Main Boom Extension 18

Main boom extension 18
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18
Detail ”X”
4
”A”
Z 52 773
2/267 250--1--1180--015
18 Main boom extension

(Z 52 773)
The main boom extension is marked with the construction

number of the crane. It may only be fitted on the crane
which bears this construction number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).
The main boom extension may only be installed and re-

moved by qualified personnel who have been instructed
accordingly.
18.1 Important information
- The maximum main boom extension length is 36 m. At this

length, the main boom extension comprises 4 parts:
− intermediate section (1)
− intermediate section (2)
− the basic boom (3)
− the tip section (4).
Details on how to combine the parts of the lattice mast are

contained in chapter 18.2 of these operating instructions.
- Installation and removal as well as crane operation with main

boom extension may only be carried out with the crane on
outriggers.
The reduced outrigger span is only permissible in
accordance with the specifications in the corresponding
lifting capacity tables.
- To assemble the main boom extension, only those bolts may

be used that are cylindrical at one end (refer to item “A” in
detail “X”). Every bolt must be secured by 2 correctly
functioning retaining springs.
Before each pinning procedure these biconical pins should
be greased well.
- To install and to remove the main boom extension, the

superstructure must be rotated in such a way that the boom
is to the rear or at the side (90°).
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18
Z 52 774
Z 52 775 Z 52 776
4/267 250--1--1180--015
- The main boom extension can only be installed or removed

using an auxiliary crane.
- Check that there is no damage to the piping at the lattice mast

components of the main boom extension. If you discover
damaged pipes during a visual inspection then continuing to
work with the main boom extension is prohibited.
- The main boom extension must be attached to the outrigger

span at which the crane is to be subsequently operated.
- The counterweight required for crane operation must be fitted

before attaching the main boom extension to the
superstructure.
- If the crane is equipped with a hinged head roller or a runner

then these must be removed before fitting the main boom
extension or, in the case of a head roller, must alternatively
be folded into transport position.
- Crane operation with the main boom extension can be done

below 0° or in folded position. The maximum angle between
the main boom and the main boom extension is 40°. The
angle can be set infinitely variable via two adjusting cylinders
(5) fitted to the basic boom (Z 52 774). The hydraulic
pressure of these adjusting cylinders is supplied using a
HATZ diesel engine (Z 52 775) installed in the basic boom.
The adjusting cylinders are extended and retracted via the
IC--1 display in the crane cab or via a mobile control panel
(Z 52 776).
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18
6
7
3
Z 52 778 Z 52 779
“X”
10
8
11
9
8
10
11 “Y”
10
1--(2)
Z 52 780
6/267 250--1--1180--015
- Before fitting the main boom extension on the main boom, the
rotor of the anemometer and the air traffic control light at the
main boom head must be removed. Risk of damage! (Z
52 778)
- For all lengths of the main boom extension, the hoisting rope
must be moved over the rope idler (6) attached to the basic
boom (3) when reeving. (Z 52 779)
This rope idler is hinged and must be swung open from
transport position to working position before reeving. This is
achieved by extending a hydraulic erecting cylinder that is
supplied with pressure by the HATZ diesel engine (7).
You can find the folding procedure for this rope idler in section
18.6.2 “Preparation of the rope idler and the top rollers before
reeving”, as from p. 173 of these operating instructions.
- For a main boom extension length of 28 m or 36 m, during the

reeving process, the hoist rope must be lead through a top
roller (8) attached to the intermediate section (2) or
intermediate connections (1) and (2) (Z 52 780).
To make sure that the hoist rope can be pulled through, the
corresponding top roller must be unlocked.
To do this, release and tighten the bolts (9), loosen the stop
bolt (10) (refer to detail “X”) and swivel up the rocker arm (11)
(refer to detail “Y”). You can find the tensioning of the rope
after reeving as well as the rope guide between hoist and
main boom extension head for all operating lengths in
sect. 18.6 “Reeving the hoist rope”, as from p. 163.
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18
3
4
Z 52 781
Z 52 782 Z 55 245
8/267 250--1--1180--015
- When moving the crane or during crane operation at the main

boom, the basic boom (3) or the basic boom (3) and the tip
section (4) can be folded laterally at the main boom basic
case (Z 52 781).
Intermediate sections (1) and (2) must be transported
separately.
When moving the crane, the permissible axle load must be

observed (refer to the operating instructions of the crane
chassis, part 2, section 6).
When moving the crane with the main boom extension
folded onto the main boom, the axle loads exceed 12 t
(”Technical drivability”).
“Technical drivability” is only permitted on construction
sites or private roads.
When lifting a load when the main boom extension is folded
into transport position, then minimum loads must be
calculated. You can find these minimum loads related to the
main boom length and configuration of the main boom
extension (basic boom “3” / tip section“4” or basic boom “3”
and tip section“4” folded in) in the minimum load table in the
“Instructions for crane operation”, that were supplied
together with the load capacity tables.
You can find the attachment of the main boom extension for
separate transport in sect. 18.4.
You can find the folding procedure for the main boom extension
from working to transport position in sect. 18.5.3, as from p. 125.
You can find the folding procedure for the main boom extension
from transport to working position in sect.18.5.2, as from
page 87.
- Folding and pulling up the main boom extension onto the

run--up rails (Z 52 782) as well as locking it to the swivel
bearing is achieved by means of a hydraulic cylinder. The
designation of this cylinder corresponds to the positions (“1”
to “4”) at the mobile control panel.
Example (Z 55 245): Before the cylinder (1) is extended or
retracted, the preselector (8) at the mobile control panel must
be brought to position “1”.
Actual swivelling from transport position to working position
is done manually using an auxiliary rope.
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18
72 Z 54 285
”X”
12
5 HA
”C”--13 ”C”--13
3 5
3
2
”D”--12 ”A”
”Y” 12
”A”--12
13
Z 54 286
10/267 250--1--1180--015
- To enable all assembly work to be carried out as safely as

possible, a ladder is supplied as standard with the vehicle. It
is not permitted to climb or walk on the main boom extension.
The folding/sliding ladder (72) delivered with the machinery
is fixed below the basic boom 3. This ladder must be removed
from the basic boom before attaching the main boom
extension and/or before folding from transport position into
working position (Z 54 285).
- Before the main boom is extended with the main boom

extension attached in working position, the main boom must
be moved to steep position (angle > 78°) and the main boom
extension must be at an angle of 0° to the main boom.
This also applies when extending and retracting the
telescope of the main boom.
If the main boom is not raised to steep position, then
extending or retracting is not permitted. The load limit device
switches off. This lower deviation of the minimum permissible
luff angle is then indicated. The main boom must then be
made steeper.
- The main boom extension is folded depending on the working

length at the main boom head (HA) or at the intermediate
section (2). Please also note the details in chapter 18.2
(Z 54 286).
The bottom bolt joints are always closed using biconical pins
(12) in item (”A”, left side) and item (”D”, right side). These
pins must each be secured by two retaining springs (refer
also to detail “X”).
Regardless of the working angle of the main boom extension
(0° to 40°), the upper bolt joints of the inclinable basic boom
(3) must be closed with the intermediate section (2) / main
boom head (HA) with coupling pins (13) at points “C” (left
side) and “F” (upper right side). These coupling pins connect
the piston rod of the luffing cylinder (5) to the corresponding
straps at the main boom head (HA) or at the intermediate
section (2). These pins must each be secured by one
retaining spring (refer also to detail “Y”).
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18
1 ”B”--12 1 ”B”--12
I II
”A”--12 ”A”--12
”B”--12
III
2
”E”--12
1
”A”--12
”D”--12
”E”--12
IV
”B”--12
4 3
”A”--12
”D”--12
Z 54 287
12/267 250--1--1180--015
- The connecting of:

− the intermediate sections (1) and (2) to the main boom
head (figures I and II),
− the intermediate section (2) to the intermediate section (1)
(figure III)
− and the tip section (4) to the basic boom (3), (figure IV)
is always done using 4 biconical pins (12) at points “A”, “B”,

“D” and “E”(Z 54 287).
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18
14/267
36m
4 3 2 1
9104 10808 8000 8000
35912
28m 4 3 2
9104 10808 8000
27912
20m 4 3
9104 10808
19912
10.4m 3
10377
10808
Z 52 777
250--1--1180--015
18.2 Combination of the various components
The main boom extension can be used in the following lengths:

-- 10.4 m / : Basic boom (3)
34.1 ft
-- 20 m / : Basic boom (3) + tip section (4)
65.6 ft
-- 28 m / : Intermediate section (2) + basic boom (3) + tip
91.9 ft section (4)
-- 36 m / : Intermediate section (1) + intermediate section
118.1 ft (2) + basic boom (3) + tip section (4)
The possible combinations are contained in the drawing

(Z 52 777)
The length and the weight of the individual parts are contained
in the diagram shown here as well as in the following table:
Part Designation Length (mm) Approx.

no. weight (kg)
1 Intermediate sec- 8 000 655
tion
2 Intermediate sec- 8 000 900
tion
3 Basic boom 10 808 1690
4 Tip section 9 104 720
Work can be carried out for every main boom extension length at
an angle of 0° to a maximum 40°. The angle of inclination is
always set at the basic boom (3).
For main boom extension lengths of 10.4 m and 20 m, the offset

is set at the main boom head.
For main boom extension lengths of 28 m and 36 m, the offset is

set at the intermediate section.
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18
2000 2640
1 ”a” ”b”
”X”
8000
2000 3810
2 ”a” ”b”
8000
3035
1995
5405 1035
3 ”a” ”b” ”c” ”d”
10377
1800 3000
4 ”a” ”b”
9104
4 ”a” ”c”
3 ”b”
Z 55 246
16/267 250--1--1180--015
18.3 Attachment points

(Z 55 246)
The main boom extension is comprised of various

subcomponents. 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.
The parts must not swing out or dangle at an angle when they
are raised.
The length and the weight of the individual components are

described in chapter 18.2 “Combination of the various
components”.
Select the auxiliary crane and the securing equipment
accordingly.
Part Designation Slinging points

no. ”a” ”b” ”c” ”d”
1 Intermediate section x x
2 Intermediate section x x
3 Basic boom x x
4 Tip section x x
3+4 Basic boom x x x
+ tip section
The basic boom (3) has 4 slinging points.

If only the basic boom is attached, then slinging points “b”
(left side) and “d” (right side) should be used.
If the basic boom (3) is attached with the tip section folded
in transport position, then the slinging points “a” (right side),
“b” (left side) and “c” (right side) at the basic boom (3)
should be used.
To ensure that this transport combination is horizontal, 2
chains of the 3--line--suspension gear must be shortened.
For this reason we suggest that shortening claws be
attached to two of the three suspension chains (refer to
detail “X”).
The securing equipment must be supplied by the customer.
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18
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18.4 Attaching the main boom extension
If the main boom extension has been transported separately, you

can fit it using an auxiliary crane.
When assembling or removing the main boom extension

components, there is a risk of crushing
* when the individual components are joined / separated!
* between the main boom head and components to be
attached there.
Therefore, no--one should be in the danger area. In particu-

lar, you should take note of the warnings in section 1.4.8,
”Assembling and dismantling crane components” and the
procedures described below.
All assembly work must be carried out using suitable
equipment (ladders, lifting platforms, frames, auxiliary
crane).
If work can not be carried out using such equipment or from
the ground then the assembly personnel must be protected
by suitable means (e.g. safety belt) against the RISK OF
FALLING!
During assembly/disassembly, no--one must be present

under suspended loads or in the area where there is a dan-
ger of falling.
Select the auxiliary crane and securing equipment in such

a way that the load bearing capacity clearly exceeds, or is
sufficient for, the weight of the component to be installed
or removed in order to lift the components to be installed
or removed within the required working radius.
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18
5 5
13
Z 52 785 Z 52 787
“X”
10
Z 52 786
20/267 250--1--1180--015
18.4.1 Before fitting

To fit the main boom extension, the following conditions must be
complied with:
− The crane must be on outriggers and horizontally aligned.
− Slewing gear brake locked.
− The main boom should be completely retracted, locked and
in horizontal position
− The required counterweight should be attached for crane
operation
− The bottom hook block should be unreeved and the switching
weight of the lifting limit switch at the main boom head should
be placed in transport position and secured (Z 52 787)
− Completely retract the adjusting cylinder (5) at the basic
boom (3) and remove the coupling pins (13) (Z 52 785)
− Ensure that the top and bottom pulley shaft at the main boom
head is in horizontal position. In the case of the bottom shaft,
also make sure that the chamfer part points forwards (refer
to detail “X”, Z 52 786).
− The stop bolt (10) at the lower--left fork head of the basic
boom (3) should be in “released” position (as shown in
diagram “Z 52 786”)
− There should be no biconical pins fitted to the fork heads at
the foot of the basic boom (3).
− Folding/sliding ladder released and removed from the basic
boom (3).
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18
20
Z 54 256
22
21
Z 54 257
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18.4.2 Fitting the 10.4 m main boom extension
The 10.4 m main boom extension is comprised only of the

basic boom (3).
The tip section (4) is dismantled from the basic boom for the
assembly described in this chapter. If work is to be carried
out with a main boom extension length of 20 m, details of the
assembly of the tip section may be found in sect. 18.4.3 of
this operating manual.
If the tip section (4) is attached to the basic boom (3) in
transport position, the tip section must be attached to the
20m main boom extension in working position for crane
operation. This folding procedure is described in chapter
18.5of these operation manual.
To attach the 10.4 m main boom extension, proceed as follows:
1. Check the following filling quantities at the ”power pack”:

− the engine oil level using the dip stick (20, Z 54 256).
You will find the procedure in the operating instructions for
the HATZ diesel engine in part 5 of this documentation.
− the hydraulic oil level at the oil--level gauge (21, Z 54 257)
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 filter,
top up the oil and screw the cover back on.
Also observe the lubrication and maintenance guidelines
for the superstructure in part 3 of this documentation.
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18
”X”
”Y”
Z 52 788
Z 52 789 Z 55 244
24/267 250--1--1180--015
2. Remove the biconical pins from the transport bracket on the

basic boom (Z 55 244).
3. Tie down the auxiliary crane (two--fall) at the appropriate

eyelets of the basic boom (3) (”X”,Z 52 788).
With the tip section folded in transport position, a 3--fall lift-

ing tackle is required.
Slinging points: see chapter 18.3 of these operating instructions,

page 17.
4. Raise the basic boom with the auxiliary crane and move into
locking position at the main boom head (”Y”, Z 52 788).
Risk of crushing.
There is a risk of crushing between the main boom head
and the basic boom! Proceed with appropriate caution.
No--one must be present under suspended loads or in the
area where there is a danger of falling.
The auxiliary crane must be able to hold the load until the
bolting at all locking points has been completed.
5. Now make a visual check that the bore holes of the lower fork
heads are aligned to the bores of the pulley shaft of the main
boom head (Z 52 789).
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18
”X”
12
”A”
3
Z 52 790
26/267 250--1--1180--015
6. Establish a bottom connection between the main boom head

and the basic boom (3) via the lower fork heads ”A” and ”D”
using the 2 biconical pins (12). Secure each of the biconical
pins with 2 retaining springs (Z 52 790).
When carrying out such installation work at a certain

height, use the supplied installation ladder or a suitable al-
ternative (e.g. lifting platform). Be sure that the device used
provides solid and safe footing.
The use of biconical pins ensures that the pins can always
be driven downwards from above during assembly and dis-
assembly. In order that the pins can not be knocked
through unintentionally, thereby creating a risk of acci-
dents, the upper locking spring has to be inserted and se-
cured before the pins are inserted. When the bottom lock-
ing hole is visible, insert the second retaining spring and
then close (refer to detail ”X”, Z 52 790).
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18
”F”--13
”C”--13
5
3
Z 52 793
”E”--12
”X”
”E”
Z 52 794
28/267 250--1--1180--015
7. After you have ensured that the bolting at the bottom has
been correctly established, now make the top connection
between the main boom head (3) and the basic boom
using the piston rods of the adjusting cylinders.
If the bolting at the top is made via the piston rods of the adjusting
cylinders (5) then the crane can be operated both in a non--folded
condition (0° position) as well as in folded condition (0° --40°
position). The piston rods of the adjusting cylinders are extended
via the HATZ diesel engine and pegged and secured at points “C”
and “F” with coupling pins (13) (Z 52 793).
To do this pinning, proceed as follows:
7.1 Make a visual check that the bore holes of the upper
fork heads are aligned to the bore holes of the pulley
shaft of the main boom head.
Before the piston rods are pinned to the main boom head, the
basic boom (3) must be pinned on one side to the main boom
head via fork head “B” or “E” using a biconical pin (12).
Only then can you be sure that the angle between main boom
and main boom extension is 0° thereby ensuring that the
piston rods are extended correctly in their head bearing. The
basic boom is also sufficiently secured against tilting.
7.2 Example (Z 52 794)

Establish a connection between the main boom head
and the basic boom (3) via fork head ”E” using a
biconical pin (12). Secure each of the biconical pins
with 2 retaining springs (refer to detail ”X”).
be driven downwards from above during assembly and dis-
cured before the pins are inserted. If the lower locking hole
is visible, insert and secure a second locking spring.
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18
”X360”
”A”
Z 52 795
”X360”
”B”
Z 52 796
30/267 250--1--1180--015
Because the basic boom of the main boom extension is now

connected to the main boom head at 3 points with biconical pins
(bottom left and right / top right), the piston rods of the adjusting
cylinder (5) can be extended. The piston rods are extended and
retracted by the HATZ diesel engine. To start the engine, the
electrical connection must first be established between basic
boom and main boom head as well as within the basic boom.
Proceed as follows:
7.3 Establish the electrical connection between the

distribution box ”X 360” in the foot of the basic boom
and the distribution box ”X 550” at the main boom head
(connection ”A”, Z 52 795).

distribution box ”X 365” in the head of the basic boom
and the distribution box ”X 360” in the foot of the main
boom (connection ”B”, Z 52 796).
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18
Z 52 775 Z 52 776
”X360”
”G”
”C”
Z 54 223
32/267 250--1--1180--015
The adjusting cylinder is supplied with pressure by the HATZ

diesel engine (Z 52 775); the control for extending and retracting
the piston rods is at the mobile control desk (Z 52 776).
7.5 Connect the mobile control panel at the socket ”X 360”

to the distributor box at the foot of the basic boom and
check at the same time that the connection between
socket ”G” and the HATZ diesel motor is established
(Z 54 223).
7.6 Start the HATZ diesel engine (Z 52 775).
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 area 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 part 5 of these operating
instructions. Pay special attention to the chapter ”Important
information on operational safety at the engine”,
”Operating” and ”Maintenance”.
Depending on the ambient temperature of the “power pack”

(below 0° C), the engine is preheated automatically.
For a cold start of the engine, it is preheated at 0° C automatically
up to --20° C for maximum 2 minutes. Below --20° C the
preheating time is 2 minutes. Preheating continues during
start--up. The starting 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 s 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
preheating procedure, the starting procedure is terminated.
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18
9B
9A
Z 52 775 Z 200 113
Z 54 288
34/267 250--1--1180--015
To start the engine, proceed as follows:

− Switch on the ignition at the ignition lock (62) in the crane
cab.
Starting and operating the HATZ engine (and therefore the

operation of the adjusting cylinders) is only possible if the ignition
is switched on.
− Switch the selector switch (8) at the mobile control panel

to ”3” position and press the rocker switch (9A) (starting
impulse) -- the starting procedure begins. If temperatures
are above 0° C, the engine must start up (Z 200 113 and
Z 52 775).
In the event of low outside temperatures, it could happen that the

engine does not ignite immediately when the switch (9A) is
actuated. In that case, there will first be a glow start before the
engine is started.
The preheating time is maximum 2 min., the starting time 7 s (see
also information on p. 33).
7.7 Extend the adjusting cylinder (5) carefully until the bore
hole of the right piston rod aligns with the bore hole of
the corresponding strap at the main boom head
(Z 54 288).
If required, correct the pinning position slightly using
the auxiliary crane.
To extend the piston rod, switch the selector lever (8)

at the mobile control desk to ”1” position and press the
rocker switch (9A) until the locking position has been
reached (Z 200 113).
First pin the piston rod at the side where the main boom head and
the basic boom are pinned via the fork head by a biconical pin (in
this example it is the right side).
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18
31 ”F”--13
Z 54 289
32 32
“Y”
“X”
31 30
Z 54 290
36/267 250--1--1180--015
7.8 Insert the coupling pin (13) at point “F” on the right side
from the outside to the inside and secure with a locking
spring (Z 54 289).
If, during this pinning procedure, there are differences in level

between the pinholes of the mounting links on the main boom
head and the piston rods, then you can use the supplied
eccentric (30, Z 54 290) for level compensation.To do this,
proceed as shown in figure (Z 54 290, Z): The rope securing pin
(31) must be moved accordingly to the left or right, so that the
eccentric can be engaged (detail “X”)!
If, when the basic boom (3) is attached to the intermediate
section (2), there are also level differences at the pinning holes,
proceed in the same way. The eccentric (30) must be engaged
at the transverse tube (32) of the attached straps (detail “Y”).
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18
”F”--13 ”X”
”E”--12
Z 54 291
”F”--13
”C”--13
5
Z 55 227
38/267 250--1--1180--015
7.9 As the piston rod of the right--hand adjusting cylinder

(5) is correctly pinned to the main boom head at point
“F” with the coupling pin (13), the biconical pin (12) at
point ”E” can and must be removed (see detail “X”,
Z 54 291).
To do so loosen the upper locking spring and drive out
the pin (12) in a downward direction.
There is a DANGER OF ACCIDENTS when driving out the

bolt. Make sure that nobody is in the danger--zone.
7.10 Now extend or retract the piston rod of the left--hand

adjusting cylinder (5) until the bore hole of the piston
rod is in alignment with the bore hole of the
corresponding strap at the main boom head (Z 55
227).
To do so proceed in the same way as for positioning the
piston rod on the right side.
7.11 Insert the coupling pin (13) at point ”C” from the outside
to the inside and secure using retaining springs.
(Z 55 227)
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18
Z 54 200
40/267 250--1--1180--015
7.12 As the main boom extension is now correctly pinned to

the main boom head, insert the one remaining
biconical pin in the assigned transport retainer and
secure it (Z 54 200).
Check once more that the basic boom is connected to the 4

points of the main boom head and that the 3rd biconical pin
is engaged in the assigned transport retainer and not in a
fork head of the upper belt tube.
7.13 Release the auxiliary crane from the main boom

extension.
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18
6 6
Z 55 222
”X360”
9B
”C”
9A
Z 52 797 Z 200 113
42/267 250--1--1180--015
8. Because when reeving the hoist rope the rope is always

guided over the rope idler attached to the basic boom, the
roller (6) must be released from transport position before
reeving and folded up slightly (Z 55 222).
You can find the raising of the rope idler (6) for reeving the hoist
rope in sect. 18.6.2.1 “Preparation of the rope idler”, as from
p. 173 of these operating instructions.
9. Switch the selector switch (8) at the control desk into position
”3” and press the rocker switch (9b) until the HATZ diesel
engine stops (Z 200 113) and then switch off the ignition in
the crane cab.
10. Remove the mobile control desk from socket ”C” at the
distribution box ”X 360” in the foot of the basic boom and
close the socket with a protective cap (Z 52 797).
If the mobile control panel is not removed, then the functions

required for crane operation with main boom extension will
not be possible from at the crane cab.
11. Move hoisting rope to the head of the main boom extension
and reeve in the bottom sheave.
You can find the reeving of the hoist rope in sect. 18.6 “Reeving
the hoist rope”, as from p. 163 of these operating instructions.
250--1--1180--015 43/267
18
20
19
“X”
21
Z 54 210
23
22
Z 54 211
44/267 250--1--1180--015
12. Fit the aircraft warning light (19) as well as the rotor (20) of
the anemometer at the head of the main boom extension
(Z 54 210).
The rotor is inserted in the appropriate holder and the locknut (21)
is screwed onto the thread of the base part of the rotor and
securely tightened (refer to detail “X”).
13. If not fitted, attach the lifting limit switch (22) as well as the
switching weight (23) to the head of the main boom
extension (Z 54 211).
250--1--1180--015 45/267
18
24
24 ”b”
24
”a”
Z 54 212
D 20
19
25
22
Z 54 213
46/267 250--1--1180--015
14. If the outrigger feet (24) are still in position “a”, they must be
released and pushed up to transport position “b”.
Secure both outrigger feet with linch pins (Z 54 212).
15. Close the electrical safety chain at the distribution box ”X

365” in the head of the basic boom (3). To do this (Z 54 213):
15.1 Establish the connection between the plug socket (D)

and the hoist limit switch (22).
15.2 Establish the connection between the plug socket (E)

and the air traffic control light (19).
15.3 Establish the connection between the plug socket (F)

and the rotor (20) of the anemometer.
If there is no air traffic control light, then the plug socket (E)
must be closed by a protective cap (as shown in the adjacent
diagram).
If there is no anemometer then the plug socket (F) must

always be covered by a dummy plug (25).
The bus shutoff system is integrated into this dummy plug.
250--1--1180--015 47/267
18
3
4
”X”
4
10
”Y”
”Z”
Z 55 247 Z 55 248
48/267 250--1--1180--015
18.4.3 Fitting the 20 m main boom extension

The 20 m main boom extension consists of the basic boom (3)
and the tip section (4).
Since the 10.4 m basic boom is attached to the main boom head
(as described in sect. 18.4.2), the tip section (4) can be attached
as follows:
RISK OF ACCIDENTS!
The fitting of both parts (3) and (4) in straight condition side
by side is prohibited!
1. Check that the stop bolt (10) is located at the bottom left fork
head of the basic boom (3) in the ”released” position (as
shown in figure “Z 55 247”, detail “X”).

tip section (Z 55 248).

eyelets of the tip section (4) (”Y”,Z 55 248).
Slinging points: see sect. 18.3 of these operating instructions,

page 17.
4. Raise the tip section with the auxiliary crane and move into
locking position at the basic boom (”Z”, Z 55 248).
Risk of crushing.
There is a risk of crushing between the basic boom and the
tip section. Proceed with appropriate caution.
No--one must be present under suspended loads or in the
5. Now make a visual check that the bore holes of the straps of
the tip section (4) are aligned with the bore holes of the pulley
shaft of the main boom head (3) (Z 55 247).
250--1--1180--015 49/267
18
12
12
4 3
12
Z 54 220
20
4 19 “X”
21
22
Z 54 221 Z 54 222
50/267 250--1--1180--015
6. Join the basic boom (3) and the tip section (4) using four
biconical pins (12). Secure each biconical pin with 2 locking
springs (Z 54 220).

be struck downwards from above during assembly and dis-
7. Loosen the hoist limit switch (22) and the shift weight at the
head of the basic boom and attach them to the head of the
tip section (4) (Z 54 221).
8. Move hoisting rope 1 to the head of the tip section and reeve
in the bottom sheave.
You can find the reeving of the hoist rope in sect. 18.6 “Reeving
the hoist rope”, as from p. 163 of these operating instructions.
9. Fit the aircraft warning light (19) as well as the rotor (20) of
the anemometer to the head of the tip section (Z 54 222).
The rotor is inserted in the appropriate holder and the locknut (21)
is screwed onto the thread of the base part of the rotor and
securely tightened (refer to detail “X”).
250--1--1180--015 51/267
18
”X371” D
25
4
Z 54 224
”X371” 20
19
H
K
22
25
4
4
Z 54 225
52/267 250--1--1180--015
10. Arrange the distributor box ”X 365” in the head of the basic
boom (3) as follows: (Z 54 224):
10.1 Unplug the hoist limit switch plug from socket (D) and
plug jump connector plug into the socket.
10.2 Unplug the aircraft warning light plug from socket (E)
and close the socket with a protective cap.
10.3 Unplug the socket of the anemometer or the blind

socket (25) from the socket (F) and establish electrical
connection between the distributor box ”X 371” in the
head of the tip section (4) and the socket (F).
11. Close the electrical safety chain at the distribution box ”X

371” in the head of the tip section (4). To do this (Z 54 225):
11.1 Establish the connection between the plug socket (H)

and the hoist limit switch (22).
11.2 Establish the connection between the plug socket (I)

and the air traffic control light (19).
11.3 Establish the connection between the plug socket (K)

and the rotor (20) of the anemometer.
If there is no air traffic control light then the plug socket (I)
must be closed by a protective cap (as shown in the adjacent
diagram).
If there is no anemometer then the plug socket (K) must

always be covered by a dummy plug (25).
The bus shutoff system is integrated into this dummy plug.
250--1--1180--015 53/267
18
2 12
12
Z 54 226 Z 54 228
“X”
Z 54 227
54/267 250--1--1180--015

The 28 m main boom extension consists of the intermediate
section (2), the basic boom (3) and the tip section (4) (Z 54 226).
The intermediate section (2) is pinned to the pulley shafts of the
main boom head using four biconical pins (12).
To attach the 28 m main boom extension, proceed as follows:
1. Ensure that the top and bottom pulley shafts at the main
boom head are in horizontal position.
For the bottom shaft, also make sure that the chamfer part
points forwards (refer to detail “X”, Z 54 227).

intermediate section (2) (Z 54 228).
250--1--1180--015 55/267
18
2 ”X”
”a”
2 2 ”Y”
Z 54 229
Z 54 230
56/267 250--1--1180--015

eyelets of the intermediate section (2) (”X”,Z 54 229).
Slinging points: refer to chapter 18.3 of these operating

instructions, page 17.
One intermediate section (2) differs from another intermediate

section (1) at the following points (see detail ”a”, Z 54 229):
− additional attachment plates at the upper boom tubes for
pinning the piston rods of the luffing cylinder.
− additional lateral axis at the lower boom tubes for pinning the
basic boom.
4. Raise the intermediate section with the auxiliary crane and

move into locking position at the main boom head (”Y”, Z 54
229).
When attaching the intermediate section (2), take care to

ensure that the top roller (8) is directed towards the main
boom head.
Risk of crushing.
There is a risk of crushing between the intermediate sec-
tion and the basic boom. Proceed with appropriate caution.
No--one may be present under suspended loads or in the
heads are aligned to the bore holes of the pulley shaft of the
main boom head (Z 54 230).
250--1--1180--015 57/267
18
2 ”X”
12
”A”
2
12 ”D”
Z 54 231
12
2 12
”E” ”B”--12
”X”
”B”
”A”
2
12 ”D”
12
Z 54 232
58/267 250--1--1180--015
6. Establish a bottom connection between the intermediate

section and the basic boom (2) via fork heads ”A” and ”D”

then close (refer to detail “X”, Z 54 231).
been correctly made, now establish the top connection
between the intermediate section head and the basic boom
using the fork heads (Z 54 232).
7.2 Establish a top connection between the intermediate

section and the basic boom (2) via fork heads ”A” and
”D” using the 2 biconical pins (12). Secure each of the
biconical pins with 2 retaining springs (refer to detail
“X”).

250--1--1180--015 59/267
18
2
3 10 20
Z 54 233
Z 54 234
60/267 250--1--1180--015
Since the intermediate section (2) is now properly corrected to

the main boom using four biconical pins, the basic boom (3) can
be pinned to the intermediate section (2).
This section deals with the removal of the tip section from
the basic boom (3) and its separate assembly.
If the tip section (4) is attached to the basic boom (3) in
transport position, the tip section must be attached to the
28m main boom extension in working position for crane
operation. This folding procedure is described in section
18.5.2.3117of these operation instructions.
RISK OF ACCIDENTS!
The fitting of both parts (3) and (4) in straight condition side
by side is prohibited!
Proceed as follows to attach the basic boom (3) to an

intermediate section (2):
8. Check that the stop bolt (10) located at the bottom left fork
head of the basic boom (3) is in the ”released” position (as
shown in figure ”Z 54 233”).
9. Check that the lower axle (20) on the intermediate section (2)
is in horizontal position and that the chamfered part points
forwards (as shown in figure ”Z 54 233”).
10. Remove the biconical pins from the transport retainer at the
basic boom.

eyelets of the basic boom (3) (Z 54 234).
With the tip section stowed in transport position, a 3--fall

lifting tackle is required.

250--1--1180--015 61/267
18
2
3
Z 54 235
”X”
2
3 ”A”--12 ”D”--12
Z 54 236
62/267 250--1--1180--015
12. Raise the tip section with the auxiliary crane and move into
locking position at the intermediate section (2) (Z 54 235).
Risk of crushing.
bolting at all locking points has been completely termi-
nated.
heads are aligned to the bore holes of the transverse shaft
of the intermediate section (2) (Z 54 235).

section (2) and the basic boom (3) via fork heads ”A” and ”D”

250--1--1180--015 63/267
18
5
3
”C”--13
”F”--13
5
”B”
”E”
Z 52 791
”C”--13
Z 54 238
64/267 250--1--1180--015
15. After you have made sure that the bolting at the bottom has
between the intermediate section (2) and the basic boom (3)
using the piston rods of the adjusting cylinders.
If the bolting at the top is made via the piston rods of the adjusting
cylinders (5) then the crane can be operated both in non--folded
condition (0° --position) as well as in folded condition (0° --40°
position). The piston rods of the adjusting cylinders are extended
via the HATZ diesel engine and pegged and secured at points ”C”
and ”F” with coupling pins (13) (Z 52 791 and 54 238).
Proceed here in the same manner as described in sect. 18.4.2

”Fitting the 10.4 m main boom extension”, page 29, Item 7..

250--1--1180--015 65/267
18
”X359”
”A”
2
Z 54 239
”X360”
”X359”
”C”
Z 54 240
66/267 250--1--1180--015
16. Because the extension and retraction of the piston rods of

the luffing cylinders takes place by means of the HATZ diesel
engine, the electrical connection between the distributor box
”X 550” on the main boom head and the distributor box ”X
360” in the basic boom foot needs to be established in order
to start the engine. Proceed as follows to accomplish this:

distribution box ”X 359” at the intermediate section (2)

and the distribution box ”X 359” at the intermediate
section (2) (connection ”C”, Z 54 240).
250--1--1180--015 67/267
18
”X360”
”B”
Z 52 796
4 3 2
Z 54 241
68/267 250--1--1180--015
17. Establish the electrical connection between the distribution

box ”X 365” in the head of the basic boom and the distribution
box ”X 360” in the foot of the main boom (connection ”B”,
Z 52 796).
Because the basic boom (3) is now correctly linked to the

intermediate section (2) by means of two biconical pins and two
coupling pins and in addition the electrical connection between
the distributor box ”X 550” at the main boom head and the
distributor box ”X 365” in the basic boom head has also been
established, the tip section (4) at the basic boom (3) can be
attached (Z 54 241).
Risk of crushing.
There is a risk of crushing between the basic boom and the
tip section. Proceed with appropriate caution.
250--1--1180--015 69/267
18
12
12
4 3
12
Z 54 220
70/267 250--1--1180--015
18. Join the basic boom (3) and the tip section (4) using four
biconical pins (12). Secure each biconical pin with 2 locking
springs (Z 54 220).

Proceed with the attachment of the tip section (4) at the basic
boom (3) and with the closing of the safety chain at the head of
the tip section in exactly the same way as described in
Chap. 18.4.3 ”Fitting of the 20 m main boom extension”, starting
on page 49.
250--1--1180--015 71/267
18
1 12
12
Z 54 242 Z 54 244
“X”
Z 54 243
72/267 250--1--1180--015

section (1), the basic boom (3) and the tip section (4) (Z 54 242).
The intermediate section (1) is pinned to the pulley shafts of the
main boom head using four biconical pins (12).
To attach the 36 m main boom extension, proceed as follows:
1. Ensure that the top and bottom pulley shafts at the main
boom head are in horizontal position.
For the bottom shaft, also make sure that the chamfer part
points forwards (refer to detail ”X”, Z 54 243).

intermediate section (1) (Z 54 244).
250--1--1180--015 73/267
18
1 8
”X”
”a”
12 1
1 1
”Y”
2
Z 54 245
Z 54 230
74/267 250--1--1180--015

eyelets of the intermediate section (1) (”X”,Z 54 245).

One intermediate section (1) differs from another intermediate

section (2) at the following point (see detail ”a”, Z 54 245):
− the four upper boom tubes are designed in such a way that
they can be pinned to the fork heads of the intermediate
section (2) using the four biconical pins (12).
4. Raise the intermediate section with the auxiliary crane and

move into locking position at the main boom head (”Y”,
Z 54 245).
When attaching the intermediate section (1), take care to

ensure that the top roller (8) is directed towards the main
boom head.
Risk of crushing.
heads are aligned to the bore holes of the pulley shaft of the
main boom head (Z 54 230).
250--1--1180--015 75/267
18
1 ”X”
12
”A”
1
12 ”D”
Z 54 246
12
1 12
”E” ”B”--12
”X”
”B”
”A”
1
12 ”D”
12
Z 54 247
76/267 250--1--1180--015

section and the basic boom (1) via fork heads ”A” and ”D”

between the intermediate section head and the basic boom
using the fork heads (Z 54 247).
7.2 Establish a top connection between the intermediate

section and the basic boom (1) via fork heads ”A” and
”D” using the 2 biconical pins (12). Secure each of the
biconical pins with 2 retaining springs (refer to detail
“X”).

250--1--1180--015 77/267
18
2 1
12
12
1
12
12
Z 54 248
78/267 250--1--1180--015
8. Since the intermediate section (1) is now properly connected

to the main boom using four biconical pins, the intermediate
section (2) can be pinned to the intermediate section (1).
The pinning of the intermediate section (2) to intermediate

section (1) is also done using 4 biconical pins (12, Z 54 248).
Proceed with the attachment of the intermediate section (2) to the

intermediate section (1) in the same way as when fitting the
intermediate section (1) to the main boom head.
You will find this attachment procedure at the beginning of this
section 18.4.5 ”Attachment ....”, starting from page73.
250--1--1180--015 79/267
18
2
13
1
1212
2
3
3
Z 54 249
80/267 250--1--1180--015
9. Since the intermediate section (2) is now properly connected

to the intermediate section (1) using four biconical pins, the
basic boom (3) can be pinned to the intermediate section (2)
(Z 54 249).
To attach the basic boom (3) to the intermediate section (2),

proceed in the same way as described in Sect. 18.4.4 “Fitting of
the 28 m main boom extension“ starting at page 61, item 8..
250--1--1180--015 81/267
18
”X358”
”A”
Z 54 250
”X358”
”X359”
”D”
Z 54 251
82/267 250--1--1180--015
10. Because the extension and retraction of the piston rods of

the luffing cylinders is done by means of the HATZ diesel
engine, the electrical connection between the distributor box
”X 550” on the main boom head and the distributor box ”X
360” in the basic boom foot needs to be established in order
to start the engine. Proceed as follows to accomplish this:


section 2 (connection ”D”, Z 54 251).
The further assembly of the 36 m main boom extension as well

as the closing of the safety chain of the various components with
each other should be carried out exactly as described in Sect.
18.4.4 “Fitting of the 28 m main boom extension“ starting at
page 67, item 16.2.
RISK OF ACCIDENTS!
The attachment of both parts (3) and (4) in straight condi-
tion side by side is prohibited!
250--1--1180--015 83/267
18
84/267 250--1--1180--015
18.5 Folding procedure
As long as the main boom extensions with the lengths 10.4 m and
20 m are not needed, the extension can be transported attached
to the main boom if it is folded in transport position and pinned.
When driving in this condition, observe the applicable axle

loads!
18.5.1 Before folding
The conditions described here as follows must be observed when

folding from transport position to working position (Sect. 18.5.2)
as well as in the opposite direction (Sect. 18.5.3):
∗ The crane must be on outriggers and horizontally aligned.
∗ Counterweight attached according to the planned
configuration of the crane. Note here the specifications in the
corresponding load capacity tables.
∗ Slewing gear brake closed.
∗ Main boom entirely retracted, pinned and horizontal (caution:
in transport position the main boom is in approx. --0.5°).
Securing and pinning unit secured at the corresponding
telescopic section (refer to section 12.5 ”Condition of main
boom for operating the crane in transport position”).
∗ Main boom extension not folded (i.e. 0° position).
Before every locking procedure, the upper and lower pins of

the rotation point cylinder and the biconical pin should be
well greased.
RISK OF ACCIDENTS!
Use the foldable/extendable ladder delivered for carrying
out assembly work on the main boom extension. The use
of the main boom extension or of the main boom is not per-
missible!
Always mount the ladder safely and in such a way that the
object it leans against cannot fold away (e.g. when a pin is
loosened).
250--1--1180--015 85/267
18
Z 54 174
51
71 72
Z 54 198
86/267 250--1--1180--015
18.5.2 Folding from transport to working position
18.5.2.1 Main boom extension 10.4 m with only the main boom
attached
(Z 54 174, Z 54 198)
Only the basic boom (3) is attached to the main boom in transport
position.
During the folding procedure and during the pinning and

unpinning procedures, no--one should be present in the
slewing range or beneath the main boom extension or in
the area where components could fall!
The sequence of the operating steps during the folding pro-

cedure must be followed.
1. Follow all instructions in sect. 18.5.1 “Before folding”.
(Z 54 198)
2. Fasten the delivered guiding rope with snap hook to the head
of the main boom extension at attaching point (51).
The main boom extension can be pulled and also braked

using the guide rope. Use of the rope means that nobody
may be present under the main boom extension or in an area
where parts may fall down when folding.
(Z 54 198)
3. Remove the folding/sliding ladder (72) from transport
position after releasing the 4 latches (71, tightening straps)
and make it ready.
The weight of the ladder is approximately 8 kg.
250--1--1180--015 87/267
18
30a
13
14
30b
30b
14 13
30a
Z 55 163 Z 55 164
30b
13
13
30a 30a
14
14 30b
Z 55 165 Z 55 166
88/267 250--1--1180--015
(Z 55 163, Z 55 164)
4. Folding the starting rail from transport to working position.
Proceed as follows:
(Z 55 163)
4.1 Loosen and remove pin (13) -- with grip -- to release the
transport lock of the thrust rail.
(Z 55 164)
4.2 Fold forward the component (30a) of the rail, until it is
aligned with the fixed component (30b) of the rail.
(Z 55 164)
4.3 Set the thrust rails to working position (Z 55 164). Peg
with pins (13) from beneath as shown and secure the
pins with a linch pin.
RISK OF ACCIDENTS!
Always only one pin -- the pin (13) with the grip -- may be
pulled and reinserted.
The pin (14) without a grip must always remain in place.
Version for dolly preparation (optional)

(Z 55 165, Z 55 166)
If your crane is prepared for driving with the dolly, then

component (30a) of the rail is folded away in transport position
(Z 55 165) to the other (left) side. The folding procedure is carried
out in the same way as described above.
Remove pin (13) -- with grip --, fold part (30a) of the rail forwards
and lock the rail in working position (Z 55 166) with pin (13).
RISK OF ACCIDENTS!
Always only one pin -- the pin (13) with the grip -- may be
pulled and reinserted.
The pin (14) without a grip must always remain in place.
250--1--1180--015 89/267
18
7
9
Z 54 151
”A”
”B”
10
Z 54 158
90/267 250--1--1180--015
(Z 54 151)
5. Connect the mobile control panel (9) to the free socket of the
distributor box “X 510” (7) on the main boom basic case, left
hand side.
6. Start the superstructure engine and set the rotation speed to

approximately 1000 to 1200 min --1.
(Z 54 158)
7. Check that the upper and lower pulley shafts are in horizontal
position.
In the case of the bottom shaft on the left hand side (detail
”B”), also make sure that the chamfer part points forwards.
This chamfer serves later as a ramp chamfer when folding
the retracting fork head or stop bolt.
(Z 54 158, detail “A”)

8. Check that the stop bolt (10) is in the self--engaging position
as shown.
250--1--1180--015 91/267
18
3-- FRONT
”K” ”G”
”X” 11
22 4
23
2
”Y”
3 6
“M”
3
4
21
Z 54 154
92/267 250--1--1180--015
RISK OF ACCIDENTS!
Ensure that the main boom extension is pinned to the main
boom pinned at pivot point ”G” (cylinder 3) before loosen-
ing the connecting pin as described in the following (22, de-
tail ”K”).
The pin employed by it (4) must clearly protrude from the
upper and lower locking points (as shown).
This must be checked. The lower locking point is visible
from the ground.
A red display flap (11) is fitted to the upper locking point for
this purpose (11). The upper locking point is only pinned
when this display flap is erected as shown in figure
(Z 54 154, detail ”G”).
This safe configuration must be attained before the follow-
ing steps may be carried out.
The main boom extension is not shown on the enlarged dia-
gram of cylinder (3).
RISK OF ACCIDENTS!
In addition, check that the hook jaw (21) of cylinder (1) is
clicked into the position provided on the main boom exten-
sion (refer to detail ”M”).
Otherwise, after loosening the connecting pins (22, magni-
fying “K”) as described below, undesired and uncontrolled
swinging of the main boom extension is possible.
(Z 54 154, detail ”K”)

9. Remove the connecting pins (22). The connection between
main boom extension and main boom is released.
Loosen the actuating lever (23) from its lock--in position ”X”,
turn it 180° down to position ”Y” and reengage.
The main boom extension is not depicted in the diagram.
250--1--1180--015 93/267
18
“E”
2-- FRONT
1 ”D/E”
“D”
“3,G”
Z 54 159
8
9B
9A
Z 54 161
94/267 250--1--1180--015
(Z 54 159)
10. Carefully extend the cylinder (1) until the bore holes of the
upper and lower fork heads are flush with the corresponding
bore holes of the pulley shafts at the points (”D”) and (”E”).
(Z 54 161)
Switch the selector switch (8) on the mobile control panel to
position ”1” and hold down the rocker switch (9B) until the
position has been reached.
The main boom extension then rotates around the pivot point
“G” (cylinder “3” or the pin it uses).
When folding the main boom extension out of transport

position into operating position, there may be a danger of
crushing, shearing or falling objects (e.g. forgotten tools).
No--one may be present in the endangered area during the
folding procedure.
It is prohibited to walk between the main boom extension
and the main boom.
250--1--1180--015 95/267
18
”E” 12
”D”
12
Z 54 160
96/267 250--1--1180--015
(Z 54 160)
11. Remove the biconical pins (12) from the transport retainer on
the main boom extension, insert them at the upper (”E”) and
lower connection points (”D”) of the pulley shafts together
with the fork heads of the main boom extension and secure
with two locking springs.
For detailed information about the use of the biconical pins,
refer to sect. 18.4.2, ”Assembly....”, starting with Item 6.,
S. 27.
RISK OF ACCIDENTS!
Only biconical pins which are cylindrical at one end should
be used.
Retracting the cylinder (3) as described below is only al-

lowed when the main boom extension is pinned to the main
boom head at points (“D”) and (“E”) using both biconical
pins (12) -- as described above.
The cylinder (3) and the biconical pins (12) must never be
unpinned/removed at the same time.
Otherwise the main boom extension may fall down. Risk of
fatal injury!
During the following unpinning and swinging procedure,
no--one may be present under the main boom extension or
in the area where there is a danger of falling objects.
Risk of accidents!
250--1--1180--015 97/267
18
8
”D/E”
4
9B
“3,G” 9A
3 4
3
12
13
15
5
Z 54 168 Z 52 228
98/267 250--1--1180--015
(Z 54 168, Z 52 228, shown without main boom extension)
12. Disconnect the main boom extension at the basic case of the
main boom by retracting the cylinder (3) at point ”G”.
To do, first remove rope (15) from the holding device. Pull this
rope and thereby pull back the retracting lock (13) of the pins
(4) used by the cylinder (3). These are then unlocked. The
locking catch must be held in this position until cylinder (3)
or pins (4) are retracted -- as described below.
To do this, switch the selector switch (8) on the mobile control
panel to position ”3”. Press the rocker switch (9A) until the
cylinder (3) or pins (4) are completely retracted.
RISK OF ACCIDENTS!
It is permitted to unpin the cylinder (3) or the pins (4) only
when the main boom extension is pinned with the two bi-
conical pins to the main boom head at points (D/E).
RISK OF ACCIDENTS!
Make sure that rope (15) which is used to release the me-
chanical retraction guard of the pins (4) is always fastened
to the corresponding holding device. It should not hang
loose as pulling on this rope would cause the mechanical
retracting lock of the pins (4) to be released.
The rope (15) may not be so tight that the lever (12) is pulled
down and the safety catch (13) can no longer be engaged
in position.
250--1--1180--015 99/267
18
92
91
72
Z 55 174
1
2
9B
9A
8
1 9B
9A
8
21
Z 54 162 Z 54 167
100/267 250--1--1180--015
(Z 54 162)
13. Extend cylinder (1) completely. Switch the selector switch (8)
on the mobile control panel to position ”1” and press the
rocker switch (9B).
The main boom extension can slew on its own after the fol-
lowing releasing of the hook jaw of cylinder (1). Use the
guiding rope to act against undesired movements.
(Z 55 174)
14. Release rod (91) from its transport position at the
folding/extendable ladder (72).
To do so remove pipe linch pin (92) and extract rod (91) from
both retaining sheets.
(Z 54 162)
15. Lift hook jaw (21) with the rod out of the engaged position
and fold main boom extension a little at the guide rope. The
hook jaw of cylinder (1) can then be let off again without
being clicked into position again.
(Z 55 174)
16. Reattach rod (91) back in transport position to the ladder
(72). To do so, insert the rod in both retaining sheets and
secure it in the corresponding bore hole with the pipe linch
pin (92) against slipping out.
(Z 54 167)
17. Retract cylinder (1) completely (using the mobile control
panel, position ”1”, button ”9A”), fold into transport position
and secure with pins (2).
250--1--1180--015 101/267
18
9 ”D/E”
Z 54 151
”A”
10
Z 54 164 Z 54 163
102/267 250--1--1180--015
(Z 54 151)
18. Remove the mobile control panel (9) from the distributor box
”X 510” (7) and close the free socket with a protective cap.
When folding the main boom extension and during pinning

and unpinning there must be no--one in the slewing range
or beneath the main boom extension or in areas at risk of
falling equipment etc.
(Z 54 163, Z 54 164)
19. Fold the main boom extension around the pinned pivot
points (D/E) to working position using the guide rope until the
bore holes of the fork heads are flush with the bore holes of
the pulley shafts on the left hand side of the main boom head.
Take particular care that the stop bolt (10) at the connection
point (”A”, Z 54 164) clicks into position behind the pulley
shaft. The main boom extension is then in the correct
position to carry out the following unpinning.
RISK OF ACCIDENTS!
If the stop bolt (10) does not secure the main boom exten-
sion, uncontrolled swinging of the main boom extension
can occur when carrying out the following pinning.
250--1--1180--015 103/267
18
”B”
12
”A”
Z 54 165
5
”C”--13
”B”
Z 54 166
104/267 250--1--1180--015
(Z 54 165, Z 54 166)
20. The main boom extension should be pinned in working
position onto the main boom head. Pin with biconical pins
(12) on the left hand side of the main boom head at the lower
locking point (”A”) and secure with two locking springs each.
21. The upper locking point (”B”) is not pegged on the left hand
side with a biconical pin. The connection takes place instead
by means of the piston rods of the luffing cylinder (5,
Z 54 166). This is described below.
21.1 Establish electrical connection, connect the mobile

control panel at the distributor box ”X 360” at the foot
of the basic boom and start the HATZ diesel engine.
Follow the instructions in sect. 18.4.2 ”Assembly...”,
p. 31--33.
21.2 Extend the piston rods (5) of the luffing cylinder and at
first pin only the left hand piston rod with coupling pins
(13) at point (”C”) and secure as shown in the
illustration (Z 54 166).
This is described in detail in sect. 18.4.2 “Fitting...” as
from p. 35, item 7.7, to p. 39, item 7.11.
250--1--1180--015 105/267
18
106/267 250--1--1180--015
22. Peg the right piston rod with coupling pins on the right hand
side and secure (as already carried out for the left hand side).
Details of this can be found in sect. 18.4.2 ”Fitting...”, p. 39,
Items 7.9 and 7.12.
Then release and remove the pegged biconical pin upper
locking point.
RISK OF ACCIDENTS!
This sequence must be complied with strictly! Only then is
there sufficient protection against swinging away or col-
lapse of the main boom extension.
If one of the hydraulic cylinders (1) or (3) has to be controlled

using the mobile control panel during the following procedure, the
control desk must be plugged out of the ”X 360” distributor box
in the basic boom of the main boom extension and then plugged
into the ”X 510” distributor box on the left--hand side of the main
boom basic case.
250--1--1180--015 107/267
18
9-- TOP
Z 54 510
108/267 250--1--1180--015
Check if the correct pin is used (one cylindrical end) and

check the secure fit of all pins and interlocks.
This completes the folding of the main boom extension 10.4 m to

working position.
To make the crane ready for use, proceed as follows:
(Z 54 510)
23. Fold the auxiliary shackle at the end of the basic boom to
transport position and peg and secure there with the second
pin.
24. Attach the aircraft warning light and the rotor of the
anemometer at the head of the main boom extension.
Refer to p. 45, Item 12..
25. Attach the hoist limit switch and shift weight to the position
intended for this purpose on the main boom extension.
Refer to p. 45, item 13..
26. Connect the main boom extension to the electrical power

supply.
Refer to page 31, items 7.3 and 7.4 in addition to page 47,
item 15.
27. Reeve in the hoist rope and bring the hinged rope idler at the
basic boom to working position. To do so refer to sect. 18.6
“Reeving in the hoist rope”, as from p. 163.
28. For the further procedure, refer to sect. 18.7 “Erecting”, as

from p. 199, and sect. 18.8 “Crane operation at the main
boom extension”, as from p. 221.
RISK OF ACCIDENTS!
Be sure to check the attached counterweight once more be-
fore operating the crane. Check also that the load limit de-
vice is set for the actual crane configuration.
250--1--1180--015 109/267
18
”A”
”B”
”Z”
28
23
3 4
Z 54 169
110/267 250--1--1180--015
18.5.2.2 Main boom extension 10.4 m, basic boom

and tip section attached.
(Z 54 169)
As has already been described in sect. 18.5.2.1, only the basic

boom (3) of the main boom extension is folded from transport
position to working position.
The tip section (4) which is also attached remains pinned in
transport position on the main boom.

unpinning procedures, there must be no--one in the slew-
ing range or beneath the main boom extension or in the
area where components could fall!

1. Observe all specifications from sect. 18.5.1 “Before folding”,

starting at p. 85.
2. Check to make sure that the tip section (4) is connected at

the following two points to the basic case of the main boom:
− Magnifying glass (“A”), point (“Z”):
the tip of the respective pin must be visible (see arrow). The
actuating lever (23) of the pin needs to be in the position
displayed (lock--in position) and may not be actuated under
any circumstances during the following folding procedure.
− Magnifying glass (”B”):
The lever (28) must be folded downwards. The pin employed
must interlock the corresponding shackles of the tip section
and main boom.
RISK OF ACCIDENTS!
Both points must be pinned without fail. Otherwise the dan-
ger exists that the tip section will fall later after the connec-
tion with the basic boom is released.
250--1--1180--015 111/267
18
”G”
11
3 6
“M”
3
4
21
Z 54 173
112/267 250--1--1180--015
(Z 54 173)
RISK OF ACCIDENTS!
Do not fail to convince yourself before the following release
of the connection between the basic boom of the main
boom extension and tip section that the main boom exten-
sion is pinned to the main boom at the pivot point ”G” (cyl-
inder 3).
The pin employed by it (4) must clearly protrude from the
upper and lower locking point (as shown).
from the ground.
A red display flap (11) is fitted to the upper locking point for
this purpose (11). The upper locking point is only pinned
when this display flap is erected as shown in figure
(Z 54 173, detail ”G”).
This safe configuration must be attained before the follow-
ing steps may be carried out.
The main boom extension is not shown on the enlarged dia-
gram of cylinder (3).
RISK OF ACCIDENTS!
In addition, check that the hook jaw (21) of cylinder (1) is
clicked into the position provided on the main boom exten-
sion (refer to detail ”M”).
Otherwise an involuntary and uncontrolled swinging out of
the main boom extension could occur afterwards following
the release of the connection between the basic boom of
the main boom extension and the tip section.
250--1--1180--015 113/267
18
29
Z 54 171
12
3
4
12
Z 54 172
114/267 250--1--1180--015
3. Releasing connection between basic boom (3) and tip

section (4). Proceed as follows:
(Z 54 171)
3.1 Release and remove pin (29). The connection point
shown is located approximately 1 m away from the
head of the tip section.
(Z 54 172)
3.2 Release and remove both biconical pins (12) and peg
them in their transport retainers at the tip section and
secure them.
The basic boom (3) is thus released from the tip section (4) and
can be folded in working position.
To accomplish this, proceed at first the same way as described
starting on page 87, item 2. (fastening guide rope) up to page 91,
item 8. (Checking the position of the stop bolt).
Then skip the following item 9., page 93, -- do not carry it out.
RISK OF ACCIDENTS!
93The item 9. that then follows (release of the connecting
pin ”22” at the main boom) may NOT take place, because
it is by means of this pin that the tip section is secured in
transport position at the main boom.
Releasing the pin (22) would lead to tipping of the tip sec-
tion.
Proceed as described from page 95, item 10. (Extending

cylinder ”1” ) to page 109, item 28. (additional procedural
methods).
Releasing the auxiliary shackle (item 23.) is not required in this

case, because no auxiliary shackle was required.
RISK OF ACCIDENTS!
250--1--1180--015 115/267
18
”A”
”B”
12
3
4
29
12
3 4
Z 54 175
116/267 250--1--1180--015
18.5.2.3 Main boom extension 20 m

(Z 54 175)
The basic boom (3) and the tip section (4) are attached in
transport position at the main boom. They should both be folded
in working position.



starting at p. 85.
2. Check to make sure that the basic boom (3) and the tip
section (4) are pinned together at the two points listed below:
− Magnifying glass “A”:
attached to the illustrated bolt joint with 2 biconical pins (12)
and these are secured by 2 locking springs each.
− Magnifying glass “B”:
attached at the illustrated point with pin (29) and locked.
250--1--1180--015 117/267
18
28
3 4 Z 54 177
4
12
12
Z 54 178
118/267 250--1--1180--015
(Z 54 177)
3. Release front connection point between the main boom
extension, i.e. the tip section and the main boom.
Fold the lever (28) upwards while doing so from the
displayed position (Z 54 177) by 180°. As a result, the
associated pin moves out of the corresponding locking
shackles and the connection is released.
Proceed as described from page 87, item 2. (secure the guide

rope) to page 107, item 22. (pinning the right hand side piston
rod).
(Z 54 178)
The tip section (4) must then be folded from transport position at
the basic boom (3) to working position. This procedure is carried
out in principle in exactly the same way as the folding of the main
boom extension to working position at the main boom head. You
will find a detailed description starting on the following page.
250--1--1180--015 119/267
18
29
4
Z 54 179
12
10
12
Z 54 180
120/267 250--1--1180--015
(Z 54 180)
4. Check that the stop bolt (10) is in the self--engaging position
as shown.
5. Release the guide rope from the fixed point for the rope at
the basic boom and attach to the fixed point for the rope of
the tip section.
The tip section can slew on its own after the following re-
lease of the connection between the basic boom and the tip
section. Use the guide rope to act against undesired move-
ments.
(Z 54 179)
6. Releasing connection between tip section (4) and basic
boom (3). Release and remove pin (29) to do so.
When swinging the main boom extension and during pin-

ning and unpinning there must be no--one in the slewing
range or beneath the tip section or in areas at risk of falling
equipment etc.
(Z 54 180)
7. Swing the tip section around the biconical pin (12) into
working position using the guide rope until the bore holes of
the attachment plates are flush with the bore holes of the fork
heads on the left hand side of the basic boom.
Take particular care that the stop bolt at the lower connection
point clicks into position at the intended position. The tip
section is then in the correct position to carry out the following
unpinning.
RISK OF ACCIDENTS!
If the stop bolt does not secure the tip section, the tip sec-
tion can swing away in an uncontrolled manner when the
following pinning is carried out.
250--1--1180--015 121/267
18
12
12
4 3
Z 54 181
122/267 250--1--1180--015
(Z 54 181)
8. Pinning tip section (4) into working position at the basic boom
(3). On the left hand side of the basic boom pin the upper and
lower locking points using two biconical pins (12) and secure
with two locking springs each.

This completes the folding of the main boom extension 20 m to

working position.
To make the crane ready for use, proceed as follows:
9. Attach the aircraft warning light and the rotor of the

anemometer to the head of the tip section.
10. Attach the hoist limit switch and shift weight to the top box
piece at the position intended for this purpose.
11. Connect the tip section to the electrical power supply.

Refer to page 31, items 7.3 and 7.4 in addition to page 53,
items 10.11.
12. Reeve in the hoist rope. To do so refer to sect. 18.6 “Reeving

in the hoist rope”, as from p. 163.
13. For the further procedure, refer to sect. 18.7 “Erecting”, as

from p. 199, and sect. 18.8 “Crane operation at the main
boom extension”, as from p. 221.
RISK OF ACCIDENTS!
250--1--1180--015 123/267
18
Z 54 182
23
Z 54 187
124/267 250--1--1180--015
18.5.3 Folding from operating position to transport position
18.5.3.1 Main boom extension 10.4 m with only the main boom
attached
(Z 54 182, Z 54 187)
Only the basic boom (3) is attached to the main boom head in
working position.



starting at p. 85.
2. Unreeve the hoist rope and remove the shift weight of the
hoist limit switch, aircraft warning light and rotor of the
anemometer. Refer to the analogous items 27.--24., page
109.
Alternately, the switching weight of the hoist limit switch (23,

Z 54 187) can also be pegged and secured in transport position
at the basic boom.
250--1--1180--015 125/267
18
9-- TOP
71
51
Z 54 183
126/267 250--1--1180--015
(Z 54 183)
3. Pin the auxiliary shackle (71) to the upper right hand fork
head of the basic boom in such a way that the shackle with
the open bore hole sticks out at a right angle.
It will be required later in order to pin the folded basic boom
to transport position.
(Z 54 183)
4. Fasten the delivered guide rope with snap hook to the head
of the main boom extension at attaching point (51).

must stand under the main boom extension or in an area
where collapse is possible when swinging.
250--1--1180--015 127/267
18
”F”--13
5
”C”--13
”B”
Z 54 189
”E”
”D”
Z 54 190
128/267 250--1--1180--015
First the upper locking point on the right--hand side, which is

indeed created by means of the piston rod of the adjusting
cylinder (see figure ”Z 54 189”, display on the left hand side),
needs to be rebuilt. To do this, proceed as described below.
RISK OF ACCIDENTS!
The following two points must be carried out under all cir-
cumstances in the sequence given here! Only then is there
sufficient protection against the main boom extension
swinging away or collapsing.
(Z 54 189, Z 54 190)
5. Pin the upper fork head on the right hand side with biconical
pins to the upper pulley axle and secure with 2 locking
springs.
Point ”B” in the illustration (Z 54 189) is shown for this

reason on the left side -- which is not pegged by a biconical
pin! Before the biconical pin in inserted, the right side looks
just the same.
(Z 54 189)
6. Then release and remove the pin (13) on the right side from
point “F”.
Point ”C” is displayed in this context in the illustration

(Z 54 189) on the left hand side. The right--hand side has the
same appearance.
Risk of crushing!
Carefully pull out the pin (13) so that there is no danger of
being crushed at the biconical pin.
The right hand side must ultimately be in the state displayed in

the illustration (Z 54 190) at points (”E”) and (”D”).
Only then can the folding operation be carried out afterwards with
points (”D/E”) as pivot points.

250--1--1180--015 129/267
18
”K”
22
23
”Y”
Z 54 184
1
2
9B
9A 21
8
Z 54 167 Z 54 185
130/267 250--1--1180--015
(Z 54 184)
7. Make sure that pin (22) is not pinned. The corresponding
actuating lever (23) must be in the displayed position ”Y”
(lock--in position).
RISK OF ACCIDENTS!
Only if this is guaranteed can the main boom extension be
later retracted at this position and be pinned to transport
position.
8. Fold the rail into working position, connect the mobile control
panel to the distributor box ”X 510” and start the
superstructure engine.
Proceed as described in items 4.--6., page 91.
(Z 54 167, Z 54 185)
9. Bring the cylinder (1) to working position for taking up the
main boom extension. For this, release the locking pin (2),
slew the cylinder (1) forwards by 90° and extend it completely
(switch selector switch ”8” at the mobile control panel to
position ”1” and actuate rocker switch ”9B”).
The cylinder (1) and the hook jaw (21) must then be in
position as displayed in the illustration (Z 54 185), so that the
hook jaw can later engage at the corresponding position of
the main boom extension.
250--1--1180--015 131/267
18
12 ”A”
5
3 4
10
3
”X”
12
13
15 10
4
5
Z 54 186 Z 55 249
132/267 250--1--1180--015
(Z 54 186)
10. Now check that cylinder (3) on the main boom basic case is
retracted and that the pins operated by it (4) are not retracted
into the pinning points (5).
The pins (4) must be clearly visible outside the
corresponding guides -- as shown in figure (Z 54 186).
RISK OF ACCIDENTS!
Only if this is guaranteed can the main boom extension be
later retracted at this position and be pinned as sole pivot
point.
If the cylinder (3) is not retracted, then proceed for retracting as

described in item 12., page 99.
(Z 54 188)
11. Bring the stop bolt (10) at the bottom left fork head of the
basic boom (3) should to the “released” position (as
displayed in diagram “Z 55 249”, detail ”X”)
RISK OF ACCIDENTS!
Do not lean the ladder against the main boom extension,
because it will otherwise lose its hold and fall when the
main boom extension is folded.
250--1--1180--015 133/267
18
5
”C”--13 9B
9A
Z 54 191
9B
9A
8
16
”S”
”O” 17
Z 54 199
134/267 250--1--1180--015
When swinging the main boom extension and during pin-

ning and unpinning there must be no--one in the slewing
range or beneath the main boom extension or in areas at
risk of falling equipment etc.
(Z 54 191)
12. Release the pin (13) on the left hand side at the upper locking
point (”C”), remove it and peg it in transport position.
13. Now that the piston rods are unpinned on both sides, insert
these as follows:
13.1 Connect the mobile control panel at the distributor box

”X 360” at the foot of the basic boom and start the
HATZ diesel engine.
Follow the instructions in sect. 18.4.2 ”Fitting...”,
p. 31--33.
13.2 Switch the selector lever (8) at the mobile control panel
to position ”1” and press the rocker switch (9B) until the
piston rods (5) are completely retracted.
(Z 54 199)
14. Lower the rope idler (6) hydraulically from working position
to transport position. To do so, proceed as described from
page 245 item 2.3 to page 253 item 5.4.
Risk of crushing!
The danger of crushing between the rope idler and the ad-
justing cylinder and/or the basic boom exists when lower-
ing the rope idler. Maintain a safe distance accordingly.
250--1--1180--015 135/267
18
72
12
”A”
10 Z 54 192
136/267 250--1--1180--015
Since one of the hydraulic cylinders (1) or (3) has to be controlled

using the mobile control panel during the following procedure, the
control desk must be plugged out of the ”X 360” distributor box
in the basic boom of the main boom extension and then plugged
into the ”X 510” distributor box on the left--hand side of the main
boom basic case.
(Z 54 192)
15. Remove the main boom extension socket (72) from the
distributor box ”X 550” at the main boom head and fit the
bridging plug instead at the free socket.
RISK OF ACCIDENTS!
Because the stop bolt (10, Z 54 192) is in “released” posi-
tion, after the following unpinning of the bottom left fork
head, uncontrolled folding back of the main boom exten-
sion is possible! Use the guide rope to act against unde-
sired movements.

bolt. Make sure that nobody is in the danger--zone!.
object it leans against cannot move away (e.g. when a pin
is loosened).
(Z 54 192)
16. Release the biconical pin (12) on the left hand side at the
lower connection point (A), remove it and peg it in the
transport retainer.
250--1--1180--015 137/267
18
”D/E”
9B
9A
8
“3,G”
1
1
21
Z 54 162
3
2-- FRONT
25
Z 54 193 Z 54 194
138/267 250--1--1180--015
(Z 54 193, Z 54 162)
17. Slew the main boom extension with the help of the guide
rope around the pinned pivot point (D/E) in the direction of
transport position until the hook jaw (21) of the cylinder (1)
has engaged at the corresponding main boom extension
position (as displayed in the illustration ”Z 54 162”).
(Z 54 162, Z 54 505)
18. Switch the selector switch (8) at the mobile control panel to
position ”1” and retract the cylinder by pressing the rocker
switch (9A) cylinder (1) -- the main boom extension will be
drawn to the main boom.
Retract the cylinder (1) as long as necessary until the
attachment plates of the basic boom (3) of the main boom
extension are retracted at the lower locking point (see
Z 54 194) and at the upper locking point into the respective
metal sheets (25) at the cylinder (3) and the bore holes are
aligned.
RISK OF ACCIDENTS!
The correct retraction of the shackles of the main boom ex-
tension to the pinning positions of the basic case of the
main boom must be checked by the assembly personnel.
Only then can it be guaranteed that the pins do not retract
into locking points (25) alone i.e. without the shackles of
the main boom extension being pinned as well, when the
subsequent pinning procedure for cylinder (3) is carried
out.
250--1--1180--015 139/267
18
8 11
”D/E”
4
9B
“3,G” 9A
2
3
6
12
15
3
13
2-- FRONT
Z 54 195 Z 52 230
140/267 250--1--1180--015
(Z 54 195, Z 52 230, shown without main boom extension)

19. Pin the main boom extension on the basic case of the main
boom by extending the cylinder (3) to point ”G”.
To do this, switch the selector switch (8) on the mobile control
panel to position ”3”. Press the rocker switch (9B) until the
cylinder (3) is completely extended.
The pin operated by it (4) must clearly protrude from the
upper and lower locking points (as shown in figure
“Z 52 230”).
RISK OF ACCIDENTS!
from the ground.
A display flap (11) is fitted to the upper locking point for this
purpose (11). The upper locking point is only pinned when
this display flap is erected as shown in figure (Z 52 230).
Only when this safe condition is achieved can the biconical
pins ”BZ” be withdrawn from the pivot bearings ”D/E”.
In figure (Z 52 230), the main boom extension is not shown.
The correct retraction of the shackles of the main boom ex-
tension in the pinning positions on the basic case of the
main boom must be checked by the assembly personnel --
as already described on the previous page.
In the extended condition of the cylinder (3), the pins (4)

retracted in the pinning positions are automatically secured
by a safety snapper (13).
RISK OF ACCIDENTS!
Make sure that rope (15) which is used to release the me-
chanical retraction guard of the pins (4) is always fastened
to the corresponding holding device. It should not hang
loose as pulling on this rope would cause the mechanical
retracting lock of the pins (4) to be released.
The rope (15) must not be so tight that the lever (12) is
pulled down and the safety catch (13) can no longer be
clicked into position.
250--1--1180--015 141/267
18
”E” 12
”D”
12
Z 54 160
12, “D/E”
2-- FRONT
1 3, “G”
Z 54 196
142/267 250--1--1180--015
(Z 54 160, Z 54 196)
In the following, the biconical pin (12) must be knocked out of the
pivot bearings (”D”) and (”E”). This can only be done if the main
boom extension at point (G) has been properly pinned to the main
boom using cylinder “3” and the safety catch has engaged.
Therefore, just before you knock out these pins you should check
that the display flap at the upper pinning point of cylinder (3) -- and
the corresponding pin -- is erect at point (G).
RISK OF ACCIDENTS!
If the biconical pins (12) are removed and the main boom
extension in point (G) / cylinder (3) has not been properly
pinned with the main boom basic case, the main boom ex-
tension will fall down.
RISK OF FATAL INJURY!
When the pins are being knocked out, persons must stay
clear of the area beneath the main boom extension and
where items could fall.
20. Knock out the biconical pin (12) from the pivot bearings
(”D/E”), peg and secure in the transport retainer.
250--1--1180--015 143/267
18
9B
9A
8
21
Z 54 162
”K”
”X” ”Z”
23
22
”Y”
Z 54 197
144/267 250--1--1180--015
(Z 54 162)
21. Retract cylinder (1) up to the stop. The main boom extension
is then completely drawn onto the rail.
position ”1” and press the rocker switch (9A).
The attached auxiliary shackle must be retracted into the

locking point (Z) instead of the tip section (4) which is
displayed in the illustration (Z 54 197, detail ”A”).
Risk of crushing!
When the main boom extension is drawn onto the rail, there
must be no--one beneath it (or in the area endangered by
falling equipment) or between the main boom and main
boom extension.
(Z 54 197)
22. Insert the pins (22) at connection point (”Z”). The main boom
extension is pinned to the main boom.
Loosen the actuating lever (23) from lock--in position ”Y”,
turn it up through 180° to position ”X” and engage again. The
tip of the pins (22) has to be visible at connection point “Z”
(see arrow).
The main boom extension is not shown in detail ”K”.
RISK OF ACCIDENTS!
The actuating lever (23) must be engaged and engage at the
lowest point of the stop position, so that uncontrolled
swinging out of the main boom extension is not possible
later.
23. Fold the rail in transport position (see items 4.1 -- 4.3,
page 89, in similar fashion in reverse sequence) and remove
mobile control panel and guide rope.
250--1--1180--015 145/267
18
146/267 250--1--1180--015
24. Switch off the superstructure engine.
25. Reattach folding/sliding ladder and adjust at the 4 points

provided for this purpose.
The main boom extension -- consisting only of the basic boom (3)
is now in transport position.
Observe the appropriate permissible axle loads (see part 2,
sect. 6 ”Moving”) when moving the crane in this condition.
Main boom operation can also be carried out with the main boom
extension folded in transport position.
The load capacities specified in the load capacity tables are then
reduced.
250--1--1180--015 147/267
18
3
4
Z 54 500
”Z”
23
Z 54 512
148/267 250--1--1180--015
18.5.3.2 Main boom extension 10.4 m, basic boom

and tip section attached.
(Z 54 500)
As has already been described in sect. 18.5.3.1, only the basic

boom (3) of the main boom extension is folded from working
position to transport position.
The tip section (4) is pinned in transport position on the main
boom.



starting at p. 85.
The rest of the procedure is initially identical with the description

in sect. 18.5.3.1, page 125, starting with item 2. (unreeve hoist
rope) up to page 129, item 5. “Converting the right side for the pivot
point”. Proceed as follows.
When doing this, item 3. (Attaching the auxiliary shackle) does
not apply.
Risk of accidents! (Z 54 512)

The following point 7., page 131, does not apply here since
the tip section (4) has been bolted in transport position at
the main boom. So point “Z” has to remain pinned. The cor-
responding actuating lever (23) needs to be in the position
displayed (lock--in position) and may not be actuated under
any circumstances during the following folding procedure.
At this stage, the basic boom (3) is not yet in the transport
position shown.
Proceed as described as from page 131, item 8. (”Fold thrust rail”)

to page 143, item 20. (Unpin bearing cap ”D/E”).
250--1--1180--015 149/267
18
9B
9A
8
21
Z 54 162
150/267 250--1--1180--015
(Z 54 162)
The basic boom and the tip section are retracted into each
other at two positions.
Risk of crushing!
falling equipment) or between the main boom/tip section
and main boom extension/tip section.
250--1--1180--015 151/267
18
”A”
”B”
12
3
4
29
12
3 4
Z 54 175
152/267 250--1--1180--015
(Z 54 175)
3. Connect basic boom (3) and tip section (4) to each another
at two points. Proceed as follows:
3.1 Peg pin (29) at the connection point (detail ”B”) and
secure it in such a way that the basic boom (3) and the
tip section (4) are pinned together.
3.2 Pin the fork heads of the basic boom (3) to the
corresponding shackles of the tip section (4) (see
detail ”A”). Remove the two biconical pins (12) from
their transport keepers, drive them in and secure with
two locking springs each.
4. Continueasdescribedatitems23.,page145,to25.,page147.
The main boom extension -- consisting of the basic boom (3) and
the tip section (4) -- is now in transport position.
extension folded in transport position.
reduced.
250--1--1180--015 153/267
18
3 4
Z 54 501
81
Z 54 502
154/267 250--1--1180--015
18.5.3.3 Main boom extension 20 m

(Z 54 501)
The basic boom (3) and the tip section (4) are attached in working
position at the main boom. They should both be folded in
transport position.
First the tip section (4) is folded against the basic boom (3) and
then both are folded against the main boom basic case.

unpinning procedure, there must be no--one in the slewing
range or beneath the main boom extension or in the area
where components could fall!


starting at p. 85.
2. Unreeve the hoist rope, detach the electrical connection and

remove the shift weight of the hoist limit switch, the aircraft
warning light and the rotor of the anemometer from the tip
section. Observe in a similar fashion items 12.--9., page 123.
Alternatively, the switching weight of the hoist limit switch can

also be pegged and secured in transport position at the
corresponding device (Z 54 502, 81).
3. Fasten the supplied guide rope with snap hook to the head
of the tip section at the attaching point.

where components may fall down when folding.
250--1--1180--015 155/267
18
12
4 12
10
Z 54 503
“P”
12
29 4
3
12
3
Z 54 504 Z 54 505
156/267 250--1--1180--015
(Z 54 503)
4. Check to make sure that the inside stop bolt (10) at the lower
locking point on the left hand side is engaged. The tip section
is then in the correct position to carry out the following
unpinning.
RISK OF ACCIDENTS!
If the stop bolt (10) does not secure the tip section, uncon-
trolled swinging of the main boom extension can occur
when carrying out the subsequent unpinning.
RISK OF ACCIDENTS!
Do not lean the ladder against the tip section, because it
will otherwise lose its hold and fall when the tip section is
folded.
(Z 54 503)
5. Release both biconical pins (12) on the left hand side,
remove them and peg in transport retainer.
RISK OF ACCIDENTS!
Uncontrolled swinging away of the main boom extension is
possible after loosening the stop bolt (10). Use the guide
rope to act against undesired movements.
6. Unlatch the stop bolt (10) by turning by 180°.
(Z 54 504, Z 54 505)
7. Slew the tip section (4) with the help of the guide rope around
the pinned pivot point (P) in the direction of transport position
until it runs onto the corresponding metal sheet at the basic
boom (3).
(Z 54 505)
8. Peg the pin (29) and secure it in such a way that the basic
boom (3) and the tip section (4) are pinned together.
250--1--1180--015 157/267
18
Z 54 506
9B
9A
8
1
51
21
Z 54 507 Z 54 162
158/267 250--1--1180--015
(Z 54 506)
This means that the tip section (4) is pinned to the basic boom (3)
and can now be folded together with it to transport position at the
main boom basic case.
Continue the folding procedure as follows:
(Z 54 507)
9. Release the guide rope from the fixed point for the rope at
the tip section and attach to the fixed point for the rope (51)
of the basic boom.

where components may fall down when folding.
The rest of the procedure is initially identical with the description

in sect. 18.5.3.1, page 129, starting with item 6. (Reconfigure the
right side for the pivot point) up to page 143, item 20. (Unpin the
bearing cap ”D/E”). Proceed as follows.
(Z 54 162)
Risk of crushing!
falling equipment) or between the main boom and main
boom extension.
250--1--1180--015 159/267
18
”K”
”X” ”Z”
23
22
”Y”
Z 54 197
28
3 4 Z 54 177
160/267 250--1--1180--015
(Z 54 197)
11. Insert the pins (22) at connection point (”Z”). The main boom
extension/tip section is pinned to the main boom.
Loosen the actuating lever (23) from the lock--in position ”Y”,
turn it up by 180° to position ”X” and engage again. The tips
of the pins (23) must be visible (see arrow).
The main boom extension is not shown in detail ”K”.
RISK OF ACCIDENTS!
The actuating lever (23) must be engaged and engage at the
lowest point of the stop position, so that uncontrolled
swinging out of the main boom extension is not possible
later.
(Z 54 177)
12. The main boom extension/tip section still needs to be pinned
to a second point at the main boom basic case. Fold the lever
(28) downwards for this purpose. The pin employed must
interlock the corresponding shackles of the tip section and
the main boom.
13. Continueasdescribedatitems23.,page145,to25.,page147.
The main boom extension -- consisting of the basic boom (3) and
the tip section (4) -- is now in transport position.
extension folded to transport position.
reduced.
250--1--1180--015 161/267
18
”b”
Z 42 980
”a”
Z 42 976 Z 55 202
162/267 250--1--1180--015
18.6 Reeving in the hoist rope
Before the hoist rope is reeved in at the main boom extension

head, you should under all circumstances read and take into
account the instructions in sect. 17 ”Reeving in”:
− Sect. 17.1: “General information”
− Sect. 17.2: “Load lifting equipment”.
18.6.1 Rope guide
The rope is lead from hoist 1 / hoist 2 under a rope bracket

(Z 55 202, “a”, single rope bracket) or (Z 55 202, “b”, dual rope
bracket) to the main boom head.
If it is unavoidable for personnel to walk on the main boom

during this procedure, suitable safety measures must be
taken.
There is a risk of accidents as a result of slipping /
stumbling on the main boom or if the hoist is incorrectly
operated.
Due to the risk of falling, it is prohibited to walk on the
lattice mast components to pull out the hoist rope; this
must be done from the side!
When reeving in, there is a danger of winching and re-

tracting at the head rollers and at the hook blocks.
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
Risk of crushing.
Touch the hook block only using the handrails provided
(Z 42 980). Under no circumstances should hands get
near the following areas:
* between the rope sheaves, side plates and covers.
* in the area of the fixing points (sometimes hinged), of
the hook, of the hook nut, of the lifting beam or of the
hoop guards.
Work on the hook block may only be carried out (i.e.
reeved in), when it is set down in a stable position on
firm ground (Z 42 976).
250--1--1180--015 163/267
18
H1 32
Z 55 203
32
H1
Z 55 204
164/267 250--1--1180--015
The guiding of the rope within the rope bracket on the main boom
basic case depends on:
− whether the crane is only equipped with hoist1
− whether the crane is equipped with hoist 1 and hoist 2
(optional) and the rope of hoist 1 at the main boom extension
head is reevedin
− whether the crane is equipped with hoist 1 and hoist 2
(optional) and the rope of hoist 2 at the main boom extension
head is reevedin
18.6.1.1 Crane only equipped with hoist 1
If the crane is only equipped with hoist 11, the hoist rope (H1) is
lead beneath the single bracket (32) (Z 55 203 and Z 55 204).
250--1--1180--015 165/267
18
58
H1 58
42a
Z 55 205
H1
12
10
11 12 11
42a
Z 55 735
166/267 250--1--1180--015
18.6.1.2 Crane equipped with hoist 1 and hoist 2;

rope of hoist 1 reeved in
If the crane is equipped with hoist 1 and hoist 2 (optional), and if

the rope (H1) is to be reeved in, then the rope is lead over rope
bracket (42a). To do this, proceed as follows (Z 55 205,
Z 55 735):
− remove both linch pins
− remove holding plate (10)
− remove one of the two sheaves (11)
− feed the hoist rope (H1) under the rope guide roller (12) and
insert in the rope groove of the remaining sheave
− reattach dismounted rope sheave, put keeper plate (10) back
on and then both linch pins.
The rope bracket slots moves with the attached rope sheaves --
depending on the course of the rope on the cable drum from the
left to the right.
The additional carrier rollers (58) on the individual main boom

telescopic sections must be removed. They are only used for dual
sheeving at the main boom head and on the runner or at the
hinged head roller at the side (refer to sect. 17.2 under “Reeving
in/unreeving the hoist rope”).
The hoist rope is lead over the standard carrier rollers and over
the carrier rollers at the main boom head (see also sect. 18.6.1.4
“Guiding the rope between rope bracket and hook block”, p. 171).
250--1--1180--015 167/267
18
58
H2 58 42b
Z 55 207
10 12
11 12 11
42b
H2
Z 55 736
168/267 250--1--1180--015
18.6.1.3 Crane equipped with hoist 1 and hoist 2;

rope of hoist 2 reevedin
If the crane is equipped with hoist 1 and hoist 2 (optional), and if

the rope (H2) is to be reeved in, then the rope is lead over rope
bracket (42b). To do this, proceed as follows (Z 55 207,
Z 55 736):
− remove both linch pins
− remove holding plate (10)
− remove one of the two sheaves (11)
− feed the hoist rope (H2) under the rope guide roller (12) and
insert in the rope groove of the remaining sheave
− reattach dismounted rope sheave, put keeper plate (10) back
on and then both linch pins.
The rope bracket slots moves with the attached rope sheaves --
depending on the course of the rope on the cable drum -- from
the left to the right.
The additional carrier rollers (58) on the individual main boom

telescopic sections must be removed. They are only used for dual
sheeving at the main boom head and on the runner or at the
hinged head roller at the side (refer to sect. 17.2 under “Reeving
in/unreeving the hoist rope”).
The hoist rope is lead over the standard carrier rollers and over
the carrier rollers at the main boom head (see also sect. 18.6.1.4
“Guiding the rope between rope bracket and hook block”, p. 171).
250--1--1180--015 169/267
18
170/267
E
”C” ”B” ”F”
1--(2)
3 3
36m 4 3 2 1 HA
57 56
K ”E” ”D”
4
K 3 ”A”
Z 55 209
250--1--1180--015
18.6.1.4 Guiding the rope between rope bracket and hook

block
The rope is guided between the rope bracket on the main boom
basic case and the hook block (Z 55 209):
− using the standard carrier role (56) on the individual main
boom inner sections and (57) on the main boom head (see
detail “A”).
− using the rope idler (6) on the basic boom (3) for all main
boom extension lengths (see detail “B”).
− using the rope idler (E) on the basic boom head (3) for the
10.4 m main boom extension (see detail “C”).
− using the head roller (K) on the basic boom (3) for the 10.4
m main boom extension (see detail “D”) or on the tip section
(4) for all other main boom extension lengths (see detail “E”)..
− using the top roller (8) on the intermediate section (2) or on
intermediate sections (1) and (2) for the main boom
extensions of 28 m and 36 m (see detail “F”).
250--1--1180--015 171/267
18
6
5
”X”
20
Z 55 210
172/267 250--1--1180--015
18.6.2 Preparation of the rope idler and the top rollers

before
reeving in
18.6.2.1 Preparation of the rope idler
The basic boom (3) with the attached rope idler (6) is available
with all length combinations of the main boom extension
(Z 55 210).
To reduce the risk of falling as far as possible when reeving in, the
rope idler must be raised until the rope protection pin (20) is
above the adjusting cylinders (5) and therefore able to be pulled
(see detail “X”).

250--1--1180--015 173/267
18
”X360”
”G”
”C”
14
Z 54 223 Z 54 202
6 15
Z 54 203
174/267 250--1--1180--015
Proceed as follows to lift a rope idler:
1. Connect the mobile control panel at socket ”X 360” to the

distributor box at the foot of the basic boom and check at the
same time that the connection between the socket ”G” and
the HATZ diesel motor is established (Z 54 223).
2. Start the HATZ diesel engine.
To start the HATZ diesel engine, proceed in the same manner as

already described in sect. 18.4.2 ”Attaching the 10.4 m main
boom extension”, item7.6, p.33
3. Remove the coupling pin (14), which is required to peg the

rope idler in working position, from the transport retainer at
the joint straps (Z 54 202).
4. Unlock the stop bolt (15, transport safety lock) and thereby
release the rope idler (6) from transport position (Z 54 203).
250--1--1180--015 175/267
18
8
6
9B 18
9A
Z 200 113 Z 54 207
16
”H”
”O” 17
Z 54 204
176/267 250--1--1180--015
5. Pull out the pull knob (16) and thereby release the stop cock
(17) from locking position (Z 54 204).
6. Switch the stop cock (17) from “0” position to position “H”
(preselection “Raise rope idler ”), (Z 54 204).
7. Switch the selector switch (8) at the mobile control desk to

the ”2” position and press the rocker switch (9A) (Z 200 113).
8. On pressing the rocker switch (9a, Z 200 113) the erection

cylinder (18) moves out and the rope idler (6) is raised
(Z 54 207).
250--1--1180--015 177/267
18
6
”X” ”Y”
20
15
3
Z 55 223
16
”H”
”O” 17
Z 54 209
178/267 250--1--1180--015
9. If the locking pin (20) of the rope idler (6) is above the
adjusting cylinders (5) and there in a position to be removed,
interrupt the lifting procedure (Z 55 223), detail “X”).
To do so pull out the knob (16) and switch the stop cock (17)
over from “H” position to “0” position (neutral position,
(Z 54 209).
The folding up of the rope idler to its final position (working

position) is done by reeving in the hoist rope and inserting the
locking pin (20).
10. Set the stop bolt (15) to position ”a” so that it can later
self--engage after folding out the rope idler (6) in transport
position (transport safety lock, refer to detail ”Y”, Z 55 223).
250--1--1180--015 179/267
18
1
8
“Y”
2 8
8
11
10
”X”
10
9
10
1--(2)
11
Z 55 211
180/267 250--1--1180--015
18.6.2.2 Preparation of the top rollers
The intermediate sections (1) and (2) are each equipped with a
top roller (8) (Z 55 211).
The hoist rope is lead under the roller (8) on the intermediate
section (2) of the 28m main boom extension or under the rollers
(8) on the intermediate sections (1) and (2) of the 36 m main
boom extension.
Before reeving in the hoist rope, the corresponding top roller (8)
must be released, the rocker (11) must be swivelled upwards (see
detail “Y”).
You can find the release of the top rollers in sect. 18.1 “Important
information” on page 7.

As soon as the hoist rope was lead under the corresponding top
roller, the rope must be tensioned. To do so bring the stop bolt
(10) in “locked” position so that it can automatically engage
downwards after swivelling the rocker (11) (rope tensioning lock).
Stick pin (9) through and lock (see detail “X”). The hoist rope is
tensioned and must be pulled downwards to pull out.
250--1--1180--015 181/267
18
6 ”A”
3
3
3
K
”B”
K
E
E
15
4
4
K
K
”C”
Z 55 212
182/267 250--1--1180--015
18.6.2.3 Preparation of the rope and run--in rollers
Due to the press--fitting (15) attached to the end of the hoist

ropes, the rope locking pins of all rope sheaves must be removed
before reeving. This applies to (Z 55 212):
− the rope idler (6) on the basic boom (3), see detail “A”
− the run--in roller (E) on the basic boom (3), see detail “B”
− the head rollers (K) on the basic boom (3) or on the tip section
(4), see details “B” and “C”
You can find the preparations to be made before unreeving or

winding on of the hoist rope for the appropriate cable drum in
sect. 18.10 “Removal of the main boom extension”, item 3., page
247.
Before reeving in a hoist rope with press fitting all rope

protection arrangements such as rollers or bolts on the
deflection rollers or idlers to be reeved in must be removed
or opened.
If this is not done the hoist rope cannot be drawn through
with the press fitting or may cause damage.
250--1--1180--015 183/267
18
21
3
6
20
12
13
11
H
H
K ”X”
3
4
F
H
K
H
F
Z 55 213
184/267 250--1--1180--015
18.6.3 Reeving in the hoist rope at the main boom extension

head
Only 2--fold reeving on the 1--sheave hook block is intended

for crane operation at the main boom extension.
If it is unavoidable for personnel to walk on the main boom

when the hoist rope is pulled out, suitable safety measures
must be taken.
There is a risk of accidents as a result of slipping / stum-
bling on the main boom or if the hoist is incorrectly oper-
ated.
Due to the risk of falling, it is prohibited to walk on the lat-
tice mast components to pull out the hoist rope; this must
be done from the side!
After pulling out the hoist rope from the ground, the hoist rope
must be set down in the attached intermediate rack (21) on the
basic boom (3) before the rope idler (6) is reeved in using the rope
cradle (2). From here the rope idler can then be reeved in and the
hoist rope secured against jumping off by the rope locking pin
(Z 55 213).
The connection of the hoist rope to the fixing point at the basic
boom (3) or the tip section (4) is done using a flanged pin that
must be secured with a linch pin.
Before reeving, please pay attention to the information and
warnings in section 17 “Reeving in” at the item “Rope end
connections”.
RISK OF ACCIDENTS!
The hoist rope may only be placed under load later if the
press fitting (13) is secured with safety flap (12) and the
locking pin (11) is locked in place (see detail ”X”).
In the version displayed, the rope pocket may only be used

for low--twist or twist--free ropes.
250--1--1180--015 185/267
18
”X”
H
H
”Y”
Z 55 219
186/267 250--1--1180--015
If the hoist rope at the basic boom head (3) or the tip section head
(4) is pinned to the fixing point, the shift weight must under all
circumstances be released from transport position (detail “X”)
and attached to the last fall of the hoist rope (detail “Y”)
(Z 55 219).
The shift weight should be fitted on 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 de-
scribed -- 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 length. There is the risk of the hoist rope breaking
and therefore the hook block / load falling down!
You can find the fitting of the shift weight in sect. 17 “Reeving”
under the item “Reeving in / unreeving the hoist rope”.
250--1--1180--015 187/267
18
”A”
6
”A”--14
3
6
”B”
”X”
K
3
FK
2
E
U
K
Z 55 214
188/267 250--1--1180--015
18.6.3.1 Reeving in at the 10.4 m main boom extension
The 10.4 m main boom extension is comprised only of the basic

boom (3).
1. Stick to the following sequence to pull out or reeve the hoist

rope (Z 55 214):
1.1 Hoist -- rope bracket on the basic case

− For hoist rope 1: rope bracket (32), see p. 165, or rope
bracket (42a), see p. 167
− For hoist rope 2: rope bracket (42b), see p. 169.
1.2 Rope bracket -- rope idler (6)
1.3 Rope idler (6) -- run--in roller (E)
1.4 Run--in roller (E) -- head roller (K)
1.5 Head roller (K) -- hook block (U)
1.6 Hook block (U) -- fixing point (FK) on the basic boom
After reeving in the hoist rope, the rope locking pins at the
rope idler (6, detail “A”) as well as the run--in roller (E) and
the head roller (K, detail “B”) must be used.
After inserting the rope locking pin, the rope idler (6, detail
“A”) must be lifted to working position and secured.
The hoist rope may only be reeved in in the way shown. Other
reeving configurations would disrupt the function of the load
limit device.
The lifting of the rope idler should be carried out as described in

sect. 18.6.2.1 “Preparation of the rope idler”, as from p. 175,
item 1..
2. Secure the rope idler (6) after reaching working position. To

do so insert coupling pin (14) at point “A” of the joint plate and
secure with the linch pin (see detail “X”).
If the rope idler (6) is in working position and not secured

with pin (14) and linch pin, crane operation is NOT allowed!
250--1--1180--015 189/267
18
”X360”
9B
”C”
9A
Z 52 797 Z 200 113
16
”H”
”O” 17
Z 54 209
190/267 250--1--1180--015
3. Pull out the pull knob (16) and thereby release the stop cock
(17) from the locking position (Z 54 209).
4. Switch the stop cock (17) over from “H” position to “0”
position (neutral position, (Z 54 209).
5. Switch the selector switch (8) at the control desk to position

”3” and press the rocker switch (9b) until the HATZ diesel
engine stops (Z 200 113) and then switch off the ignition in
the crane cab.
6. Remove the mobile control desk from socket ”C” at the

distribution box ”X 360” in the foot of the basic boom and
close the socket with a protective cap (Z 52 797).
If the mobile control panel is not removed, then the functions

required for crane operation with main boom extension will
not be possible from at the crane cab.
250--1--1180--015 191/267
18
”A”
6
6
3
4
”B”
3
K
FK
4
2
K
1
U
Z 55 215
192/267 250--1--1180--015
18.6.3.2 Reeving in at the 20 m main boom extension
The 20 m main boom extension consists of the basic boom (3)

and the tip section (4). The hoist rope is reeved in at the tip section
head.
Stick to the following sequence to pull out or reeve in the hoist

rope (Z 55 215):
1. Hoist -- rope bracket on the basic case

2. Rope bracket -- rope idler (6) on the basic boom (3)
3. Rope idler (6) -- head roller (K) on the tip section (4)
4. Head roller (K) -- hook block (U)
5. Hook block (U) -- fixing point (FK) at the tip section
After reeving the hoist rope, the rope locking pins at the rope
idler (6, detail “A”) as well as the rope idler (E) and the head
roller (K, detail “B”) must be used.
After inserting the rope locking pin, the rope idler (6, detail
“A”) must be lifted to working position and secured.
limit device.
The lifting of the rope idler should be carried out as described in

sect. 18.6.2.1 “Preparation of the rope idler”, as from p. 175,
item 1..
The securing of the rope idler in working position, the switching
off of the pressure feed as well as the detachment of the mobile
control panel should be carried out as described in sect. 18.6.3.1
“Reeving at the head of the 10.4 m main boom extension”, as
from item 2., p. 189.
250--1--1180--015 193/267
18
”C”
2
8b
2
8b
2
”A”
6
6
3
3
4
”B”
K
4
FK
1 2
K
Z 55 216
194/267 250--1--1180--015

section (2), the basic boom (3) and the tip section (4). The hoist
rope is reeved in at the tip section head.

rope (Z 55 216):

2. Rope bracket -- top roller (8b) on the intermediate section (2)
3. Top roller (8b) -- rope idler (6) on the basic boom (3)
As soon as the hoist rope is lead under the top roller (8b), the
rope must be tensioned and lead downwards to be pulled
out.
Pull out the hoist rope from the ground until it can be reeved
in at the main boom extension head.
You can find the tensioning of the hoist rope in sect. 18.6.2.2
“Preparation of the top rollers”, p. 181 (see also detail “C”).
limit device.
The additional caution notes for inserting the rope locking pin and
lifting the rope idler as well as the required instructions for
completing this reeving procedure can be found in sect. 18.6.3.2,
on page 193 (see also details “A” and “B”).
250--1--1180--015 195/267
18
196/267
K 4 3 6 2 8b 1 8a
2
1
U
FK
”A”
”B” ”C”
K 4 8
3 6
2
1--(2)
Z 55 217
250--1--1180--015

sections (1) and (2), the basic boom (3) and the tip section (4).
The hoist rope is reeved in at the tip section head.

rope (Z 55 217):

2. Rope bracket -- top roller (8a) on the intermediate section (1)
3. Top roller (8a) -- top roller (8b) on the intermediate section (2)
4. Top roller (8b) -- rope idler (6) on the basic boom (3)
As soon as the hoist rope is lead under the top roller (8a) on
intermediate section (1), the rope must be tensioned and
lead downwards to be pulled out.
Pull out the hoist rope from the ground in a forward direction
until it can be pulled through the top roller (8b) on
intermediate section (2).
You can find the tensioning of the hoist rope in sect. 18.6.2.2
“Preparation of the top rollers”, p. 181 (see also detail “C”).
limit device.
The additional caution notes for reeving in the top roller (8b), for
inserting the rope locking pin and lifting the rope idler as well as
the required instructions for completing this reeving procedure
can be found in sect. 18.6.3.3, on page 195 (see also details “A”
and “B”).
250--1--1180--015 197/267
18
Z 54 252
5
13 5 13
2
3
13
3
Z 54 253
198/267 250--1--1180--015
18.7 Erecting
18.7.1 Checks before erecting
Before raising the main boom extension and selecting the

operating length check:
-- that the main boom extension and main boom head are
correctly locked together.
-- the correct interlocking of the different components with
one another.
-- that all pins are fitted and locked correctly.
-- that all connecting pins are secured with the correct
functioning locks in accordance with the regulations.
-- that no tube damage is present on the lattice mast
components. If you discover damaged tubes during a
visual inspection then continuing to work with the main
boom extension is prohibited.
-- that the main boom is well lubricated. This is especially
important for long main boom extension lengths. Before
all operations, the slides and the rear linings must be well
lubricated.
-- that the load limit device is set to the load program to be
run in the ”Main boom extension” operation (see sect. 10
of these operating instructions as well as the respective
load capacity table).
-- that the main boom is retracted and pinned.
-- that the fitted counterweight corresponds to the one
specified in the corresponding load capacity table.
-- that the angle between main boom and main boom
extension amounts to 0° (Z 54 252).
-- that the upper pinning of the basic boom (3) to the main
boom head or to the intermediate section (2) is
fundamentally established by means of the piston rods
of the luffing cylinders (5) using 2 cotter pins (13). The
upper biconical pins must be removed without fail for
crane operation (Z 54 253).
250--1--1180--015 199/267
18
4
22
”X”
”Y”
24
23
Z 54 254
”X371”
25 K
25
3
4
Z 54 255
200/267 250--1--1180--015
Before raising the main boom extension and selecting the

operating length check:
-- that the hoist rope (H) is correctly reeved in at the basic

boom head (3) or the tip section (4).
The hoist limit switch (22) needs to be attached to the
corresponding head and the hoist rope must be pulled
through the shift weight (23) (details ”X” and ”Y” in
Z 54 254).
The connection between the hoist limit switch and the
shift weight needs to be established using the chain (24).
-- that the socket (F) at the distributor box ”X 365” or the
socket (K) at the distributor box ”X 371” is provided with
the dummy plug (25) in the event that the anemometer is
not connected to the basic boom (3) or to the tip section
(4).
The bus shutoff system is integrated into this dummy
plug.
250--1--1180--015 201/267
18
24
23
25
Z 54 258
11
13
Z 54 259
202/267 250--1--1180--015
Check before raising the main boom extension and extending to

the working length that sufficient fuel is in the tank (23) of the
HATZ diesel engine (Z 54 258).
Because telescoping of the main boom is only possible

when the main boom extension is in 0° position, efforts must
be made to ensure that the main boom extension can still be
moved over the luffing cylinder in 0° position following
completion of crane operation with angled main boom
extension.
After setting the IC--1 to “Main boom extension mode” (refer to

sect. 18.7.2, as from p. 205) the fuel level is indicated on the
screen (13) of the IC--1 display. During crane operation you can
monitor the fuel level at this display (Z 54 259).
You can fill the fuel tank after opening the tank cover (24)
(Z 54 258).
You will find the procedure as well as the appropriate diesel fuel
in the operating instructions for the HATZ diesel engine in part 5
of this documentation.
If the working position of the main boom extension is not

achieved with the auxiliary crane attached but rather by
folding out from the transport position, then both the engine
and the hydraulic oil levels must be checked in addition at
the ”power pack”. You will find this procedure in
sect. 18.4.2., item 1., on page 23.
Depending on the weather conditions (outside temperature)
and the number of starting procedures of the HATZ diesel
engine the battery (25) can discharge appropriately fast
(Z 54 258).
In spite of the indication (11, Z 54 259) of the battery voltage
at the IC--1 display we recommend that the battery at the
”power pack” is recharged regularly to be on the safe side.
250--1--1180--015 203/267
18
Z 54 260
Z 54 261
204/267 250--1--1180--015
18.7.2 Erection procedure
The operating mode corresponding to the crane configuration

must be correctly set prior to the raising of the main boom.
RISK OF ACCIDENTS!
No crane movement is permissible unless the load limit de-
vice is set to the actual crane configuration.
Proceed as follows:
1. Switch on the ignition in the superstructure cab.
The IC--1 is automatically started when the ignition is switched

on. Depending on the temperature of the computer (monitor) the
”Operating type selection” screen appears at the display after a
corresponding warm--up period.
The display of this screen corresponds with the last set operating
condition (example “Z 54 260”: working with the main boom with
74.5 t counterweight, 8.5 m outrigger span and single reeving).
2. Now select the various parameters of the current crane

configuration at the ”Operating type selection” screen.
To do this -- beginning in the first field “Type” -- open the
corresponding pull--down menu and select HAVHY (for
operation of the hydraulic main boom extension) (Z 54 261).
If, when this parameter is changed another one is also

automatically changed by the system, then it is displayed
in red fonts. Values in ”red” must be confirmed by the
user; this means the key must be actuated again.
If then the key appears with a red background and black
fonts, then this rigging mode can not be set due to the
current crane status.
You can find additional information in sect. 10 “Safety devices” in

the subsection “Selection of operating mode”.
250--1--1180--015 205/267
18
Z 54 260
Z 54 261
206/267 250--1--1180--015
3. Proceed in analogous fashion to select the additional

parameters. This applies to Z 24 260):
− Field 2: main boom extension length
− Field 3: not allocated
− Field 4: attached counterweight
− Field 5: outrigger span
− Field 6: number of reeves.
If the main boom head is not reeved in and/or its shift weight is
set to transport position by the hoist limit switch, the following key
appears on the display: (Z 54 261)
With this button, the hoist limit switch on the main boom head is
bypassed.
250--1--1180--015 207/267
18
Z 54 262
Z 54 263
208/267 250--1--1180--015
4. Check now whether the data entered corresponds with the

current configuration of the crane (Z 54 262).
In this case:
− Field 2: main boom extension length: 10.4
− Field 4: attached counterweight: 74.5
− Field 5: outrigger span: 8.5
− Field 6: number of reeves: 2--fold.
5. Before pressing the Alteration key -- the hoist limit

switch on the main boom head is bypassed. In the bypassed
condition, the key lights up in red (Z 54 262).
6. Exit the “Operation mode selection” screen via to

confirm the alteration screen (Z 54 263).
If your selection is not activated, press key .(Z 54 263)
The correct selection of the values of all relevant input

fields corresponding to the actual current configuration
of the crane is the sole responsibility of the crane driver.
The load limit device cannot check the selection made.
Incorrect inputs mean that the load limit device cannot
monitor the subsequent crane operation.
Operating the crane in this manner is not permitted! Risk
of accidents!
250--1--1180--015 209/267
18
Z 52 988
Z 54 264
210/267 250--1--1180--015
7. While the preparation procedure is being carried out, screen

(Z 52 998) is displayed.
After preparations have been completed, screen (Z 54 264)
appears.
250--1--1180--015 211/267
18
Z 54 265
1 2
Z 54 266
212/267 250--1--1180--015
8. When in the screen “Quick Menu” (Z 54 265), the key

is pressed, the screen for the operation of the main boom
extension appears (Z 54 266).
Four keys appear in this mask, which are necessary for
crane operation with main boom extension:
-- key (1) HATZ diesel engine Start / Stop

-- key (2) Conversion of “Luffing the main
boom extension” to the corre-
sponding control lever “Telescop-
ing”
-- key (3) Conversion of the engine speed
from medium to maximum rotation
speed and the other way around.
-- key (4) Switching off of the preheating
system of the HATZ diesel engine
Press key (Z 54 266) to get back to the starting screen

(Z 54 265).
250--1--1180--015 213/267
18
23 24 25 5 6 7
22
8
21
9
20 10
11
19 12
13
18 17 16 15 14
Z 54 267
214/267 250--1--1180--015
The indicators or indicator lights necessary for crane operation

with the main boom extension are listed here: (Z 54 267).
(5) -- indicator light -- engine oil pressure too low
(6) -- indicator light -- alternator faulty
(7) -- indicator light -- engine temperature too high
(8) -- display -- engine speed
(9) -- display -- ambient temperature at the “Power pack”
(10) -- display -- preheating time
(11) -- display -- battery voltage
(12) -- indicator light -- insufficient fuel
(13) -- beam display -- fuel quantity
(14) -- display p3 -- pressure on the ground side of the adjusting
cylinders 1+2
(15) -- display -- angle of the main boom extension relative to the
horizontal
(16) -- display p2 -- pressure on the rod side of the adjusting
cylinder 2 (right hand side)
(17) -- display p1 -- pressure on the rod side of the adjusting
cylinder 1 (left hand side)
(18) -- display -- HATZ diesel engine in operation
(19) -- display -- main boom foot angle relative to the horizontal
(20) -- display -- rigging mode; is indicated at longitudinal code
(LC 1), if there are no table values for the current crane
configuration. Lifting of loads is not permitted.
(21) -- display -- folding--out angle between the main boom
extension to the main boom (0° to 40°)
(22) -- display -- see item (15)
(23) -- display -- rigging mode: no lifting capacity released
-- crane operation: max. permissible lifting
capacity
(24) -- display -- main boom head angle relative to the horizontal
(25) -- display -- rigging mode: no lifting capacity released
-- crane operation: LMI utilisation rate (%)
The general handling of the IC--1 as well as the additional

controls, fittings and indicators for crane operation can be found
in Sect. 10 “Safety devices”.
250--1--1180--015 215/267
18
Z 54 268
216/267 250--1--1180--015
9. As the main boom is now completely retracted and pinned,

the angle between the main boom and the main boom
extension is 0° and the longitudinal code “LC 1” has been
set, the main boom can be raised using to luffed position the
luffing gear (min. 78°) (Z 54 268).
The luffing operation and the regulating of the luffing speed can
be found in sect. 13 of this operating instructions.
10. After starting the superstructure engine, raise the main boom
by extending the luffing cylinder to luffed position with the
corresponding control lever.
RISK OF ACCIDENTS!
It is the crane operator’s responsibility to check the current
control lever configuration before initiating a crane move-
ment.
Otherwise there is risk of accidents if accidental crane
movements are triggered!
The current mode (here: 1) is displayed by the corresponding

symbol in the uppermost row of the IC--1 display
(Z 54 268).
The main boom may not be raised at high speed when the
main boom extension is attached.
It is prohibited to raise a load from the ground using the luf-

fing gear! This can only be done using the hoist!
250--1--1180--015 217/267
18
23 25
20
Z 54 269
218/267 250--1--1180--015
11. As the main boom is now in luffed position, the main boom
can be extended to the desired working length (Z 54 269).
During the extension process, the rigging displays (20), (23)
and (25) are shown at the IC--1 display.
There is a danger of crushing when the telescopic sections

are retracted and extended.
For this reason people are not permitted to be in the area
of danger.
Before extending, the longitudinal code (LC) necessary for the

desired main boom working length must be selected.
For information about this, please consult chapter 12
”Telescoping” and especially the sub--points “Telescoping
procedure”, “Telescoping display” and “Selection of the
longitudinal code”. These longitudinal codes have to be in
agreement with the respective load capacity table.
Check which mode has been selected for the assignment of the
control levers. The current mode (here: 1) is displayed by the
corresponding symbol in the top line of the IC--1 display
(Z 54 269).
You will find detailed information on the selection and range of the
different modes in section 10 “Safety devices”.
RISK OF ACCIDENTS!
ment.
If the main boom is extended or retracted and pinned at its

final working length, the LPU must be completely retracted.
Lifting capacities will only be released or achieved after the
LPU has been completely retracted.
250--1--1180--015 219/267
18
HA
3
3
2
Z 54 270
Z 54 271
220/267 250--1--1180--015
18.8 Crane operation at the main boom extension
Crane operation at the main boom extension can be carried out

at any level below an angle of 0° to 40°. This angle is the folding
out angle between the main boom and the main boom extension.
For a main boom extension length of 10.4 m or 20 m, the angle
is set at the main boom head (HA) (Z 54 270).
For a main boom extension length of 28 m or 36 m, the angle is
set at the intermediate section (2) (Z 54 270).
The load capacity tables supplied together with the crane are
divided into 5 angle stages: 0°, 10°, 20°, 30° and 40°.
The maximum permitted lifting capacity quoted in the
corresponding load capacity table is shown on the IC--1 display
in the “MAX (t)” field, (Z 54 271, here 13.0).
If a load is to be raised at an angle between two angle levels (e.g.

25°), there is no load capacity table for this. The corresponding
maximum permitted lifting capacity is then calculated
(interpolated) by the IC--1 and only displayed in the “MAX (t)” field
(Z 54 271).
250--1--1180--015 221/267
18
21
Z 54 272
222/267 250--1--1180--015
18.8.1 Folding the main boom extension
Folding the main boom extension (luffing down from 0° to 40° /

luffing up from 40° to 0°) is achieved by extending or retracting
the two adjusting cylinders (5) on the basic boom (3).
The current folding angle is shown on the IC--1 display (pos. 21).
250--1--1180--015 223/267
18
1 4
10
18
Z 54 273
224/267 250--1--1180--015
Proceed as follows to fold out the main boom extension:
1. Start the superstructure engine.
Observe sect. 5 of these operating instructions when starting up

the motor.
To start the HATZ diesel engine from the superstructure cab, it is

sufficient that the ignition be switched on. For safety reasons, it
is recommended that the superstructure engine be started
immediately, so that dangerous operating states can be avoided
by using certain crane functions.
2. As described in sect. 18.7.2, from page 205, callup thescreen

for operation of the main boom extension (Z 54 273, right
hand side of figure).
3. Start the HATZ diesel engine by pressing the key (1)

(Z 54 273).
Depending on the ambient temperature of the “power pack”

(below 0° C), the motor is preheated automatically. This is
signalled by the lighting up of key (4). The preheating time is
shown on the display (10) and is set back to 0.
The maximum preheating time (at --20° C and below) is 2 min.,
the maximum start--up time 7 s (see also information in
sect. 18.4.2 “Fitting of the 10.4 m main boom extension”,
item 7.6, p. 33).
Because the sensor measures the ambient temperature of the
“power pack” and not of the engine, it is possible that preheating
will occur at low outside temperatures, even though the engine
is warm. Automatic preheating can then be switched off manually
by pressing the key (4).
As soon as the engine is running, the following appears on the
display (18, HATZ diesel engine in operation).
250--1--1180--015 225/267
18
Z 54 274
226/267 250--1--1180--015
4. By pressing the key (2), convert the “Luffing the main boom
extension” crane function to the control lever assigned with
the “Telescoping” function. Telescoping of the main boom is
now no longer possible (Z 54 274).
The key (2) lights up green.
RISK OF ACCIDENTS!
ment.
5. Using the corresponding control lever, luff the main boom

extension down until the hook block is over the load to be
lifted. Tie down the load (Z 54 274).
250--1--1180--015 227/267
18
3
U
K 3
Z 55 220
228/267 250--1--1180--015
18.8.2 Raising the load above the main boom extension
The weight of the load to be lifted must be known. The

reeving in of the hook block must be carried out in such
a way that a maximum rope pull of 11.8 t per line is not
exceeded when lifting the total load (weight of load and
hook block).
In the load capacity tables, the reevings quoted are not

less than twofold. If a single--fold reeving is required, the
lifting capacities quoted in the tables should be reduced
by 20%. This is also valid if the lifting capacity lies below
the maximum permissible rope pull of 11.8 t per line.
It is forbidden to lift a load by luffing up the main boom

extension (retracting of the adjusting cylinder).
The load may only be lifted from the ground using the
hoist.
If the load is still in contact with the ground and raising
of the hoist has been shut down, the load is too heavy.
For operating the crane at the 20 m main boom extension --

if the main boom is in steep position and the main boom
extension is at 0° position -- then there is the risk of collisions
between the hook block (U) and the head roller (K) on the
basic boom (3) when lifting or putting down this hook block.
Danger of damage to the basic boom head and the hook
block! (Z 55 220) Proceed appropriately!
250--1--1180--015 229/267
18
25
Z 54 275
230/267 250--1--1180--015
Proceed as follows to lift a load:
1. Using the corresponding control lever, lift the load using the
hoist until the load is no longer in contact with the ground.
Pay attention here to the display (25, “Utilisation of the load
limit device”, Z 54 275).
The section “Hoists” (sect. 14 and 15) should also be read

before lifting a load.
RISK OF ACCIDENTS!
ment.

(Z 54 275).
250--1--1180--015 231/267
18
17 16 14
Z 54 276
232/267 250--1--1180--015
2. Because the load is now hanging freely, it can be lifted by

luffing up the main boom extension. This is achieved by
retracting the adjusting cylinder (5) at the basic boom (3),
(Z 54 276).
RISK OF ACCIDENTS!
ment.

(Z 54 276).
The pressure in the adjusting cylinders (5) can be read off at the
IC--1 display:
− Pos. 17: (P1) -- maximum operating pressure on the rod side
of the left hand side adjusting cylinder
− Pos. 16: (P2 -- maximum operating pressure on the rod side
of the right hand side adjusting cylinder
− Pos. 14: (P3) -- maximum operating pressure on the whole
ground side of both adjusting cylinders.
The maximum permissible operating pressures, (P1) and

(P2) on the rod side of both adjusting cylinders (5) are
160 bar. The pressure protection is set to 265 bar.
The maximum permissible operating pressure, (P3), on the
whole ground side of both adjusting cylinders (5) is 60 bar.
If a pressure of 160 bar is exceeded, the main boom
extension cannot be raised. The load attached is too heavy.
250--1--1180--015 233/267
18
2
21
18
Z 54 277
234/267 250--1--1180--015
18.9 Lowering the main boom extension
Proceed as follows to lower the main boom extension:
1. Start the superstructure engine, set down the load and lift the
main boom to luffed position.
2. Start the HATZ diesel engine from the superstructure cab as

described in sect. 18.8.1 “Folding out”, p. 225. The symbol
(18) lights up.
3. Check now that the key (2) is lit up green (Z 54 277).

If this key is lit up, the “Luffing the main boom extension”
crane function is switched to the control lever assigned with
the “Telescoping” function.
RISK OF ACCIDENTS!
ment.
4. Using the corresponding control lever, lift the main boom

extension by retracting the adjusting cylinders (5) on the
basic boom (3) until the angle between the main boom and
the main boom extension is 0°.
The folding angle can be read off at the display (21)
(Z 54 277).
Retraction of the main boom is only possible if the main boom

extension is in 0° position.
250--1--1180--015 235/267
18
23 25
20 1
18
“X”
Z 55 218
236/267 250--1--1180--015
5. As the main boom extension is now in 0° position to the main

boom, press key (2) on the IC--1 display and thus switch the
“Telescoping the main boom” crane function to the control
lever assigned with the “Luffing the main boom extension”
function. The green lamp in the key (2) goes out (Z 55 218).
6. Turn off the HATZ diesel engine by pressing the key (1) on
the IC--1 display. Display (18) goes out.
7. Retract the main boom completely.
There is a danger of crushing when the telescopic sections

are retracted and extended.
For this reason people are not permitted to be in the area
of danger.
(Z 55 218)
If the main boom is in luffed position (80--82°) and entirely
retracted, the crane movements must be carried out with
appropriate care and at low speed. In particular you avoid
swinging movements of the hook block (1) this way, that
could cause collisions with the luffing cylinder (2) (see detail
“X”).
Risk of damage!
Before retracting, the longitudinal code (LC) required for the

desired main boom working length must be selected (here: LC 1).
For information about this, please consult chapter 12
”Telescoping” and especially the sub--points “Telescoping
procedure”, “Telescoping display” and “Selection of the
longitudinal code”. These longitudinal codes have to be in
agreement with the respective load capacity table.
Check which mode has been selected for the assignment of the
control levers. The current mode (here: 1) is displayed by the
corresponding symbol in the uppermost row of the IC--1
display (Z 55 218).
During the retraction process, the rigging displays (20), (23) and
(25) are shown on the IC--1 display.
250--1--1180--015 237/267
18
23 25
20
Z 54 279
238/267 250--1--1180--015
RISK OF ACCIDENTS!
ment.
If the main boom is completely retracted and pinned, the LPU

must be completely retracted.
Lifting capacities will only be released or achieved after the
LPU has been completely retracted.
8. As the main boom is now completely retraced and pinned,

the angle between the main boom and the main boom
extension is 0° and the longitudinal code “LC 1” is set, the
main boom can be completely lowered using the luffing gear
(Z 54 279).
The luffing operation and the regulating of the luffing speed can
be found in sect. 13 of these operating instructions.
During the lowering process, the displays (20), (23) and (25) are
shown for the longitudinal code (LC 1) selected if there are no
values given in the table for the current crane configuration
(Z 54 279).
9. Lower main boom by moving the luffing cylinder with the

corresponding control lever to flat position.
RISK OF ACCIDENTS!
ment.

(Z 54 279).
The main boom may not be lowered at high speed when the
main boom extension is attached.
250--1--1180--015 239/267
18
”X”
3
”Y”
4
Z 54 280
240/267 250--1--1180--015
18.10 Removing the main boom extension
Remove the main boom extension by following the fitting

sequence in reverse order.
1. Loosen the hoist rope at the head of the tip section (4) or the
basic boom (3) (see detail “Y”) and unreeve the hoist rope at
the hook block (Z 54 280).
When unreeving, there is a danger of winching and re-

tracting at the head rollers and at the hook blocks.
Proceed with appropriate caution.
Risk of crushing.
Touch the hook block only using the handrails provided
(see detail ”X”). Under no circumstances should hands
get near the following areas:
* between the rope sheaves, side plates and covers.
* in the area of the fixing points (sometimes hinged), of

the hook, of the hook nut, of the crosshead or of the
protecting cages.
One may only work (unreeving) on the hook block if it
is set down firmly on the ground.
250--1--1180--015 241/267
18
”X”
6
”A”--14
Z 55 225
20
”X360”
6
5
”G”
3
”C”
Z 54 223 Z 55 224
242/267 250--1--1180--015
2. Lower rope idler (6).
To reduce the risk of falling when unreeving as far as possible, the

rope idler must be lowered until the rope protection pin (20) is
above the adjusting cylinders (5) and therefore able to be pulled
(55 224 see detail X”).

Risk of crushing!
Proceed as follows to lower the rope idler:

the socket ”G” and the HATZ diesel motor is
established (Z 54 223).
Start the HATZ diesel engine.
Proceed when starting the diesel engine as described in

sect. 18.4.2, starting at page 33.
2.2 Release rope idler (6). To do so, unlock coupling pin

(14) at point “A” of the joint plate and pull (see detail “X”,
Z 55 225).
250--1--1180--015 243/267
18
8
9B
9A
6
16
”S”
17
”O”
Z 54 292
16
”S” 6
”X” ”Y”
”a”
20
”Z”
15
17
”O”
6
15
5
3
Z 55 226
244/267 250--1--1180--015
2.3 Lower rope idler (6) hydraulically from its working

position (Z 54 292). To do so:
− Release the stop cock (17) by pulling the knob (16)
from the lock position.
− Switch the stop cock (17) from “0” position to
position “S” (preselection “Lower rope idler ”).
− Switch the selector switch (8) at the mobile control
desk to ”2” position and press the rocker switch (9A).
On actuating rocker switch (9A) the rigging cylinder
is retracted and the rope idler (6) is lowered.
Risk of crushing!
2.4 If the locking pin (20) of the rope idler (6) is above the
adjusting cylinders (5) and there in a position to be
removed, interrupt the lowering procedure (Z 55 226,
detail “X”).
To do so pull out the knob (16) and switch the stop cock
(17) over from “S” position to “0” position (neutral
position, see detail ”Z”, Z 55 226.
The folding down of the rope idler in its end position (transport
position) is done by unreeving the hoist rope and inserting the
locking pin (20).
2.5 Now check that the stop bolt (15) is in ”a” position
(locked) so that it can later self--engage after folding
out the rope idler (6) in transport position (transport
safety lock, refer to detail ”Y”, Z 55 226).
250--1--1180--015 245/267
18
HA
6
1
3
2
K 4
11
10
11
3
1--(2)
15
4
8
36m
Z 55 737
246/267 250--1--1180--015
3. Wind the hoist rope onto the corresponding cable drum.
Before winding the hoist rope (Z 55 737):

-- the rope locking pins at the rope and run--in rollers at the
basic boom head (3) of the 10.4 m main boom extension
or the tip section head (4) must be removed for the
remaining main boom extension lengths (see details “A”
and “B”).
-- the rope locking pin at the rope idler (6) on the basic boom
(3) must be removed (see detail “C”).
-- the top section rollers (8) at the intermediate sections
(1)/(2) must be released (see detail “D” as well as
sect. 18.1 “Important information”).
-- a rope sheave must be removed from the corresponding
rope bracket slots. Detach both linch pins, remove the
keeper plate (10) and remove one of the two rope sheaves
(11) (see detail “E”).
This combination with the double rope bracket and rope sheaves
(detail “E”) is optional if hoist 2 is available. Otherwise, the rope
bracket consists of a steel frame with an inbuilt rope roller (see
detail “F”).
In this case, no disassembly of the rope bracket is necessary.
If this is not accounted for, there is the danger of damage to

the rope sheaves from the press fitting (15) attached to one
end of the hoist rope.
250--1--1180--015 247/267
18
4 3
12
12
4 3
12
Z 54 282
248/267 250--1--1180--015
4. Remove the tip section (4) (Z 54 282).

Proceed as follows:
4.1 Detach the electrical connection between the “X 371”

distributor box on the tip section (4) and the “X 365”
distributor box on the basic boom (3).
4.2 Tie down the auxiliary crane two--fall at the appropriate

eyelets of the tip section (4).

4.3 Disconnect the joint between the basic boom (3) and
the tip section (4) by removing the four biconical pins.
To do this, remove the top retaining spring of the
corresponding biconical pin (12) and drive the bolts out
downwards. During this procedure, the tip section
must be held by the auxiliary crane in such a way so
that it cannot swing away.

is loosened).
4.4 Remove the tip section (4) using the auxiliary crane.
If the tip section (4) is to be removed together with the basic boom
(3), the tip section must first be folded to transport position and
locked. A 3--fall sling is necessary in this case. The slinging points
are described in sect. 18.3, page 17, and the folding procedure
in sect. 18.5.3.3, starting from page 155.
RISK OF ACCIDENTS!
The removal of both parts (3) and (4) in straight condition
side by side is prohibited!
250--1--1180--015 249/267
18
Z 54 283
”X360”
”G”
”C”
Z 54 223
250/267 250--1--1180--015
5. Remove the basic boom (3).

Proceed as follows:
5.1 Tie down the auxiliary crane (two--fall) at the

appropriate eyelets of the basic boom (3) (Z 54 283).
With the tip section stowed in transport position, a 3--fall

lifting tackle is required.


the socket ”G” and the HATZ diesel motor is
established (Z 54 223).
Start the HATZ diesel engine.
Proceed when starting the diesel engine as described in

sect. 18.4.2, starting at page 33.
250--1--1180--015 251/267
18
”X”
14
”Y” 16
”S”
”Z”
17
6 15
”O”
Z 54 293
252/267 250--1--1180--015
5.3 Because the hoist rope is now unreeved (see item 3 of

this section), lower the rope idler (6) at the basic boom
(3) to transport position and secure.
Risk of crushing!
5.4 If the rope idler (6) is in transport position (Z 54 293),

then:
− the coupling pin (14) at the joint plate must be
pegged in transport position (detail “X”)
− it must be checked that the stop bolt (15, transport
safety lock) is engaged correctly (detail “Y”)
− the stop cock (17) must be switched from position
“S” to position “0” (neutral position, detail ”Z”) after
being released by pull knob (16).
250--1--1180--015 253/267
18
13--”C”
2
Z 54 294
9B
9A
Z 54 295
254/267 250--1--1180--015
5.5 Tension lifting tackle with auxiliary crane and hold

basic boom (3) in such a way that the coupling pins (13)
of the piston rods at points “C” and “F” can be pulled
(Z 54 294).

is loosened).
5.6 Unlock coupling pin (13) at point “C” on the left side and
point “F” on the right side and pull (Z 54 294).
5.7 Switch the selector lever (8) at the mobile control panel
to position ”1” and press the rocker switch (9B) until the
piston rods (5) are completely retracted (Z 54 295).
250--1--1180--015 255/267
18
”X360”
”G”
”C”
Z 54 223
”X360”
”X359”
”C”
Z 54 240
256/267 250--1--1180--015
5.8 Because the upper hydraulic pinning between basic

boom (3) and intermediate section (2) is now unlocked:
− disconnect the mobile control panel from socket “C”
of the distributor box “X 360” at the foot of the basic
boom (Z 54 223).
Close socket with protective cap,
− switch off the HATZ diesel engine.
− Disconnect the electrical connection between the
section (2) ( Z 54 240).
There is the risk of damage to the connecting cable when

unlocking the lower bolt--connection!
250--1--1180--015 257/267
18
”X”
10
2
3 ”A”--12 ”D”--12
Z 54 296
24
24
24
”a” ”b”
Z 54 297
258/267 250--1--1180--015
Before the following unlocking of the biconical pin, check

that the stop bolt (10) at the bottom left fork head of the basic
boom (3) is in the ”released” position (see detail “X” in
Z 54 296).
5.9 Detach the bottom connection between basic boom (3)

and intermediate section (2) by removing the 2
biconical pins at points “A” and “D”.
To release the pin, remove the top retaining spring of
the corresponding biconical pin (12) and drive the bolts
out downwards. During this procedure, the basic boom
(3) must be held by the auxiliary crane in such a way
so that it cannot swing away (54 296).

Always mount the ladder safely and in such a way that ob-
jects it leans against cannot move away (e.g. when a pin is
loosened).
5.10 Remove the basic boom (3) using the auxiliary crane.
Before setting the basic boom down on the ground or flatbed

trailer, unlock outrigger feet (24) and extend from transport
position “a” to working position “b”. Secure both outrigger
feet with linch pins (Z 54 297).
250--1--1180--015 259/267
18
5 ”F”
”A”--12
Z 54 298 Z 54 299
”X360”
”A”
Z 52 795
260/267 250--1--1180--015
For the main boom extension lengths of 10.4 m and 20 m, the

basic boom (3) is pinned directly to the main boom head.
To remove the basic boom (3) from the main boom head, proceed
in exactly the same way as described in this section at item 5., as
from p. 251.
If the tip section (4) is to be removed together with the basic boom
(3), the tip section must first be folded to transport position and
locked. A 3--fall sling is necessary in this case. The slinging points
are described in sect. 18.3, page 17, and the folding procedure
in sect. 18.5.3.3, starting from page 155.
− First the upper coupling pins at points “C” and “F” must be
pulled and the piston rods (5) removed completely
(Z 54 298).
− The electrical connection between the distribution box ”X
360” in the foot of the basic boom and the distribution box ”X
550” at the main boom head is released (connection ”A”, Z 52
795).
− finally the bottom biconical pins (12) at points “A” and “D” are
driven out downwards (Z 54 299).

lower pins. Make sure that nobody is in the danger--zone!.
is loosened).
250--1--1180--015 261/267
18
”X358”
”X359”
”D”
Z 54 251
12
2
2
12
12 1
12
Z 55 200
262/267 250--1--1180--015
6. Remove the intermediate section (2). Proceed as follows:
6.1 Disconnect the electrical connection between the

section 2 (connection ”D”, Z 54 251).

eyelets of the intermediate section (2).

6.3 Disconnect the joint between the intermediate section

(2) and the intermediate section (1) by removing the
four biconical pins (Z 55 200).
To do this, remove the top retaining spring of the
corresponding biconical pin (12) and drive the bolts out
downwards. During this procedure, the intermediate
section must be held by the auxiliary crane in such a
way so that the piece cannot swing away.

object it leans against cannot move away (e.g., if a pin is
loosened).
6.4 Remove the intermediate section (2) using the

auxiliary crane. (Z 55 200)
250--1--1180--015 263/267
18
”X358”
”A”
Z 54 250
1 12 1
12
Z 55 201
264/267 250--1--1180--015
7. Remove the intermediate section (1) from the main boom

head. Proceed as follows:
7.1 Disconnect the electrical connection between the


eyelets of the intermediate section (1).

7.3 The disconnection of the bolt joints between

intermediate section (1) and main boom head as well
as the removal of this intermediate section is carried
out in the same way as described under item6., p. 263,
for intermediate section (2) (Z 55 201).

object it leans against on cannot move away (e.g. when a
pin is loosened).
250--1--1180--015 265/267
18
Z 55 221
266/267 250--1--1180--015
18.11 Emergency lowering
With the main boom extension attached in working position, the

main boom may always only be retracted or extended in 0°
position of the main boom extension.
In an emergency situation, i.e. if the HATZ diesel engine fails,

the luffing up of the main boom extension from folded position to
0° position is no longer possible, you can retract the main boom
in spite of the folded main boom extension from working length
to basic length (14.5 m) (Z 55 221).
It is PROHIBITED to extend the main boom with folded main

boom extension! Overload of the telescopic system!
Before retracting the main boom, the following must be observed:

− the load must be lowered over the respective hoist and set
down.
− the main boom must be lifted over the luffing gear to luffed
position (lock position) (see sect. 13.1 “Luffing mode”).
− the load limit device must be bypassed (see in sect. 10
“Safety devices” the sub--item “Load limit device”).
This retracting with folded main boom extension (0° to 40°)

must be carried out with great care and low speed. It may
only be done in an EMERGENCY situation. There is the risk
of overloading the telescopic system!
You can find a detailed description of telescoping in sect. 12

“Telescoping”, especially at the sun--items “Automatic
telescoping” and “Manual telescoping”.
250--1--1180--015 267/267

Main Boom Extension 18

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Main boom extension 18

18 Main boom extension

The main boom extension is marked with the construction

The main boom extension may only be installed and re-

18.1 Important information

- The maximum main boom extension length is 36 m. At this

Details on how to combine the parts of the lattice mast are

- Installation and removal as well as crane operation with main

- To assemble the main boom extension, only those bolts may

- To install and to remove the main boom extension, the

- The main boom extension can only be installed or removed

- Check that there is no damage to the piping at the lattice mast

- The main boom extension must be attached to the outrigger

- The counterweight required for crane operation must be fitted

- If the crane is equipped with a hinged head roller or a runner

- Crane operation with the main boom extension can be done

- For a main boom extension length of 28 m or 36 m, during the

- When moving the crane or during crane operation at the main

When moving the crane, the permissible axle load must be

- Folding and pulling up the main boom extension onto the

- To enable all assembly work to be carried out as safely as

- Before the main boom is extended with the main boom

- The main boom extension is folded depending on the working

- The connecting of:

is always done using 4 biconical pins (12) at points “A”, “B”,

9104 10808 8000 8000

9104 10808 8000

18.2 Combination of the various components

The main boom extension can be used in the following lengths:

The possible combinations are contained in the drawing

Part Designation Length (mm) Approx.

For main boom extension lengths of 10.4 m and 20 m, the offset

For main boom extension lengths of 28 m and 36 m, the offset is

3 ”a” ”b” ”c” ”d”

18.3 Attachment points

The main boom extension is comprised of various

The length and the weight of the individual components are

Part Designation Slinging points

The basic boom (3) has 4 slinging points.

18.4 Attaching the main boom extension

If the main boom extension has been transported separately, you

When assembling or removing the main boom extension

Therefore, no--one should be in the danger area. In particu-

During assembly/disassembly, no--one must be present

Select the auxiliary crane and securing equipment in such

18.4.1 Before fitting

18.4.2 Fitting the 10.4 m main boom extension

The 10.4 m main boom extension is comprised only of the

To attach the 10.4 m main boom extension, proceed as follows:

1. Check the following filling quantities at the ”power pack”:

2. Remove the biconical pins from the transport bracket on the

3. Tie down the auxiliary crane (two--fall) at the appropriate

With the tip section folded in transport position, a 3--fall lift-

Slinging points: see chapter 18.3 of these operating instructions,

6. Establish a bottom connection between the main boom head

When carrying out such installation work at a certain

To do this pinning, proceed as follows:

7.2 Example (Z 52 794)

Because the basic boom of the main boom extension is now

7.3 Establish the electrical connection between the

7.4 Establish the electrical connection between the

The adjusting cylinder is supplied with pressure by the HATZ