.2.1 Transport Dimensions / Weights

(Z 82 374)
Part no. Transport dimensions Approx. weight
Length Width Height (kg / lbs)
mm mm mm
(in) (in) (in)
1 12315 mm 880 mm 1600 mm 1140 kg /
(485 in) (34.7 in) (63 in) 2515 lbs
2 1340 kg / 2)
12040 mm 882 mm 1565 mm 2955 lbs
(474 in) (34.7 in) (61.6 in) 1590 kg / 3)
3505 lbs
3 9590 mm 770 mm 915 mm 710 kg /
(377.6 in) (30.3 in) (36 in) 1565 lbs
2+3 1) 2050 kg / 2)
12040 mm 1055 mm 1565 mm 4520 lbs
(474 in) (41.6 in) (61.6 in) 2300 kg / 3)
5070 lbs
1) folded together
2) Basic boom MBE for MBE with fixed operating angles (design with
tension plates)
3) Basic boom MBE for MBE with hydraulically smooth operating
angle adjustment (HAVHY)
082−1180−82201c_en 113/221
18
b d
1
a c
6 4 8 2
2
5 3 7 1
n
3
m
Z 82 446
114/221 082−1180−82201c_en
18.6.2.2 Attachment Points

(Z 82 446)
The main boom extension is comprised of various partial compo-

nents. 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 required, suspension tackle equipped with
shortening claws must be used.
The load handling equipment must be supplied by the custo-
mer.
Part Description Attachment points

no. ”a ”c ”m ”n
8 7 6 5 4 3 2 1
/ / ” ”
b” d”
1 Intermediate section x x
Basic boom MBE (HAV) 1) x x x x
2 Basic boom MBE 2) x x x x
(HAVHY)
3 Tip section x x
Basic boom MBE (MBE)
+ box top piece 1) x x x x
(folded together)
2+3 Basic boom MBE
(HAVHY)) 2) x x x x
+ box top piece
(folded together)
1) Basic boom MBE for MBE with fixed operating angles (design with tension plates)
2) Basic boom MBE for MBE with hydraulically smooth operating angle adjustment
(HAVHY)
082−1180−82201c_en 115/221
18
”a” ”b”
32
33
31 32
Z 82 448
116/221 082−1180−82201c_en
18.6.3 Fitting and Removing for Separate Transportation

The components of the main boom extension can be transported
separately.
The components for the individual desired MBE length can be fit-
ted using an auxiliary crane.
The parts must be attached at the attachment points provided.
A description of the attachment points can be found in section

18.6.2.2 on page 115.
18.6.3.1 General Instructions for Fitting

(Z 82 448)
Slew the superstructure forwards in the supported condition

(check the level) and luff the main boom into the horizontal (0°)
position.
For the planned configuration, the counterweight with the corres-
ponding support base as specified in the load tables must be fit-
ted.
Only the supplied fixing pins may be used to assemble the

main boom extension and/or for the transport position.
Each fixing pin must be secured with 2 functional locking
springs (32) to prevent it from falling out.
Depending on the location, there are two pin variants:

Location Pin variant Diameter (Z 82 448)
Fork head from a Fixing pins 45 mm / ”a”
part (31) 1.8 in
Fork head as wel- Fixing pins 40 mm / ”b”
ded metal construc- (33) 1.6 in
tion
Before each pinning procedure, these fixing pins must be well

greased.
082−1180−82201c_en 117/221
18
3 2 1
Z 82 451
118/221 082−1180−82201c_en
(Z 82 451)
The pinning points below are marked with Roman numbers −

where it appears useful:
Pinning point Connection between
Box top piece (3) and basic boom MBE
I
(2)
Basic boom MBE (2) and intermediate
section (1)
(HAV 23.4 m / 76.8 ft
HAV 33 m / 108.3 ft)
II
Basic boom MBE (2) and head of the
main boom
(MBE 11.4 m / 37.4 ft;
MBE 21 m / 68.9 ft)
Intermediate section (1) and head of
the main boom
III
(MBE 23.4 m / 76.8 ft;
MBE 33 m / 108.3 ft)
For pinning and securing the MBE, use the supplied multi−
purpose ladder or a suitable step−up ladder (ladder, scaf-
folding). Make sure that the climbing aid is on firm / secure
ground. Walking on the MBE or on the top of the main boom
is prohibited.
Persons must not stand or walk beneath suspended loads

or in areas where loads/equipment could fall.
The auxiliary crane must hold the parts to be fitted until all
pinning points have been pinned and locked correctly.
The basic boom MBE, intermediate section and box top

piece may not be fitted on the main boom head outstret-
ched and pinned together.
The basic boom MBE and box top piece can be fitted indivi-
dually or folded together on the main boom head.
When outstretched and pinned together, there is a risk of
accidents when fitting the main boom extension.
082−1180−82201c_en 119/221
18
L: R:
23 63.1 63.1
”B”
24 ”A”
63.2 63.2
1 2
3
Z 82 896 Z 104 165
120/221 082−1180−82201c_en
Hoist limit switch on the main boom head
In order to ensure that the load limit device (LLD) will continue to
function later when loads are being lifted with the main boom ex-
tension, the hoist limit switch on the main boom head must be
overridden, d.h. blocked in opened configuration:

1. If not already occurred:
Fit the hoist limit switch shift weight (23) of the main boom
(Z 104 165)
2. Block (override) the hoist limit switch of the main boom head
in opened configuration.
Figure (Z 104 165 figure ’R’) shows the hoist limit switch in the
bridged state. In order to bridge the hoist limit switch, the restrai-
ner (63.2) must first be fitted onto the actual hoist limit switch
(63.1). 1 Then the jumper wire is pulled away to the side, 2 then
rotated in the longitudinal direction of the restrainer (63.2), 3
and finally relaxed. This procedure jams the restrainer (63.2) by
the jumper wire’s spring resistance.
082−1180−82201c_en 121/221
18
H(F)
31
32
2
I(G)
Z 82 945
”a” ”b” F 31
H
32
33 I
31 32 G 31
Z 82 448 Z 82 944
122/221 082−1180−82201c_en
18.6.3.2 Fitting the 11.4 m MBE (37.4 ft)

(Z 82 945, Z 82 448, Z 82 944)
1. Observe all instructions in section 18.6.3.1 ”General instruc-

tions on fitting” (page 117).
2. Using the auxiliary crane, hang the basic boom MBE (2) in
front of the main boom head at the designated attachment
points (see 18.6.2.2 / page 115) so that the basic boom MBE
(2) can be pinned in the next work step.
3. Knock in fixing pins (31, x 4) in points (F, G, H, I) in the se-

quence described below and secure them against falling out
with 2 locking springs (32) each.
3.1 Fit fixing pins (31, x 2) in points (F, G) on the right−hand
side of the basic boom MBE (2).
3.2 Fit bottom fixing pin (31) in point (I) on the left−hand
3.3 MBE with fixed operating angles (design with tension
plates):
Lower the basic boom MBE (2) somewhat so that the
holes are aligned at the 4th pinning point (point H).
plates):
Fit upper fixing pin (31) in point (H) on the left−hand
(Z 82 944)

(HAVHY):
4. Detach the basic boom MBE (2) from the auxiliary crane.
082−1180−82201c_en 123/221
18
124/221 082−1180−82201c_en
5. Continue the procedure with step 18. (page 55) to step 30.
(page 63) from section ”18.5.3.2.1.1 Folding over the 11.4 m
(37.4 ft) MBE from the transport into the operating position”.
The removal procedure is the same, but in the opposite se-

quence.
No−one may be in the area where loads/equipment could

fall when loosening the fixing pins (31).
082−1180−82201c_en 125/221
18
3 2
31
32 32
33
Z 82 449
”a” ”b” F 31
H
32
33 I
31 32 G 31
Z 82 448 Z 82 944
126/221 082−1180−82201c_en
18.6.3.3 Fitting the 21 m MBE (68.9 ft)

(Z 82 449, Z 82 448, Z 82 944)

2. Using the auxiliary crane, hang the basic boom MBE (2) in
3. Knock in fixing pins (31, x 4) in points (F, G, H, I) in the se-

with 2 locking springs (32) each.
plates):
plates):
(Z 82 944)

(HAVHY):
082−1180−82201c_en 127/221
18
”X0550”
C1
A1 A F
Z 82 111
128/221 082−1180−82201c_en
(Z 82 111)
5. Connect plug of the basic boom MBE cable harness with
connection (A) on distribution box ”X0550” on the left−hand
justment (HAVHY): Connect the plug of the basic boom MBE
CAN line to connection (C) on distribution box ”X0550” on the
left−hand side of the main boom head.
(C1).
082−1180−82201c_en 129/221
18
L: R:
23 63.1 63.1
”B”
24 ”A”
63.2 63.2
1 2
3
Z 82 896 Z 104 165
”a” ”b”
32
33
31 32
Z 82 448
3 2
31
32 32
33
Z 82 449
130/221 082−1180−82201c_en
(Z 82 896)
7. Fit hoist limit switch shift weight (23) onto the bracket fitted
on the right−hand side of the main boom head and secure
it against falling out with locking spring (24).
(Z 104 165)
(Z 82 448, Z 82 449)
8. Using the auxiliary crane, hang box top piece (3) in front of
the basic boom MBE (2) at the designated attachment points
(see 18.6.2.2 / page 115) so that box top piece (3) can be pin-
ned in the next work step.
9. Knock in fastening pins (33, x 4) in pinning point (I) and se-
cure against falling out with two locking springs (32) each.
10. Detach box top piece (3) from the auxiliary crane.
11. Continue the procedure with step 11. (page 95) to the last
work step from section ”18.5.3.3.1 Folding over the 21 m
(68.9 ft) MBE from the transport into the operating position”.

quence.

082−1180−82201c_en 131/221
18
2 1
Z 82 453
”a” ”b”
”X0550”
32
C
33
31 32 C1
A1 A F
Z 82 448 Z 82 111
132/221 082−1180−82201c_en
18.6.3.4 Fitting the 23.4 m MBE (76.8 ft)

(Z 82 453, Z 82 448)

2. Using the auxiliary crane, hang intermediate section (1) in

points (see 18.6.2.2 / page 115) so that intermediate section
3. Knock in fixing pins (31, x 4) in pinning point (III) in the se-

using 2 locking springs (32) each.
3.1 Fit fixing pins (31, x 2) on the right−hand side of inter-
mediate section (1).
3.2 Fit bottom fixing pin (31) on the left−hand side of inter-
3.3 Fit upper fixing pin (31) on the left−hand side of inter-
4. Detach intermediate section (1) from the auxiliary crane.
(Z 82 453, Z 82 111)
5. Connect plug of the intermediate section (1) cable harness
with connection (A) on distribution box ”X0550” on the left−
hand side of the main boom head.
justment (HAVHY): Connect the plug of the intermediate sec-
tion (1) CAN line with connection (C) on distribution box
”X0550” on the left−hand side of the main boom head.
(C1).
082−1180−82201c_en 133/221
18
L: R:
23 63.1 63.1
”B”
24 ”A”
63.2 63.2
1 2
3
Z 82 896 Z 104 165
134/221 082−1180−82201c_en
(Z 82 896)
(Z 104 165)
082−1180−82201c_en 135/221
18
2 1
Z 82 453
”a” ”b” F 31
H
32
33 I
31 32 G 31
Z 82 448 Z 82 944
136/221 082−1180−82201c_en
(Z 82 453, Z 82 448, Z 82 944)
8. Using the auxiliary crane, hang basic boom MBE (2) in front
of intermediate section (1) at the designated attachment
9. Knock in fixing pins (31, x 4) in pinning point (II) in the se-

plates):
plates):

(HAVHY):
11. Plug cable harness plug of the basic boom MBE (2) into the
corresponding connection at the front on intermediate sec-
tion (1).
justment (HAVHY): Connect the CAN line plug of the basic
boom MBE with the corresponding connection at the front on
intermediate section (1).
082−1180−82201c_en 137/221
18
2 73 1
Z 82 458
2
73 1
Z 82 457
2 148 5 1 5
42 40
Z 82 459 Z 82 416
138/221 082−1180−82201c_en
(Z 82 458, Z 82 457)
Danger!
(Z 82 458, Z 82 457)
for section, starting from the main boom head, over the inter-
mediate section (1) and basic boom MBE (2) so that the pla-
tes (arrows in the respective figure) welded onto the upper
chord prevent the fitted sections of hoist rope (5) from falling
down.
(Z 82 459)
16. Guide hoist rope (5) over the front rope sheave of interme-
diate section (1), fit rope guard pin (148) and secure against
falling out.
(Z 82 416)
falling out.
MBE with fixed operating angles (design with tension plates):

If the main boom extension is to be fitted with an operating angle
of 205 or 405, the operating angle must be set before fitting the
hoist rope and reeving the hook block.
082−1180−82201c_en 139/221
18
48 5
”X0560”
49
S2 A F H
A1 H1
63
64
Z 86 554 Z 315 590
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
3
1
Z 104 166
140/221 082−1180−82201c_en
(Z 86 554)
basic boom MBE, fit rope guard pins (48) and (49) and reeve
the hook block (see section 17).
Remaining tasks
(Z 86 554, Z 315 590)


forelocks.
17).
(Z 86 554, Z 104 166)

be fitted.
082−1180−82201c_en 141/221
18
61
”X0560”
62 48 5
49 A F H
S2 A1 H1
63
64
Z 86 553 Z 315 590
142/221 082−1180−82201c_en
(Z 86 553, Z 315 590)
21. Fit the hazard light (61, optional) and the rotor (62) of the
wind measuring device to the head of the basic boom MBE
and connect to electric connections (F) and (A).

Danger

quence.

082−1180−82201c_en 143/221
18
3 2 1
Z 82 451
”a” ”b”
”X0550”
32
C
33
31 32 C1
A1 A F
Z 82 448 Z 82 111
23
24
Z 82 896
144/221 082−1180−82201c_en
18.6.3.5 Fitting the 33 m MBE (108.3 ft)

(Z 82 451, Z 82 448)
2. Using the auxiliary crane, hang intermediate section (1) in

points (see 18.6.2.2 / page 115) so that intermediate section
3. Knock in fixing pins (31, x 4) in pinning point (III) in the se-

3.1 Fit fixing pins (31, x 2) on the right−hand side of inter-
3.2 Fit bottom fixing pin (31) on the left−hand side of inter-
3.3 Fit upper fixing pin (31) on the left−hand side of inter-
(Z 82 451, Z 82 111)
4. Connect plug of the intermediate section (1) cable harness
with connection (A) on distribution box ”X0550” on the left−
hand side of the main boom head.
justment (HAVHY): Connect the plug of the intermediate sec-
tion (1) CAN line with connection (C) on distribution box
”X0550” on the left−hand side of the main boom head.
(C1).
(Z 82 896)
082−1180−82201c_en 145/221
18
L: R:
63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 104 165
3 2 1
Z 82 451
146/221 082−1180−82201c_en
(Z 104 165)
(Z 82 451)
7. Using the auxiliary crane, hang basic boom MBE (2) in front
of intermediate section (1) at the designated attachment
082−1180−82201c_en 147/221
18
3 2 1
Z 82 451
”a” ”b” ”X0560”

32
33 A F H
31 32 A1 H1
Z 82 448 Z 315 590
F 31
H
I
G 31
Z 82 944
148/221 082−1180−82201c_en
(Z 82 451, Z 82 448, Z 82 944)
8. Knock in fixing pins (31, x 4) in pinning point (II) in the se-

plates):
plates):

(HAVHY):
10. Plug cable harness plug of the basic boom MBE (2) into the
corresponding connection at the front on intermediate sec-
tion (1).
justment (HAVHY): Connect the CAN line plug of the basic
boom MBE with the corresponding connection at the front on
intermediate section (1).
12. Using the auxiliary crane, attach box top piece (3) to the desi-
gnated attachment points (see 18.6.2.2 / page 115) in front of
the basic boom MBE (2).
082−1180−82201c_en 149/221
18
3 2 1
Z 82 451
”a” ”b” F 31
H
32
33 I
31 32 G 31
Z 82 448 Z 82 944
”X0560”
A F H
A1 H1
Z 315 590
150/221 082−1180−82201c_en
(Z 82 451, Z 82 448, Z 82 944)
13. Knock in fastening pins (33, x 4) in pinning point (I) and se-
cure against falling out with two locking springs (32) each.
14. Detach box top piece (3) from the auxiliary crane.
(Z 315 590)
15. Connect the cable harness plug of the box top piece with dis-
tribution box ”X0560” of the basic boom MBE in connection
(A).
16. Connect strapping plug (H1) with distribution box ”X0560” of
the basic boom MBE in connection (H).
082−1180−82201c_en 151/221
18
2 73 1
Z 82 458
3
2
73
Z 82 434
3 2
73
Z 82 435
152/221 082−1180−82201c_en
(Z 82 458, Z 82 434, Z 82 435)
Danger!
(Z 82 458, Z 82 434, Z 82 435)
for section, starting from the main boom head, over interme-
diate section (1), basic boom MBE (2) and box top piece (3)
so that the plates (arrows in respective figure) welded onto
the upper chord prevent the fitted sections of hoist rope (5)
from falling down.
082−1180−82201c_en 153/221
18
2 148 5 1 5
42 40
Z 82 459 Z 82 416
5 S3
54
53
S4 3
63
64
Z 86 556
154/221 082−1180−82201c_en
(Z 82 459)
falling out.
(Z 82 416)
falling out.
MBE with fixed operating angles (design with tension plates):

of 205 or 405, the operating angle must be set before fitting the
hoist rope and reeving the hook block.
(Z 86 556)
fit rope guard pins (54; 2x) and reeve the hook block (see
section 17).
piece (3).
082−1180−82201c_en 155/221
18
5 S3
”X0561”
54
53
S4 3
63 A F H
A1
64
Z 86 556 Z 315 702
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
3
1
2 Z 104 166
156/221 082−1180−82201c_en
Remaining tasks
(Z 86 556, Z 315 702)


forelocks.
17).
(Z 86 556, Z 104 166)

be fitted.
082−1180−82201c_en 157/221
18
61
”X0561”
5 S3 54
62
54
53
S4 3 F H
A
63 A1
64
Z 86 557 Z 315 702
158/221 082−1180−82201c_en
(Z 86 557)
25. Fit the hazard light (61) and the rotor (62) of the wind measu-
ring device onto the head of box top piece (3) and plug the
corresponding electrical connections into the electrical ter-
minal box (53).
(Z 315 702)
Danger
082−1180−82201c_en 159/221
18
5 2
”a”
3 5 2
”b”
2 5 1
”c”
3 2 5 1
”d”
Z 82 461
160/221 082−1180−82201c_en
18.6.3.6 Converting from One Length to Another

In order to convert the MBE from one length to another, it might
be necessary to first remove the MBE components of the ”original
length” in accordance with the corresponding section; or already
assembled components can be fitted.
Then the ”desired length” is created in accordance with the cor-
responding section.
18.7 Rope Guide / Reeving the Hoist Rope

The main boom can be luffed down to carry out the work descri-
bed in the following.
Work that cannot be carried out from the ground may only be car-
ried out using suitable auxiliary equipment (e.g. supplied multi−
purpose ladder, hoist platform).
Danger
Risk of falling due to unsuitable auxiliary equipment!
Only use suitable equipment to carry out work at height.
Some of the plates for safely attaching the multi−purpose ladder

to the main boom head and to parts of the main boom extension
can only be used when the main boom extension is in a horizontal
position.
Danger
Risk of falling if the multi−purpose ladder is attached in a
way that is unsuitable for the specific operation!
Ensure the ladder is held securely before getting onto the
multi−purpose ladder.
Starting situation
− 0°MBE fitted to the main boom in the operating position.
Procedure for fitting the main boom extension as described
in the corresponding section.
(Z 82 461)
The rope guidance of hoist rope (5) depends on the length of the
fitted main boom extension (MBE).
082−1180−82201c_en 161/221
18
2 73 1
Z 82 458
3
2
73
Z 82 434
3 2
73
Z 82 435
162/221 082−1180−82201c_en
Fitting the hoist rope onto the main boom extension:
The description below is for the procedure for fitting hoist rope (5)
onto the three parts of the main boom extension in principle.
(Z 82 458, Z 82 434, Z 82 435)
Danger!
(Z 82 458, Z 82 434, Z 82 435)
for section, depending on the length of the fitted MBE, star-
ting from the main boom head, over intermediate section (1),
basic boom MBE (2) and box top piece (3) so that the plates
(arrows in respective figure) prevent the fitted sections of ho-
ist rope (5) from falling down.
082−1180−82201c_en 163/221
18
6.2 6 6.1 5 2 148 5 1
E2
Z 82 484 Z 82 459
5
42 40
Z 82 416
164/221 082−1180−82201c_en
Course of hoist rope (5) on the main boom head
(Z 82 484)
1. Fit hoist rope (5) onto intake sheave (E2) on the main boom
head.
1.1 Remove forelock (6.1).
1.2 Pull out rope sheave (6.2) sideways.
1.3 Guide hoist rope (5) over intake sheave (E2).
1.4 Slide rope sheave (6.2) back in and secure against fal-
ling out with forelock (6.1).
1.5 Fold entire rope guard protection (6) upwards.
Course of hoist rope (5) at the front on intermediate section

(1) (MBE 23.4 m / 76.8 ft) and (MBE 33 m / 108.3 ft)
(Z 82 459)
falling out.
Course of hoist rope (5) on the rear rope sheave of basic

boom MBE (2) (all MBE variants)
(Z 82 416)
falling out.
082−1180−82201c_en 165/221
18
61
62 48 5
5
49 3 2
S2
63
64
Z 86 553 Z 82 488
61
5 S3 54
62
54
53
S4 3
63
64
Z 82 557
166/221 082−1180−82201c_en
Course of hoist rope (5) at the front on the basic boom MBE
(2) (MBE 11,4 m / 37.4 ft and MBE 23,4 m / 76.8 ft)
of 205− or 405, the operating angle must be set before reeving the
hook block (see section 18.8 from page 169).
(Z 86 553)
basic boom MBE, fit rope guard pins (48) and (49), reeve the
hook block (see sect. 17), fit and electrically connect the ho-
ist limit switch with shift weight in the functioning condition,
the hazard light and rotor of the wind measurement equip-
ment.
Course of hoist rope (5) at the front on the basic boom MBE
(2) (MBE 21 m / 68.9 ft and MBE 33 m / 76.8 ft)
(Z 82 488)
After fitting onto the main boom extension, hoist rope (5) is on the
support roller (marked with an arrow in the figure) in the correct
position.
Course of hoist rope (5) on box top piece (3)

(MBE 21 m / 68.9 ft and MBE 33 m / 76.8 ft)
of 205− or 405, the operating angle must be set before reeving the
hook block (see section 18.8 from page 169).
(Z 86 557)
fit rope guard pins (54; x 2), reeve the hook block (see sec-
tion 17), fit the hoist limit switch with shift weight in the func-
tioning state, fit hazard light and rotor of the wind measure-
ment equipment.
piece (3).
082−1180−82201c_en 167/221
18
11.4 m (37.4 ft) 23.4 m (76.8 ft)
1
”a” ”c”
21,0 m (68.9 ft) 33,0 m (108.3 ft)
”b” ”d”
Z 82 493
P20 P40
5 43 45 36 33 31 32 5 43 45 36 35
F/H
2 31 G/I 2 31 G/I
32 32
”a” ”b”
Z 82 489
168/221 082−1180−82201c_en
18.8 Setting the Operating Angle (Design with Fixed Ope-

rating Angles; with Tension Plates)
18.8.1 Instructions on Risks and General Instructions
(Z 82 493)
The crane can be operated with an MBE under an angle of 0°, 20°
or 40° to the main boom longitudinal axis.
However, fitting the MBE with an auxiliary crane and folding over
the main boom extension (MBE) is only possible in the 0°−posi-
tion.
For the 11.4 m / 37.4 ft MBE (Z 82 493 ”a”) and the 21 m / 68.9 ft
MBE (Z 82 493 ”b”), the main boom extension is angled on the
head of the main boom.
For the 23.4 m / 76.8 ft MBE (Z 82 493 ”c”) and the 33 m /
108.3 ft MBE (Z 82 493 ”d”), the main boom extension is angled
at the front on the intermediate section (1).
05 operating angle
(Z 82 489 ’a’)
If the basic boom MBE is fitted with a 0° operating angle, the four
fixing pins (31) are knocked in place in points (F), (G), (H) and (I)
on the head of the main boom (see figure Z 82 489) or at the front
on intermediate section (1), depending on the MBE variant, and
secured against falling out.
Risk of accidents!
After setting the operating angle, check that with an opera-

ting angle of 05, the four fixing pins (31) are fitted in points
(F), (G), (H) and (I) and are secured against falling out.
(Z 82 489)
The components which are important for angling the basic boom
MBE (2) on the head of the main boom are shown as an example
in figure (Z 82 489). If the basic boom MBE (2) is angled on the
intermediate section (1), the figure applies correspondingly.
082−1180−82201c_en 169/221
18
P20 P40
5 43 45 36 33 31 32 5 43 45 36 35
F/H
2 31 G/I 2 31 G/I
32 32
”a” ”b”
Z 82 489
2
3
Z 82 496 Z 82 497
170/221 082−1180−82201c_en
Basic procedure for setting the operating angle

(Z 82 489)
The basic procedure for setting the operating angle is the same
for all main boom extension lengths.
The adjusting mechanism is designed so that two tension bars

(43) have to be adjusted at once. The pins described in the next
sections always come in pairs.
Sliding the main boom extension on the ground while setting

the operating angle
(Z 82 496, Z 82 497)
When setting the operating angle, the basic boom MBE (2) and/
or box top piece (3) slides on the ground. A hinged support is
used on the basic boom MBE (2) to do so. The front part of box
top piece (3) slides directly on the ground. Wooden blocks are put
down for sliding to prevent damage to the main boom extension
or to prevent the main boom extension from digging into the
ground if the ground is soft.
The wooden blocks must have a cross section of 10 cm x 10 cm
(4 in x 4 in) and a minimum length of 180 cm (71 in).
Two wooden blocks each are needed for the basic boom MBE (2)
and the box top piece (3).
If the hoist rope is lying on the main boom extension during the
corresponding operating step, it must be pulled to the side.
DANGER!
Risk of damage for the hoist rope.
Lay the hoist rope to the side before the basic boom MBE (2)
or box top piece (3) touches the ground.
When sliding on the ground, ensure that the hoist rope does
not get under the sliding surfaces.
082−1180−82201c_en 171/221
18
172/221 082−1180−82201c_en
Working at height
Work that cannot be carried out from the ground may only be car-
ried out using suitable auxiliary equipment (e.g. supplied multi−
purpose ladder, hoist platform).
Danger
Risk of falling due to unsuitable auxiliary equipment!
Only use suitable equipment to carry out work at height.
Some of the plates for safely attaching the multi−purpose ladder

to the main boom head and to parts of the main boom extension
can only be used when the main boom extension is in a horizontal
position.
Danger
Risk of falling if the multi−purpose ladder is attached in a
way that is unsuitable for the specific operation!
Ensure the ladder is held securely before getting onto the
multi−purpose ladder.
082−1180−82201c_en 173/221
18
Z 200 294
174/221 082−1180−82201c_en
18.8.2 Switching from the 0 − Degree to the 20 − Degree Po-

sition (and Vice Versa)
The procedure for switching over from the 0° position into the 20°
position (and vice versa) is the same for all main boom extension
(MBE) lengths in principle. However, in the figures in this section
only assembly states without intermediate section (1) are shown.
To do so, 4 wooden blocks with a cross section of 10 cm x 10 cm
(4 in x 4 in) and a minimum length of 180 cm (71 in) are used.
Initial situation:
− Crane assembled in accordance with the subsequent confi-
guration (apart from the operating angle of the main boom ex-
tension) with the main boom extension; operating mode para-
meters set accordingly in crane control
− MBE fitted in the 0° operating position on the main boom
head (0° operating position as described in section ”18.8.1 In-
structions on risks and general instructions” , page 169)
(Z 200 294)
− Superstructure slewed in the 0°− , 90°− or 270° position
Procedure
1. Observe all specifications in section 18.8.1 ”Instructions on

risks and general instructions” (from page 169).
2. For the 11.4 m (37.4 ft) and the 21 m (68.9 ft) MBE, tele-
scope the main boom out with length code LK13.
3. If the hook block was reeved before this operating step, set
the hook block down on the ground next to the main boom
extension and unreeve.
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18
Z 82 504
176/221 082−1180−82201c_en
Caution!
Risk of damage for the hoist limit switch for main boom ex-
tension variants with box top piece (3) (21 m / 68.9 ft MBE
and 33 m / 108.3 ft MBE), if the head of the box top piece
slides along the ground in a subsequent operating step.
Remove the hoist limit switch from the box top piece after
unreeving the hoist rope.
4. For main boom extension variants with box top piece (3)
(21 m / 68.9 ft MBE and 33 m / 108.3 ft MBE), the hoist limit
switch must be removed from the box top piece.
(Z 82 504)
5. Tilt the main boom down until the hinged support (see arrow
in Z 82 504) on the basic boom MBE (2) can be placed in the
operating position.
6. Place the hinged support (see arrow in Z 82 504) in the ope-

rating position (see 18.8.4, page 189).
082−1180−82201c_en 177/221
18
3 2
Z 86 580
72A
72
72B
Z 83 457
178/221 082−1180−82201c_en
(Z 86 580)
7. For MBE variants with box top piece (3), place 2 wooden
blocks next to each other under the sliding tube on the head
of the box top piece. The wooden blocks must have a cross
section of 10 cm x 10 cm (4 in x 4 in) and a minimum length
of 180 cm (71 in).
The sliding length on the wooden blocks during the subsequent

angling procedure is approx. 150 cm (59 in).
8. Tilt the main boom down completely (approx. 1.3°).
(Z 83 457)
9. Retract the counterweight lift cylinders in order to pull the co-
unterweight combination up against the superstructure
frame if the counterweight combination has been lowered.
To do so, press luminous pushbutton (72) in the top half (72a)
and hold in this position until the counterweight combination
is safely up against the superstructure frame on both sides.
Note
For technical reasons, the counterweight combination can be lo-
wered slightly during crane operation. This does not impair nor-
mal operation.
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18
Z 82 515
3 2
31
32 F/H
Z 82 506
180/221 082−1180−82201c_en
Caution
Risk of damage for the counterweight lift cylinders!
The counterweight combination must be pulled up against
the superstructure frame to prevent damage to the counter-
weight lift cylinders before tilting the chassis in the next
work step.
Carry out ”Retract counterweight lift cylinders” conscien-
tiously.
Caution
Risk of damage for crane components when the crane chas-
sis is in the inclined position!
In the next work step, do not tilt the crane chassis more than
1.5°.
(Z 82 515)
Caution!
Risk of damage for the hoist rope in MBE variants without
box top piece (3) (11.4 m / 37.4 ft MBE and 23.4 m / 76.8 ft
MBE).
Lay the hoist rope to the side before the support touches the
ground (Z 82 515).
(Z 82 506)
10. Tilt the crane chassis via the support cylinders until the sup-
port (marked with an arrow in the figure) on the basic boom
MBE (2) is on the ground and fixing pins (31) in points F and
H are relieved of load.
Note
The support may not be placed under too much load, as fixing
pins (31) in points F and H are then loaded to such a degree that
these fixing pins cannot be dismantled in one of the next work
steps.
Note
Operation of the supports is described in the operating instruc-
tions of the crane chassis in the section ”Outriggers”.
082−1180−82201c_en 181/221
18
P20 P40
5 43 45 36 33 31 32 5 43 45 36 35
F/H
2 31 G/I 2 31 G/I
32 32
”a” ”b”
Z 82 489
47 35
Z 82 957
182/221 082−1180−82201c_en
Danger!
Risk of accidents due to the main boom extension falling
down.
When removing the two fixing pins (31) from the upper fork
heads (points F and H) in the following step, ensure that the
fixing pins in the bottom fork heads (points G and I) always
remain pinned.
(Z 82 489)
11. On the first side of the basic boom MBE (e.g. left), remove
fixing pin (31) from the left−hand upper fork head (here: point
H).
12. Release transport lock (33) of the left−hand tension plate

(43).
13. Peg pin (36) in point (P20) (or leave it pegged in place).
(Z 82 489 “b”)
14. Pull tension plate (43) on this side forward and pin to the pin-
ning point on the main boom head or on the intermediate
section using pin (35) and secure with locking spring (47)
(Z 82 957).
(Z 82 489)
15. On the second side of the basic boom MBE (here: right),
carry out steps (11.) to (14.).
16. For MBE variants without box top piece (3) (11.4 m / 37.4 ft
MBE and 23.4 m / 76.8 ft MBE), place the support in the
transport position. To do so, luff up the main boom until the
components of the support can be swung into their transport
position. The relevant procedure is described in section
”18.8.4.2 Placing the hinged support in the transport posi-
tion” (page 191).
Note
For MBE variants with box top piece (3) (21 m / 68.9 ft MBE and
33 m / 108.3 ft MBE), the support can remain unfolded during
subsequent raising of loads with an angled main boom exten-
sion, as the distance between the lifted hook block and the sup-
port is large enough.
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18
P20 P40
5 43 45 36 33 31 32 5 43 45 36 35
F/H
2 31 G/I 2 31 G/I
32 32
”a” ”b” Z 82 489
Z 86 576
Z 86 577
184/221 082−1180−82201c_en
(Z 82 489)
Risk of accidents!
Check the following after setting an operating angle of 205
or 405:
− The two pins (35) on the main boom head must be inser-
ted and secured against falling out.
− The two pins (36) connect the adjusters (45) with the ten-
sion plates (43) and must be secured against falling out.
− The two fixing pins (31) in points (G) and (I) must be in-
serted and secured against falling out.
(Z 86 576, Z 86 577)
Note
For MBE variants with box top piece (3) (21 m / 68.9 ft MBE
and 33 m / 108.3 ft MBE), the box top piece is set down on the
wooden blocks under the head of the box top piece when luffing
up the main boom and slides over the wooden blocks which have
been placed underneath.
Caution!
Risk of damage for the hoist rope for main boom extension
variants with box top piece (3) (21 m / 68.9 ft MBE and 33 m
/ 108.3 ft MBE).
Lay the hoist rope to the side before the box top piece
touches the ground. It might be required to remove one of the
rope guard pins to do so (see arrow in figure Z 82 513).
17. Level the crane chassis, i.e. position it horizontally.

While this is done, the main boom extension slides over the
wooden blocks which have been placed underneath.
082−1180−82201c_en 185/221
18
Z 86 578
P20 P40
5 43 45 36 33 31 32 5 43 45 36 35
F/H
2 31 G/I 2 31 G/I
32 32
”a” ”b” Z 82 489
186/221 082−1180−82201c_en
(Z 86 578)
18. Continue to luff up the main boom until the angle of the desi-
gnated angling on the main boom extension is achieved.
While this is done, the main boom extension slides over the
wooden blocks which have been placed underneath until it
lifts off the ground. Figure (Z 86 578) shows this state for the
21 m / 68.9 ft MBE.
The equipment is converted from the 20° position to the 0° posi-

tion in the same way, only in the reverse order.
18.8.3 Switching from the 0 − Degree to the 40 − Degree Po-

sition (and Vice Versa)
(Z 82 489)
Proceed as described in 18.8.2.

However, pin (36) must be fitted in point (P40) instead of in point
(P20) during the fitting procedure.
The equipment is converted from the 40 °position to the 0° posi-

tion in the same way, but in the reverse order.
082−1180−82201c_en 187/221
18
”a” ”b”
3 4 5
1 2 2 5
1 4
3
Z 82 500
188/221 082−1180−82201c_en
18.8.4 Hinged Support on the Basic Boom MBE
18.8.4.1 Placing the Hinged Support in the Operating Position
Initial situation:
(Z 82 500)
− MBE fitted, pinned in the operating position (0°)

− Main boom tilted so far down that the components are acces-
sible but the support frame (4) can be swung from the trans-
port position to the front.
Procedure
(Z 82 500 “a”)
Danger
Risk of accidents due to the braces (1) and support frame
(4) swinging round unchecked.
When pulling out the fixing pins in the next work steps, hold
onto the braces (1) and/or support frame (4) and let the
parts swing down in a controlled manner.
1. On the first side of the basic boom MBE (e.g. left), remove
locking spring from pin (2).
2. Hold onto brace (1) with one hand and remove pin (2) with
your other hand. Using your hand, let brace (1) swing down
in a controlled manner. Insert pin (2) back in the same hole
in the transport position and secure against falling out using
the locking spring.
3. On the second side of the basic boom MBE (e.g. right), carry
out steps 1. and 2..
082−1180−82201c_en 189/221
18
”a” ”b”
3 4 5
1 2 2 5
1 4
3
Z 82 500
190/221 082−1180−82201c_en
(Z 82 500 “a”)
4. Remove forelock from pin (5).
5. Hold onto support frame (4) with one hand and remove pin
(5) with the other hand. Using your hand, let support frame
(4) swing down in a controlled manner. Insert pin (5) back in
the same hole in the transport position and secure against
falling out using the locking spring.
(Z 82 500 “b”)
6. Position support frame (4) so that it can be pinned to the first

brace (1) using a pin (3).
7. Pin the second brace (1) to the support frame (4) using a pin
(3).
18.8.4.2 Placing the Hinged Support in the Transport Position
Initial situation:
(Z 82 500)
− Main boom tilted so far down that the components are acces-
sible but the support frame (4) can be swung from the opera-
ting position to the rear.
Procedure
(Z 82 500 “b”)
Danger
Risk of accidents due to the braces (1) and support frame
(4) swinging round unchecked.
When pulling out the fixing pins in the next work steps, hold
onto the braces (1) and/or support frame (4) and let the
parts swing down in a controlled manner.
1. Remove pin (3) on the first side of the support (e.g. left).
082−1180−82201c_en 191/221
18
”a” ”b”
3 4 5
1 2 2 5
1 4
3
Z 82 500
7 4 6
1
Z 82 522
192/221 082−1180−82201c_en
(Z 82 500 “b”)
2. On the second side of the support, remove locking spring

from pin (3).
3. Hold onto support frame (4) with one hand and remove the
second pin (3) with the other hand. Using your hand, let sup-
port frame (4) swing down in a controlled manner.
4. If the main boom extension is in the horizontal position, the

procedure is continued with step 9. (page 193).
(Z 82 522)
5. If the main boom extension is not in the horizontal position,

fold the support frame (4) in the transport position direction
and fix in place on the basic boom MBE as shown in figure
(Z 82 522) using e.g. the draw and guide rope (6) (for folding
the MBE over into / out of the transport position).
6. Fasten support frame (4) and the two braces (1).
6.1 Fasten support frame (4) to basic boom MBE (2) using
a fixing device (6).
6.2 Fasten the two braces (1) to support frame (4) using a
fixing device (7).
Lashing straps can be used for fastening.
7. Luff the main boom down until pin (5) can be reached.
8. Remove fixings (6) and (7). The two braces (1) and the sup-
port frame (4) swing downward.
(Z 82 500 “a”)
9. Fasten support frame (4) to the basic boom MBE using pins
(5). Secure bolts (5) against falling out.
10. Pin both braces (1) to support frame (4) using pins (2). Se-
cure the pins (3) against falling out.
082−1180−82201c_en 193/221
18
48 46.1 35
2
46 46
31 G/I
2
2
Z 82 914 Z 82 911
11.4 m (37.4 ft) 23.4 m (76.8 ft)
1
”a” ”c”
21,0 m (68.9 ft) 33,0 m (108.3 ft)
”b” ”d”
Z 82 934
194/221 082−1180−82201c_en
18.9 Setting the Operating Angle on the Hydraulically

Luffing MBE (”HAVHY”)
18.9.1 Instructions on Risks and General Instructions
(Z 82 914)
Crane operation with the hydraulic luffing main boom extension
can be carried out smoothly below an angle of 0° to 40° to the
main boom longitudinal axis.
The angle is adjusted by angling the basic boom MBE (2). To do
so, the two hydraulic adjusting cylinders (46) are telescoped in
and out.
This adjusting cylinder (46) is supplied hydraulically via a hydrau-
lic power pack (48) fitted in the basic boom MBE (2). This hydrau-
lic power pack (48) is driven via a Hatz diesel engine (see section
18.9.2.2, page 201).
During crane operation, telescoping the two adjusting cylinders
in and out is controlled from the crane operator’s cab.
(Z 82 934)
For the 11.4 m (37.4 ft) MBE (Z 82 934 ”a”) and the 21 m (68.9 ft)
MBE (Z 82 934 ”b”), the main boom extension is angled on the
head of the main boom.
For the 23.4 m (76.8 ft) MBE (Z 82 934 ”c”) and the 33 m
(108.3 ft) MBE (Z 82 934 ”d”), the main boom extension is angled
at the front on the intermediate section (1).
(Z 82 934, Z 82 911)
Fitting the MBE with the auxiliary crane and folding over the main
boom extension (MBE) is only permitted in the 0° position to the
main boom longitudinal axis.
First, the MBE is fitted to the main boom head or intermediate
section (1) as described under ”18.5 Main boom extension fitted
on the main boom (page 31)” or ”18.6 Main boom extension
transported separately (page 111)”. Then the adjusting cylinders
are pinned as described under ”18.9.2.4.1 Pinning the adjusting
cylinders (page 215)”.
Risk of accidents!
After fitting the MBE, check that the two bottom fork heads
and the two pins between the adjusting cylinder and the
main boom head are pinned and secured against falling
out.
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Z 82 249
196/221 082−1180−82201c_en
(Z 82 249)
The load capacity tables which are delivered with the crane are
divided into five angle levels: 0°, 10°, 20°, 30° and 40° to the main
boom longitudinal axis.
If a load is to be raised at an angle between two angle levels (e.
g. 25°), the corresponding permitted maximum capacity is calcu-
lated by crane control (interpolated).
The permitted maximum capacity is displayed in the ”Crane ope-
ration” screen in the MAX (t) field.
The hydraulic power pack is controlled at crane control’s opera-

ting panel in the ”HAVHY” screen (see 18.9.2.3.2, page 209).
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18
46
Z 82 946
198/221 082−1180−82201c_en
18.9.2 Operating Elements and Auxiliary Equipment
18.9.2.1 Hydraulic Adjusting Cylinders

(Z 82 946)
The angle between the main boom and the mobile component of
the MBE can be adjusted smoothly with the hydraulic adjusting
cylinders (46) for crane operation.
The adjusting cylinders (46) are fitted on the basic boom MBE (2)
as shown.
The adjusting cylinders (46) must be pinned to the main boom

head for raising the load before erecting the MBE. To do so, see
18.9.2.4.1 Pinning the adjusting cylinders, page 215.
Danger of accidents through residual hydraulic energy!

When the main boom extension is removed, strong pressu-
res (up to a maximum of 265 bar / 3844 psi) can build up
(sunlight) on the adjusting cylinders (46).
For that reason, the pressure must be reduced in appro-
priate fashion by correspondingly qualified personnel be-
fore repair and/or replacement work is carried out!
082−1180−82201c_en 199/221
18
20
Z 54 256
24
22
21
Z 56 664
200/221 082−1180−82201c_en
18.9.2.2 Hydraulic Power Pack with Hatz Engine
18.9.2.2.1 General
The tasks described below must be carried out before every ope-
ration (on the ground).
18.9.2.2.2 Checking the engine oil level
(Z 54 256)
Check the engine oil level on the dip stick (20, Z 54 256).
The procedure can be found in the operating instructions of the
Hatz diesel engine in the part ”Various” in these documents.
18.9.2.2.3 Checking the Hydraulic Oil Level
(56 664)
Check the hydraulic oil level at the oil level display (21, Z 56 664)
of the hydraulic oil reservoir.
The oil level needs to be above the middle of the gauge glass
when the luffing cylinders are completely retracted.
If necessary, remove the cover (22) from the return flow filter, top
up the oil and screw the cover back on.
Also observe the lubrication and maintenance instructions in
these documents.
18.9.2.2.4 Filling up
(Z 56 664)
Fill up the fuel tank of the Hatz diesel engine.

Open the filler cap (24, Z 56 664) (fold up) and fill the tank com-
pletely. By doing this, the fuel system is aired automatically. Close
the filler cap again.
Risk of accidents!
Never fill the tank when the engine is running! Never fill the
tank in the vicinity of open flame or ignitable sparks; do not
smoke in the area! Use only pure fuel and clean filling con-
tainers! Do not spill fuel!
082−1180−82201c_en 201/221
18
202/221 082−1180−82201c_en
Use appropriate diesel fuels which meet the minimum require-

ments of the following specifications:
− EN 590 or
− BS 2869 A1 / A2 or
− ASTM D 975−1D / 2D.
If ambient temperatures are below 0 °C (32 °F), use winter fuel

or add petroleum in good time. Observe the following table:
Lowest ambient Petroleum percentage with

temperatures for
starting summer fuel winter fuel
0 °C to −10 °C 20% −
(32 °F to 14 °F)
−10 °C to −15 °C 30 % −
(14 °F to 5 °F)
−15 °C to −20 °C 50 % 20%
(5 °F to −4 °F)
−20 °C to −30 °C − 50 %
(−4 °F to −22 °F)
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204/221 082−1180−82201c_en
18.9.2.2.5 Starting / Switching off the Engine of the

Hydraulic Power Pack (Hatz Diesel Engine)
18.9.2.2.5.1 General / Warnings
Never start the engine in closed or badly aired rooms − dan-

ger of poisoning.
Before starting, always make sure that nobody is in the
danger zone of the engine and that all safety devices have
been installed.
Never use starter spray.
Before starting the engine, read the ”HATZ Diesel” operating

instructions attached in the part ”Various” of these opera-
ting instructions. Pay special attention to the section ”Im-
portant information on operational safety at the engine”,
”Operation” and ”Maintenance”.
Depending on the ambient temperature of the hydraulic power

pack (below 05 C / 325 F), the engine is automatically preheated.
With a cold start, the engine is preheated a maximum of two minu-
tes at 05 C (325 F) − automatically rising till −205 C (−4 5 F). The
preheating time of two minutes remains with temperatures below
−205 C (−45 F). Preheating continues during start−up. The star-
ting time is maximum 7 s. If the engine does not start after 7 s
starting time, then the engine must be checked. This maximum
starting time of 7 seconds also applies to a cold start.
Suitable fuel as well as the correct engine and hydraulic oil are
preconditions for starting well at low temperatures.
To avoid damage when the engine is running it is equipped with
a repeat start lock. If the start switch is actuated during the pre-
heating procedure, the starting procedure is terminated.
Carry out the tasks described in the section ”18.9.2.2 Hydraulic

power pack with Hatz engine” before every operation (on the
ground).
082−1180−82201c_en 205/221
18
4 21.2 11
10
21.1
21.3
Z 82 947 Z 82 948
13
Z 82 949
206/221 082−1180−82201c_en

Using the Control Panel (during Configuring)
1. Switch on the ignition in the crane operator’s cab (super-
structure).
2. Switch selector switch (21.3) on the mobile control panel to

position ”3” and actuate rocker switch (21.1) (starting im-
pulse) − the starting procedure begins.
For ambient temperatures at which preheating is automatic, you

must remember that the engine only starts after a time delay of
up to 2 minutes (see 18.9.2.2.5.1 , page 205).

at the Operating Unit of Crane Control
(Z 82 948, Z 82 949)
Condition:
− Ignition switched on or crane engine running
1. Start the HATZ diesel engine by pressing the key (1).
Depending on the ambient temperature of the Hatz diesel engine

(below 05 C / 325 F), the engine is automatically preheated. This
is displayed by button (11) lighting up in orange. The preheating
time is shown on the display (10) and is set back to 0.
The maximum preheating time (at −205 C / −4 5 F and below) is
2 minutes, the maximum starting time is 7 s (see also correspon-
ding notes on page 18.9.2.2.5.1 , page 205).
As the probe records the ambient temperature of the Hatz diesel
engine and not the engine temperature, it is possible that prehea-
ting occurs at low ambient temperatures even though the engine
is warm. Automatic preheating can then be switched off manually
by pressing the key (11).
As soon as the HATZ diesel engine is running, the following ap-
pears on the display (13).
082−1180−82201c_en 207/221
18
25
Z 82 955
28
29
30
31 13
Z 82 937
Z 82 912
208/221 082−1180−82201c_en
(Z 82 955)
Depending on the weather conditions (ambient temperature)

and the number of starting procedures of the HATZ diesel en-
gine, the battery (25, Z 82 955) in the hydraulic power pack
can discharge quickly.
In spite of the indication of the battery voltage on the IC−1
display, we recommend that the battery is recharged regu-
larly to be on the safe side.
18.9.2.3 Displays in Crane Control
18.9.2.3.1 State of the Crane Area in the ”Crane Operation”

Screen
(Z 82 937)
Display of status information on the hydraulic luffing MBE
(HAVHY)

13 Display: Hatz diesel engine in operation
28 Display: Bending angle of the main boom extension (can be
luffed hydraulically) to the main boom
29 Display: Head angle of the main boom extension (can be luffed
hydraulically) to the horizontal
30 Display: Additional symbol ”Main boom extension (can be luf-
fed hydraulically)”
31 Display: minimum / maximum bending angle (0° / 40°) achie-
ved
Load limit device will shut down.
18.9.2.3.2 ”HAVHY” screen
(Z 82 912)
Press the key depicted in the quick menu (part of the crane opera-
tion screen) to call up the ”Main boom extension (can be luffed
hydraulically)” screen.
In addition, observe the detailed specifications in section 10

”Safety equipment”, particularly the information on the topic
of the ”Selection of the operating mode” screen.
082−1180−82201c_en 209/221
18
1 2
12 3
11 4
10
5
9 8 7 6 Z 82 913
210/221 082−1180−82201c_en
(Z 82 913)
1 Start and switch off Hatz diesel engine key
grey Actuate: Start Hatz diesel engine
yellow Display during the starting procedure
orange Starting procedure interrupted

(if the engine does not start, the starting procedure
is interrupted after 7 s and the starting procedure
must be started again)
green Hatz diesel engine running
Actuate: Switch off Hatz diesel engine
2 Engine speed display

3 Display of ambient temperature on the hydrau-
lic power pack
4 Battery voltage display
5 Fuel supply bar display
6 Fuel supply indicator light

grey Fuel supply sufficient
red Fuel in the reserve range
7 Indicator light − engine temperature

grey Engine temperature in permitted range
red Engine temperature too high
082−1180−82201c_en 211/221
18
1 2
12 3
11 4
10
5
9 8 7 6 Z 82 913
212/221 082−1180−82201c_en
(Z 82 913)
8 Generator indicator light
grey Generator is supplying sufficient electricity
yellow Voltage of the generator too low
red Generator is not supplying electricity

− Engine off
− Generator defective
9 Engine oil pressure indicator light
grey Engine oil pressure in permitted range
red Engine oil pressure too low
10 Display − preheating time in seconds

11 Preheating key
11 grey Actuate: Switch off the automatic preheating sy-
stem of the HATZ diesel engine
orange Preheating display
11 Display − preheating time interrupted

During preheating (orange symbol), the preheating
process can be interrupted by actuating the ”Pre-
heating” key (if e.g. the engine is already warm)
yellow Post heating display
12 Speed adjustment key (Hatz diesel engine)

grey runs with idling mixture
press the key to switch the Hatz diesel engine to
full throttle and figure with arrow pointing upward
appears
grey runs at full throttle
press the key to switch the Hatz diesel engine to
low speeds and figure with arrow pointing down-
ward appears
082−1180−82201c_en 213/221
18
F 31
46 H
31
”F” 46.1 I
G 31
Z 82 950 Z 82 944
”X0570”
21.3
21 21.2
21.1
125 126 127 128 129

Z 82 951 Z 200 508
214/221 082−1180−82201c_en
18.9.2.4 Tasks to Be Carried out
18.9.2.4.1 Pinning the Adjusting Cylinders

(Z 82 950, Z 82 944)
Prerequisites:
− MBE fitted at the front on the main boom head. To do so, see
the corresponding description in the sections ”18.5 Main
boom extension fitted on the main boom” and/or ”18.6 Trans-
porting the main boom extension separately”
− pinned at the top in point ”F” or/and ”H” with one or two fixing
pins (31)
This upper pinning with a fixing pin (31) is only provisional.

The final connection is made at a later point by pinning the
piston rods (46.1) of adjusting cylinders (46).
Nevertheless, this upper pinning must be carried out as des-
cribed with a fixing pin. Only then can you be sure that the
angle between main boom and main boom extension is 05,
thereby ensuring that the piston rods will be able to be exten-
ded correctly into their head bearing. The basic boom MBE
is also sufficiently secured against tilting over.
The one−sided upper pinning can in principle be carried out on

either the right−hand or the left−hand side. The right−hand side
is specified here, because then the least possible effort is requi-
red to carry out the following steps.
1. Plug mobile control panel (Z 82 951) into free connection

(128) on junction box ”X0570”.
082−1180−82201c_en 215/221
18
47 35
21.2
21.3
21.1
Z 82 952 Z 82 957
46 46.1 31 32 46 46.1 35
F/H
2 2
”a” ”b”
Z 82 953
”X0570”
21.3
21 21.2
21.1
125 126 127 128 129

Z 82 951 Z 200 508
216/221 082−1180−82201c_en
2. Turn the selector switch (21.3) on the mobile control panel

to position ”1”, actuate rocker switch (21.1), thereby carefully
extending the piston rods (46.1) of adjusting cylinders (46)
until the holes of the piston rods (46.1) are in alignment with
the hole of the corresponding shackle on the main boom
head.
3. Fit pins (35; Z 82 953 ”b”) from the outside inward on both si-
des and secure with locking springs (47) (Z 82 957).
4. Actuate rocker switch (21.2), thereby retracting the two

piston rods (46.1) of adjusting cylinders (46) carefully until fi-
xing pin/s (31) in the upper fork head are relieved of load in
points ”F” and ”H”.
5. Remove fixing pin/s (31) from the upper pinning point/s (”F”
and ”H”) and peg in the transport position. This means that
the basic boom MBE (2) is only connected at the top on the
two piston rods (46.1) of adjusting cylinder (46) by the two
pins (35) with the main boom head.
Check again that the basic boom MBE (2) is connected with
the main boom head or with intermediate section (1) in 4
points.
Figure (Z 82 953 ”b”) shows the main boom extension when the
previous steps have been carried out as described.
6. Remove the mobile control panel (Z 82 951) from junction

box ”X0570” (Z 200 508).
082−1180−82201c_en 217/221
18
2
28
46
13
2
Z 82 914 Z 82 915
52
Z 82 954
218/221 082−1180−82201c_en
18.9.2.4.2 Setting the Operating Angle

(Z 82 914, schematic diagrams Z 82 915)
The main boom extension is angled (luff down from 0° to 40° / luff
up from 40° to 0°) by extending or retracting the piston rods of the
two adjusting cylinders (46) which are fitted on the basic boom
MBE (2).
This is generally carried out when the MBE is in the load raising
position.
Condition:
− Crane with fitted MBE is in the load raising position
1. Call up ”HAVHY” screen for operation of the hydraulic main

boom extension (see section 18.9.2.3.2, page 209).
2. Press the depicted key to start the Hatz diesel engine (see
section 18.9.2.2.5, page 205).
(Z 82 954)
3. Press button (52) in the crane operator’s cab to set the ope-
rating angle of the MBE.
The current folding−down angle (28) is displayed in the ”Crane

operation” screen.
4. Press the depicted key to switch off the Hatz diesel engine
(see section 18.9.2.2.5, page 205).
082−1180−82201c_en 219/221
18
220/221 082−1180−82201c_en
18.10 Emergency Set down in the Case of Telescoping Pro-

blems
If it is impossible to telescope the main boom in due to a malfunc-
tion, the main boom must be set down as an emergency precau-
tion.
Depending on the state of assembly (outriggers, counterweight),
the main boom can be set down directly. Otherwise, an auxiliary
crane must be used. Corresponding instructions will be given on
enquiry.
082−1180−82201c_en 221/221
Head sheaves 21
082−1210a_en 1/23
21
1500
700
600
Z 84 365 Z 84 366
2/23 082−1210a_en
Head sheaves 21
21 Head Sheave (Optional)

(Z 84 365, Z 84 366)
Length Width Height Weight

1500 4.9 700 2.3 600 2 155 342
082−1210a_en 3/23
21
1b
1
1a
Z 84 351
4/23 082−1210a_en
Head sheaves 21
21.2 General
(Z 84 351)
The head sheave (1) is for raising small loads with single strand
reeving.
If the crane is equipped with hoist 2, the hook block can remain
reeved on the main boom head.
The head sheave (1) consists of the frame (1b) and a hinged rok-
ker arm (1a) which is pinned in place .
The head sheave can be folded to the side on the main boom for
transport.
The opposite depiction shows the head sheave in the operating

position (rocker arm ”1a” folded down).
The head sheave is marked with the construction number of

the crane. It may only be fitted on the crane with this con-
struction number.
082−1210a_en 5/23
21
1a 1b
1
Z 84 352
13
16
15
14
Z 84 362 Z 84 361
6/23 082−1210a_en
Head sheaves 21
21.3 Fitting and Removal

(Z 84 352, Z 84 361, Z 84 262)

When fitting or removing the head sheave, there is risk of

crushing between the main boom head and the head
sheave!
Pay particular attention to the notes on risks in section
1.4.8 ”When assembling and dismantling crane compo-
nents” as well as procedure described below.
ment).
It is prohibited to walk on the boom.
Prior to installation, the head sheave (1) is in mounting position

on the ground.
This means that the hinged rocker arm (1a) is pinned with cou-
pling pin (8) in the straight position, as shown. Secure the cou-
pling pin with forelock.
1. Support the crane on outriggers, align it and fit the counter-

weight −in accordance with the regulations of the capacity ta-
ble.
2. Attach head sheave (1) to the auxiliary crane with three falls
and position on the main boom head in the fitting position.
To do so, the respective holes (13) on both sides of the head
sheave frame must be flush with the holes of the mounting
plates (14) at the front side of the main boom head.
In the following procedure, the head sheave may not swing

out or dangle at an angle when it is raised.

fall as long as the head sheave is attached to the auxiliary
crane or has not yet been completely pinned.
082−1210a_en 7/23
21
16
15
1a 1b 10
14
Z 84 361 Z 84 353
8/23 082−1210a_en
Head sheaves 21
(Z 84 361, Z 84 353)
The pivot point is pinned at holes (15) at a later point.

After folding it to the rear in the transport position, the head
sheave is secured mechanically by pinning at hole (16) at a later
point.
3. Knock in one biconical pin (9) each at the two pinning points
so that the head sheave is pinned to the main boom head at
these two points.
Secure each of the biconical pins (9) with 2 retaining springs
(Z 52 790).
4. Knock in pin (10) and secure with forelocks at the top and
bottom.
The head sheave can be folded to the rear in the transport
position around this point at a later point.
This means that the head sheave is connected to the main

boom head in 3 points.
5. Remove the lifting tackle.
The head sheave is then fitted in the assembly position

(Z 84 353). The assembly position is only for fitting and dismant-
ling and for folding the head sheave to the rear in the transport
position.
Risk of accidents!
This assembly position is expressly NOT permitted to be
used for the raising of loads. To do so, the head sheave
must first be put in the operating position. Be sure to ob-
serve the section 21.4 ”Folding down into operating posi-
tion” starting on the following page.
The removal of the head sheave also needs to take place in the
assembly position. To do so, proceed in the same manner just in
the opposite sequence.
082−1210a_en 9/23
21
8
1b
9
1a
1a 1b 10
Z 84 372 Z 84 354
Z 84 355
10/23 082−1210a_en
Head sheaves 21
21.4 Fold down in operating position

(Z 84 372, Z 84 354, Z 84 355)
To fold down the head sheave from the assembly position into the
operating position, proceed as follows:
(Z 84 372)
1. Raise the hinged rocker arm (1a) slightly to relieve the cou-
pling pins (8) of load.
2. Unlock coupling pins (8) and pull out.
The gas−operated positioner holds the rocker arm in the ho-
rizontal position.
Risk of crushing!
There is a risk of crushing between the rocker arm and the
frame of the head sheave as soon as the rocker arm moves
itself or is moved.
(Z 84 354, Z 84 355)
3. Press rocker arm (1a) down against the pressure of the gas−
operated positioner until the corresponding hole of the rok-
ker arm is flush with the rear one on the head sheave frame.
Then pin, using pin (8), and secure as illustrated. This locks
the rocker arm in the folded−down position.
Only after this has happened is the head sheave inopera-

ting position .
Risk of accidents!
Operation with the head sheave in assembly position is not
permitted under any circumstances!
4. Feed the hoist rope from the hoist drum to the run−in shea-
ves on the main boom head.
Observe the detailed specifications contained in section 17
”Reevings” under the subpoint ”Reeving/unreeving the hoist
rope”.
082−1210a_en 11/23
21
1 1b
1a
2
E1 E2
3 63
R
Z 84 397
63
64
Z 84 356
12/23 082−1210a_en
Head sheaves 21
(Z 84 397)
5. Guide the hoist cable over the run−in roller (E2) on the main
boom head to the rope sheave (R) of the head sheave and
pin to hook suspension gear (4), model 12.5.
Risk of accidents!
The head sheave may only be operated with single−strand
lines.
The rope may not be fed via run−in roller (E1) as this would
make the deflection angle of the hoist rope too large. Risk
of damage to the rope!
During reeving, there is a risk that all involved sheaves be-

come entangled and wound up. Proceed with appropriate
caution.
(Z 84 397, Z 84 356)
6. Attach the hoist limit switch (63) with the corresponding shift
weight (3) to the head sheave. To do so, peg the hoist limit
switch to the respective mandrel at the tip section of the head
sheave on the left−hand side − as shown − and secure with
a linch pin.

The hoist limit switch (63) fitted on the head sheave must
be in the functioning state. The restrainer (64) of the hoist
limit switch must not be fitted.
Figure (Z 84 356) shows the hoist limit switch in the functio-
ning state.
This hoist limit switch and its corresponding shift weight can be
used on all additional devices. That is the reason that there is
only one of them for all additional equipment. It may therefore be
necessary to remove them from a different additional device so
that they can then be used on the head sheave.
7. Then fit the shift weight (3) of the hoist limit switch to the hoist
rope of the head sheave.
Make sure that the shift weight is hanging freely! Only then
is it guaranteed to function properly!
082−1210a_en 13/23
21
L: R:
63 63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 84 358 Z 104 165
64
Z 83 987
14/23 082−1210a_en
Head sheaves 21
(Z 84 358, Z 83 987, Z 104 165)
8. Put the hoist limit switch (63) on the main boom head out of
operation:
8.1 Bridge the hoist limit switch with restrainer:

To do so, the restrainer (63.2) must first be fitted onto
the actual hoist limit switch (63.1). 1 Then the jumper
wire is pulled away to the side, 2 then rotated in the
longitudinal direction of the restrainer (63.2), 3 and fi-
nally relaxed. This procedure jams the restrainer (63.2)
by the jumper wire’s spring resistance.
Figure (Z 104 165 ’R’) shows the hoist limit switch in
the bridged state.
8.2 Attach shift weight (64) to the side on the main boom
head in the transport position and secure it against fal-
ling down.
082−1210a_en 15/23
21
”X0550”
A
”X0560.1”
A H
Z 84 357
16/23 082−1210a_en
Head sheaves 21
(Z 84 357)
9. Connect the head sheave electrically (close the safety

chain):
Distributor box ”X0550” on the main boom head
9.1 Connection ”A”:

Connect the cable plug of the head sheave distribution
box.
The two other connections are assigned as for main
boom operation (see section 10 ”Safety equipment”
under ”Electrical safety chain”).
Distribution box ”X0560.1” on the head sheave
9.2 Connection ”H”:

Remove the protective cap and connect the hoist limit
switch plug.

Remove the protective cap and connect the air speed
indicator plug.
During operation without the air speed indicator, close

connection ”A” using the protective cap.
Risk of accidents!
During operation without the air speed indicator, adhe-
rence to the permitted wind speeds can no longer be moni-
tored in the crane control screen. In this case, suitable al-
ternative measures must be taken.
The aircraft warning light (optional equipment) and the rotor of the
anemometer remain mounted on the main boom head.
The head sheave is folded up into the assembly position in the

analogously reverse order.
082−1210a_en 17/23
21
Z 84 359
18/23 082−1210a_en
Head sheaves 21
21.5 Operation
(Z 84 359)
1. Attach the head sheave, fold downwards into operating posi-

tion, attach hoist cable and pin on hoist suspension gear, at-
tach hoist limit switch and associated shift weight and then
connect the head sheave electrically.
This is described in detail in the preceding pages (starting on
page 7).
2. Enter the operating mode.

The head sheave is operated in one main boom operating
mode. For this reason, select accordingly (here: ”HA”).
3. Set ”Number of reeved rope lines” parameter to ”1”.
Risk of accidents!
The head sheave may only be operated with single−strand
lines!
4. Select all other parameters in accordance with the actual

crane configuration, which must correspond to the relevant
You will find details on operating mode selection in section 10

”Safety devices”.
082−1210a_en 19/23
21
64
Z 84 360
20/23 082−1210a_en
Head sheaves 21
21.6 Fold backwards into transport position
If the head sheave is not required, it can be folded laterally back-

wards to the main boom head.
When folding the head sheave there is a risk of crushing

between the main boom head and head sheave. Proceed
During the folding procedure, no−one person is permitted
in the area where loads/equipment could fall.
1. Unreeve the hoist rope and reel onto the rope drum.
2. Bring the electric safety chain on the main boom head back
into the state required for main boom operation.
Observe the point ”Electric safety chain” in section 10 “Sa-
fety equipment”.
(Z 84 360)
3. Dismantle the hoist limit switch and corresponding shift
weight (64).
Alternatively, pin shift weight (64) on the right−hand side of
the head sheave’s top section in the transport position and
secure.
082−1210a_en 21/23
21
18
10
17
Z 84 363
10 17
Z 84 364
22/23 082−1210a_en
Head sheaves 21
(Z 84 363, Z 84 364)
4. First, fold the head sheave up out of the operating position

into the assembly position.
To do so, proceed as described for folding down on page 11,
points 1. − 3., but in the opposite sequence.
(Z 84 363)
5. Check that pin (10) is pinned correctly and is secured at the
top and bottom, which means that the head sheave is con-
nected to the main boom head in the pivot point.
Risk of the head sheave falling down!

The following step may only be carried out if this is ensu-
red. The head sheave is then held only by pin (10).
(Z 84 363, Z 84 364)
6. Unlock both biconical pins (9) and remove them. Pin pins to
the corresponding plates on the head sheave in the park po-
sition and secure.
(Z 84 363)
7. Unlock coupling pin (17) and remove from the park position.
Otherwise, it would bump into the transport lock plate on the
main boom head during the following folding procedure.
(Z 84 363, Z 84 364)
8. Fold the head sheave around and over pin (10, pivot point)
to the rear until the hole of the head sheave’s mounting plate
is flush with the corresponding plate hole (18) on the main
boom head.
(Z 84 363, Z 84 364)
9. Pin the head sheave in this position using coupling pin (17)
and secure it.
This secures the head sheave against folding away from the
main boom head.
The folding back of the head sheave to the front in assembly posi-
tion and/or the further folding down into operating position is car-
ried out in the analogously reverse order.
082−1210a_en 23/23
Dismantling and Assembly of the Main Boom 31
31 Dismantling and Assembly of the Main Boom (Optio-

nal)

There is a risk of crushing when fitting and removing the

main boom:
− between the main boom foot section and bearings.
− between the main boom and superstructure frame.
This is why no person is permitted in the danger zone!
Pay particular attention to the notes on hazards in section
nents” as well as to the procedure described in the follo-
wing.
ment).
In particular it is prohibited to enter the area beneath or in
the vicinity of a suspended load (main boom) during the as-
sembly/dismantling procedure!
Make sure that you maintain sufficient safety clearance!
Main boom assembly and dismantling must be carried out

by a team familiar with the process. Every individual as-
sembly and dismantling step must be planned exactly. All
component parts must be safely and securely supported or
held using auxiliary cranes.
In addition, the crane manufacturer recommends that trai-

ning be carried out on a safely cordoned−off piece of land
to enable the assembly team to practise all relevant proce-
dures, under observation of all applicable health and safety
measures, BEFORE the actual onsite set−up is carried out.
Responsibility for the assembly and dismantling and ope-

rational supervision belongs primarily to the crane opera-
tor.
082−1310−82201a_en 1/35
31
2/35 082−1310−82201a_en
31.1 General
The main boom can be removed from the superstructure for re-
pair purposes and/or to achieve certain axle loads. Two auxiliary
cranes are required for this purpose.
The transport condition without the main boom is described in the

operating instructions of the crane chassis, in the section “Dri-
ving” at ”Defined driving condition”.
To dismantle the main boom, the bolt between the luffing cylinder
and the main boom (luffing cylinder headpin) and the one bet-
ween the main boom and superstructure (main boom foot section
pin) must be removed. This is done with a mobile hydraulic cylin-
der.
To position the mobile cylinder and to hold the pulled bolts, loca-
ting shells are installed directly below these two bolts on the right
side of the crane.
Risk of collision!
If the counterweight base plate is put down on the crane
chassis, there is a danger of collision between the draw bars
of the counterweight base plate and the locating shell at the
luffing cylinder headpin while setting the main boom down
in the boom support. Therefore this shell must then be dis-
mantled.
082−1310−82201a_en 3/35
31
L: R:
63 63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 84 358 Z 104 165
64
Z 83 987
4/35 082−1310−82201a_en
31.2 Before Removal

(Z 84 358, Z 104 165, Z 83 987)
1. Support the crane on outriggers and align horizontally. The

support width must be at least 5.54 m / 18.2 ft.
To fit and remove the main boom, the crane must be suppor-
ted on outriggers.
2. Make sure that:

− Telescopic sections are retracted and pinned.
− No counterweights are fitted.
− An operating mode has been selected that corresponds to
the actual crane status.
3. Unreeve the hook block or hook suspension gear and reel

the hoist rope onto the rope drum.
operation:

the bridged state.
ling down.
082−1310−82201a_en 5/35
31
31
49
Z 84 400 Z 84 962
6/35 082−1310−82201a_en
31.3 Dismantling
31.3.1 Perform Preparative Work
1. Raise the main boom to approximately 45° using the luffing

gear and rotate the superstructure approximately 15° to the
side.
This ensures that the assembly personnel does not need to
go under the raised main boom during the following installa-
tion of the luffing cylinder support mount.
Risk of accidents!
Persons must stay clear of the area beneath the raised
main boom!
(Z 84 400)
2. Set up the luffing cylinder support mount (31) in the designa-
ted area at the end of the chassis frame between the two
pieces of sheet metal.
The lashing belt is attached to these plates later on, to fasten
the dismantled luffing cylinder.
Risk of collision!
Use the luffing cylinder support mount for nothing else ex-
cept setting down the luffing cylinder. Otherwise remove it.
3. Slew the superstructure so that the main boom is to the rear.
(Z 84 962)
4. Lock the slew gear parking brake. To do this, actuate the
switch (49) accordingly. The indicator light in the switch is not
illuminated.
082−1310−82201a_en 7/35
31
31 32
Z 84 951
8/35 082−1310−82201a_en
(Z 84 951)
5. Luff down the main boom until the luffing cylinder (32) is posi-
tioned immediately above (3−5 mm / 0.1−0.2 in) the luffing
cylinder support mount (31).
Risk of damage!
The luffing cylinder support mount is constructed solely for
the weight of the luffing cylinder; the luffing cylinder is there-
fore not permitted to transmit the weight of the main boom
onto the luffing cylinder support mount.
082−1310−82201a_en 9/35
31
”B”
6100
”A”
Z 84 398
10/35 082−1310−82201a_en
(Z 84 398)
6. Attach the main boom on to two auxiliary cranes using 2−fall
suspension tackle for each crane:
− Attachment points on the main boom foot section: see de-
tail ”A”. Depending on the design of the device, the attach-
ment points can also be designed as load attachment
eyes.
− Attachment points at the front bearing points of the basic
case: see detail ”B”.
Position the auxiliary cranes such as to bring the boom head

exactly into a vertical position above the corresponding at-
tachment points.
The weight of the main boom is about 20,600 kg (45,415 lbs). The
resulting vertical attached loads are:
− on main boom foot section: about 10,600 kg (23,369 lbs)
− on the front bearing points of the basic case: about
10,000 kg (22,046 lbs)
The centre of gravity of the main boom is about 6.1 mm (20 ft)
from the main boom base bearing in the direction of the sheave
head.
Risk of accidents!
Select auxiliary cranes and lifting tackle in accordance
with the specified main boom weight (and/or trailer loads)!
The load bearing capacities required, including adequate
safety factors – especially in terms of the simultaneous uti-
lisation of two cranes – are to be determined in accordance
with the regulations which apply in the country in which the
work is being performed!
7. Tension the lifting tackle with the auxiliary cranes. The auxi-
liary cranes must take over the main boom load.
082−1310−82201a_en 11/35
31
X0087
X300
Z 84 952
11
Z 84 963
12/35 082−1310−82201a_en
(Z 84 952)
8. Release the quick−release locks of the hydraulic couplings
(1), (2), (3), (4), (5), (10) and (11) in the area of the brackets
of the hydraulic quick connections and close each of them
with a protective cap.
The overview of the crane in the adjacent image only serves to

locate the separation points of hydraulics and electrics. The posi-
tion of the superstructure ”to the front” does not correspond to the
actual position at this time.
Hydraulic connections may only be made and released in de-

pressurised state, i.e. the engine must not be running.
(Z 84 952)
9. Disconnect the electrical connections. To do so:
9.1 Release the “X0087” plug at the “X300” distribution

box. The corresponding hose clip must be released;
otherwise the connector cable would still be connected
to the mounting plate at the basic case.
9.2 Release the plug coupling of the two violet CAN ca-
bles.
9.3 For the version with hook camera (optional): Release

the plug coupling of the video receiver cable.
(Z 84 963)
10. Connect the quick release couplings (11) of the two supplied
10 m (32.8 ft) hydraulic hoses at the couplings (1) and (4) of
the released hydraulic hoses.
082−1310−82201a_en 13/35
31
10
13
22
15
P
T
Z 84 953 Z 84 399
10 11
17 15
Z 84 955
14/35 082−1310−82201a_en
(Z 84 953)
11. Connect the mobile cylinder (15) hydraulically. To do this, at-
tach the two free couplings of the 10 m (32.8 ft) hydraulic ho-
ses which were connected in point 10. to the crane hydrau-
lics in the following way:
− Hose of coupling ”4” of the crane hydraulics at coupling ”P”
of the mobile cylinder
− Hose of coupling ”1” of the crane hydraulics at coupling ”T”
of the mobile cylinder
Make sure in each case that the hydraulic connections have

been joined correctly, i.e. that the couplings open properly.
Hydraulic connections may only be made and released in de-
pressurised state, i.e. the engine must not be running.
31.3.2 Pulling the Luffing Cylinder Headpin
A description is given below as to how the pin with which the luf-
fing cylinder and the main boom are connected is to be removed
(luffing cylinder headpin).
(Z 84 399)
1. First release the two inner screws (22) on the left boom side.
2. For the version with the superstructure central lubricating sy-

stem (optional): Release the connection of the lubricating li-
nes for the two lubricating nipples at the bearing socket of the
luffing cylinder headpin.
(Z 84 955)
3. Place the mobile cylinder (15) in such a way in the locating
shell (17) on the luffing cylinder headpin that the support ele-
ments (10) of the mobile cylinder are located in the inside
bearing points.
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the locating shell. Proceed with caution!
The weight of the mobile cylinder is approximately 20 kg
(44 lbs).
082−1310−82201a_en 15/35
31
Z 84 967
Z 84 968
16/35 082−1310−82201a_en
(Z 84 967, Z 84 968)
4. Start the engine.
5. Enable supply of the mobile cylinder with hydraulic oil. To do

so:
5.1 Press the depicted key in the ”Quick menu” screen to

do so – the ”Main menu” screen appears.
5.2 Activate the displayed key here – the ”Function dis-

play” screen appears.
5.3 Actuate the button there for the ”telescoping” crane

movement – it becomes ”green”.
Only then does the ”Hydraulic oil enable” button ap-
pear at the bottom of the screen.
5.4 Actuate the ”Hydraulic oil enable” button shown – it be-

comes ”green”.
Only then is the supply of the mobile cylinder with hy-

draulic oil enabled.
082−1310−82201a_en 17/35
31
Z 84 969
18/35 082−1310−82201a_en
(Z 84 969)
6. Make sure that the luffing cylinder is depressurised.
To do this, call up the ”Function display” screen on the control
display.
Proceed as described on the page 17 at points 5.1 and 5.2
for this.
7. Actuate the ”Luffing gear” button there – it becomes ”green”.
8. ”Scroll through” the display until the end – there the displays
appear with the current luffing cylinder pressure.
The displayed actual value must be in the range of ”0” (dis-
play in bar). Only then can you be sure that the luffing cylin-
der is without pressure.
If the displayed value is too high, then you must proceed as fol-
lows in order to depressurise the luffing cylinder:
− Make sure that both auxiliary cranes have taken over the
main boom load completely.
− Luff the luffing cylinder somewhat downwards by actuating
the corresponding control lever until the required value has
been achieved.
The pulling of the luffing cylinder headpin with the mobile cy-
linder described below will not be possible until the luffing
cylinder has been depressurised.
082−1310−82201a_en 19/35
31
9
11
16
17
15
10
Z 84 956
9 11
16
17 16 15
10
15
Z 84 957 Z 84 979
20/35 082−1310−82201a_en
Risk of overturning exists during the entire working proce-
dures described below when pressure is relieved on the
mobile cylinder! the mobile cylinder could tip over to the
rear out of the locating shell.
(Z 84 956)
9. Extend the mobile cylinder (15) by actuating the control lever
(11) accordingly. To do this, lightly tilt the mobile cylinder (15)
in the locating shell (17) back and forward so that the clams-
hell (9) hooks on the cross bar of the head of bolt (16).
10. Retract the mobile cylinder (15) completely by actuating the

control lever (11) accordingly. The luffing cylinder pin will be
thereby pulled by about 3/4.
(Z 84 957)
11. Take the mobile cylinder (15) out of the locating shell (17) and
insert it in the outer bearing points with support elements
(10), extend the piston rod with the clamshell (9) and tip it
back into the locating shell (17) in such a way that the clams-
hell (9) hooks on the cross bar of the head of bolt (16).
(Z 84 957, Z 84 979)
12. Retract the mobile cylinder (15) by actuating the control lever
(11) accordingly. This leads to the luffing cylinder pins (16)
being completely pulled (final state is shown in Z 84 979).
13. Switch off the engine.
14. Remove the mobile cylinder and keep it ready for the follo-
wing work step “Pulling the main boom foot section pin”.
082−1310−82201a_en 21/35
31
16
23
21
Z 84 958
220
Z 84 964
22/35 082−1310−82201a_en
(Z 84 958)
15. Secure the luffing cylinder headpin in the locating shell
(transport position). To do this, release the coupling pins (21)
from the transport position and pin them as illustrated.
Secure the coupling pins (21) with tube clips (23) to prevent
them from falling out.
(Z 84 964)
16. Block the bottom of the luffing cylinder. To do this, put the
stop valve (220) at the luffing cylinder into locked position.
That should ensure that the luffing cylinder does not extend.
082−1310−82201a_en 23/35
31
1 2
1
Z 84 980 Z 84 981
Z 84 982
24/35 082−1310−82201a_en
31.3.3 Pulling the Main Boom Foot Section Pin
A description is given below as to how the pin with which the su-
perstructure frame and main boom and the main boom are con-
nected is to be removed (main boom foot section pin).
Basically, this pin is pulled analogously to the sequence descri-

bed on the previous pages concerning the luffing cylinder head-
pin. There are, however difference in details.
Risk of accidents!
In the following description, the pins (2) must always be in-
serted in the position shown. It is used as the pivot point
and ensures that the foldable part of the shell cannot fall
down.
(Z 84 980, Z 84 981)
1. First fold the locating shell of the main boom foot section pin
(right side of the care below the main boom foot section pin)
out of transport position (Z 84 980) in the operating position
(Z 84 981).
To do this, release the bolt (1), fold the folded part of the shell
to the front and pint into this position with the bolt (1).
Secure the bolts at the top and bottom with forelock.
(Z 84 982)
2. Release both screws (3).
3. For the version with the superstructure central lubricating sy-

stem (optional): Release the connection of the lubricating li-
nes for the lubricating nipples at the bearing socket of the
main boom foot section pin.
082−1310−82201a_en 25/35
31
18 9
11
15
Z 84 983
11
15
10
27
Z 86 486
26/35 082−1310−82201a_en
(Z 84 983, Z 86 486)
4. Switch on the superstructure engine and hydraulic supply

(see point 4., page 17, and 5., page 17).
5. Extend the mobile cylinder (15) completely by actuating the

control lever (11) accordingly.
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the locating shell. Proceed with caution!
The weight of the mobile cylinder is approximately 20 kg
(44 lbs).
Risk of overturning exists during the entire working proce-
dures described below when pressure is relieved on the
mobile cylinder! the mobile cylinder could tip over to the
rear out of the locating shell.
(Z 84 983)
6. Position the mobile cylinder (15) – as shown – so that the
clamshell (9) hooks on the cross bar of the bracket (18),
which is screwed together with the main boom foot section
pin.
(Z 86 486)
7. Lower the mobile cylinder (15) into the locating shell (27) in
such a way that the support elements (10) of the mobile cylin-
der are set down in the inside bearing points.
082−1310−82201a_en 27/35
31
11
15
10
27
Z 86 486
19 15
Z 84 984
28/35 082−1310−82201a_en
(Z 86 486, Z 84 984)
8. Retract the mobile cylinder (15) completely by actuating the

control lever (11) accordingly. This leads to the main boom
foot section pin being partially pulled – corresponding to the
stroke of the mobile cylinder.
9. Place the mobile cylinder (15) into next outer bearing points
of the locating shell (27) and repeat the procedure as in the
previous two points.
10. Repeat this procedure until the supporting elements of the

mobile cylinder (15) are finally located in the outermost bea-
ring points of the locating shell and the main boom foot sec-
tion pin (19) is completely pulled out.
This is shown in the last state in the figure (Z 84 984).
11. Turn off the superstructure engine and remove the mobile
cylinder.
12. Disconnect the hydraulic hoses from the mobile cylinder and
from the corresponding couplings on the superstructure and
remove them.
Close off free couplings with protective caps.
13. Put the loose hydraulic hoses and cables at the superstruc-
ture into transport position.
To do this, wrap the hoses and cables with hose bundling
band, place them on the light carrier pipe and secure them
against slipping with carabiner hook at the screw connection
of the counter−weight lifting cylinder.
082−1310−82201a_en 29/35
31
41 42
Z 55 702
30/35 082−1310−82201a_en
14. Vertically lift the main boom out of the bearing with auxiliary
cranes at the main boom foot section and luffing cylinder
head.
RISK OF ACCIDENTS!
When lifting out the main boom, make sure that it is not allo-
wed to start swinging!
The area around the free−hanging main boom must be kept

completely clear!
Risk of crushing!
When lifting out the main boom there is a risk of crushing
between the main boom and superstructure frame or bet-
ween the main boom and the support on the ground and/or
the support of the transport vehicle.
Make sure that the main boom does not twist on the bearing
points.
15. Lower the main boom onto the transport vehicle, support and
lash in place.
16. Release the lifting tackle on the main boom and remove it.

17. Firmly lash the luffing cylinder (42) on the luffing cylinder sup-
port mount with the lashing belt (41).
18. Manually push the main boom foot section pin all the way into
the superstructure frame again and re−secure it with the
screws that were loosened in point 2., page 25.
19. Fold back the foldable part of the locating shell into transport
position.
To do so, proceed as described under point 1., page 25, but
in reverse order.
Risk of damage!
The locating shell in operating position would exceed the
permitted transport width.
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31
40
Z 57 664
32/35 082−1310−82201a_en
20. Retract the outriggers of the crane.

21. Insert warning light (40) in the luffing cylinder head hole and
secure. Insert the electrical supply line at the rear of the vehi-
cle in the respective socket (6−pin, rear underride guard).
To prevent the electric supply lead of the warning light being des-
troyed, it must be fastened to the luffing cylinder so that it does
not fall onto the road surface.
When driving the crane in this configuration, observe the

section on ”Driving” at ”Defined driving condition” in the
operating instructions of the crane chassis.
082−1310−82201a_en 33/35
31
22
Z 84 399
Z 84 982
34/35 082−1310−82201a_en
31.4 Fitting the Main boom

(Z 84 399, Z 84 982)
The main boom is fitted in the same way as it is removed, only in

the reverse order.
Make sure that:

− The crane is correctly supported and aligned (see point 1.,
page 5).
− Main boom foot section and luffing cylinder set up on their
bearing correctly.
− The electric and hydraulic connections are re−established
correctly (plugs and connections with the same number, hy-
draulic couplings must open correctly).
− The O−rings for sealing of the bearing sockets of the main
boom foot section pin are replaced before the re−installation
of the main boom.
After the reattachment of the main boom foot section and luffing
cylinder headpin, this bolt absolutely must be secured, and this
is to be done by screwing together with the respective axis holder.
The screws used for this (two for each) must be tightened up to
the prescribed torque.
Fitting lo- Screw (zinc flake Torque

Item
cation coated) Nm lbf ft
Luffing cylin-
22 M 20 x 50, 10.9 470 ±35 347 ±26
der head
Main boom
3 M 24 x 100, 10.9 810 ±60 597 ±44
foot section
No crane operation is permissible as long as these bolts are

not correctly fastened to the respective axis holder!
As soon as the main boom is assembled, the unloaded rok-

ker cylinder frame must be removed again and transported
separately.
082−1310−82201a_en 35/35
Radio Remote Control 34
082−1340−82201a_en 1/53
34
0 1
201
Z 70 397
202
Z 70 398
2/53 082−1340−82201a_en
34 Radio Remote Control (Optional)

(Z 70 397, Z 70 398)
34.1 Intended use
The radio remote control, which mainly consists of the transmitter

(201) and the receiver (202), is used to control machines and for
data transmission. You must always comply with the occupatio-
nal safety and accident prevention regulations valid in each case.
Proper application in accordance with regulations also includes
reading the operating instructions and following all safety instruc-
tions contained therein.
The radio remote control may not be used in an area at risk of

explosions or to control machines for passenger transport unless
these types of use have been expressly permitted by the manu-
facturer of the radio remote control.
Only qualified personnel who have been trained and authorised

by HBC−radiomatic may make changes to the radio remote con-
trol. All changes must be recorded ex works in the master file of
the radio remote control.
Safety devices belonging to the radio remote control may not be

modified, removed or bypassed. In particular, modifications to the
entire emergency stop system of the radio remote control are pro-
hibited.
082−1340−82201a_en 3/53
34
4/53 082−1340−82201a_en
34.2 Safety Instructions
Carefully read the following instructions and the operating in-

structions of the manufacturer of the radio remote control before
working with it. This is also particularly important for the installa-
tion, commissioning and maintenance of the radio remote control
system.
The operating instructions are part of the radio remote control sy-
stem and must be kept accessible for the responsible personnel
at all times.
Risk of accidents (when opening)!

Components in the interior of the receiver could be live
which is potentially a risk to life.
The receiver must only be opened by trained personnel.
The supply voltage to the machine must be switched off
before opening the receiver.
Please remember that under no circumstances may anyone be

in the area at risk − particularly under the load − when using the
remote control. This also specifically applies to the operator of the
radio remote control.
Select a safe location when using the remote control, from which
you can fully see the operating movements of the machine, the
load movements and the surrounding operating conditions. A
spotter must be used if necessary.
It is prohibited to lay aside an active remote control unsupervised.

Always switch the remote control off when it is not needed. This
is particularly important when you change your location, when
working without the radio remote control, during operating breaks
or at the end of operation. Always ensure the remote control is
protected from unauthorised use, for example, by locking it away.
In an emergency or if there are any faults, switch the remote con-

trol off immediately by pressing the quick stop button.
082−1340−82201a_en 5/53
34
6/53 082−1340−82201a_en
Only use the radio remote control when it is in a technically fault-

less condition. Malfunctions and faults which could impair safety
must be rectified by qualified personnel who have been trained
and authorised by HBC−radiomatic before the device is re−com-
missioned.
Work with the radio remote control with care and familiarise your-
self with its functions. This is particularly important when working
with it very infrequently or for the first time.
For this reason, only authorised and specifically trained persons
may work with the radio remote control.
In particular, you must keep in mind that the direction of move-

ment of the operating elements can appear to be inverted, de-
pending on the location and your viewing angle to the machine.
Only operate the remote control using the harness supplied in the
scope of delivery. This prevents the risk of confusion with regard
to the operating elements.
Only have repairs carried out by expert personnel who have been
trained and authorised by HBC−radiomatic. Only original spare
parts and accessories (for example, batteries) must be used, as
otherwise the safety of the machine could be impaired and the
extended warranty will not apply.
Check the function of the quick stop switch before starting any
work.
The status LED (2) and the displays in the transmitter must go out
if the quick stop switch is pressed with the transmitter switched
on. If the status LED and the displays do not go out, the radio re-
mote control must be taken out of operation immediately.
Remove the battery and the electronic key from the transmitter
and consult the customer service team.
If the crane is equipped with an optional quick stop device with

an air shut−off valve, the shut−off valve must be unlocked ma-
nually (see section 5 ”Engine”).
082−1340−82201a_en 7/53
34
2 201
16 12
25 21
23
33
Z 80 119
202
Z 70 398
8/53 082−1340−82201a_en
34.3 General
(Z 80 119, Z 70 398)
Your crane is equipped with a radio remote control which mainly

consists of two components:
− mobile radio transmitter with control panel (201)
− radio receiver (202).
The transmitter is equipped with an electronic radiomatic iON key

(33). The radiomatic iON contains all of the data required for ope-
ration of the transmitter. Operation is not possible without the ra-
diomatic iON.
Depending on the design, the radiomatic iON can also be used
to operate replacement transmitters if they are constructed in the
same way.
The transmitter is also equipped with a start button (25).
When the radio link is activated or interrupted (for example, in the

case of network failure or if the range is exceeded), the radio re-
mote control will respond by automatically returning to the zero
position.
Release all operating elements so they can return to the zero po-
sition and press the start button (25). Only then will the crane re-
spond to radio commands again. This prevents any uncontrolled
crane movements after a disruption to the radio link.
082−1340−82201a_en 9/53
34
Z 315 349
10/53 082−1340−82201a_en
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 radio remote control is switched on, the orange lamp
behind the crane operator’s cab will flash (Z 315 349).
082−1340−82201a_en 11/53
34
202
202.1 202.2 202.3 202.4 202.5
Z 70 400
12/53 082−1340−82201a_en
34.4 Radio Receiver

(Z 70 400)
The radio receiver (202) is on the superstructure.
Make sure that the radio receiver and the antenna do not come
into contact with other objects.
The antenna’s fitting location can also be separate from the radio
receiver − deviating from the opposite figure.
There are 5 indicator lights (LEDs) in the cover of the radio recei-
ver which indicate the operating state 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 lights up with the transmitter switched off and goes
out as soon as the transmitter is switched on and the receiver re-
ceives 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.
082−1340−82201a_en 13/53
34
202
202.1 202.2 202.3 202.4 202.5
Z 70 400
14/53 082−1340−82201a_en
(Z 70 400)
(202.3) − ”Si 1”
If the green LED remains illuminated after the transmitter has
been switched on, this means the receiver has identified its trans-
mitter by their common 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.
The ”Si 2” display must light up only when one or several power
unit commands (for example, slewing, hoist, etc.) have been is-
sued.
(202.5) − ”Check−back message”

The yellow LED lights up if the receiver sends a check−back mes-
sage to the transmitter.
082−1340−82201a_en 15/53
34
2 3 4 5a 5b 6 7 8
1 1
17
16 15 14 13 12 9
11 10 11 10
35 21
25
33 24 23
Z 80 101
16/53 082−1340−82201a_en
34.5 Radio Transmitter
34.5.1 Operating Elements of the Radio Transmitter

(Z 80 101)

1 Handle
2 Status LED Flashing green: charging state of
the battery is OK
Flashing red: battery requires char-
ging
3 Buzzer Acoustic warning signals
4 Rotary switch LC input ”+” = up
LC input ” − ” = down
1st step each = 1 step
2nd step = 10 steps
5a Display, left Details on the telescoping system
(see page 21)
5b Display, right Specifications on load, load utiliza-
tion, radius and hoist limit switches
(see page 23)
6 Rotary switch Selection of the crane movement
for fine tuning with item 14
7 Pressure / rotary switch Switch on the display lighting
8 Control lever, right Hoist / luffing gear
9 Flip switch ” + ” = increase engine speed
” − ” = reduce engine speed
10 Harness
11 Attachment eyelets for harness
12 Flip switch Engine start = up
Engine stop = down
13 Rotary switch Assignment of the control levers
(see page 25)
082−1340−82201a_en 17/53
34
2 3 4 5a 5b 6 7 8
1 1
17
16 15 14 13 12 9
11 10 11 10
35 21
25
33 24 23
Z 80 101
18/53 082−1340−82201a_en
(Z 80 101)

14 Key switch Overriding ”Raise luffing gear”
Risk of accidents!
This switch must be pressed only
briefly and only if this cannot
cause a hazardous situation.
You must follow the instructions in
section 10 ”Safety equipment” un-
der the subpoint ”Overriding the
load limit device”.
15 Flip switch Fine tuning crane movements: slew
gear left/right, luffing gear, hoists
16 Toggle switch Slew gear brake:
top − closed
bottom − open
17 Control lever, left Telescopic sections / slew gear
21 Button Horn
23 Switch Engine quick stop
24 Button Only with hydraulic luffing main
boom extension (HAVHY, option):
Start / switch off Hatz diesel engine
25 Button Switch on transmitter
33 Key−operated switch Transmitter on / off (preselection)
35 Button High speed
082−1340−82201a_en 19/53
34
5a.1
5a.2
Sl2 LOCKED 5a.3
5a 5a.4
5a.5
! 2 5a.6
5a.7
5b.1 LOAD 5b
5b.2 12.3 t 55 %
5b.5
5b.3 22.9 t
5b.4 1.3 m 5b.6
16 17 8
Z 315 763
20/53 082−1340−82201a_en
34.5.2 Screens on the Displays

(Z 315 763)
The display consists of a left screen (5a) and a right screen (5b).
Left screen (5a)
(5a.1) − Strength of received signal

Strong received signal
Weak received signal:
A weak signal will impair the quality of the ra-
dio link and can lead to the link breaking
down. Change your location.
There is no connection to the receiver.
(5a.2) − Fault code display (if required)
without dis- Standard display: no fault
play
SI2 LOCKED In the following situations, the adja-
cent fault code is displayed and the
transmitter is locked when the radio re-
mote control is switched back on:
− Radio remote control switched on
with the slew gear brake open.
Action:
Place toggle switch (16) in the top
position ”Slew gear brake closed”.
− Control lever (8) or (17) steered
when the radio remote control is
switched on.
Action:
Place the control lever in the neutral
position.
− Function button actuated on side.
Action:
Release function button.
− Fault in the transmitter.
Action:
Have the transmitter repaired.
082−1340−82201a_en 21/53
34
5a.1
5a.2
Sl2 LOCKED 5a.3
5a 5a.4
5a.5
! 2 5a.6
5a.7
5b.1 LOAD 5b
5b.2 12.3 t 55 %
5b.5
5b.3 22.9 t
5b.4 1.3 m 5b.6
16 17 8
Z 315 763
22/53 082−1340−82201a_en
(Z 315 763)
(5a.3) − Battery display

Charged battery
Discharged battery
In addition, an acoustic signal goes off and
the LED in the transmitter flashes red.
Change the battery, otherwise the transmitter
will switch off after a few minutes. Immedia-
tely recharge the discharged battery using
the appropriate charging device.
(5a.4) − Position display of the locking and pinning unit (LPU)
(5a.5) − Selected length code (LC)
(5a.6) − Display appears when selected LC has been reached
(5a.7) − Bar display of the selected LC
Right screen (5b)
(5b.1) − Display of load utilization as a bar diagram and percen-

tage value
(5b.2) − Current gross load
The gross load includes the weight of the hook block,
the hoist rope and all load handling devices.
(5b.3) − Max. capacity in accordance with the capacity table
(5b.4) − Radius
(5b.5) − Display of advanced warning / overload
Advanced warning range (90 − 100 % of the
load moment); advanced warning symbol is
flashing.
Overload range (from 100 % of the load mo-
ment); Overload symbol is flashing.
The LLD switches off the movements ”Raise
load”, ”Telescoping out” and ”Luffing gear”.
(5b.6) − Display of hoist end
If the hoist end symbol lights up, the hoist limit
HE
switch has been triggered.
082−1340−82201a_en 23/53
34
0 1
13
Z 80 102
Z 82 089
24/53 082−1340−82201a_en
34.6 Control Lever Assignment

(Z 80 102, Z 82 089)
As soon as the radio remote control has been switched on, the
position of rotary switch (13) determines the control lever assign-
ment. In this case, it is not important which mode of control lever
assignment has been selected on the IC−1.
In particular, the selection options on this rotary switch also serve
to enable the control of hoist 2 (optional).
(Z 82 089)
The display of the selected mode in the top line of the IC−1 dis-
play adapts accordingly.
For detailed specifications on the control lever assignment mo-
des, see section 10 ”Safety equipment” under ”Control lever as-
signment screen”.
Risk of accidents!
If the assignment of the control levers is changed, a check
must be carried out to ensure the crane movements are car-
ried out properly with the new assignment.
ment.
082−1340−82201a_en 25/53
34
0 1
13
Z 80 102
26/53 082−1340−82201a_en
(Z 80 102)
Switch Control lever, right

Mode Control lever, left
position
Luffing
SLH = Slew gear SRH =
gear
”o” “1”
SLV = Tele SRV = Hoist 1
2 SLH = Slew gear SRH = Hoist 2

“3”
SLV = Tele SRV = Hoist 1
Luffing
2
gear
“2”
SLV = Hoist 2 SRV = Hoist 1
2 SLH = Slew gear SRH = Hoist 2
”3” with
HAVHY Luffing
SLV = SRV = Hoist 1
HAVHY
Luffing
”1” with gear
HAVHY Luffing
SLV = SRV = Hoist 1
HAVHY
S = control lever, R = right, L = left, H = horizontal, V = vertical
082−1340−82201a_en 27/53
34
41
Z 80 143 Z 83 495
28/53 082−1340−82201a_en
34.7 Commissioning of the Radio Remote Control

(Z 80 143, Z 83 495)
(Z 80 143)
1. Place the charged battery (41) with the decals facing inward
in the corresponding compartment underneath the control
panel so that the contacts are connected and the battery
clicks into position.
(Z 83 495)
2. Switch on the ignition in the cab (see section 5 ”Engine”). The
IC−1 ramps up and mask (Z 83 495) “Selection of the opera-
ting mode” appears.
082−1340−82201a_en 29/53
34
54
55
Z 83 492 Z 83 494
Z 83 493 Z 315 349
30/53 082−1340−82201a_en
(Z 83 492, Z 83 494, Z 315 349)

3. Switch the key switch (55) to radio remote control and re-
move the key.
The orange lamp behind the crane operator’s cab starts to
flash. The displayed ”Radio remote control” key appears in
the “Selection of the operating mode” screen.
The indicator light (54) is only illuminated when the system is fully
functional, i.e. transmitter and receiver are active and the trans-
mission path is stable.
4. Check whether the set parameters in the ”Selection of the

operating mode” screen correspond with the actual state of
the crane. Then either confirm as described in the following
point 5. or first adjust the parameters.
Risk of accidents!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane! This responsibility lies with the crane operator
alone! It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation!
(Z 83 493, Z 83 494)
5. Press the key displayed in the ”Selection of the operating
mode” screen to confirm the parameters. The following
”Crane operation” screen also appears with the depicted ra-
dio remote control symbol.
It is no longer possible to change the crane configuration on the

IC−1 once crane operation with ”Radio remote control” has been
confirmed as long as the radio remote control remains active.
Implementation of crane movements from the cab is disabled.
To rule out unintentional crane movements or disrup-

tions, remove the key from key switch (55), lock the
crane operator’s cab and take both keys with you.
082−1340−82201a_en 31/53
34
16 12
25 21
23
33
Z 80 113
5a.2
202
Sl2 LOCKED
!2
202.1 202.2 202.3 202.4 202.5
Z 70 400 Z 315 471
32/53 082−1340−82201a_en
(Z 80 113, Z 70 400, Z 315 471)
6. Ensure that the quick stop switch (23) has been unlocked. If
required, unlock the quick stop switch by turning it.
7. Switch on the radio transmitter. To do so, turn the key switch

(33) clockwise and then press button (25) ”On”.
The status LED (2) then flashes in green and both displays
are switched on − the transmitter is ready for operation.
If the status LED (2) on the transmitter lights up in red and

/ or an acoustic signal sounds, the battery is almost dischar-
ged . In this case, you must immediately:
− Replace the discharged battery with a charged one.
− Recharge the discharged battery (see section 34.10.2
”Battery charging device”, from page 47).
The transmitter will switch itself off after a few minutes if the di-
scharged battery is not replaced with a charged one.
If ”SI2 Locked” appears under (5a.2) on the transmitter, there

is a fault in the transmitter.
Then rectify possible faults as described in section ”34.5.2
Screens on the displays” (page 21) under (5a.2).
082−1340−82201a_en 33/53
34
202
202.1 202.2 202.3 202.4 202.5

54
55
Z 70 400 Z 83 492
16 12
25 21
23
33
Z 80 113
34/53 082−1340−82201a_en
(Z 70 400, Z 83 492, Z 80 113)
A radio link to the receiver (Z 70 400) has been established if the

red LED ”HF” (202.2) on the radio receiver goes out and if the
green LED ”Si1” (202.3) lights up once the transmitter has been
switched on.
Control commands can then be input using the radio transmitter’s
control panel.
If the transmission path is stable, indicator light (54) in the instru-
ment panel is illuminated to indicate that the system is operatio-
nal.
8. Start the crane engine using the radio remote control (engine
start: flip switch ”12” − up).
Danger!
You must always do the following every time before star-
ting work:
− Press button (21) ”Horn”. This warns your colleagues
to expect crane or hook movements at this point in time.
− Check the proper functioning of the quick stop switch

(23).
082−1340−82201a_en 35/53
34
5a.1
5a.2
Sl2 LOCKED 5a.3
5a 5a.4
5a.5
! 2 5a.6
5a.7
5b.1 LOAD 5b
5b.2 12.3 t 55 %
5b.5
5b.3 22.9 t
5b.4 1.3 m 5b.6
16 17 8
Z 315 763
36/53 082−1340−82201a_en
34.8 Crane Operation Using Radio Remote Control

(Z 315 763)
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.
If ”SI2 Locked” appears under (5a.2) on the transmitter, there is

a fault in the transmitter. For notes on rectifying faults, see seg-
ment ”34.5.2 Screens on the displays” (page 21) under (5a.2).
If the load utilization of the crane reaches the advanced warning
range, the ’Caution’ symbol appears under (5b.5).
If the LLD switches off crane movements, the ’Stop’ symbol ap-
pears under (5b.5).
In this case, the crane operator must check the cause of the shut−
down on the operating unit of crane control in the crane opera-
tor’s cab.
Using this information, the crane operator can decide how to get
out of the shut−down.
For other malfunctions, see segment 34.11 ”Troubleshooting”
(page 51).
082−1340−82201a_en 37/53
34
16 12
25 21
23
33
Z 80 113
54
55
Z 83 492
38/53 082−1340−82201a_en
34.9 Putting the Radio Remote Control Out of Operation
Risk of accidents!
Control commands can be transmitted even when the
crane is out of sight. For this reason, remove the key (33)
from the transmitter and store it safely when not in use.
34.9.1 Standard Switch−down

(Z 80 113, Z 83 492)
1. Close the slew gear brake. To do so, place the toggle switch
(16) in the top position.
If the switch was switched off with the slew gear brake open,
an unsafe state of the crane could arise when it was switched
on again. For this reason, a fault message is displayed (see
page 21) when switched back on and the transmitter is lok-
ked until the slew gear brake is closed using toggle switch
(16).
2. Switch the crane engine off using the radio remote control
(engine stop: flip switch ”12” − down).
3. Switch the key switch (55) back to standard crane operation.
The indicator light (54) goes out.
Crane control can be operated again using the IC−1 and the
control levers.
4. Switch off the radio transmitter. To do so, turn the key

switch (33) anti−clockwise.
A quick stop is initiated if the radio transmitter is switched off be-

fore key switch (55) is switched back to standard crane operation.
If the optional quick stop device with air shut−off valve is fitted,
the air shut−off valve must be opened again. See section 5 ”En-
gine”.
082−1340−82201a_en 39/53
34
16 12
25 21
23
33
Z 80 113
40/53 082−1340−82201a_en
34.9.2 Shutting down Using the Quick Stop Switch

(Z 80 113)
Switch the transmitter on and off using the key switch (33).
Use the quick stop switch (23) only in an emergency or if
there are faults in the operating range.
1. Press the quick stop switch (23).
The following steps must be taken to continue using the transmit-

ter if it was switched off using the quick stop switch (23):
1. Unlock the quick stop switch (23) by turning it.
If the crane is equipped with an optional quick stop device with

an air shut−off valve, the shut−off valve must be unlocked ma-
nually (see section 5 ”Engine”).
2. Switch the radio transmitter back on. Press the ”On” button
(25) to do so.
082−1340−82201a_en 41/53
34
16 12
25 21
23
33
Z 80 113
42/53 082−1340−82201a_en
34.9.3 Automatic Shut−down of the Transmitter

(Z 80 113)
The transmitter shuts down automatically if it has not been used

for a certain period of time.
This function can be activated or deactivated and the shut−down
time can be set at the master level (customer service team).
The automatic transmitter shut−down is for safety reasons and
improves the durability of the battery.
After an automatic shut−down you must press the ”On” button
(25) to reactivate the transmitter.
Risk of accidents!
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.
An automatic shut−down of the transmitter causes a quick stop.

If the optional quick stop device with air shut−off valve is fitted,
the air shut−off valve must be opened again. See section 5 ”En-
gine”.
082−1340−82201a_en 43/53
34
41
Z 80 105
44/53 082−1340−82201a_en
34.10 Power Supply
34.10.1 Nickel Metal Hydride Accumulator Battery (Battery)

(Z 80 105)
The battery (41) must be in the corresponding compartment un-

derneath the control panel of the radio transmitter − as shown.
The capacity of the battery depends on its age and the ambient
temperature. The capacity of older batteries decreases over
time. The battery capacity decreases more quickly if temperatu-
res are below 0° C / 32° F and above 40 ° C / 104° F.
With proper handling, more than 500 charging cycles can be
achieved. For this reason, follow these instructions:
− Charge the battery fully before its first use and / or after it has
been in storage for more than 6 months. Remember that the
battery achieves full capacity only after 3 − 5 charging cycles
(fully charged and discharged).
− Use only the appropriate HBC charger to charge the battery.
− Charge the battery at an ambient temperature of 0−40° C
(32−104° F).
− Charge the battery only if the status LED in the transmitter is
flashing red and an acoustic signal sounds.
− Fully charge the battery before it is placed in storage for an
extended period Otherwise the battery could become totally
discharged.
− Store the battery at room temperature.
− Protect the battery from short−circuiting and always use the
supplied protective cap for storage.
082−1340−82201a_en 45/53
34
51
41
Z 80 116
46/53 082−1340−82201a_en
34.10.2 Battery Charging Device

(Z 80 116)
Depending on customer requirements, an AC or DC charging de-

vice is available.
Risk of accidents!
Only charge the batteries listed on the serial plate using the
charging device.
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 operate the charging device in vehicles or in enclosed

interior spaces.
Operate the charging device only within the indicated tem-

perature range.
Protect the charging device from overheating, dust and hu-

midity.
Do not cover the charging device during operation.
Disconnect the charging device from the power supply if it

is not being used.
Immediately take the charging device out of operation if

there is a fault in the device or the connecting cable.
Do not make any technical modifications to the charging

device or the connecting cable.
Only have an expert carry out repairs.
082−1340−82201a_en 47/53
34
51
41
Z 80 116
48/53 082−1340−82201a_en
Charging the battery

(Z 80 116)
1. Connect the charging device to the power supply using the

connecting cable supplied.
2. Insert the battery (41) into the charging compartment of the

charging device (51). The charging procedure starts auto-
matically.
If an FuB 9 NM or a BA2220_ battery is to be charged, you must

insert the adapter into the charging compartment.
The current operating status is indicated by three LEDs:
The green − lights up when the battery has been char-

LED ged.
The orange − lights up when the battery is being charged.
LED
The red LED − lights up when the battery is fully discharged
or is faulty.
Specifications
Operating voltage 100 − 240 V AC (QA109600)
10 − 30 V DC (QD109300 / QD309300)
Charging time 1 − 2 hours
Operating tempera- +10° C − +40° C
ture (+50° F − +104° F)
Housing material Plastic
Device protection II
class
082−1340−82201a_en 49/53
34
50/53 082−1340−82201a_en
34.11 Troubleshooting
Please check the functions first using the cab or cable control
unit.
Problem Possible cause Measures

No response when No operating voltage Check the battery contacts for damage or
the transmitter is present dirt.
switched on
Place a charged battery in the battery com-
partment.
Charge the battery fully.

Low voltage warning Battery contacts con- Check the battery contacts for damage or
after just a short ope- taminated or dama- dirt.
rating time ged
Charge the battery fully.
Battery not charged
Check that the charging procedure is pro-
Battery defective ceeding correctly.
Check the transmitter function with a fully

charged or a replacement battery.
The status LED in The receiver has no Check the connection cable to the receiver.
the transmitter is flas- operating voltage
hing green, but con- Check the functions using the LEDs in the
trol commands can- No radio connection cover of the receiver.
not be implemented
The command
”Crane on” has not
been given
Individual commands The receiver is de- Check that the connecting cable to the re-
are not being carried fective ceiver is securely attached.
out
The connecting line
to the crane is inter-
rupted
If none of the measures listed resolves the problem, please

contact the customer service team.
082−1340−82201a_en 51/53
34
52/53 082−1340−82201a_en
34.12 Servicing
To a large extent, the radio remote control is maintenance−free.

However, comply with the following points:
− Check the functionality of the quick stop switch regularly. Dirt
deposits on the switch could impair the mechanism and ne-
gatively affect its function.
− Check the bellows and/or rubber seals of the operating ele-
ments regularly for leak−tightness. Defective bellows and/or
rubber seals must be replaced immediately as humidity and
dirt could penetrate and impair the function of the operating
elements.
− Never clean the transmitter or receiver with a high−pressure
cleaner or with sharp and pointed objects.
− The transmitter batteries must be charged and discharged re-
gularly.
− If electrical welding is to be carried out on the crane:
− Switch the radio remote control off.
− Switch the crane off.
− Disconnect all electric connections to the receiver.
Otherwise, the receiver electronics could be destroyed.
In case of a fault
Risk of accidents!
You may not continue to work with a faulty radio remote
control.
Do not attempt to access the electronics of the radio remote con-

trol yourself. We must reject any warranty claims if this is attemp-
ted. Please consult the customer service team.
082−1340−82201a_en 53/53
Emergency Operation 36
082−1360−82201e_en 1/87
36
Malfunction
Electric
OW engine Yes Pumps Yes Emergency control system
O.K.? O.K.?
connect
No No
Functions
O.K.?
Yes
Hydraulic Electric
Emergency lowering Emergency control system
Z 171 371
2/87 082−1360−82201e_en
36 Emergency Operation (Optional)
36.1 General
(Z 171 371)
To make it possible to initiate suitable measures in case of an

emergency (power loss during crane operation) for recovery / de-
configuring the crane, the operator has at his disposal the proce-
dures described in the following, which are supported by the con-
trol system, depending on the individual emergency scenario
(worst case):
− ”Hydraulic emergency lowering” (see sect. 36.2, starting

on page 5)
− ”Electrical emergency control system” (see section

36.3, from page 25).
The ”Emergency operation” procedure must be practised at

least once prior to crane operation. The driver of the crane
must understand/have a mastery of emergency operation!
Only this will ensure safe operation and rapid handling in
emergency situations.
082−1360−82201e_en 3/87
36
4/87 082−1360−82201e_en
36.2 Emergency Hydraulic Lowering
36.2.1 Intended use
”Hydraulic emergency lowering” which is described in the follo-

wing is only for recovering small loads (load pressures < 210 bar
/ 3046 psi) safely if the diesel engine or a pump fail.
Emergency operation is not equipped or suitable for maintaining
normal crane operation.
36.2.2 Safety Instructions
Before placing a component in operation, first make sure

you are familiar with the respective system involved!
You must read and observe the entire section in order to do
so!
If any directions are unclear, contact our Customer Service
technicians before operating the system!
Only authorised and correspondingly trained personnel are
permitted to operate the emergency actuation!
All instructions and descriptions in the corresponding sec-
tions (”8 − Slewing the superstructure”, ”13 − Luffing”,
”14 / 15 − Hoists”) in these operating instructions must also
be observed.
All of the movements of the crane and of the load must be in

the crane operator’s field of view! A spotter must be used if
necessary.
Neither the operator nor the spotter are allowed in the dan-
ger zone of the crane during crane operation.
Follow all safety instructions which are also valid for nor-
mal operation.
082−1360−82201e_en 5/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
6/87 082−1360−82201e_en
36.2.3 General
(Z 84 970)
You will find a detailed description below on how to receive assi-

stance in case of a corresponding fault.
If the crane is to provide assistance, also observe the description
of the corresponding interface (optional) on page 23.
The required connections (hydraulic interfaces) arestandardi-

sed.
The required auxiliary unit is a hydraulic transformer, which pri-
marily comprises a pump and a motor. Such a transformer can be
ordered from the cranemanufacturer.
The engine (2) of the transformer is driven by an external hydrau-

lic system (e.g., an ”assisting” crane or a specific power unit) and
it in turn drives the transformer pump (3), which supplies the su-
perstructure’s hydraulic system.
The transformer, which can be obtained from the crane manufac-

turer, has the following connections:
− for the assisting crane:
− (TUW) − tank connection
− (PUW) − pressure connection
− (LUW) − leak oil connection
− for the crane receiving assistance:
− (T) – tank connection
− (1) – pressure connection
The following movements can then be moved by activating the

control lever in the superstructure:
− Luffing
− Lower hoists
− Turning.
The crane movements are carried out at a slower pace.
The load limit device and any operating range limits that may be
programmed remain unaffected, which means that they continue
to be effective.
The required hydraulic transformer and all requiredhoses must

be supplied by the customer or can be delivered as optional
equipment.
082−1360−82201e_en 7/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
8/87 082−1360−82201e_en
36.2.4 Connecting the Transformer

(Z 84 970)
Below is an example of external supply by an assisting crane.
In addition, observe the corresponding operating instructions of

the assisting crane.
When using other sources, the corresponding operating manuals
should be used.
Initial situation:
− Crane receiving assistance in the corresponding operating

configuration (outrigger support area, counterweight and si-
milar) with small attached load.
− Configuration of the crane receiving assistance:
∗ Failure of the diesel engine or pump
∗ Hydraulics and electrical system functioning
Caution!
If the crane’s electrical system is not operational, i.e. the bat-
teries are discharged, ”Hydraulic emergency lowering” is
not possible.
In this case, the crane’s electrical system must first be made
operational using external batteries (see the operating in-
structions of the crane chassis, section ”Engine” under
”Jump starting”).
∗ Engine and ignition off.

− Configuration of the assisting crane:
∗ Engine and ignition off.
− Use of a standard transformer In the following, the transfor-
mer (Z 84 970) which should be obtained from the crane ma-
nufacturer is described as an example.
When using another transformer, the corresponding operating

manual should be used.
082−1360−82201e_en 9/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
Z 86 836
10/87 082−1360−82201e_en
(Z 84 970, Z 86 836)
(Z 84 970)
1. Unfold protection caps on the relevant couplings of the trans-
former and unscrew hydraulic hoses.
(Z 84 970)
2. Using hoses, connect the motor of the transformer with the
corresponding hydraulic couplings TUW, LUW and PUW on the
assisting crane.
The corresponding coupling sleeves and plugs are marked

with plates as follows:
TUW − tank connection of assisting crane
LUW − leak oil connection of assisting crane
PUW − pressure connection of assisting crane.
Follow the corresponding operating instructions for the fitting lo-

cation of these couplings on the assisting crane.
For transformers without leak oil connection, coupling ”LUW ” on

the assisting crane remains free.
(Z 86 836)
3. The required connections on the crane receiving assistance
are partially behind the covers. For this reason, first unlock
the flap on the crane chassis and fold down.
Tools needed depending on the design of the crane:

Allen key 8 mm or bit key.
082−1360−82201e_en 11/87
36
4 1
3 T
L UW
S2
TUW 2
PUW
Z 84 970 Z 84 972
Z 84 973
12/87 082−1360−82201e_en
(Z 84 970, Z 84 972, Z 84 973)

4. Using hoses, connect the pump of the transformer to the cor-
responding hydraulic couplings of the crane receiving assi-
stance:
− Coupling ”T” (transformer) with coupling ”S2” (crane)
− Coupling ”1” (transformer) with coupling ”P” (crane).
The coupling sleeves and plugs are marked with plates.
In order to establish the hydraulic connections, the correspon-

ding protective caps on the transformer must be folded up and
the protective caps screwed onto the crane must be removed.
This completes the procedure of connecting the transformer with

both cranes.
082−1360−82201e_en 13/87
36
Z 84 974
Z 83 961
14/87 082−1360−82201e_en
36.2.5 Recovering a Small Load

(Z 84 974, Z 83 961)
1. Connect the transformer as described in detail, starting on

page 9.
(Z 84 974)
2. Move the stop valve from the ”open” position (dotted line)
into the locked position (continuous line).
If the stop valve is not placed in the locked position, some of the
oil will flow out and the speed of the crane movements during ”Hy-
draulic emergency lowering” will be additionally reduced.
After completing ”Hydraulic emergency lowering”, the stop

valve must be placed back in the ”open” position for normal
operation. Otherwise, this will cause knocking in the hydrau-
lic system as there can no longer be any release of pressure.
3. Set crane control to ”Hydraulic emergency lowering”. To do

so, switch on the ignition in the superstructure. This starts the
IC−1 automatically.
(Z 83 961)
4. Select the correct operating mode and actuate the key for
”Main menu” in the ”Crane operation” screen.
(Z 83 961)
5. Press the depicted key in the main menu to switch crane con-
trol to ”Hydraulic emergency lowering”. The key changes in
appearance as shown.
In addition, the symbol shown appears in the Crane operation

screen.
Caution!
The function ”Hydraulic emergency lowering” must be acti-
vated at the IC−1. Otherwise, no further crane movements
can be made using the control levers of the superstructure
cab.
082−1360−82201e_en 15/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
16/87 082−1360−82201e_en
(Z 84 970)
6. Move the stop valve (4) of the transformer into the ”open” po-
sition (in the illustration ”Z 84 970”, the stop valve is dis-
played in the locked position).
Now, the transformer is switched to the depressurised cycle.
This prevents an overheating of the hydraulic oil during lon-
ger idle operation.
The stop valve (4) should be brought into the locked position
shown immediately before initiating a crane movement.
7. Start the engine of the assisting crane.
082−1360−82201e_en 17/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
11
Z 84 976
18/87 082−1360−82201e_en
(Z 84 970, Z 84 976)
The following crane movements can be made using the ”Emer-

gency hydraulic lowering” function, in order to recover a small
suspended load.
The crane movements will be carried out at a slower speed.
Only operate the transformer as long as required to recover

the load and do not leave it running in idle for a longer period
of time.
If the transformer is operated for a longer period of time, the
oil can overheat.
− Turning
First, move the stop valve (4) on the transformer into the locked
position. Then, this crane movement – as in normal operation –
is controlled by operating the corresponding control lever. Refer
to section 8 ”Slewing the superstructure”.
In addition, to carry out this movement, actuate control knob (11)

to slowly increase the corresponding throttle. This ensures that
slewing can be controlled very precisely and that there is no un-
welcome movement (rocking) of the load to be retrieved.
With emergency hydraulic lowering, the turning will take place au-
tomatically in a closed circuit.
− Luffing
to the information contained in section 13 ”Luffing”.
− Lower hoists
to the information contained in section 14 ”Hoist 1” and section
15 ”Hoist 2”.
082−1360−82201e_en 19/87
36
4 1
3 T
L UW
TUW 2
P
UW
Z 84 970
Z 84 975
20/87 082−1360−82201e_en
36.2.6 After recovering a small load

(Z 84 970, Z 84 975)
(Z 84 970)
1. Move the stop valve (4) of the transformer into the ”open” po-
sition (in the illustration ”Z 84 970”, the stop valve is dis-
played in the locked position).
Now, the transformer is switched to the depressurised cycle.
This prevents an overheating of the hydraulic oil during lon-
ger idle operation.
2. Switch off the engine of the assisting crane.
3. Switch the ”Hydraulic emergency lowering” function off in the

IC−1 of the crane receiving assistance and switch off the igni-
tion.
(Z 84 975)
4. Place the stop valve back in the ”open” position.
After completing ”Hydraulic emergency lowering”, the stop

valve must be placed back in the ”open” position for normal
operation. Otherwise, this will cause knocking in the hydrau-
lic system as there can no longer be any release of pressure.
5. Disconnect all connections of the transformer again and refit

the protective caps on the couplings.
6. Close all open covers again according to instructions.
082−1360−82201e_en 21/87
36
4 1
3 T
L UW TUW
TUW 2
PUW
Z 84 970 Z 84 977
LUW
PUW
Z 84 978
22/87 082−1360−82201e_en
36.2.7 Interface for Drive of the Hydraulic Emergency Lowe-

ring (Optional)
(Z 84 970, Z 84 977, Z 84 978)
At this interface (optional), the crane described here can be con-

nected to the motor of the hydraulic transformer in order to act as
an assisting crane to carry out hydraulic emergency lowering on
another crane.
To do so, connect the correspondingly marked connections of the

transformer (TUW), (PUW) and (LUW) with the corresponding con-
nections.
The figures opposite show where these corresponding connec-

tions can be found.
Connection PUW is not a free coupling, but is a standard clo-

sed connection for the supply of a steering circuit.
For this reason, this connection must first be separated be-
fore the hose of connection PUW of the transformer can be
connected here.
Risk of accidents when driving the crane.

If the hydraulic transformer is connected to connection
PUW, the crane may not be driven due to its restricted stee-
ring function.
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24/87 082−1360−82201e_en
36.3 Electrical emergency control system
36.3.1 Safety Instructions
Before placing a component in operation, first make sure

you are familiar with the respective system involved!
You must read and observe the entire section in order to do
so!
If any directions are unclear, contact our Customer Service
technicians before operating the system!
Only authorised and correspondingly trained personnel are
permitted to operate the emergency actuation!
All instructions and descriptions of the corresponding sec-
tions (”8 − Slewing the superstructure”, ”12 − Telesco-
ping”, ”13 − Luffing”, ”14 / 15 − Hoists”) in this operating
manual must also be complied with.
All of the movements of the crane and of the load must be in

the crane operator’s field of view! A spotter must be used if
necessary.
Neither the operator nor the spotter are allowed in the dan-
ger zone of the crane during crane operation.
Follow all safety instructions which are also valid for nor-
mal operation.
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ON
Z 104 168 Z 104 169
26/87 082−1360−82201e_en
36.3.2 General
(Z 104 168, Z 104 169)
The electrical emergency control system is intended exclusively

for the purpose of enabling execution of all main crane move-
ments in the event of electrical component parts failure. Both the
superstructure engine and the pumps must be completely func-
tional.
Emergency electrical control system is not equipped or suitable
for maintaining normal crane operation.
Risk of tilting! Risk of accidents!
No monitoring of the limit switches takes place in the event

of emergency operation with ”electrical emergency control
system”! Load limit devices and operating range limits are
also not in operation!
It is for that reason that there is absolutely no monitoring
or shutdown when:
− hoist limit switches / lower limit switches are triggered
− a maximum load case is reached
− min. or max. radius is exceeded
You must comply with the valid capacity tables supplied
with the crane.
All crane movements must be carried out with special care!
The crane operator/crane driver is solely responsible for

any damage or accidents that might be caused in this situa-
tion!
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ON
Z 104 168 Z 104 169
28/87 082−1360−82201e_en
36.3.3 Function and Component Parts

(Z 104 168, Z 104 169)
In the event of hardware errors in control system components or

CAN bus stops of the superstructure control system components,
the movements relevant to the recovery such as ”luffing gear, ho-
ist, slew gear and telescoping” can be implemented by means of
the electrical emergency control system.
The electrical emergency control system directly influences the
solenoid valves of the hydraulic system by using the vehicle ca-
bles for transmitting signals.
The electrical emergency control system basically consists of the

following components:
− mobile control unit (Z 104 168),
− mobile manual operating panel (Z 104 169)
− Connecting cable set
The actuation of the respective movement is accomplished by

means of the mobile manual control panel. The driver of the crane
can control all functions/crane movements from the crane opera-
tor’s cab.
Risk of accidents!
For safety reasons, the crane operator must be in the crane
operator’s cab when working with the electric emergency
control system.
The Fast STOP push−button for switching off the engine in
case of danger is located in the crane cab.
In addition, the engine speed can be regulated in the crane
cab with the gas pedal, depending on the hydraulic oil re-
quirements.
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30/87 082−1360−82201e_en
Instructions on using an electrical emergency control sy-

stem of another crane
Instructions on the connecting cable set

There are different connecting cable sets for electric emergency
control, depending on the crane type and delivery date.
You must ensure that it fits if a connecting cable set supplied with
another crane is to be used.
Instructions on the software version of the electrical emergency

control system
In order for the electrical emergency control system to function
in another crane type, it must also be possible to select the cor-
responding crane type (see page 49). If this is not the case, the
software must be updated. Consult our service department to do
so.
Instructions on testing the functionality

If the electrical emergency control system of another crane is to
be used, it should first be fitted as a test and the functionality must
be checked.
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
32/87 082−1360−82201e_en
(Z 65 189)
36.3.4 Mobile Manual Control Panel
36.3.4.1 Operating Elements of the Locking and Pinning Unit

(LPU)
(1) Button unlock

(2) Button lock
(3) Button unpin
(4) Button pin
36.3.4.2 Position Sensor System of the LPU
(5) Approach position locking achieved

(6) LED, Follow−up position locking achieved
(7) green Not assigned
(8) Not assigned
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
34/87 082−1360−82201e_en
(Z 65 189)
36.3.4.3 State Sensor System of the LPU
Number
Item Symbol State of the LPU LED of the
state
(9) unlocked and pinned Green 1
(10) locked and pinned Green 2
(11) locked and unpinned Green 3

locked and state
(12) yellow 23
change pinning
State change lock and
(13) yellow 12
pinned
State locking / pinning
(14) red 5
unknown
The LPU states correspond to the states for the LPU that are
shown on the screen ”manual telescoping” on the crane control
(see section 12).
36.3.4.4 Telescopic Section Identification
(15) 4 LEDs, yellow BIT 1 – BIT 4
The current telescopic section is represented by means of different

combinations of the 4 LEDs (BIT 1 – BIT 4). Please observe the follo-
wing table.
BIT 1 BIT 2 BIT 3 BIT 4
Telescopic section 1 X X
Telescopic section 3 X X X
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
36/87 082−1360−82201e_en
(Z 65 189)
36.3.4.5 Function Elements
(16) Display
− Crane type
− Current telescopic section, for example SEC3 (for te-
lescopic section 3)
− Reservoir loading pressure (bar) e. g. 0082
Selection crane type

(17) Button Scroll by pressing key (21) or
(22) at the same time
Selection crane movement
(18) Button Scroll by pressing key (21) or
(22) at the same time
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
38/87 082−1360−82201e_en
(Z 65 189)
36.3.4.6 Crane Movements
(19) Rocker switch
The further down the self−return rocker switch (19) is pressed at

(19A) or (19B), the quicker the selected crane movement is car-
ried out.
The current assignment of the self−return rocker switch (19) de-

pends on which crane movement was previously selected using
keys (21) or (22).
(19A) Movement
− Slew Gear on the Right
− Lower hoists
− Lower luffing gear
− Extend telescopic drive
(19B) Movement
− Slew Gear on the Left
− Raise hoists
− Raise luffing gear
− Retract telescopic drive
(20) selected crane movement

− Not assigned
− Telescoping
− Slew gear
H1
− Hoist 1
H2
− Hoist 2
− Luffing gear
The corresponding LED is illuminated in red at the symbol of the

selected crane movement.
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
40/87 082−1360−82201e_en
(Z 65 189)
”Scrolling” key:
Press at the same time toge-
ther with key (17):
Scroll to the
(21) Selection ”Crane type”
left
ther with key (18):
Selection ”Crane movement”
”Scrolling” key:
ther with key (17):
Scroll to the
(22) Selection ”Crane type”
right
ther with key (18):
Selection ”Crane movement”
36.3.4.7 Accumulator Loading Pressure ”LPU”
Display of pressure value (bar) on the

(23)
screen (16)
(24) Manual reloading of the LPU accumulator
This function is only possible when Telescoping has been selec-

ted.
The loading pressure must be within the 80 − 85 bar (1160 –
1233 psi) range.
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X2
Z 84 966 Z 83 967
X2
Z 83 968
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36.3.5 Commissioning
(Z 84 966, Z 83 967, Z 83 968)
The following steps must be followed with the ignition switched

off.
(Z 84 966)
1. Open covering flap. Use the multi−purpose ladder as a step
ladder for this.
(Z 83 967)
2. Put the multi−purpose ladder together as a leaning ladder.
Position the ladder as illustrated. To secure the ladder, the
attachment hooks must be hung in the corresponding groo-
ves as illustrated.
(Z 83 968)
3. Climb the ladder to switchbox ”X2”and hook the personal
protective equipment into the safety eyelets, as illustrated.
4. Open switchbox ”X2”.
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32
31
Z 83 969
44/87 082−1360−82201e_en
(Z 83 969)
5. Loosen the mounting plates (31) on both upper corners in-
side the switchbox ”X 2” and fold them down to the front. This
will clear the way for access to the PLC components (32).
6. Loosen all connectors to the PLC components (32).

This will exclude the possibility of the control system in the
crane interfering with the ”emergency operation”.
7. Fold the mounting plate (31) back up and secure it in place.
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X2
X9100
2c
2b
2a
2
1 1a
Z 84 371
46/87 082−1360−82201e_en
8. Connect the mobile control unit (2) of the emergency control

system. To do so:
8.1 Plug in connection cable plug (2a) into mobile control

unit (2).
8.2 Plug connection cable plug (2c) into socket ”X9100” of

distribution box ”X2”.
Connection cable plug (2b) is not plugged in – it is used only for

tasks by the service team.
9. Plug plug (1a) of the cable of the manual control panel (1)
into mobile control unit (2).
10. Switch on the ignition in the superstructure.

The power supply to the emergency control system is ensu-
red once the ignition has been switched on.
If the power supply is interrupted because of the failure of
one or more batteries, then auxiliary power can be fed in
through the external start outlets (see in this connection sec-
tion 5 ”Engine”, under the item ”Starting aid”).
Risk of accidents!
The operator of the ”electric emergency control unit” must
remain in the crane operator’s cab during operation for sa-
fety reasons!
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
48/87 082−1360−82201e_en
(Z 65 189)
11. Select crane type. In addition, at the manual control panel:
11.1 Press and hold down push−button (17).
11.2 Press push−button (21) or (22); this will initiate scrol-

ling through the available selection options (see ”Dis-
play at emergency control system” in the following ta-
ble):
Display at emer- Type of crane

gency control sy-
stem
type no valid crane type selec-
ted; always appears after
the manual control panel
has been connected
CHAL Challenger (all types)
EPLO Explorer (all types)
100.4 AC 100/4, Roadmaster,
AC 120/4J
100.5 AC 100 (old, with 5 axles)
250.6 AC 250−1
300.6 AC 300/6
350.6 AC 350/6
500.8 AC 500−2 (8 Axles)
1000 AC 1000
11.3 Interrupt scrolling as soon as the desired crane type is

displayed, and release the push−button (17).
The displayed crane type is now selected and the elec-
trical emergency control system is ready for operation.
The selection of the crane type must be in accordance with

the crane which is subsequently to be operated with the elec-
trical emergency control system!
Incorrect selection can lead to malfunctions!
12. Start the crane engine from the crane operator’s cab.
If the engine does not start, there could be a fault in the CAN com-
munication between the superstructure and the crane chassis. In
this case, start the engine from the driver’s cab.
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
50/87 082−1360−82201e_en
36.3.6 General Instructions on Driving the

Crane Movements during Emergency Control Opera-
tion
(Z 65 189)
Observe all instructions in section 36.3.1 ”Safety instructions”,

page 25.
Risk of accidents!
Before a crane movement is initiated, the crane operator is
responsible for ensuring that:
− the desired is correctly selected
− all criteria for operation of the crane movement are fulfil-
led
− the selected crane movement is carried out at adapted
speed.
Risk of tilting! Risk of accidents!
No monitoring of the limit switches takes place in the event

of emergency operation with ”electrical emergency control
system”! Load limit devices and operating range limits are
also not in operation!
It is for that reason that there is absolutely no monitoring
or shutdown when:
− hoist limit switches / lower limit switches are triggered
− a maximum load case is reached
− min. or max. radius is exceeded
You must comply with the valid capacity tables supplied
with the crane.
All crane movements must be carried out with special care!
The crane operator/crane driver is solely responsible for

any damage or accidents that might be caused in this situa-
tion!
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
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36.3.7 Slew gear

(Z 65 189)
1. Press and hold down push−button (18).
2. Press push−button (21) or (22). The available selection op-

tions (movements) will be scrolled through as a result.
3. Interrupt scrolling as soon as the desired movement ”slew

gear” is displayed (see symbol shown) and release the
push−button (18).
The associated LED lights up.
4. Drive the desired turning movement using self−return rocker

switch (19).
(19A) − Turning to the right
(19B) − Turning to the left
Depending on how far down the self−return rocker switch (19) un-
der (19A) or (19B) has been pressed, the selected movement is
carried out more slowly or more quickly.
5. In order to brake the turning movement, slowing release

self−return rocker switch (19). The turning movement is
brought directly to a halt due to the fixed oil column.
In the event of emergency control operation, the slew gear

will generally be operated in a closed circuit. The position of
the switch ”Switch−over slew gear: open / closed circuit”
has no meaning in this case.
Also refer to section 8 ”Slewing the superstructure”.
Risk of accidents !
Handle the slew gear with care! Select low slewing speeds.
Slowly return to neutral position!
This is especially valid for operation with fitted fly jib or un-
der special local conditions.
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
54/87 082−1360−82201e_en
36.3.8 Hoists
(Z 65 189)

3. Interrupt scrolling as soon as the desired movement ”hoist”

H1
is displayed (see symbol shown) and release the push−but-
H2
ton (18).
4. Execute the desired ”hoist” movement using the rocker

switch (19).
(19A) − Lower hoist
(19B) − raise hoist
Also observe in this connection section 14 ”Hoist 1” or sec-

tion 15 ”Hoist 2”.
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
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36.3.9 Luffing gear

(Z 65 189)

3. Interrupt scrolling as soon as the desired movement ”luffing

gear” is displayed (see symbol shown) and release the
push−button (18).
4. Execute the desired ”luffing gear” movement using the rok-

ker switch (19).
(19A) − Lower luffing gear
(19B) − Raise luffing gear
Refer also to section 13 ”Luffing”.
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Z 66 156
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36.3.10 Telescoping
”Telescoping” means retracting or extending the main boom. The

main boom consists of a basic case and six telescopic sections:
(0) − Basic case
On principle, the smallest (furthest inward) telescopic section to

be telescoped must be started with whenever the main boom is
to be extended.
The largest (furthest outward) telescopic section to be telesco-
ped must be started with whenever the main boom is to be retrac-
ted.
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
60/87 082−1360−82201e_en
(Z 65 189)
Manual telescoping is carried out without the supervision of the

load limit device and is therefore only permitted in emergency
situations.
The display and operating elements (1) – (15) and (23) and
(24) refer solely to emergency controls for the telescoping
and LPU functions and should be reserved for specially trai-
ned service personnel.
36.3.10.1 Telescoping the LPU

3. Interrupt scrolling as soon as the desired movement ”tele-

scoping” is displayed (see symbol shown) and release the
push−button (18).
4. Execute the desired ”Telescoping” movement using the rok-

ker switch (19).
(19A) − Extend telescopic drive
(19B) − Retract telescopic drive
Refer also to section 12 ”Telescoping”.
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
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36.3.10.2 LPU states

(Z 65 189)
The automatic telescopic control essentially follows sequential

work steps which are automatically run through in one circuit. In
emergency operation, these must be retraced and run through
manually by the operator.
All of the LPU states described below are run through during a
completed telescoping procedure. In this case, the progression
of the states is dependent on the telescoping direction. The struc-
tural design ensures that no safety−critical conditions can arise
because of incorrect operation of the locking or pinning procedu-
res.
Possible configurations of the ”locking and pinning unit

(LPU)”
State 1: LPU unlocked and pinned

The LPU can be moved freely and can be moved to a telescopic
section.
State 2: LPU locked and pinned

Mechanical connection between telescoping cylinder and tele-
scopic section has been established. The boom section is pinned
to the next larger boom section.
State 3: LPU ”locked and unpinned”

LPU linked mechanically with the telescopic section. The telesco-
pic section is not pinned to the next−largest telescopic section
and can be moved / telescoped.
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
64/87 082−1360−82201e_en
(Z 65 189)
Pinned means that telescopic sections are connected mechani-

cally with one another.
Locked means that the LPU with telescoping cylinder is connec-
ted mechanically with the telescopic section.
In view of the fact that a control system could fail at any time, the
first step to be carried out in the above−mentioned sequence is
dependent on the time of the failure. The following steps within
the sequence must be carried out as necessary so that it is possi-
ble, for example, to move the LPU freely to the next possible pin-
ned telescopic section.
Generally, locking procedures must only be actuated manually
when the corresponding fine position has been reached. This is
the case when the LEDs for approach position and follow−up po-
sition light up simultaneously.
It is only then ensured that the pins will be positioned precisely
in the middle above the associated bore holes.
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
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36.3.10.3 Telescopic Section Identification

(Z 65 189)
Every telescopic section can be unambiguously identified using

a bit combination which is presented in the following table. The
bit combination of BIT 1 to BIT 4 is represented on the operating
console with the aid of the LEDs (15).
BIT 1 BIT 2 BIT 3 BIT 4

If the LPU is positioned in an identified telescopic section, then

this will be shown in plain text on the display (16) (e.g. ”SEC 3”
for telescopic section 3).
36.3.10.4 Hydraulic oil supply to the LPU
It may happen under certain conditions that the pressure level in

the LPU reservoir is no longer sufficient to permit a complete pin-
ning and/or locking sequence to take place (pressure <80 bar
/1160 psi).
In this case, the pressure can be displayed by means of the
push−button shown in the display (16).
Hydraulic recharging can be carried out with the displayed push−
button – if necessary – (80−85 bar / 1160 – 1233 psi).
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2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
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36.3.10.5 Move the LPU to the home position(unlocked and

pinned, max. telescoped in)
(Z 65 189)
All LPU states are monitored by sensors which indicate the cur-
rent state of the mechanics. The LPU states are displayed using
light−emitting diodes (9) − (14). All final states and all their inter-
mediate stages during the signal transitions are displayed here
during the course of a fault. If the LPU is currently in an interme-
diate stage (symbol with question mark, LEDs ”12”, ”13” or ”14”),
a final state must be induced by direct actuation. It may under cer-
tain circumstances be necessary to adjust the fine position of the
locking or the pinning by retracting or extending for this purpose.
The LPU must be moved to ”State 1” to be able to move it freely
and without a load.
The first step for accomplishing this is to determine which state
the LPU is currently in. In accordance with the display on the ope-
rating console, there are ”6” different possibilities here.
State 1: LPU ”unlocked and pinned”

LED (9) is illuminated.
The LPU can be completely telescoped in and the basic position

is achieved.
State 12: LPU ”configuration change lock and pinned”

1. Actuate rocker switch (19) and thereby move LPU with the
aid of telescoping into ”Fine position locking” (LEDs ”5” and
”6” are illuminated simultaneously).
2. Press button (1) to ”unlock” the LPU.
As soon as unlocking and pinning has taken place, you can fully
telescope in and the basic position is achieved.
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
70/87 082−1360−82201e_en
(Z 65 189)
State 2: LPU ”locked and pinned”

State 23: LPU ”locked and status change pinning”

1. Activate self−return rocker switch (19), placing the LPU in

front of the pinning position by telescoping (take the telesco-
ping device into consideration).
2. Activate button (4) in order to initiate the pinning procedure.

The corresponding pin extends up to the inner side of the
next largest telescopic section and is lying against it.
3. Activate self−return rocker switch (19), moving the LPU furt-

her in the direction of the pinning position.
When the pinning position is reached, the corresponding pin
retracts into the corresponding pinning hole due to compres-
sive pretensioning (LED “10” is illuminated).
4. Press the rocker switch (19), thus moving the LPU by tele-
scoping into ”Fine position locking” (LEDs ”5” and ”6” are illu-
minated simultaneously).
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1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
72/87 082−1360−82201e_en
(Z 65 189)
State 3: LPU ”locked and unpinned”

1. Activate self−return rocker switch (19), placing the LPU in

front of the pinning position by telescoping (take the telesco-
ping device into consideration).
2. Activate button (4) in order to initiate the pinning procedure.

The corresponding pin extends up to the inner side of the
next largest telescopic section and is lying against it.
3. Activate self−return rocker switch (19), moving the LPU furt-

her in the direction of the pinning position.
When the pinning position is reached, the corresponding pin
retracts into the corresponding pinning hole due to compres-
sive pretensioning (LED “10” is illuminated).
4. Press the rocker switch (19), thus moving the LPU by tele-
scoping into ”Fine position locking” (LEDs ”5” and ”6” are illu-
minated simultaneously).
State 5: LPU ”No information about configuration available”

LED (14) is illuminated in red.
If LED (14) lights up, there is a serious problem in the LPU sensor
system and/or in its power supply. Without this sensor system, it
is not possible to use the emergency control system to operate
the telescopic section.
082−1360−82201e_en 73/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
74/87 082−1360−82201e_en
36.3.10.6 Retraction of the Boom from the LPU to the Basic Po-
sition
(Z 65 189)
In order to ensure that all locking and pinning procedures can be

run through safely, actuate the push−button shown in order to
monitor the reservoir loading pressure. It should be (80−85 bar
/ 1160 – 1233 psi).
If necessary, recharge by actuating the push−button shown until
the required pressure value is reached.
No matter what extension state is, it is necessary for proper tele-
scoping in that all of the extended telescopic sections be telesco-
ped in starting with those having the largest cross−section (smal-
lest telescopic section number) and ending with those that have
the smallest cross−section (highest telescopic section number).
1. After identifying the telescopic section with the largest

cross−section which can be achieved with extended configu-
ration of the LPU, actuate rocker switch (19) and thereby
cause the LPU to extend out until the section identification
display shows that the target telescoping section has been
reached.
Example: telescopic section 3 reached:
LEDs BIT1, BIT 2 and BIT 3 light up in yellow. ”SEC3” is also
shown in the display (16) as an alternative to the Bit code.
2. Once it has been ensured that the correct section has been
reached, continue telescoping until the ”Fine position lok-
king” has been reached (LEDs ”5” and ”6” light up simulta-
neously).
3. Press button (2) to ”lock” the LPU.

Once the locking procedure has been completed success-
fully, the LPU will report back the state ”locked and pinned”.
As long as the button is actuated, the hydraulic cylinder for car-

rying out the ”LPU movement” is pressurised.
Only after the state of the LPU has changed (the corresponding
LED lights up) can the button be released.
082−1360−82201e_en 75/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
76/87 082−1360−82201e_en
(Z 65 189)
4. Press self−return rocker switch (19) briefly in the telescoping

out direction, in order to relieve the pins to the next largest
telescopic section of load. To do so, the LPU must be moved
approx. 5 mm (0.2 in) in the telescoping out direction in order
to achieve the pinning / unpinning position.
If the length measuring device of the LPU is operational it can

be used as an aid.
If the length measuring device is not operational, the adjust-
ment length must be estimated.
5. Press button (3) in order to initiate the unpinning procedure.

Once the unpinning procedure has been completed suc-
cessfully, the LPU reports the state ”locked and unpinned”.
The locked telescopic section is now only attached by the
locking pins.
If the attached telescopic section does not unpin directly, you
must drive back and forth within the millimetre range (approx.
0.1 in) in the telescoping in and out direction using self−re-
turn rocker switch (19) until the pin is relieved of load and un-
pins due to compressive pretensioning.

6. Activate self−return rocker switch (19), bringing the LPU right

up to the pinning ”position by telescoping in 0%”.
If the length measuring device of the LPU is working, the pin-
ning position of the telescopic drive can be derived from the
table of ’Locking and pinning position of the telescopic drive’
in section 12.
If the length measuring device is not working, the pinning po-
sition must be estimated.
082−1360−82201e_en 77/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
78/87 082−1360−82201e_en
(Z 65 189)
7. Activate button (4) to ”pin” the telescopic section, retracting

or extending around the pinning point until the boom section
is pinned.
Once the pinning procedure has been completed success-
fully, the LPU reports back the state ”locked and pinned”.


Once the unlocking procedure has been completed suc-
cessfully, the LPU reports back the state ”unlocked and pin-
ned”. LED (9) is illuminated.
The telescoping in of one telescopic section is completed.

In order to telescope further telescopic sections in, the previously

described steps 1. − 9. must be repeated until the main boom is
completely retracted.
082−1360−82201e_en 79/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
80/87 082−1360−82201e_en
36.3.10.7 Example of manual telescoping procedure

(Z 65 189)
The 1st boom section (telescopic section 1) must be driven out

of the 100% pinning hole into the 0% pinning hole.
Detailed specifications concerning the identification of telesco-

ping sections can be found on page 67.
The current telescoping configuration can be determined from

the LED displays. The telescoping procedure must start on the
basis of this state.
Check the reservoir loading pressure before and during the

telescopic procedure (key 23). If required, recharge key (24)
to approx. 80 to 85 bar (1160 − 1233 psi).
1. Check to make sure that the LPU is currently in the state ”un-
locked and pinned” − the LED (9) must be illuminated.
In this state the LPU can be driven using the self−return rok-
ker switch (19) without a boom section being moved.
2. Once the LPU has been fully retracted, it must be ”extended”

in order to be able to be locked ”as desired” to the fully exten-
ded first telescopic section.
Press rocker switch at (19A) for telescoping extension while
doing so.
The LPU is moved to the 1st telescopic section. As soon as

the LPU has moved into ”Approach position locking”, LED
(5) will light up. Now continue to drive slowly. As soon as
”Follow−up position locking” has also been reached, LED
(6) will also light up. This means that the ”fine position” for lok-
king has been reached.
If the ”Fine position locking” has been bypassed during tele-

scoping extension by too−rapid extending of the telescopic
drive, then the LED (5) will go out again. The LPU is in the
”Follow−up position locking”.
In order to be able to reach ”Fine position locking” again, the

rocker switch now needs to be actuated at (19B) for telesco-
ping in. LEDs (5) and (6) will light up as soon as the fine posi-
tion has been reached.
082−1360−82201e_en 81/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
82/87 082−1360−82201e_en
(Z 65 189)
3. Press button (2) to ”lock” the LPU.
Please make sure you observe the correct order:

First move to the locking position, then Lock!
The locking procedure is completed as soon as the LPU is in the

state ”locked and pinned”. LED (10) is illuminated.
4. Press rocker switch (19A), thereby extending the LPU out

slightly.
5. Activate button (3) in order to ”unpin” the telescopic section.

If required, the LPU must be retracted or extended slightly
using self−return rocker switch (19) until the pinning proce-
dure of the LPU has actually been executed.
Once the unpinning procedure has been completed suc-
cessfully, the LPU reports the state ”locked and unpinned”.
The telescopic section is now just hanging by the locking
pins and can be telescoped in, using the following proce-
dure.
6. Activate self−return rocker switch (19B), telescoping the
LPU locked to the 1st telescopic section from the 100% pin-
ning hole to the 0% pinning hole.
If the length measuring device of the LPU is working, the pin-
ning position of the telescopic drive can be derived from the
table of ’Locking and pinning position of the telescopic drive’
in section 12.
If the length measuring device is not working, the pinning po-
sition must be estimated.
7. Activate button (4) in order to ”pin” the telescopic section.

While doing so, slowly telescope in or out around the pinning
point until the telescopic section is pinned.
Please make sure you observe the correct order:

First move to the pinning position, then pin!
The pinning procedure is completed as soon as the LPU is in the

state ”locked and pinned”. LED (10) is illuminated.
082−1360−82201e_en 83/87
36
1 3
2 4
7
5 8
6 12
9 13
10 14
11
15
16
crane
17 type enable 18
19A
19
19B
20
21 22
23 ON 24
Z 65 189
84/87 082−1360−82201e_en
(Z 65 189)

Once the unlocking procedure has been completed suc-
cessfully, the LPU reports back the state ”unlocked and pin-
ned”. LED (9) is illuminated.
The boom section is pinned to the next larger boom section. The
telescopic drive can be driven freely.
As a result, the sample manual telescoping procedure is in effect

over. Proceed in analogous fashion to telescope the remaining
telescopic sections.
After the completion of the emergency control system and all

electrical connections to the central electrical unit have been re-
stored, the position of all of the individual telescopic sections
must be ”taught” (set and saved) (see section 12 ”Telescoping”
under ”Manual telescoping” ).
The states of the locking and pinning unit are locked against each
other mechanically and cannot lead to critical situations, even if
operated incorrectly.
082−1360−82201e_en 85/87
36
16
18
ON
Z 69 593
86/87 082−1360−82201e_en
36.3.11 Fault Messages

(Z 69 593)
Monitoring element Display Comments (action)

Display message Err0
CAN−BUS – communication between HMI (mobile hand−held
Display (16) control) and the mobile control unit “Master”
Check that the hand−held control is connected to the mobile
“Master” control unit correctly. If required, change cables. Con-
tact a service technician if the fault persists.
CAN bus – communication between master and slave interrupted
Display (16) Check that the components master and slave of the mobile con-
trol unit are connected correctly and that the cables have not
been confused. If required, change cables. Contact a service
technician if the fault persists.
CAN bus – communication between master and slave interrupted
Display (16) (at slave)
Cables between master and slave interchanged. Swap over the
cables. Contact a service technician if the fault persists.
Controller on the wrong interface
Display (16) Controller connected incorrectly. Check the connections. Control-
ler ”Master” must be connected to “X9100” and controller ”Slave”
to “X9101”. Contact a service technician if the fault persists.
Display (16) Different software releases on the Master and Slave of the mo-
bile control unit. Contact a service technician.
The fault messages can be acknowledged by pressing the ”Ena-

ble” key (18).
082−1360−82201e_en 87/87
082−1370−82201_en 1/21
37
Z 83 497
2/21 082−1370−82201_en
37 Emergency Operation (Optional)
37.1 General
(Z 83 497)
Emergency operation means that all the main crane movements

for recovery / deconfiguration can still be carried out even if the
crane engine or a pump fail. To do so, an external emergency unit
(see figure opposite) must take over the supply of the crane hy-
draulics.
The description below refers only to the 50 kW unit which can be

obtained from the crane manufacturer.
Detailed information on this unit which goes beyond the scope of

these operating instructions can be found in the manufacturer’s
documents in part ”Various”. This information must also be obser-
ved.
Danger!
Comply with all safety instructions for emergency opera-
tion which are also valid for normal operation!
Emergency operation must be trained for at least once be-

fore carrying out this special operating mode. The crane
operator must understand / master emergency operation!
Only this will ensure safe operation and rapid handling in
emergency situations.
082−1370−82201_en 3/21
37
1
2.1
2
Z 83 498
10 5
9
7
Z 83 499
4/21 082−1370−82201_en
37.2 Emergency Unit
37.2.1 Intended Use
The emergency unit may only be used for the purpose described
below − emergency operation of a crane.
CAUTION!
The emergency unit may not be used for jump starting the
crane as this could cause damage to the power unit and to
the crane.
37.2.2 Main Components of the Emergency Unit

(Z 83 498, Z 83 499)
A diesel engine drives 3 hydraulic pumps for the 50 kW emer-

gency unit described.
Item Designation
1 Diesel engine (HATZ) − detailed information can be
found in the corresponding manufacturer’s documents
in part ”Various”
2 Junction box
2.1 Park position for control cable plug of the junction box
3 Pumps
4 Operating and monitoring elements, see page 7
5 Serial plate
6 Control cable for speed control lever
7 Hydraulic connections, see page 11
8 External Start−Socket 24V
9 Starter batteries
10 Fuel tank (diesel); filler necks under cover plate
082−1370−82201_en 5/21
37
4.2
4
4.3
4.4
4.5
4.6
4.1
4.7
Z 83 500
4.5
EGR
STOP
EGR
4.6
ehb
Z 83 972
6/21 082−1370−82201_en
37.2.3 Operating and monitoring controls

(Z 83 500)

4.1 Key Ignition switch
0 = off
1 = operation
2 = start
4.2 Indicator light Engine in operation
4.3 Indicator light Charge control
4.4 Indicator light Oil pressure
4.5 Indicator light Engine temperature
4.6 Indicator light Change or clean air filter
4.7 Indicator light Preheating
(Z 83 972)
Indicator lights (4.5)/(4.6) are assigned as listed below for the en-
gine design with exhaust return valve (EGR):
4.5 Indicator light Engine diagnosis
4.6 Indicator light Malfunction in the exhaust gas re-
circulation system
37.2.4 Technical data
In this regard, observe the manufacturer’s documents in part ”Va-

rious”.
082−1370−82201_en 7/21
37
Z 83 497
Z 83 951 Z 83 952
8/21 082−1370−82201_en
37.2.5 Transport and Storage

(Z 83 497)
The emergency unit weighs approx. 850 kg (1874 lbs).
The emergency unit can be transported either by attaching it to

the 4 lifting lugs using the corresponding lifting tackle or with a for-
klift truck.
CAUTION!
When transported using a fork lift truck, the fork lift truck
must grip under the emergency unit in the centre and it must
be moved using appropriate care.
The emergency unit must be protected from the effects of the

weather and contamination using the supplied tarpaulin (in other
words, cover it after every use).
37.3 Connecting the Emergency Unit
(Z 83 951)
1. Set the emergency unit down safely in the area of the corres-
ponding hydraulic connections on the crane chassis (left−
hand side, behind the driver’s cab).
The corresponding hydraulic connections are behind a flap in the

crane chassis trim. The distance between the hydraulic connec-
tions of the crane chassis and the unit must be selected so that
the hydraulic hoses can subsequently be fitted without strain or
stresses.
Length of the connection hoses is 2.50 m / 3.00 m (8.2 ft / 9.8 ft).
(Z 83 951, Z 83 952)
2. Unlock the flap on the crane chassis and fold down.
Tool required: Allen key, 8 mm.
082−1370−82201_en 9/21
37
EGR
STOP
EGR
N ehb
P2
P2 N
P1
P1 P3 A
S2
A
B
S1 S1
S2
B
T
T
P4
Z 83 953
P2 S1
P2
S1
S2
T
S2
P1
N B
N B
Z 89 954
10/21 082−1370−82201_en
(Z 83 953, Z 83 954)
3. Connect the hydraulic lines. No diesel engine (neither unit
nor crane) may be running to do this.
To do so, connect the hydraulic couplings from the emer-
gency unit listed below with the identical ones on the crane.
The hydraulic hoses needed to make the connection are

supplied with delivery.
Due to the different nominal widths (NW) of the individual
couplings, they can be assigned without risk of being confu-
sed or interchanged. In addition, the hoses are marked ac-
cordingly.
Nominal width
Coupling Function
(NW)
P1 Pump P1 16
Pump 4 (control
P2 16
pressure)
Slew gear, functions
B 16
of the crane chassis
T Tank 20
N Anticavitation 25
S2 Suction S2 32
S1 Suction S1 40
Characteristics
Hydraulic coupling ”P3” is connected internally to the emergency

unit and therefore already assigned.
Hydraulic coupling ”A” on the emergency unit is not needed and

remains closed with the cap.
082−1370−82201_en 11/21
37
P2
S1
S2
X4250B
N B
Z 83 973
Z 83 974
12/21 082−1370−82201_en
(Z 83 973)
4. Move the stop valve from the ”open” position (dotted line)
into the locked position (continuous line).
If the stop valve is not placed in the locked position, some of the
oil will flow out and the speed of the crane movements during
emergency operation will be reduced additionally.
After completing emergency operation, the stop valve must

be placed back in the ”open” position for normal operation.
Otherwise, this will cause knocking in the hydraulic system
as there can no longer be any release of pressure.
(Z 83 973)
5. Connect the electric cables.
To do so, move the control cable plug of the emergency unit
junction box out of the park position (see page 5) and plug
into the corresponding socket (X4250B).
(Z 83 974)
The emergency unit is now fully connected − hydraulically and
electrically − with the crane to be driven during emergency opera-
tion.
Hose connections are only partially depicted.
082−1370−82201_en 13/21
37
4.2
4
4.3
4.4
4.5
4.6
4.1
4.7
Z 83 500
1.6
1.1
1.5
1.2
1.4
1.3
Z 69 825
14/21 082−1370−82201_en
37.4 Carrying out Emergency Operation
The crane movements can only be carried out at reduced

speeds during emergency operation. This is why emergency
operation is only for completing crane work which had al-
ready been started or for placing the crane in a safe state.
Emergency operation can be carried out for superstructure func-

tions (such as slewing, telescoping, luffing, raising, configuring
the counterweight and tilting the cab) as well as for functions on
the crane chassis (suspension, outriggers).
Emergency operation is not possible if the crane’s electrical

system is not ready for operation (e.g. if the batteries are di-
scharged).
The crane’s electrical system must first be made ready for
operation.
1. Connect the emergency unit (see from page 9).
Risk of damage!
This must be done before starting the emergency unit motor,
which is described below.
Otherwise, the pumps could run dry.
You must also observe the detailed specifications in the motor

manufacturer ’s instructions in part ”Various” for the points listed
below before, during and after starting the motor.
2. Before first starting the emergency unit motor or if the fuel sy-
stem has been run dry, bleed the system using fuel hand
pump (1.5).
3. Before starting the emergency unit motor, always check the

oil level at oil dipstick (1.1), top up motor oil if required.
082−1370−82201_en 15/21
37
1.6
1.1
1.5
1.2
1.4
1.3
Z 69 825
4.2
4
4.3
4.4
4.5
4.6
4.1
4.7
Z 83 500
16/21 082−1370−82201_en
(Z 83 500, Z 69 825)
4. Start the emergency unit motor. To do so:
4.1. Set the speed control lever (1.2) to 1/2.
4.2. Insert starter key (4.1) up to the stop and set to position
”1”.
Battery charge indicator (4.3) and oil pressure indica-
tor light (4.4) are illuminated.
If temperatures are below 0° C, preheating lamp (4.7)
is also illuminated.
4.3. Start the engine once the preheating display has gone
out. To do so, turn starter key (4.1) to position ”2”.
As soon as the engine is running, release starter key
(4.1).
Battery charge indicator (4.3) and oil pressure indica-
tor light (4.4) must go out immediately after starting up.
The indicator light (4.2) now lights up, indicating that
the engine is running.
4.4. Set the speed control lever (1.2) back to idling.
5. Observe the points listed below after starting the motor:

− Check all hydraulic connections on the emergency unit
and on the crane chassis for leak−tightness. Switch the en-
gine off immediately if there are leaks.
− To achieve the maximum volume flow rate, the speed con-
trol lever (1.2) must be set to full throttle at a later point
when carrying out emergency operation.
− If the motor is equipped with an exhaust return valve
(EGR), a motor malfunction is indicated by one of the cor-
responding indicator lights (not shown here, see page 7)
lighting up. In this case:
Stop engine immediately, determine cause and rectify!
082−1370−82201_en 17/21
37
Z 83 961
Z 83 963
18/21 082−1370−82201_en
6. Set crane control to emergency operation. To do so, switch

on the ignition in the superstructure. This starts the IC−1 au-
tomatically.
(Z 83 961)
7. Select the correct operating mode and actuate the key for
”Main menu” in the ”Crane operation” screen.
(Z 83 961)
8. Press the depicted key in the main menu to switch crane con-
trol to ”Emergency operation”. The key changes in appea-
rance as shown.
In addition, the symbol shown appears in the Crane operation

screen.
Caution!
The function “Emergency operation” must be activated at
the IC−1. Otherwise, no further crane movements can be
made using the control levers of the superstructure cab.
The required crane movements are controlled as during normal

operation. In this regard, refer to the description in the correspon-
ding section.
If only functions on the crane chassis are to be actuated during

emergency operation, control can alternatively also be switched
to emergency operation in the cab of the crane chassis − this sa-
ves you from getting into the superstructure cab. To do so:
1. Switch on the ignition of the crane chassis.
(Z 83 963)
2. Switch on the displayed lockable switches in the cab of the
crane chassis. The fitted indicator light lights up.
082−1370−82201_en 19/21
37
Z 83 963
P2
S1
S2
N B
Z 83 962
20/21 082−1370−82201_en
37.5 After Emergency Operation
1. Switch off the emergency unit motor. To do so, turn the igni-
tion key to position ”0”.
The motor is switched off and the indicator lights go out.
2. Pull out ignition key.
3. Switch off the function ”Emergency operation” on the crane.

To do so, switch off the function ”Emergency operation” at
IC−1 and switch off the ignition.
(Z 83 963)
After emergency operation, only switch off alternative lockable
switches which are displayed on the crane chassis in the cab of
the crane chassis. The built−in indicator light goes off. Switch off
the ignition.
(Z 83 962)
4. Place the stop valve back in the ”open” position.
After completing emergency operation, the stop valve must

be placed back in the ”open” position for normal operation.
Otherwise, this will cause knocking in the hydraulic system
as there can no longer be any release of pressure.
5. Remove hydraulic hoses between the crane and the emer-

gency unit.
6. Disconnect the electrical connection between the crane and

emergency unit.
7. Close all couplings on the crane, emergency unit and hy-

draulic hoses using protective caps.
8. Close all open covers again according to instructions.
082−1370−82201_en 21/21
Assembly Jib 41
082−1410b_en 1/27
41
1322
1040 1810
Z 84 368
2/27 082−1410b_en
Assembly Jib 41
41 Assembly Jib (Optional)

(Z 84 368)
Length Width Height Weight

1810 5.9 1040 3.4 1322 4.3 450 990
Risk of damage!
The assembly jib must always be supported so that the pla-
stic rope sheaves have no contact with the ground.
They are not adequate for taking the weight of the assembly
jib.
082−1410b_en 3/27
41
1a 1
1b
1c
Z 84 369
4/27 082−1410b_en
Assembly Jib 41
41.2 General
(Z 84 369)
The assembly jib (1) is for raising loads with up to 4−fall reeving.
If the crane is equipped with hoist 2, the hook block can remain
reeved on the main boom head.
Assembly jib (1) consists of frame (1a), bracing rods (1b) and
adapter (1c).
The assembly jib can be folded to the side on the main boom for
transport.
The opposite figure shows the assembly jib in the operating posi-
tion.
The assembly jib is marked with the construction number of

the crane. It may only be fitted on the crane with this con-
struction number.
082−1410b_en 5/27
41
28
E2
1c
1a
Z 84 373
6/27 082−1410b_en
Assembly Jib 41
41.3 Fitting and Removal

(Z 84 373)

When fitting or removing the assembly jib, there is risk of

crushing between the main boom head and the assembly
jib!
Pay particular attention to the notes on risks in section
nents” as well as procedure described below.
ment).
1. Support the crane on outriggers, align it and fit the counter-

weight −in accordance with the regulations of the capacity ta-
ble.
2. Remove bracket with anemometer and hazard light (optio-

nal) from the main boom head.
Risk of damage!
If the bracket remains fitted on the main boom head, there is
a risk of collision when fitting the assembly jib in the proce-
dure described below.
3. Guide the hoist rope on the main boom head over run−in
sheave (E2) and reel off a few metres − over the prepared
assembly jib (1).
The assembly jib must be in the depicted ”folded” position for fit-
ting. In this position, adapter (1c) and frame (1a) are pinned on
both sides with pins (28) (and secured).
The rope in the auxiliary winch fitted in the assembly jib may not
be under tension. This would cause a risk of damage to the rope.
082−1410b_en 7/27
41
1c
1
1a
Z 86 841 Z 84 374
1c
Z 84 375
8/27 082−1410b_en
Assembly Jib 41
(Z 86 841, Z 84 374, Z 84 375)
In the following procedure, the assembly jib may not swing

out or dangle at an angle when it is raised.
No−one may be in the area at risk of falling equipment, etc.

as long as the assembly jib is attached to the auxiliary
crane or has not yet been completely pinned!
There are two variants of the front attachment points (Z 86 841).

The illustrations in this chapter show always the top variant. In the
bottom variant, the attachment points are only slightly offset.
4. Attach the assembly jib (1) to the auxiliary crane in the 4 at-
tachment points − as illustrated − and position on the main
boom head in the fitting position and pin. To do so:
4.1 First retract the bottom fork heads of adapter (1c) of the
assembly jib at the bottom head axis of the main boom.
4.2 On both sides, remove the biconical pins (3) from the
transport position, knock in place and secure.
4.3 Proceed in the same manner for the two top pinning
points.
5. Remove the lifting tackle.
The assembly jib is then fitted in the ”folded” position, i.e. at the
four points on the head axes of the main boom. This ”folded” posi-
tion is only for fitting and removing or folding the assembly jib over
to the rear in the transport position.
Risk of accidents!
This ”folded” position may NEVER be used for raising
loads. To do so, the assembly jib must first be brought in
the operating position.
In this case, observe section 41.4 ”Lowering in the opera-
ting position” starting on the following page.
The assembly jib must also be removed in the ”folded” position.

To do so, proceed in the same manner just in the opposite se-
quence.
082−1410b_en 9/27
41
25
1b
Z 84 376 Z 84 396
21
22
1a
28 22
25.1 23
25
25
Z 84 377
10/27 082−1410b_en
Assembly Jib 41
41.4 Lowering in the Operating Position

(Z 84 376, Z 84 377, Z 84 396)
Proceed as described below to lower the assembly jib from the

folded position into the operating position:
1. Release crank (25) from the transport position on the crane

chassis frame.
2. Check that rope (21) of auxiliary winch (22) has been fitted
properly and is taut (as shown in Z 84 377). It will have to
hold the assembly jib in the folded position after the pins (28)
are removed as described in point 3.
3. Unlock and release pins (28) on both sides.
At a later point after lowering the assembly jib, pins (28) can be
pegged and secured without function at this point (park position).
4. Lower assembly jib frame (1a). To do so, fit hook (25.1) of

crank (25) to attachment eyelet (23) of auxiliary winch (22)
and unreel the auxiliary winch rope until bracing rods (1b) of
the frame are fully stretched on both sides.
Risk of damage!
In the operating position of the assembly jib (bracing rods
stretched), loosen the auxiliary winch rope somewhat by un-
reeling it lightly so that it is never placed under load during
assembly jib operation.
The crank hook is best attached to the attachment eyelet of the

auxiliary winch from the front left.
Only after complete lowering is the assembly jib in the operating

position (Z 84 396).
5. Release crank (25) and refit it in the transport position on the

crane chassis frame and secure it (holding fixture).
082−1410b_en 11/27
41
E1 E2
31
32
R2 R1
Z 84 378 Z 84 379
4 3 2
”A”
E1 E1 E1
E2 E2 E2
R2 R2 R1 R2
FR R1 R1
FR FR
FU
3 2 2
3 4
1 2 1 1
U3 U2 FU U3 U2 U3 U2
U1 U1 U1
Z 84 380
12/27 082−1410b_en
Assembly Jib 41
(Z 84 378, Z 84 379, Z 84 380)
6. Pull out both rope guard pins (31) on the head of the assem-
bly jib, let fixed point (32) fold down in the operating position
and reeve the hoist rope.
After reeving, the two rope guard pins (31) must be fitted
again and secured.
7. Feed hoist rope to the rope sheave (R1) of the assembly jib
via intake sheave (E2).
The rope may not be fed via run−in roller (E1) as this would
make the deflection angle of the hoist rope too large. Risk of
damage to the rope.
During reeving, there is a risk that all involved sheaves be-

come entangled and wound up. Proceed with appropriate
caution.
8. Reeve the hoist rope to the hook block (4−ropes, 3−ropes or

2−ropes).

dance with the depicted reeving diagram and the following
table.
device.
example: Hook block type 80, 3−sheave
”A” − Reeving plan direction of sight

E − Intake sheaves on the main boom head
R − Sheaves at the assembly jib
FR − Fixing point at the assembly jib
Num-
ber of Guiding rope over the sheaves
lines
4 E2−R1−U1−R2−U3−FR
3 E2−R1−U2−R2−FU
2 E2−R1−U2−FR
082−1410b_en 13/27
41
R
63
Z 84 381
63
64
Z 84 356
14/27 082−1410b_en
Assembly Jib 41
(Z 84 381, Z 84 356)
9. Fit hoist limit switch(63) with the corresponding shift weight
(3) to the assembly jib. To do so, peg the hoist limit switch to
the respective mandrel on the top section of the assembly jib
on the right−hand side − as shown − and secure with a fore-
lock.

The hoist limit switch (63) fitted on the assembly jib must
be in the functioning state. The restrainer (64) of the hoist
limit switch must not be fitted.
Figure (Z 84 356) shows the hoist limit switch in the functio-
ning state.
This hoist limit switch and its corresponding shift weight can be
used on all additional devices. That is the reason that there is
only one of them for all additional equipment. It may therefore be
required that they be dismantled from a different auxiliary device
in order to be able to be used on the assembly jib.
10. Then fit the shift weight (3) of the hoist limit switch to the hoist
rope of the assembly jib.

point.
082−1410b_en 15/27
41
L: R:
63 63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 84 358 Z 104 165
64
Z 83 987
16/27 082−1410b_en
Assembly Jib 41
(Z 84 358, Z 83 987, Z 104 165)
operation:

the bridged state.
ling down.
082−1410b_en 17/27
41
”X0550”
A
”X0560.1”
A H
Z 84 382
18/27 082−1410b_en
Assembly Jib 41
(Z 84 382)
12. Fit the bracket with anemometer and hazard light (optional)
on the left−hand side on the corresponding thread pins of the
assembly jib adapter.
The bracket can be either fixed or adjustable. For this and for
installation, observe the corresponding description with re-
spect to the main boom head (see section 10 ”Safety equip-
ment” under ”Electrical safety chain”).
13. Connect the assembly jib electrically (close the safety chain):
Distributor box ”X0550” on the main boom head

Connect the cable plug of the assembly jib distribution
box.
The two other connections are assigned as for main
boom operation (see section 10 ”Safety equipment”
under ”Electrical safety chain”).
Distribution box ”X0560.1” on the assembly jib
13.2 Connection ”H”:

Remove the protective cap and connect the hoist limit
switch plug.

Remove the protective cap and connect the air speed
indicator plug.
During operation without the air speed indicator, close

connection ”A” using the protective cap.
Risk of accidents!
During operation without the air speed indicator, adhe-
rence to the permitted wind speeds can no longer be moni-
tored in the crane control screen. In this case, suitable al-
ternative measures must be taken.
The assembly jib is raised in the folded position in the same way
in the opposite sequence.
082−1410b_en 19/27
41
Z 84 383
20/27 082−1410b_en
Assembly Jib 41
41.5 Operation
(Z 84 383)
1. Fit the assembly jib, lower it in the operating position, fit the
hoist rope and reeve the hook block, fit the hoist limit switch
and corresponding shift weight and then connect electrically.
This is described in detail in the preceding pages (starting on
page 7).
2. Select the operating mode (here ”MS” for assembly jib).
3. Select all other parameters in accordance with the actual

crane configuration, which must correspond to the relevant
You will find details on operating mode selection in section 10

”Safety devices”.
082−1410b_en 21/27
41
64
Z 84 384
65
Z 84 385
22/27 082−1410b_en
Assembly Jib 41
41.6 Fold backwards into transport position

(Z 84 384, Z 84 385)
If the assembly jib is not required, it can be folded back to the side
on the main boom head.
There is a risk of crushing between the main boom head

and the assembly jib when folding the assembly jib. Pro-
ceed with appropriate caution.
During the folding procedure, no−one person is permitted
in the area where loads/equipment could fall.
1. Unreeve the hoist rope and reel onto the rope drum.
2. Bring the electric safety chain on the main boom head back
into the state required for main boom operation.
Observe the point ”Electric safety chain” in section 10 “Sa-
fety equipment”.
3. Dismantle the hoist limit switch and corresponding shift

weight (64).
Alternatively, pin the shift weight on the assembly jib in the
transport position (65) and secure.
4. Remove bracket with anemometer and hazard light (optio-

nal).
082−1410b_en 23/27
41
28
Z 84 386
5
6
Z 84 387
24/27 082−1410b_en
Assembly Jib 41
(Z 84 386, Z 84 387)
5. First, raise the assembly jib out of the operating position in

the ”folded” position.
To do so, proceed as described from page 11 for lowering,
but in the opposite sequence.
In the folded position, both elements of the assembly jib are
connected with each other on both sides by pins (28).
(Z 84 386, Z 84 387)
6. Release both biconical pins (3) on the right−hand side and
peg in the park position and secure.
This releases the connection on the right−hand side bet-
ween the assembly jib and the main boom head. In the follo-
wing step, the assembly jib is folded back round the pin con-
nection which is still in place (2 biconical pins) on the left−
hand side.
(Z 84 387)
7. On the left−hand side, unlock coupling pin (5) and remove
from the park position. Otherwise, it would bump into the
transport lock plate on the main boom head during the follo-
wing folding procedure.
After the folding procedure, the holes of plates (6) on the as-
sembly jib and of mounting plate (7) on the main boom head
are flush. The assembly jib can then be locked in the trans-
port position by pinning it with coupling pins (5).
082−1410b_en 25/27
41
Z 84 388
26/27 082−1410b_en
Assembly Jib 41
(Z 84 388)
8. Fasten the auxiliary reeving rope (provided by the customer)

at a suitable point on the left−hand side of the assembly jib.
The assembly jib can be folded from the ground using this
auxiliary reeving rope.
9. Fold the assembly jib back round the pivot point (2 biconical
pins, left−hand side) until the holes of the mounting plates of
the assembly jib are flush with the corresponding hole of the
plate on the main boom head.
Detailed depictions of these plates can be found on page 25.
10. Pin the assembly jib in this position using coupling pin (5) and
secure it.
This secures the assembly jib against folding away from the
main boom head.
11. Remove the auxiliary reeving rope.
The assembly jib is folded back to the front in the assembly posi-
tion and / or lowered further in the operating position in the same
way in the opposite sequence.
082−1410b_en 27/27
Central Lubricating System (Optional) 46
082−1460−82201a_en 1/23
46
”X”
1.0
A
2.2
6.0
5.0
3.2
4.1
3.1
C
2.1
Z 83 560
2/23 082−1460−82201a_en
46 Central lubricating system (optional)

(Z 83 560)
The central lubricating system, consisting of a lubricant pump (A)

with integrated control board, a progressive main distributor (B)
and a progressive subdistributor (C), enables automatic lubrica-
tion of all safety−relevant lubrication points during crane opera-
tion.
Legend ”A − D” for (Z 83 560):

(A) Pump element with control circuit board and safety valve
(B) Progressive main distributor
(C) Progressive subdistributor
(D) Distributor, ball bearing slewing
(“X”) Quick coupling connection, hoist 2
If hoist 2 is not fitted, the lubricating line (9) from the main
distributor (B) must be connected to the return line (R) of the
lube pump using the quick coupling connection (”X”).
Legend ”1.0 − 6.0” to (Z 83 560):

(1.0) Roller bearing slewing rim
(2.1 / 2.2) Main boom foot section bearing
(3.1 / 3.2) Luffing cylinder foot section bearing
(4.1) Luffing cylinder head bearing
(5.0) Winch, hoist 1
(6.0) Winch, hoist 2 (optional)
082−1460−82201a_en 3/23
46
Z 83 569
1 2
P
8 9
3
15 M
4 7 10
5
T
6 11
Z 315 253 Z 315 255
4/23 082−1460−82201a_en
46.1 Fitting Location of the Lubricant Pump

The lubricant pump is on the right−hand side of the crane as

shown opposite.
46.2 Components of the lubricant pump

(1) Pump element

(2) Grease containers
(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 315 255):
(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
082−1460−82201a_en 5/23
46
1 2 P
8 9
3
15 M
4 7 10
5
T
6 11
Z 315 253 Z 315 255
6/23 082−1460−82201a_en
46.3 Function
The lubrication pump automatically supplies the connected lubri-

cation points with grease via the main distributor and the local
subdistributor.
The control circuit board of the lubrication pump controls the pre-
set cycles of pause and operating times.
The sequence of pause and operating times is activated when
the ignition unit in the superstructure is switched on.
The pause time

− determines the time period in which there is no lubrication cy-
cle
(exceptions are possible with additional lubrication impulses
to be carried out manually by pressing button ”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 46.4, page 9.
The pressure limitation valve (safety valve ”3”)

− limits the build−up of pressure in the lubrication system.
− Opens in the presence of unauthorised overpressure.
If lubricant emerges at the pressure relief 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 46.8 ”Malfunctions/Elimination of malfunctions”,
starting from page 17.
082−1460−82201a_en 7/23
46
1 2 P
8 9
3
15 M
4 7 10
5
T
6 11
Z 315 253 Z 315 255
8/23 082−1460−82201a_en
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.
46.4 Setting the Interval and Operating Times
46.4.1 General
(Z 315 255, principle diagram)
The pause and operating times are controlled electronically via

the control circuit board.
The pause time begins its sequence as soon as the ignition unit
in the superstructure is switched on.
When the pause time has expired, the operating time starts,
which is the actual lubrication cycle.
082−1460−82201a_en 9/23
46
P
8 9
15 M
7 10
T
11
Z 315 255
10/23 082−1460−82201a_en
46.4.2 Time Setting

The length of a lubrication cycle depends on the lubrication requi-

rements of the safety−relevant lubrication points.
The pause and operating times are determined at the factory and
are set as follows:
− Pause time: 4 hours
− Switch position, rotary switch blue (8) = 4
− Operating time: 10 minutes
− Switch position, rotary switch red (9) = 5
The pause and operating times are set at the factory .

In order to ensure sufficient lubrication at the safety−rele-
vant lubrication points, it is not permitted to modify the times
that have been configured.
Pause time
If the preset time of 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 10 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.
082−1460−82201a_en 11/23
46
P
8 9
15 M
7 10
T
11
Z 315 255
12/23 082−1460−82201a_en
46.5 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.
Before longer downtimes and before starting the system up

again after longer downtimes, the central lubricating system
must be started again by pressing key (11) so that the bea-
rings can be lubricated again.
082−1460−82201a_en 13/23
46
2
1
Z 315 253
14/23 082−1460−82201a_en
46.6 Manual Lubrication in the Case of an Emergency

If the lube pump fails, the lubricating points can also be lubricated
manually using grease.
To do so, grease is fed into the system via the lubricating nipple
(4) using a grease gun.
46.7 Filling the Grease Container

The grease container (1) is filled via filling nipple (5) up to the
”Max.” marking (capacity = 2 l / 68 oz).
The filling takes place in an appropriate manner with a standard
commercial grease pump or a hand lever press.
The lubricant pump must be put into operation during the filling
procedure (by advance activation of the additional lubrication im-
pulse).
After complete drainage, the lubricant pump can require up to 10
minutes running time to reach maximum flow rate.
The filled grease must be free of impurities and must not

change its consistency over a period of time.
Observe the specifications on the prescribed lubricants in the

”Lubrication and maintenance instructions” (part 3).
082−1460−82201a_en 15/23
46
16/23 082−1460−82201a_en
46.8 Malfunctions/Elimination of Malfunctions
The function of the lubricant pump can be recognised from the outside by the rotation of
the agitator blade (e.g. by initiating an additional lubrication cycle) or by the LEDs of the
control board.
Fault: Lubricant pump motor is not running

Cause Remedy
Electricity supply interrupted. Check power supply / fuses. Rectify malfunc-
tion/if required replace (safety) fuses.
Inspect the line to the plug of the pump/to the
control circuit board.
Fault: Pump is not pumping

Cause Remedy
Container is empty. Fill up case with clean grease, let the lubricant
pump run (initiate additional lubrication) until
lubricant emerges from all lubricating points.
Note: Depending on the ambient temperature
and / or the lubricant, the pump elements can
require up to 10 minutes running time in order
to achieve the full pumping capacity.
Air trapped in the lubricant. Activate additional lubrication impulse. Re-
move outlet screw from the safety valve. The
lubricant must emerge without any bubbles.
Unsuitable lubricant used. Replace lubricant, see lubricant table (”Lubri-
cation and maintenance instructions”, part 3).
Intake hole of the pump element clogged. Remove pump element and examine intake
bore for foreign bodies and remove if neces-
sary.
Pump piston worn. Replace pump element.
Non−return valve in the pump element defec- Replace pump element.
tive or clogged.
082−1460−82201a_en 17/23
46
18/23 082−1460−82201a_en
Fault: different quantities of lubricant at the lubrication points

Cause Remedy
Corresponding valve body was fitted without a Remove valve body and check if there is a
clamping ring. clamping ring. If not, fit a clamping ring.
082−1460−82201a_en 19/23
46
”X”
1.0
A
2.2
6.0
5.0
3.2
4.1
3.1
C
2.1
Z 83 560
20/23 082−1460−82201a_en
Continued: Malfunctions/Elimination of Malfunctions
Fault: Blockage in the progressive system that is connected in series,

see in this connection the lubrication chart (Z 83 560)
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 lubricant pump run

fied by the following characteri- (initiate additional lubrication impulse, see section 46.5,
stics: page 13).
a) Grease leaking from the sa- 2. At the main distributor (B), remove all main lines (G) to
fety valve (A). the subdistributors one after the other. If, for example,
b) The check bolts (if present) grease leaks from all outlets of the main distributor (B)
fitted to the distributor piston when under pressure, the blockage must be found in the
are not moving. lubrication cycle of a subdistributor.
Note:
If there is a blockage in the progressive installation con-
nected in series, the lubrication lines will be under pres-
sure. The plug−in connection parts of the lubrication lines
will be almost impossible to disconnect in such cases.
Pressure on the system is to be relieved by removing the
filling nipple on the safety valve (A).
Caution:
The installation is under pressure. Carefully loosen/
remove the lubrication lines and/or filling nipple.
3. Let the lubricant pump continue to run.
4. Remove all lubricating point lines of the subdistributor (D)
one after the other. If, for example, grease leaks from the
outlet of a distributor when under pressure, the blockage
must be found in the lead of the corresponding outlet or in
the connected bearing.
5. Pump through blocked line/bearing with a hand pump.
Note:
In order to check the individual outlets, leave each outlet
loosened for a longer period of time, as there is only one
stroke per pump rotation. However, several strokes are
required for a complete run of all distributors.
6. Check the safety valve (A), replacing it if necessary.
082−1460−82201a_en 21/23
46
22/23 082−1460−82201a_en
Continued: Malfunctions / Elimination of Malfunctions
Fault: Blockage in the progressive installation connected in series
Cause Remedy
c) Distributor blocked, Exchange distributor or clean as described in the following:
(when a distributor is blocked,
no lubricant emerges at any 1. Remove all hose screw connections.
exit point). 2. Unscrew piston sealing screws.
3. Push out pistons, if possible, using a soft mandrel
(ø smaller than 6 mm / 0.24 in.).
Important note:
The pistons are fitted into the drilled distributor holes. Af-
ter removing the pistons, mark them as per the fitting po-
sition and direction in order to reassemble. They may not
be exchanged during fitting.
4. Thoroughly clean the distributor body in a grease−dissol-
ving cleaning agent and blow through with compressed
air.
5. Using a pin, press the sloped channels (ø 1.5 mm / 0.59
in.) through at the thread ends of the piston bore holes.
6. Clean and blow out distributors again.
7. Assemble distributors. Replace copper washers.
8. If possible, pump oil through the distributor several times
using a hand pump before screwing the hose connecting
screws in place. The pressure in the distributor must not
exceed 25 bar (362.8 psi).
9. The distributor must be replaced if there is a pressure
build−up in excess of 25 bar (362.8 psi).
082−1460−82201a_en 23/23

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Translation

of the Original Operating Instructions

2 Structure of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

7 Supporting the Crane on Outriggers from theCrane Operator’s

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

10.1.6.8.3 Control Lever Assignments (6 Modes) . . . . . . . . . . . . . . . . . . . . . 137

10.6 Electric Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

12.5 Capacities in the Unpinned State . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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

18 Main Boom Extension (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

21 Head Sheave (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

31 Dismantling and Assembly of the Main Boom (Optional) . . . 1

34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

37 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

41 Assembly Jib (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

These operating, lubricating and maintenance instructions are valid

Crane classification Mobile crane

Type of crane Explorer 5800

Construction number ___________________

Manufacturer Terex Cranes Germany GmbH

Among other things, these documents contain operating instruc-

The operating instructions of this crane consists of 4 parts:

At least the operating instructions of the superstructure (part 1)

Please note that the information contained in this manual corres-

In such cases we make every effort to bring your documentation

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

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

Should you discover any mistakes when reading this manual or

Handover of the crane

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 4 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 11 I then find ”Wind speeds” as item 11.1.

HOW do I find the page in section 11?

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

Please note that this option of fast and accurate access to

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

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

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

”Note” is used to indicate an important operation or assembly 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!