Operation Manual

LIEBHERR
TELESCOPIC BOOM MOBILE CRANE
LTM 1050/1
as of series 043
Operating instructions
BAL >No. 09708>02>02
pages : 1 up to 611
Crane number
Date
The operating instructions are part of the crane!
Always keep on hand!
Comply with road travel and crane operating

regulations!
LIEBHERR>WERK EHINGEN GmbH, Postfach 1361, D>89582 Ehingen / Donau

Tel. (07391) 502>0, Telex 71763>0 le d, Telefax (07391) 502>399
1
PREFACE 021643>02
These operating instructions should enable you to operate the crane safely and utilize its capabilities to the
fullest extent possible. They also provide notes on how important sub>assemblies and systems function.
Certain terms are used in these operating instructions, and in order to avoid misunderstandings while
operating, these terms should be used consistently.
DANGER: Only qualified and especially trained personnel may work on this crane!
If this is not assured, the change of causing a serious accident is greatly increased!
All regulations and guidelines applicable to the job site, such as accident prevention regulations and all
guidelines and regulations stated in the Operation Manual must be strictly adhered to.
All accident prevention and operating guidelines and regulations, etc. assume that the crane is strictly used for
lifting and transporting of loads, which are not stuck. Any other application or use does not constitute ∫specified
and proper use∫.
C A U T I O N: Pile driving and pulling tasks with vibration machinery, for example pulling pile
plankings, may only be carried out in connection with attenuator pads and may
only be performed after consultation with the crane manufacturer.
Any risks associated with unspecified or improper use are the sole responsibility of the crane's owner, operator
or user.
Using these instructions
> makes it easier to become familiar with the crane

> avoids malfunctions due to improper operation
Observing these instructions
> increases reliability in operations

> increases the operating life of the crane
> reduces repair costs and down>time
Always keep these operating instructions handy in the driver's and crane cab > they are an integral part of the
crane!
Operate this crane only with a thorough knowledge of its capabilities and limitations and in strict observance of
these instructions.
If you receive further information on the crane from us, e.g. in the form of technical information letters, this
must be observed and filed with the operating instructions.
If there are parts of these instructions or individual chapters that you do not understand, please do not hesitate
to ask us before you begin operation > we are glad to answer any inquiries you may have.
No part of these operating instructions may be circulated, nor may they be used for the purposes of competition.
All rights expressly reserved according to copyright law.
2
PREFACE 021643>02
These operating instructions are to be read and the information in them is to be observed by all persons
operating, maintaining, or otherwise working in any capacity on this crane.
Notes
Throughout these instructions, the terms "Note", " C A U T I O N " and " D A N G E R " occur > these refer
any persons working with the crane to IMPORTANT OPERATING METHODS that must be observed.
Note: The term "Note" is used whenever the observance of certain instructions or notes is
economically meaningful to the utilization of the crane.
CAUTION: The term " C A U T I O N " is used whenever damage to the crane can occur if the
operating instruction(s) is not observed and adhered to.
DANGER: The term " D A N G E R " is used whenever the nonobservance of the warning given
may injure or lead to the death of persons and damage to the crane.
Safety devices
The safety devices integrated into the crane system deserve your special attention. They must always be
checked to see that they are functioning properly. If they do not function or function incorrectly, the crane may
not be operated. Your motto should always be:
"SAFETY FIRST"
3
CONTENTS
184491
4
CONTENTS
1.00 DESCRIPTION OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.01 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.02 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.03 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.01 ROAD TRAFFIC REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.02 INSTRUCTIONS ON RUNNING>IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.03 OPERATIONAL PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.04 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety guidelines for auxiliary power supply (230 V AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Working near transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.01 CONTROLS AND INSTRUMENTS > VEHICLE ............................................ 54
3.02 BEFORE VEHICLE START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.03 AXLE SUSPENSION / LOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.04 DRIVING ON PUBLIC ROADS ........................................................... 94
3.05 THE CRANE AT THE JOBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4.01 CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE . . . . . . . . . . . 182
4.03 STARTING THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.04 SAFETY DEVICES ..................................................................... 216
4.05 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.06 REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.07 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.08 WORKING WITH A LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.09 DRIVING WITH ATTACHMENT IN PLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4.10 DRIVING FROM THE CRANE OPERATORπS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.11 CRANE OPERATION ∫FREESTANDING ∫ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.12 TWO>HOOK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5
CONTENTS
6
CONTENTS
5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

5.01 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
5.02 FOLDING JIB > TK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
5.10 MAST STUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

6.01 HEATER / ENGINE PREHEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
6.02 EMERGENCY CRANE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
6.04 SLIDING ARM MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

7.01 SERVICING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . 496
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . 518
7.06 LUBRICATION CHART, QUANTITIES .................................................. 536
7.07 SCHMIERSTOFFTABELLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

8.01 REPEAT CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
8.04 INSPECTION OF CRANE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES . . . . . . . . . . . . 604
9.02 GUIDELINES TO PREVENT FIRES IN THE ENGINE AREA
AND IMPORTANT SERVICE WORK TO BE PERFORMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
7
1.00 DESCRIPTION OF THE CRANE 021672>00
8
021672>00
Chapter 1
Description of the Crane
9
1.01 TERMINOLOGY 022415>00
182991
10
Abbreviations for the boom system
T = Telescopic boom
TK = Telescopic boom with folding fly jib 0∞, 15∞ or 30∞
Boom combinations
T > Boom combination T =10.5 m to 40.0 m

K = 9.6 m to 16.0 m
TK > Boom combination T =30.4 m to 40.0 m

K = 9.6 m to 16.0 m
11
183081
12
1 Crane carrier
1.1 3>axle chassis
1.2 Tires, axles 1 > 3 single wheels
1.3 Diesel engine with automatic transmission
1.4 Driverπs cab
1.5 Sliding arms with outrigger jacks
1.6 Outrigger pads
2 Crane superstructure
¡ Winch 1 Hoist gear when operated as T, TK
¬ Winch 2 Hoist gear when operated as T, TK
2.1 Crane operatorπs cab

2.2 Counterweight
2.3 Telescopic boom adjustment > Luffing cylinder
13
183082
14
3 Telescopic boom
3.1 Pivot section
3.2 Telescopic section 1
4 Folding fly jib

4.1 Adapter for the assembly of the fly jib below an angle of 0∞, 15∞ or 30∞
4.2 Folding fly jib, 9.6 m
4.3 End section, 6.4 m
15
1.02 PRODUCT DESCRIPTION 023214>00
The crane carrier
Frame: Liebherr designed and manufactured box type, torsion resistant, all>welded
construction made of high tensile structural steel.
Outriggers: Four point outriggers, front and rear, fully hydraulic horizontal and vertical
extension
Engine: 6>cylinder , water cooled Diesel engine, made by LIEBHERR Type D 926 TI>E
Output:
according to EC Norm (EURO 1) 230 kW (312 PS) at 2100 RPM,
max. torque 1190Nm at 1400 > 1600 RPM.
Fuel tank capacity: 300 l (79 gal.)
Transmission: Power shift reversing gear, Make: ZF 6WG 200, with torque converter and lock>up
coupling, 6 forward speeds and 2 reverse speeds.
Transfer gear box with cut in of 1st axle drive and off road gear.
Axles: All 3 axles are steerable.

Axles 1and 3 are planetary axles with differential lock.
6¥4 drive: The 2nd axle is not driven and can be raised hydraulically to improve off road
movement *.
Suspension: Hydro>pneumatic axle suspension system ∫Niveaumatic∫. Axle suspension can be

locked hydraulically.
Tires: 6 wheels, all axles provided with single tires.

Tire size: 14.00 R 25
Steering: Mechanical steering on both front axles, hydraulic supported. Additional steering
pump.
Steering of rear axle can be hydraulically added.
Hydrostatic steering of all axles from crane cab.
Steering conforms to EC Regulation 70/311 EWG
Brakes: Service brake: All wheel servo assisted air brakes, dual circuit.
Eddy current brake: Telma Eddy current brake (wear free retarder brake
Parking brake: Spring loaded, acting on wheels of axles 1 and 3.
Brakes conform to EC Regulation 70/320 EWG
Driverπs cab: 1 man cab (small size cab) *

3 man cab (large size cab)
Both cabs are made of all steel with resilient mountings, safety glass windows, full
range of control instruments.
Electr. system: 24 V DC,

2 batteries
(4 batteries optional)
* Optional
16
1.02 PRODUCT DESCRIPTION 023214>00
The crane superstructure
Frame: Liebherr>made torsion resistant, welded construction of high tensile structural steel.
Linked to crane carrier by a single roller slewing ring .
Crane drive: Axial piston pump and tripe gear pump in crane chassis, driven by the engine.
Open hydraulic circuits with ªload sensing´ control, 4 working movements can be
carried out at the same time.
Crane control: Electric servo control for hoist gear(s), slewing gear, luffing and telescoping gear, two
self centering, 4>way manual control levers.
Hoist gear: Axial piston constant motor, hoist drum with integrated planetary gear and spring
loaded static brake.
Luffing gear: 1 differential hydraulic cylinder with integrated safety check valve.
Slewing gear: Axial piston fixed displacement motor, planetary gear with spring loaded slewing
brake. Slewing speed can be regulated steplessly.
Crane operatorπs cab: Fully galvanized, all>steel construction with safety glass windows, heater, controls
and instruments for crane and travel operation.
Safety devices: ∫LICCON∫ safe load indicator system, hoist limit switch, safety valves to protect
hydraulic system against pipe and hose ruptures.
Telescopic boom: 1 pivot section and 4 telescopic sections with hydraulic extension under partial load.
Telescopic section 1 can be extended individually.
Telescopic sections 2, 3 and 4 can be extended synchronously.
Boom length : 10.5 m to 40 m.
Additional equipment
Folding jib: Single folding jib, 9.6 m long, can be installed at an angle of 0∞, 15∞ or 30∞ to
the telescopic boom.
Dual folding jib 9.6 m to 16 m long, can be installed at an angle of 0∞, 15∞ or 30∞ to
the telescopic boom.
Mast stub: For fast lifting with single line (hoist winch 2) when the main hoist rope (hoist
winch!1) remains reeved at the boom head.
2nd Hoist gear: For two hook operation, or for folding jib operation (hoist winch 2), if the main hoist
cable (hoist winch!1) is to remain reeved.
Tires: 6 tires, all axles with individual wheels.

Tire size:
16.00 R 25
20.5 R 25
6¥6 drive *: Additional drive of the 2nd axle.
* Optional
17
1.03 TECHNICAL DATA 023215>01
Dimensions
Weights
> Axle loads [t]
> Lifting tackle [kg]
Working speeds
> Travel speeds [km/h]
> Crane speeds [m/min]
Hoisting heights [m]

> Telescopic boom
> Folding fly jib
Max. supporting load per support:
Max. supporting load [t] Front Rear
per support 28 43
Tires
Tire pressure for travel on Tire pressure for crane
Tire size Tire weight [kg] public highways operation
[bar] ª free on tires ´ [bar]
according to load capacity

14.00 > 25 245 10 chart
ª free on tires ´

16.00 > 25 * 300 9 chart
ª free on tires ´

20,5 > 25 * 345 7 chart
ª free on tires ´
Emission values at the work place
Stationary sound LpAeq [db(A)]

Sound levels at nominal engine RPM
left ear right ear
Wide driver's cab, driver's side 69 69
Wide driver's cab, co>driver's side 71 72
Narrow driver's cab* 75 75
Crane operator's cab 74 74
* optional
18
184492
19
183133
20
184404
21
2.00 SAFETY 021673>00
22
021673>00
Chapter 2
Safety
23
2.01 ROAD TRAFFIC REGULATIONS 021178>05
24
Traffic regulations
The crane is approved for on>road travel if it is operated according to local and regional traffic regulations.
Before driving on public roads and highways, bring the crane to the appropriate condition to conform to local
and regional traffic regulations.
It must be assured that the weight, axle loads and dimensions remain as they are noted in the vehicle license
and that they are not exceeded.
For axle loads you must differentiate between technically possible and permissible loads, according to traffic
regulations.
In countries with EEC regulations, axles loads may not exceed 12 tons when driving on a public road or
highway.
If the crane operator drives on a road with an axle load which is higher than 12 tons, then he alone must take
the responsibility for this action.
DANGER: If axle loads or total weight exceed the permissible limit, then the braking power of
the vehicle will be reduced in proportion to the excess weight.
Brake pad wear and the danger that the brakes overheat will increase.
The steering system, the service brake, parking brake and retarder will then no
longer conform to regulations!
The life of the brakes, axles, wheel hubs, suspension cylinders and bearings will be
reduced.
A hook block may only be carried on the front if:
> it is reeved not more than 4 times,

> if it has been marked by the manufacturer on the data tag with he letter ∫E∫ for ∫entschßrft (defused)∫ and
> if the cable was attached to the front towing eyes and if the hook is held with an auxiliary cable and
attached to the towing coupling .
DANGER: When moving the crane on public highwathen the field of vision of the driver may
not be obstructed by the hook block.
Mast tip*
If a mast tip is installed, then > to prevent obstruction of the driverπs field of vision > it should be turned from the
working position to the transport position and secured in this position with pins and spring retainers.
* Optional
25
26
Travel with the crane according to the national road traffic regulations.
Carrying passengers in the crane cab is not permitted.
27
28
29
2.02 INSTRUCTIONS ON RUNNING>IN 021617>02
30
2.02 INSTRUCTIONS ON RUNNING>IN 021617>02
Instructions on running>in
CAUTION: The crane is not yet running>in
For this reason, the following instructions must be followed:
1.) During the first 2000 km (1,240 miles), the mobile crane must not be driven at more than 3/4 of its maxi>
mum speed in each gear (engine speed = max. 1900 rpm)
> Full throttle is permitted only briefly when driving or traffic conditions demand.
> At the end of the running>in period, gradually increase to full power operation.
2.) The oil pressure and temperature gauges must be monitored constantly while driving!
> If either gauge shows an excessive reading, stop operation immediately.
3.) Carry out the following service operations after the first 50 and the first 100 kilometres (30and the first 60
miles) of operation.
> Check that wheel nuts are tightened securely.
CAUTION: Do not overtighten wheel nuts!

(max. permitted tightening torque = 600 Nm; 445 ft>lb).
> Check coolant and oil levels in the engine.

> Check oil level in power>shift (Hi>Lo) or automatic transmission.
> Check engine, transmission and axle mountings for secure seating and for leaks (visual check).
> Check drive shafts for secure connection.
> Check all other chassis components for secure mounting.
> Check air pressure and conditions of the tyres (visual check).
Breaking in the brake pads
In order to obtain optimum braking acting, new brake pads must be activated or broken in. Brake in the new
pads by applying the brakes in intervals in low to medium speed range, do not brake forcefully! The braking in
route > preferably at least 500 km (310 miles) depends on the vehicle. In this phase, the maximum brake drum
or brake disk temperature of 200 ∞C (392 ∞F) may not be exceeded. The increase in temperature resulting from
each individual braking action may not exceed 15% of the maximum value.
CAUTION: DO NOT break in new brake pads through one or more continuous braking actions
over a longer period of time or by applying the brakes forefully while driving at
high speed.
DANGER: If this point is not strictly observed, you could cause a serious accident!
31
2.03 OPERATIONAL PLANNING 021674>00
32
2.03 OPERATIONAL PLANNING 021674>00
Operational planning
As well as a fully functioning crane and well>qualified personnel, operational planning is an important
precondition for safe and reliable crane operation.
The crane operator must be in possession of or procure all the necessary information before starting the crane
operation, especially:
> Nature of work
> Site location (journey distance)
> Route to be driven
> Height and side clearances
> Electrical overhead wires (complete with voltage data)
> Space requirements at the operating sites
> Movement restrictions due to surrounding structures
> Weight and dimensions of load(s) to be lifted
> Required lifting height and radius
> Load>bearing capacity of soil or surface to be operated upon
The crane operator can then use this information to decide on the correct crane operating equipment:
> Hook blocks/load blocks
> Auxiliary telescopic boom
> Lifting / slinging tackle
> Counterweight
> Underlay material for support pads
DANGER: If the crane operator does not possess all necessary and required information, it
may prove impossible to carry out the intended work, or he may be tempted to
improvise > and accidents may be the result!
33
2.04 SAFETY>TECHNICAL NOTES 021675>05
34
Requirements of the crane operator

The most important requirement of the crane operator is to control, operate and adjust the crane so that there is
no danger to the crane crew and/or third parties.
In order to fulfil this requirement, we would like to give you in the following a few important safety notes.
65% of all accidents involving vehicle cranes is due to improper crane operation.
Improper operating procedures most often carried out are:
Not paying careful attention while working in the case of, for example:
> slewing too quickly,
> quick braking of the load,
> cross pulling,
> loose cable formations
Overloading
Driving too fast with a load, or setting up and loading on an uneven surface.
Improperly slinging a load.
Operating in unsuitable conditions, especially pulling at an angle or fixed loads coming loose.
Wind on suspended load.
Improperly driving on public roads without a load, for example, engine or transmission overloaded.
Collision with bridges, ceilings, high>voltage wires.
Insufficient support; support base beneath the supports not sufficient in capacity.
Improper assembly/disassembly of telescopic booms.
20% of all accidents involving cranes are due to improper maintenance:

> Lack of oil, grease or antifreeze
> Accumulation of too much dirt
> Broken cables, defective tires, worn parts
> Emergency limit switch or load torque limiter not operational
> Brake and/or transmission failure
> Defects in the hydraulic systems; for example, tears in hoses
> Loose screws
DANGER: In your interest and in the interest of others, please learn to command your crane
thoroughly and familiarize yourself with all the dangers associated with the work to
be carried out.
35
180000
36
Selecting an operating site

To avoid accidents from the outset, the correct selection of an operating site is extremely important.
The operating site should be selected so that:
> the supports can be extended to the points prescribed in the load capacity tables.
> crane operations can be carried out within the smallest possible radius.
> no obstacles hinder necessary movements.
> the ground at the operating site is able to support expected loads.
DANGER: The most important requirement for safe crane operation is working on firm
ground with the capacity to support your loads.
Slopes and trenches

The crane must not be set up too close to slopes or trenches and depending on the type of soil, a safe distance
must always be kept from them.
Note: Safe distance is measured from the foot of the trench and is:
> soft or backfilled soil = 2 ¥ depth of trench (A2 = 2 ¥ T)
> hard or grown soil = 1 ¥ depth of trench (A1 = 1 ¥ T)
DANGER: If a safe distance can not be kept, the slope or trench must be firmly filled.
Otherwise, there is a danger that the edge of the slope or trench will give way.
37
38
Permissible ground>bearing load

When the crane is supported, the supports exert considerable pressure onto the ground. In certain cases,
individual supports must take up the weight of the crane as well as the weight of the load and this is transferred
to the ground.
The ground must always be able to stand up to the pressure exerted upon it. If the surface area of the support
pads are not sufficient, these must be fixed with a foundation corresponding to the load> bearing capacity of the
ground. The necessary supporting surface can be calculated from the load> bearing capacity of the ground and
the supporting pressure of the crane.
Support pressure
Required supporting surface = $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
Load>bearing capacity of the ground
Permissible ground>bearing load
[daN / cm2]
Type of Soil
[kg/cm2]
A) lled soil, not artificially compacted 0>1
B) Natural soil, apparently undisturbed
1. sludge, peat, marshy earth 0
2. noncohesive, sufficiently firm soil:

fine to medium sand 1,5
course sand to gravel 2,0
3. cohesive soils:
loamy 0
soft 0,4
stiff 1,0
semi solid 2,0
hard 4,0
4. rock with a minimum of fissures, in healthy, unweathered

condition and favorably situated:
in densely packed strata 15
solid or column formation 30
C) Artificially compacted ground
1. asphalt 5 > 15
2. concrete concrete groupe B I 50 > 250

concrete groupe B II 350 > 550
If there is any doubt as to the load>bearing capacity of the ground at the operating site, the ground must be
investigated; for example, with a dynamic sounding rod.
CAUTION: Only stable materials, such as wood planks of sufficient strength and size, may be
used to make a foundation beneath the support pads. In order to achieve an even
distribution of pressure above the foundation surface, the supports must be
positioned in the middle of the foundation.
39
180001
40
Support pads
Strict adherence to the support base in reference to load>capacities as given in the load>capacity table is
absolutely essential to the safety of crane operations.
Equal distribution of pressure on the support pads of the sliding arms must be established so that the
transmission of transverse force between the sliding arms is guaranteed.
The outriggers may only be used when the sliding arms are extended in these positions!
DANGER: Intermediate adjustments between the prescribed support widths may not be made
as the transmission of transverse force is only possible above lateral support bases
and, because of the absence of a support base in intermediate positions, an
incorrect initiation of force is applied to the upper boom.
The sliding arms must be pinned securely to prevent any movement of the support
jacks, which could cause a serious accident!
The pins must be fully inserted and the handle must point downward, otherwise it
could cause a serious accident, causing the crane to topple over.
Always extend all 4 sliding arms and support jacks, including those on the side opposite the load. If only the
sliding arms and support jacks on the load side are extended, the results could be dangerous as:
DANGER: 1. The load hanging on the hook tensions the hoist cable and the telescopic boom
and also the lattice fly jib if used and the guy cables) and also deforms them. If, in
this situation, the load were to drop out of the lifting tackle cables, or if the lifting
tackle cable or hoist cable were to break, the load on the boom would be suddenly
lifted and the boom would jerk up violently.
Therefore the crane may topple over.
2. Despite what has been assumed before commencing operations, it may prove
necessary to slew the load to the opposite side.
Therefore the crane may topple over.
3. When turning form longitudinal direction, the crane can tip over due to the
momentum of the boom or counterweight.
Aligning the crane

Besides the proper foundation beneath the supports, horizontal alignment of the crane is essential to
operational safety.
DANGER: If the crane is set up unevenly and the boom is swung toward a downhill grade, the
result is an extension of the boom radius, which in extreme cases can cause the
crane to topple over.
Example: At a boom length of 50 m, uneven adjustment of the crane by only 5∞ will cause an boom
radius of 10 m to be increased by a = 4 m.
41
Checking safety measures
Crane supported
> Is axle suspension blocked?
> Is the load>bearing capacity of the ground sufficient?
> Are all 4 sliding arms and support jacks extended to the support base as given in the load>capacity tables?
> Are the sliding arms secured with bolts?
> Are the support pads secured?
> Is the crane horizontally aligned?
> Is there sufficiently safe distance from slopes and trenches?
> Have the axles been relieved of loads, i.e., is there no longer contact between the ground and the tires?
> Has it been established that the crane is not in the vicinity of electrical overhead wires?
> Has the operating site been selected so that the crane may operate within the smallest possible boom
radius?
> Are there any obstacles in the area that will hinder necessary crane movements?
42
Crane operation with a load

Before beginning any work, the crane operator must be convinced that the crane is in safe operating condition.
The safety devices, such as load torque limiter, hoist limit switch, brakes, and so forth, must all be operational.
> The load torque limiter must be set to the current operating status of the crane.
> The load capacities as given in the load capacity tables must be adhered to. The crane must never be
operated with a load exceeding the permissible load capacities.
> Before beginning any operations, the crane operator must know the weight and dimensions of the load.
> All hoisting and slinging tackle must meet the requirements of the work to be carried out.
> It must be ensured that the weights of the hoisting, slinging and staying tackle are taken from the load
capacity table.
Example:
Highest permissible load capacity according to table 30.000 kg 30.000 kg
Weight of the hook block 370 kg . /. 370 kg
Weight of the slinging rope 40 kg . /. 40 kg
Actual useful load of the crane Table value = 29.590 kg
In this case, the load to be lifted may not exceed 29,590 kg.
Ballast
The required ballast is dependent on the load to be lifted and necessary boom radius for operating with that
load. Data in the corresponding load capacity table is decisive in selecting ballast.
DANGER: If ballast is not mounted according to the load capacity table, there is danger of the
crane toppling over.
Hoisting gear, hoisting cable

The lifting capacity of the crane depends on the tensile force, or pull, of the hoisting cable and the number of
possible hoist reeving cables. When working with a single cable, the crane can only lift as much as the hoisting
gear pulls.
If the load to be lifted is greater than the pull of the hoisting gear, the hoisting cable must be reeved between
the pulley head on the boom and the hook block as many times as necessary according to the principle of a block
and pulley.
When reeving, ensure that the data given in the load capacity table book and operating instructions are
observed and adhered to.
DANGER: If the maximum tensile force is exceeded, there is the danger that the cable(s) may
snap or that the hoisting gear and/or drive motor may be damaged.
43
Crane operation
D A N G E R exists if:
1. The load torque limiter is not set to the actual equipment status of the crane, and as a result, cannot
fulfil its function as a safety device.
2. The load torque limiter is defective or put out of operation.
3. The sliding arms of the hydraulic supports are not extended to the points specified in the load capacity
table.
4. The support pads are not supported with stable base material sufficiently large for the soil conditions.
5. If the load is pulled at an angle. It is particularly dangerous when pulling to the side since the telescopic
boom has a lower torque resistance to the side. The load may not be pulled at an angle.
6. An excessive load is attached to the hook during dismantling work, which then hangs freely on the
crane when it is detached.
7. If loads which have become stuck are pulled free with the hook block. Even if the weight of the load
which is stuck is no greater than the permissible lifting load, the crane may topple over backwards if the
load is suddenly freed since the tension created in the boom can cause it to jerk back violently.
8. Work is carried out in strong winds. Refer to the data given in the load capacity table.
9. The crane is not aligned horizontally and the load is slewed toward the slope.
10. The hook load begins swinging because the crane operator has not properly controlled the movements.
11. The loads and radii contained in the load capacity tables are exceeded.
12. When working in the vicinity of power cables, these are not isolated by electricity engineers or if the
hazardous area is not covered of fenced off. If it is not possible to take such measures, a sufficient safety
clearance must be maintained:
Minimum distance
Rated Voltage
[m] [ft]
up to 1 kV (1000 V) 1 3
above 1 kV up to 110 kV 3 9
if rated voltage is unknown 5 16
Note: If, despite all precautions having been taken, a flashover occurs, carry out the following
procedure:
> Keep calm.
> Do not leave the crane cab.
> Warn those around the crane not to move and not to touch the crane.
> Move the crane away from the danger area.
DANGER: Not observing the above points can lead to (fatal) accidents and damage!
44
Safety guidelines for auxiliary power supply (230 V AC)
If the crane is supplied by an auxiliary power supply from a low voltage power supply distribution network
(230!V AC), then it poses a potential danger.
Electrical power is especially dangerous if there is an interruption in the protective conductor, (due to
mechanical wear of the flexible supply line or the house installation), in case of loose terminal connections, high
line and transfer resistance, interchanged conductors, defective or non>existing protective measures in
connection with an insulation fault on the crane.
DANGER: Moisture infiltration and / or defective machines can cause voltage displacement
due to an insulation fault.
The person touching the unit will be exposed to a dangerous voltage surge.
There is a DANGER OF LIFE AND DEATH!
For that reason, it must be assured that the flexible auxiliary supply line is fully functioning and in proper
order.
If necessary, we recommend to connect a power isolating transformer.
CAUTION: To check the protective measures and to decide if the crane can be supplied with
power from the general power supply distribution network, a competent trained
electrician must be called in with the appropriate test instruments according to
VDE.
Working near transmitters
If there is a transmitter near the job site, strong electro>magnetic fields may exist.
DANGER: These electro>magnetic fields can pose direct or indirect danger to persons or
objects, for example:
> Effect on human organs due to temperature increase
> Danger of burns or inflammation due to temperature increase
> Spark or electric arc formation
In any case, before working with the crane near transmitters, contact your LIEBHERR representative .
In addition, consult a high frequency specialist.
45
189640
46
The high frequency (HF>) rays from a transmitter require an increased working protection and
special UVV>guidelines for crane operator and crane personnel
1. Every crane must be "totally" grounded. Check visually or with a simple tester to ensure that ladder, cab
and cable pulleys are grounded.
2. All persons working on the crane or on larger metal parts must carry special protective gloves without
metal connectors and suitable protective suits to protect them from burns while working.
3. If one should feel an increase in temperature, there is no need for panic. Simply act as if the affected tool,
component or carrier is "hot".
4. The temperature of the tools affected by high frequency depends on their "size". Cranes, carriers and
coverings, for example, are "hotter".
5. When moving the crane, do not allow it to touch other crane loads (light arcs).
Since burn nicks reduce the load carrying capacity of the cables significantly, contact your supervisor
(master) any time such a contact has occurred, so that the cables can be checked and inspected.
6. An insulator (1) must always be between the load hook of the crane and the tackle, this insulator (1) may
not be removed, this is strictly prohibited.
7. The cable may not be touched above the insulator (1). This is strictly prohibited!
8. Never touch the crane with attached loads with unprotected body parts after lift off or after set down.
9. Never work with exposed, unclothed upper body or short pants, this is strictly prohibited!
10. If possible, transport larger loads in horizontal direction, to reduce high frequency absorption!
11. Before carrying out any necessary manual work, ground the loads first or insulate them (place a rubber
cloth between the tool and the glove).
12. The temperature of the tool can be checked with a suitable tester.
If, for example 500 V can be measured on a tool at a distance of 1 to 2 cm, then the tool may not be touched
with bare hands.
The larger the distance, the higher the voltage is on the tool:
at a distance of 10 cm, the voltage is approx. 600 V, at a distance of 30 cm, the voltage is approx. 2000 V.
13. To prevent accidents, work on components located higher up may only be carried out with a safety belt.
14. Handling explosive matter (such as refueling) may only be done at least 6 m away from the place where
sparks could form due to handling of larger metal parts.
To refuel, use only appropriate and approved rubber hoses .
15. All accidents or special occurrences must be reported immediately to the local construction supervisor
and the safety engineer.
47
180003
48
A suspended load is always a risk

When performing any movement, the crane operator must always keep his eye on the load, and when moving
the crane without a load, he should observe the crane hook or the lifting tackle. If this is not possible, he must
only operate the crane according to instructions given to him by a signaller. These instructions may be given in
the form of hand signals or over a two>way radio. Whatever method is used, precautions must be taken to
eliminate the risk of misunderstandings.
DANGER: Hand signals must first be discussed and agreed upon and then clearly given.
Misunderstandings can lead to serious accidents.
The hand signals illustrated on the opposite page are given as recommendations for safe working.
When operating in foreign countries, always observe NATIONAL TRAFFIC REGULATIONS.
Explanation of hand signs
1 = Raise boom
2 = Lower boom
3 = Lift load slowly
4 = Lower load slowly
5 = Raise boom slowly
6 = Lower boom slowly
7 = Raise boom and hold load
8 = Lower boom and hold load
9 = Extend boom
10 = Retract boom
11 = Raise boom and lower load
12 = Lower boom and raise load
13 = Raise load
14 = Lower load
15 = Slew load this way
16 = Shut down all systems
17 = Stop!
49
50
Observing wind conditions

It is essential to adhere to the information given in the load capacity tables regarding the maximum
permissible wind speed.
Crane operations must be stopped and the boom lowered as soon as the maximum wind speed is exceeded.
Wind Force Wind Speed

Effects of Wind
in the inland
Beaufort degree Description [m/s] [km/h]
0 Calm 0 > 0,2 1 No wind, smoke rises straight up
1 Slight air 0,3 > 1,5 1>5 Wind direction is shown only by
(draft) observing the trail of smoke, not by the
wind sock
2 Light breeze 1,6 > 3,3 6 > 11 Wind can be felt on the face, the leaves
rustle, wind sock moves slightly
3 Gentle breeze 3,4 > 5,4 12 > 19 Leaves and thin twigs move
Wind extends a small breeze flag
4 Moderate 5,5 > 7,9 20 > 28 Swirls up dust and loose paper, moves
breeze twigs and thin branches
5 Fresh breeze 8 > 10,7 29 > 38 Small deciduous trees begin to sway,
foam forms at sea
6 Strong wind 10,8 > 13,8 39 > 49 Thicker branches move

Telephone lines begin to whistle,
umbrellas are difficult to use
7 Stiff wind 13,9 > 17,1 50 > 61 Entire trees swaying; difficult to walk
into wind
8 Gale force wind 17,2 > 20,7 62 > 74 Breaks twigs off trees, walking becomes
difficult
9 Gale 20,8 > 24,4 75 > 88 Minor damage to property (chimney tops
and roofing tile are blown off)
10 Severe gale 24,5 > 28,4 89 > 102 Trees are uprooted, significant damage
to property
11 Violent storm 28,5 > 32,6 103 > 117 Extensive, widespread storm damage
12 Hurricane 32,7 > 36,9 118 > 133 Major destruction
51
3.00 OPERATION OF THE CHASSIS 021676>00
52
021676>00
Chapter 3
Operation of the Chassis
53
3.01 CONTROLS AND INSTRUMENTS > VEHICLE 023216>01
185266
54
Version with wide driver's cab
Pos.:
1 * Foot pedal > Service brake
2 Retaining lever > For adjustment of steering column tilt angle
3 Steering column switch for
> Turn signal indicator lights
> Windshield wipers
> Windshield wiper > intermittent operation
> Windshield washer system
> Change headlight from dim to high beam
> Horn
> Headlight flasher
4 Foot pedal > Service brake
5 Foot pedal > Engine regulation
6 * Steering column switch > (5>stage) for optional Eddy > current brake
7 Acoustical warning > Engine overspeeding
8 Cigarette lighter
9 Interior light with switch
10 Container > Windshield washer fluid
11 Fuse and relay box
12 Slide control > Temperature selection
13 Slide control > Air inlet selector lever for air circulation / fresh air
14 Slide control > Change air flow upward or downward
15 Rotary switch > (3>stage) for blower
16 Reserved
17 Reserved
18 Reserved
19 Reserved
20 Button > Lower back support in upper area of back rest

21 Button > Lower back support in lower area of back rest
22 Lever > Release for horizontal seat adjustment
23 Lever > Adjustment of back rest angle
24 Lever > Adjustment of seat angle
25 Battery master switch > Electrical system , crane chassis
26 * EMERGENCY OFF
Button > Shut off for travel motor and complete electrical system in chassis
* Optional
55
189851
56
Pos.:
27 Reserved
28 Reserved
29 Reserved
30 Key > operated switch > Ignition , starter

31 Electrical socket > 24 V DC
33 Display > Fuel tank level
34 Indicator light > Manual brake
35 Display > Coolant temperature > Diesel engine
35 Gauge > Oil pressure > Diesel engine
36 Gauge > Diesel engine RPM
37 Trip log > Speedometer with trip odometer and clock
38 Warning light > Factory adjusted high speed has been exceeded
39 Warning light > Trip log problem ( pens do not register or diagram disk has not been in>
serted)
40 Display > Converter > oil pressure
41 Display > Converter > oil temperature
42 * Switch > Change over from chassis to superstructure operation
43 Hour meter
44 Duplex air pressure gauge for reservoir and brake pressure > brake circuit I
45 Duplex air pressure gauge for reservoir and brake pressure > brake circuit ¬
46 Reserved
47 Reserved
48 Reserved
49 Reserved
* Optional
57
189851
58
Pos.:
50 Indicator light > Preheat Diesel engine
51 Warning light > Alternator
52 Warning light > Air filter contaminated
53 Warning light > Engine oil pressure too low
54 Warning light > Error in electronic gear shift or oil pressure too low in hydraulic circuit
for torque converter > automatic transmission
55 Warning light > Error in electronic gear control
56 Display > Travel direction > vehicle
57 Warning light > Steering circuit I
58 Warning light > Air pressure supply > Brake circuit I
59 Warning light > Air pressure supply > Brake circuit ¬
60 Warning light > Air pressure supply > Brake circuit √
61 Indicator light > Hydraulic pump for crane operation has been added
62 Warning light > Rear axle steering lock / release is in intermediate position if this war>
ning light lights up
63 * Indicator light > Eddy current brake
64 * Indicator light > Telescopic boom not supported
65 * Indicator light > Rear fog light
66 Indicator light > speed limit
67 * Indicator light > Air conditioner
68 Indicator light > Beacon (s)
69 Warning light > Fuel level is too low
70 Warning light > Coolant level > travel engine is too low
71 Warning light > Coolant temperature is too high
72 * Warning light > Oil temperature in oil circuit torque converter > automatic transmission
is too high
73 Indicator light > Headlight > High beam / low beam
74 Display > Travel direction > for towing trailer
75 Warning light > Steering circuit ¬
76 Indicator light > Off road gear turned on
77 Indicator light > ∫All wheel drive∫, Drive of axle 1 (or 1 and 2 *) added
78 Indicator light > Transverse differential lock of driven axles is added
79 Reserved
80 Indicator light > Rear axle steering locked / released
81 * Kontrolleuchte > Auxiliary heater
82 * Indicator light > Telescopic boom supported
83 Warning light > ABV, Automatic brake blocking prevention on the vehicle .
This warning light must turn off at a travel speed of more than 10 km/h .
If it does not turn off, then there is a problem with the electronic ABV
control for the vehicle.
84 * Indicator light > CB Radio
85 Warning light > ABV Automatic brake blocking prevention on the trailer
When a trailer is attached, this warning light must turn off at a travel
speed of more than 10 km/h .
control for the trailer.
86 Reserved
87 Reserved
88 Reserved
89 Reserved
* Optional
59
189851
60
Pos.:
90 * Switch > Outside mirror heater
91 * Switch > Seat heater, left
92 * Switch > Seat heater, center
93 * Switch > Seat heater, right
94 Reserved
95 Reserved
96 Reserved
97 Reserved
98 Reserved
99 Reserved
100 Reserved
101 Reserved
102 Reserved
103 Reserved
104 Reserved
105 Reserved
106 Reserved
107 Reserved
108 * Switch > CB Radio
109 * Switch > Air conditioner
110 Reserved
111 * Switch > Towing installation
112 Reserved
113 Reserved
114 Switch > Release / lock of rear axle steering
115 Reserved
116 Switch > Engage off road gear
117 Switch > Engage drive for 1st ( or for 1st and 2nd*) axle , ∫All wheel drive ∫
118 Switch > Engage transverse differential lock for driven axles
119 * Switch > Raise 2nd axle (only for 6 x 4 drive)
120 Reserved
121 Reserved
122 Reserved
123 Reserved
124 Reserved
125 Reserved
126 Reserved
127 Reserved
128 Reserved
129 Reserved
130 Reserved
131 Reserved
132 Reserved
133 Switch > Hazard warning blinker with indicator light
134 Light switch >(2stage) for parking lights, head lights and instrument lighting
135 Switch > Beacon with indicator light
136 * Switch > Rear fog light
137 * Switch > Auxiliary heater for cab* and preheat system for Diesel engine*
* Optional
61
185268
62
Pos.:
140 * Rotary switch > Temperature regulator for air conditioner
141 Button > Engage rear axle steering
142 Button > ∫LEVEL™, for automatic height adjustment of axle suspension (travel
height) for on road travel
143 Indicator light > ∫LEVEL∫, lights up if axle suspension for on road travel is turned on (as
long as button (142) is depressed)
144 Reserved
145 Reserved
146 Button > Vehicle, left front Raise / lower

147 Button > Vehicle, right front Raise / lower
148 Reserved
149 Reserved
150 Button > Vehicle, left rear Raise / lower
151 Button > Vehicle, right rear Raise / lower
152 Reserved
153 Reserved
154 Switch > turned off axle suspension released (suspended)

turned on axle suspension locked
155 * Switch > Travel program for :

Routes with inclines Position > FP 2
Predominantly level routes Position > FP 1
156 Reserved
157 Reserved
158 Manual lever > Parking brake

159 * Button > Emergency release valve for parking brake (hand brake )
160 Manual lever > Engine regulation ( throttle control)
161 Gear selector switch
* Optional
63
185269
64
Version with narrow driver's cab*
Pos.:
1 * Foot pedal > Service brake
2 Retaining lever > For adjustment of steering column tilt angle
3 Steering column switch for
> Turn signal indicator lights
> Windshield wipers
> Windshield wiper > intermittent operation
> Windshield washer system
> Change headlight from dim to high beam
> Horn
> Headlight flasher
4 Foot pedal > Service brake
5 Foot pedal > Engine regulation
6 * Steering column switch > (5>stage) for optional Eddy > current brake
7 Acoustical warning > Engine overspeeding
8 Cigarette lighter
9 Interior light with switch
10 Container > Windshield washer fluid
11 Fuse and relay box
12 Slide control > Temperature selection
13 Slide control > Air inlet selector lever for air circulation / fresh air
14 Slide control > Change air flow upward or downward
15 Rotary switch > (3>stage) for blower
16 Reserved
17 Reserved
18 Reserved
19 Reserved
20 Button > Lower back support in upper area of back rest

21 Button > Lower back support in lower area of back rest
22 Lever > Release for horizontal seat adjustment
23 Lever > Adjustment of back rest angle
24 Lever > Adjustment of seat angle
25 Battery master switch > Electrical system , crane chassis
26 * EMERGENCY OFF
Button > Shut off for travel motor and complete electrical system in chassis
* Optional
65
189850
66
Pos.:
27 Reserved
28 Reserved
29 Reserved
30 Key > operated switch > Ignition , starter

31 Electrical socket > 24 V DC
33 Display > Fuel tank level
34 Indicator light > Manual brake
35 Display > Coolant temperature > Diesel engine
35 Gauge > Oil pressure > Diesel engine
36 Gauge > Diesel engine RPM
37 Trip log > Speedometer with trip odometer and clock
38 Warning light > Factory adjusted high speed has been exceeded
39 Warning light > Trip log problem ( pens do not register or diagram disk has not been in>
serted)
40 Display > Converter > oil pressure
41 Display > Converter > oil temperature
42 * Switch > Change over from chassis to superstructure operation
43 Hour meter
44 Duplex air pressure gauge for reservoir and brake pressure > brake circuit I
45 Duplex air pressure gauge for reservoir and brake pressure > brake circuit ¬
46 Reserved
47 Reserved
48 Reserved
49 Reserved
* Optional
67
189850
68
Pos.:
50 Indicator light > Preheat Diesel engine
51 Warning light > Alternator
52 Warning light > Air filter contaminated
53 Warning light > Engine oil pressure too low
54 Warning light > Error in electronic gear shift or oil pressure too low in hydraulic circuit
for torque converter > automatic transmission
55 Warning light > Error in electronic gear control
56 Display > Travel direction > vehicle
57 Warning light > Steering circuit I
58 Warning light > Air pressure supply > Brake circuit I
59 Warning light > Air pressure supply > Brake circuit ¬
60 Warning light > Air pressure supply > Brake circuit √
61 Indicator light > Hydraulic pump for crane operation has been added
62 Warning light > Rear axle steering lock / release is in intermediate position if this war>
ning light lights up
63 * Indicator light > Eddy current brake
64 * Indicator light > Telescopic boom not supported
65 * Indicator light > Rear fog light
66 Indicator light > speed limit
67 * Indicator light > Air conditioner
68 Indicator light > Beacon (s)
69 Warning light > Fuel level is too low
70 Warning light > Coolant level > travel engine is too low
71 Warning light > Coolant temperature is too high
72 * Warning light > Oil temperature in oil circuit torque converter > automatic transmission
is too high
73 Indicator light > Headlight > High beam / low beam
74 Display > Travel direction > for towing trailer
75 Warning light > Steering circuit ¬
76 Indicator light > Off road gear turned on
77 Indicator light > ∫All wheel drive∫, Drive of axle 1 (or 1 and 2 *) added
78 Indicator light > Transverse differential lock of driven axles is added
79 Reserved
80 Indicator light > Rear axle steering locked / released
81 * Kontrolleuchte > Auxiliary heater
82 * Indicator light > Telescopic boom supported
83 Warning light > ABV, Automatic brake blocking prevention on the vehicle .
This warning light must turn off at a travel speed of more than 10 km/h .
control for the vehicle.
84 * Indicator light > CB Radio
85 Warning light > ABV Automatic brake blocking prevention on the trailer
When a trailer is attached, this warning light must turn off at a travel
speed of more than 10 km/h .
control for the trailer.
86 Reserved
87 Reserved
88 Reserved
89 Reserved
* Optional
69
189850
70
Pos.:
90 * Switch > Outside mirror heater
91 * Switch > Seat heater, left
92 * Switch > Seat heater, center
93 * Switch > Seat heater, right
94 Reserved
95 Reserved
96 Reserved
97 Reserved
98 Reserved
99 Reserved
100 Reserved
101 Reserved
102 Reserved
103 Reserved
104 Reserved
105 Reserved
106 Reserved
107 Reserved
108 * Switch > CB Radio
109 * Switch > Air conditioner
110 Reserved
111 * Switch > Towing installation
112 Reserved
113 Reserved
114 Switch > Release / lock of rear axle steering
115 Reserved
116 Switch > Engage off road gear
117 Switch > Engage drive for 1st ( or for 1st and 2nd*) axle , ∫All wheel drive ∫
118 Switch > Engage transverse differential lock for driven axles
119 * Switch > Raise 2nd axle (only for 6 x 4 drive)
120 Reserved
121 Reserved
122 Reserved
123 Reserved
124 Reserved
125 Reserved
126 Reserved
127 Reserved
128 Reserved
129 Reserved
130 Reserved
131 Reserved
132 Reserved
133 Switch > Hazard warning blinker with indicator light
134 Light switch >(2stage) for parking lights, head lights and instrument lighting
135 Switch > Beacon with indicator light
136 * Switch > Rear fog light
137 * Switch > Auxiliary heater for cab* and preheat system for Diesel engine*
* Optional
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Pos.:
140 * Rotary switch > Temperature regulator for air conditioner
141 Button > Engage rear axle steering
142 Button > ∫LEVEL™, for automatic height adjustment of axle suspension (travel
height) for on road travel
143 Indicator light > ∫LEVEL∫, lights up if axle suspension for on road travel is turned on (as
long as button (142) is depressed)
144 Reserved
145 Reserved
146 Button > Vehicle, left front Raise / lower

147 Button > Vehicle, right front Raise / lower
148 Reserved
149 Reserved
150 Button > Vehicle, left rear Raise / lower
151 Button > Vehicle, right rear Raise / lower
152 Reserved
153 Reserved
154 Switch > turned off axle suspension released (suspended)

turned on axle suspension locked
155 * Switch > Travel program for :

Routes with inclines Position > FP 2
Predominantly level routes Position > FP 1
156 Reserved
157 Reserved

159 * Button > Emergency release valve for parking brake (hand brake )
160 Manual lever > Engine regulation ( throttle control)
161 Gear selector switch
* Optional
73
3.02 BEFORE VEHICLE START UP 023218>01
74
Pre>checks before start up

Before starting the vehicle, the following pre>checks must be carried out:
Note: For a more complete description of the below listed pre>check procedures, refer to
Chapter 7.04, ∫MAINTENANCE GUIDELINES > CRANE CHASSIS∫.
Check oil levels and filters

> Oil level on travel and crane engine
> Oil level on automatic transmission
> Oil level on hydraulic tank for steering, outriggers, axle suspension and crane hydraulic
> Filter on hydraulic tank
Check fuel level

Check the fuel level on the fuel gauge in the driverπs cab.
Check the coolant level

Add enough coolant via the filler nozzle to fill the coolant reservoir to the rim .
DANGER: NEVER check the coolant level if the engine is still warm! Check the coolant level
ONLY when the engine is cold, hot coolant fluid can cause serious skin burns!
Check the tires (including the spare)

> Condition of tires
> Depth of tire treads
> Tire pressure
DANGER: There is an increased danger of accidents if the tires are damaged, the treads are
worn and / or the air pressure in the individual tires varies!
Check mounting tightness of counterweights

Check locking brackets of counterweight plates and locking caps for damage.
DANGER: If the locking brackets are broken off or if there are any changes on the mounting
bracket, then the tight seating of the counterweight plates is no longer assured.
As a result, the counterweight plates could fall off.
If there is any damage,the locking system or the counterweight plate must be replaced.
If the bracket is bent, repair or replace the mounting bracket.
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General transport condition
For travel purposes, all loose parts must be securely attached to the mobile crane.
> The axle suspension system must be switched to ∫Suspended∫ (See chapter 3.03).
> The rear axle steering must be locked in ∫straight position∫.
> The change over switch (1) must be in position ™undercarriage∫, fig. 1: version with wide driver's cab
fig. 2: version with narrow driver's cab*
> The telescopic boom must be completely retracted and lowered in the boom receiver.
> The slewing brake must be applied.
> The telescopic boom must be secured to prevent it from running free by engaging the hook block (or the load
hook) in the eye hook, which has been provided for this purpose on the front tow coupling, without restricting
the view of the driver. The hoisting cable must be pulled until it is just tight.
> Check the installation ladder for the folding jib* (2x fold down lock, pos. 2) under the front bumper to make
sure it is safely closed and secured.
> All windows and doors on the crane operatorπs cab must be closed.
> The four sliding arms in the hydraulic outriggers must be individually secured with pins (12) to prevent
unintentional extension and movement. The lever position of the pins must point downward.
> The four outrigger pads must be secured and pinned in their receptacles, which must be pinned (13).
> The three wheel chocks (9, 15) must always be carried and secured in their holders to prevent them from
falling out.
> The covers (8, 14) at the sliding arms must be closed.
> The two switch and control boxes (17) must be locked.
> Secure the external engine cowling with rotary locks (6) and check all locks and door closures (6, 16 and 17)
and covering on the craneπs superstructure to make sure they are locked securely.
> Check the mounting screws on the spare tire (10).
> Check all pins and spring retainers to see if they are properly seated:
on the outrigger pad receptacle (13),
on the locking pins of the outriggers (4¥ item 12),
Pins, tow coupling (3) on the hoisting cable attachment.
> Check the counterweight deposit, make sure there are no foreign objects on the vehicle frame.
> Check if all locking pins used for the crane operation are present and secure them for transport,
such as the pins for the sliding arms (12).
DANGER: All locks, spring retainers and locking pins must be fastened and secured in such a
way, that they do not come loose during transport, which could cause an accident
or damage.
If these safety, locking and securing measures mentioned in the above chapter
∫General transport conditions∫ are not adhered to, there is an increased risk of
accidents!
NOTE: When driving on public roads, the counterweight, the hook block and the double folding fly
jib must be transported separately in order to stay within the maximum axle pressure of
12t, as described in chapter 3.04 ∫DRIVING ON PUBLIC ROADS∫.
A hook block (one or three sheaves) may only be transported on the front, if :
> it is, at a maximum, quadruple reeved,
> it has been marked by the manufacturer on the identification plate with the letter ∫E∫ for RENDERED SAFE
and
> if it has been fastened to the front tow coupling (3) with the oval ring provided for this purpose and has been
pulled tightly.
* Optional
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Adjust the driverπs seat

The pneumatically > mechanically suspended driverπs seat can be adjusted to fit any body size:
> Horizontal seat adjustment (20)

> Adjustment of back rest angle (21)
> Lower back support (22 and 23)
> Adjustment of seat surface angle (24)
The seat suspension is adjusted automatically.
Adjust the mirrors

Before travel, the outside mirrors must be cleaned and the mirrors must be properly adjusted by the driver,
while he is seated in the driverπs seat, to assure an unobstructed view to the front, side and rear.
Adjust the steering wheel

By releasing the steering wheel adjustment lever (2), the tilt angle of the steering wheel can be adjusted to suit
the driver.
CAUTION: To prevent possible knee injuries, after adjustment of the steering wheel, push the
control lever (2) ∫in∫ and turn it ∫upward∫ to align the lever position to the steering
column.
DANGER: Never adjust the steering wheel, the driverπs seat and / or the mirrors while driving!
Loosen the steering wheel adjustment lever only when the vehicle is at a standstill.
Make sure you always relock the steering wheel adjustment lever.
Any noncompliance with these points could cause a serious accident.
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Check hazard warning flashers, blower, windshield wipers and horn
Note : Turn on the battery master switch (25) to carry out these checks.
Before starting the engine, check the following::
a) Before the ignition is turned on,

> check the switch for indicator light / hazard warning flasher (133)
b) After the ignition is turned on,

(turn the ignition key in the key operated switch one notch to position ∫1∫ )
> check the rotary switch (15)** for blower > heater, ventilation (air conditioner*)
> check the windshield wiper and washer system (3)**
> check the reservoir for the windshield washer system (10)**
> check the horn (3)**
DANGER: If the hazard warning flashers, or any of the other above mentioned functions are
defective, DO NOT start to travel. Make sure that these functions are repaired by
authorized, qualified personnel before operating the vehicle, otherwise there will
be an increased risk of accidents!
Check fuses
Remove the cover on the fuse box (11)** and check all fuses. If any of them are defective, they must be replaced.
CAUTION: NEVER repair or short circuit a fuse! NEVER use a different size or stronger fuse,
use only fuses for the same amperage! If you do not use the same amperage fuse, the
total electrical system can be damaged or you could cause an electrical .
** Version with wide driver's cab: fig. 3

Version with narrow* driver's cab: fig. 4
* Optional
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Check the lights

To check the lights, the battery master switch and the ignition must be turned on .
Check all lights before starting the vehicle:
> High beam / low beam head lights (1, 2)
> Parking lights / front and rear (3)
> Turn signals (4)
> Beacon (5)
> Brake lights (6)
> Back up light (7)
> Rear fog lights (8) *
> Boom head light (9) *
> License plate illumination (10)
> Side lights (11)
> Fog light *
> Display and control panel illumination.
DANGER: Missing or defective lights increase the risk of accidents.

Any defective lights must be repaired by qualified mechanics or changed before
starting the vehicle.
* Optional
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3.03 AXLE SUSPENSION / LOCKING SYSTEM 023219>00
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Description
All axles are provided with hydro>pneumatic suspension with automatic leveling.
Each axle is connected with the frame via 2 hydraulic cylinders, which act as suspension and leveling elements.
The entire vehicle can be raised or lowered via this hydro>pneumatic suspension system, for example to reduce
the craneπs clearance height , or it can be raised to improve the vehicles fording power.
In addition, the entire vehicle can be raised or lowered either on the left and right front or on the left and right
rear .
The axles can be independently suspended or leveled.
To raise the vehicle: in suspended condition, push buttons (146, 147, 150, 151) on the ∫rear∫ ,
To lower the vehicle: in suspended condition, push buttons (146, 147, 150, 151) on the ∫front∫.
Controls and instruments

located in the driverπs cab instrument panel
in the crane operatorπs cab instrument panel
Pos.:
119 * Switch > turned on raise second axle

turned off lower second axle
This switch is only installed with 6¥4 drive.
142 Button > automatic vehicle height adjustment at low idle RPM
If this button is pressed when the switch (154) is turned off, then the vehicle will
automatically aligns itself for to the correct travel height for on road travel.
143 Indicator light > Travel height adjusted
When the correct ∫travel height∫ is reached, the indicator light stays on until the
button (142) is being released.
146 Button > To raise / lower the vehicle on the left front side
147 Button > To raise / lower the vehicle on the right front side
150 Button > To raise / lower the vehicle on the left rear side
151 Button > To raise / lower the vehicle on the right front side
154 Switch > turned on axle suspension blocked

turned off axle suspension free (suspended)
160 Manual lever > Engine speed regulation (manual accelerator) ,

to increase engine RPM
DANGER: With 6¥4 drive and 2nd axle raised, the switch (119) may not be pushed.
If this switch is pushed anyway, then the raised axle will drop ™down∫,
which can cause a serious accident!
* Optional
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1. Axle suspension ∫SUSPENDED∫

For driving on public roads, highways and off>road.
The switch (154) must be turned off, in this position, all axles are suspended.
CAUTION : The height of the crane can be regulated automatically or manually only in
this switch position .
1.1 Automatic travel height regulation

The adjustment must be made on even, hard and level ground of sufficient load carrying capacity.
To automatically regulate the travel height, push button (142) until the indicator light (143) lights up.
The crane is automatically returned into the correct travel height for on road travel by level switches,
which are installed on the suspension cylinders .
1.2 Manual travel height regulation

By actuating the button (146, 147, 150, 151), the pressure in the hydro>pneumatic system is either
increased or decreased , which allows the height of the vehicle to be adjusted as follows:
To raise / lower the vehicle on both sides:

> Push button (146 and 147) on the ∫rear∫, vehicle is being raised on front.
> Push button (146 and 147) on the ∫front∫ , vehicle is being lowered on the front.
> Push button (150 and 151) on the ∫rear∫, vehicle is being raised on the rear.
> Push button (150 and 151) on the ∫front∫ , vehicle is being lowered on the rear.
1.3 To raise / lower the vehicle on one side:

> Push button (146 ) on the ∫rear∫, vehicle is being raised on the left front.
> Push button (146 ) on the ∫front∫ , vehicle is being lowered on the left front.
> Push button (147) on the ∫rear∫, vehicle is being raised on the right front.
> Push button (147) on the ∫front∫ , vehicle is being lowered on the right front .
> Push button (150 ) on the ∫rear∫, vehicle is being raised on the left rear.
> Push button (150 ) on the ∫front∫ , vehicle is being lowered on the left rear.
> Push button (151) on the ∫rear∫, vehicle is being raised on the right rear.
> Push button (151) on the ∫front∫ , vehicle is being lowered on the right rear .
CAUTION: Never fully raise or lower the vehicle when driving on uneven roads, such as
off road!
The boom must be placed in lengthwise direction of the vehicle, towards the
front, and secured in the boom retainer for transport.
DANGER: When actuating the axle suspension / blocking system,make sure that there
are no persons within the danger range of the crane.
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2. Axle suspension ©LOCKED©

Release the switch (154) , push the symbol and turn on, the hydro>pneumatic suspension of all axles is
locked.
The axles must be locked to:
2.1 Supporting the crane,

2.2 Raising* the 2nd axle (not driven) in 6 x 4 drive
2.3 the ©oscillation*© of the 1st and 2nd axle,
2.4 the working mode ©freestanding on tires© and ©driving the crane with a load©.
2.1.1 To support the crane

Before supporting the crane, the crane must be aligned horizontally in ©SUSPENDED ©condition via
button (146, 147, 150, 151) and then the axle suspension must be ∫LOCKED∫ by turning on switch
(154).
When extending the outrigger cylinders, the axles are raised until all wheels are off the ground.
CAUTION: If this point is not observed, the axles can be damaged due to the load.
When lowering the supported crane onto the wheels, the outrigger cylinders must be retracted far
enough until the wheels touch the ground again. Then turn the switch (154) again to ∫SUSPENDED∫.
CA U T I O N : DO NOT change the switch (154) until all the wheels touch the ground again.
If this point is not observed, the axle suspension will be damaged due to the
sudden release of the axle blocking system .
DANGER: It is prohibited to change the crane in supported condition from ªLOCKED´

to ªSUSPENDED´ .
There is an increased risk of accidents, because the axles might drop.
Be especially careful when making repairs underneath the vehicle!
* Optional
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2.2.1 To raise the (non driven) 2nd axle *

On machines with 6¥4 drive, this control makes it easier to drive on uneven ground.
> Before driving into off road terrain, lower the vehicle in suspended condition on level ground of
sufficient load carrying capacity by pushing the button (146, 147, 150, 151),
> on switch (119), release the shift lock and turn the switch (119) on, this blocks the suspension of the
2nd axle, axles 1 and 3 remain suspended.
> Push button (142) until the indicator light (143) lights up, which raises the 2nd axle.
DANGER: When actuating the axle suspension or blocking system, make sure that no
personnel is in the vicinity or danger range of the crane.
In case of any improper operation, then the raised axle 2 can fall ∫down∫!
In 6¥4 drive and if the 2nd axle is raised *, the switch (119) may not be
actuated.
If this switch is pushed, the raised axle will drop down which can cause a
serious accident.
2.2.2 To raise the 2nd axle

> Lower the vehicle in suspended condition on level ground of sufficient load carrying capacity by
pushing the button (146, 147, 150, 151),
> on switch (119), release the shift lock and turn the switch (119) off, this releases the suspension of the
2nd axle.
> Push button (142) until the indicator light (143) lights up, and the vehicle is raised to travel height.
2.3.1 ©Oscillatingπ the 1st and 2nd axle

Prerequisite:
> The corresponding load capacity chart is programmed,
the boom is positioned to the rear,
the crane superstructure is mechanically locked to the chassis,
the axle suspension system is πLOCKEDπ.
C AU T I O N : The oscillation is only possible if the boom is positioned to the rear and the
crane superstructure is mechanically locked to the crane chassis, the indica>
tor light (306) must be on, the lever (261) must be positioned πdownward.π
After entering the corresponding CODE No. into the LICCON safe load indicator system and confir>
ming the entry, the 1st and 2nd axle is automatically switched to πoscillationπ in condition: axle suspen>
sion ©LOCKED. This is indicated by symbol (fig. 1) , the 3rd axle remains πBLOCKED™.
As long as the crane is operated with the load capacity chart in safe working range, the 1st and 2nd axle
is switched to oscillation.
If crane operation exits the safe range or another load capacity chart is selected, the LICCON safe load
indicator system shifts automatically back to axle suspension πLOCKEDπ, indicated by symbol (fig. 2).
* Optional
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2.4.1 Driving the crane with a load

Before driving the crane with a load, the axle suspension must be πLOCKED∫π by turning on the
switch!(154).
The adjustment must be made on level, horizontal ground with sufficient load carrying capacity.
The ground may not slope by more than ±0.15 meters over a distance of 10 meters.
C A U T IO N : The crane may only be driven with a load if it is positioned to the ∫REAR∫ ,
on level ground of sufficient load carrying capacity.
The ground may not slope by more than ±0.15 meters over a distance of 10
meters.
The crane superstructure must be mechanically locked to the chassis by mo>
ving the lever (261) πdownπ, the indicator light (306) must light up.
2.4.2 Driving the crane with attachment on a job site (see chapter 4.09)
Before driving the crane on a job site,the axle suspension must be πLOCKED∫π by turning on the
switch!(154).
The adjustment must be made on level, horizontal ground with sufficient load carrying capacity.
The ground may not slope by more than ±0.15 meters over a distance of 10 meters.
* Optional
93
3.04 DRIVING ON PUBLIC ROADS 023220>00
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Travel condition of the crane for on road travel
Before driving on public roads and highways, distribute the counterweights according to this chart, to conform
to traffic regulations according to StVZO .
In foreign countries, you must conform to NATIONAL AND LOCAL REGULATIONS.
Fig.: 1 Axle load 12 t / Axle,

with tires 14.00 R 25!* and 6.5 t total ballast
Telescopic boom placed to the front, as described in chapter 3.02, secured to prevent it from running out by
itself.
Counterweight on the crane superstructure

> 2.1 t attached with screws to counterweight frame
Tightening torque for screws =1000Nm
DANGER: The 2.1 t counterweight must be attached with 2 screws, size M 30 ¥ 140 and 2 nuts
to the counterweight frame .
The 0.5 t counterweight must be attached with 2 screws, size M 30 ¥ 200 to the
counterweight frame .
Counterweight placed on the vehicle

> 2.0 t and 1.9 t secured by placed down telescopic boom
Hook block (3pulley) attached to front tow coupling
Folding jib none
Spare tire none
Fig.: 2 Axle load 12 t / Axle,

Telescopic boom placed to the front, as described in chapter 3.02, secured to prevent it from running out by
itself.

Tightening torque for screws =1000Nm.

> 2.0 t secured by placed down telescopic boom
Folding jib with folding jib
Spare tire with spare tire
* Optional
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Fig.: 3 Axle load 13,7 t / Axle,

CAUTION : With axle loads >12 t / axle, the crane may only be driven on non>public roads, on
job sites, etc. or only in countries, which specifically permit such axle loads.
Even axle loads are only obtained if the ballast is distributed as shown .
Other ballast variations are not permitted for driving on public roads, as they could
cause increased loads and stress.
Telescopic boom Placed in lengthwise vehicle direction, to the front, as described in chapter 3.02, secured to
prevent it from running out by itself.

> 2.1 t, attached with screws to counterweight frame
> 1.0 t attached with screws to counterweight frame ,
Tightening torques for screws =1000Nm

> 2.0 t , 1.9 t and 2.2 t secured by placed down telescopic boom
Folding jib with folding jib
Spare tire with spare tire
Note: A hook block (single or triple pulley) may only be carried on the front, if it is :
> maximum 4 x reeved.
> marked on the manufacturerπs data tag with the letter ∫E∫ for ∫ENTSCH'RFT∫ (rendered
safe) and
> attached with the oval ring to the front tow coupling and tightened down.
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Turn on the battery master switch (25) .
Apply the parking brake

When the brake (158) is applied, the manual brake lever points backward, indicator light (34) lights up.
Note: To apply the parking brake, pull the manual brake lever straight out and then move it
backward.
To change over to travel operation from the driverπs cab

Prerequisites:
> The crane is positioned on level ground,
> the switch (154) is turned off, the axle suspension is active ,
> the gear selector switches in the driverπs cab (161) and in the crane operatorπs cab (208) must be in neutral posi>
tion ∫N∫. If this is not the case, the warning light (55) lights up.
> the parking brakes in the driverπs cab and in the crane operatorπs cab are applied,
> the travel motor (engine) and ignition are turned off,
> th switch (42)** is set to ∫ chassis∫ position .
CAUTION : The switch (42)** may only be changed over if the engine is not running and the
ignition is turned off.
Before changing the system over, the manual brake levers in the crane operatorπs
cab as well as in the driverπs cab must be applied.
Note: If the change over switch (42)** is actuated during the engine is running, the engine will
turn off automatically.
** version with wide driver's cab: fig. 4

version with narrow driver's cab: fig. 5
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Turn on the ignition > check instruments

Insert the ignition key into the ignition (30) and turn it one notch in clockwise direction, to position ∫1∫.
The following indicator and warning lights will come on :

> Parking brake (34)
> Preglow indicator light (50)
> Battery charge (51)
> Engine oil pressure (53)
> Insufficient oil pressure in the oil circuit for torque converter / automatic transmission (54)
> Steering circuit ¡ (57)
> Steering circuit ¬ (75)
If pressure is insufficient:
> Brake circuit ¡ (58)
> Brake circuit ¬ (59)
> Brake circuit √ (60)
If fluid level is insufficient:

> Fuel level (69)
> Coolant level (70)
Note : If the air pressure in the individual brake circuits has dropped below approx. 5 bar , war>
ning lights (58, 59, 60) will come on.
Fuel and coolant must be added before starting the engine, if warning lights (69 or 70) come
on .
To start and stop the travel and crane engine
Gear selector switch

Set the gear selector switch (161) to neutral position ∫N∫.
The engine can be started only in ∫N∫ position .
CAUTION : When the vehicle is at a standstill, the engine must be running at low idle and the
gear must be in neutral "N" position before shifting into another gear.
Do not give gas during or shortly before shifting from neutral "N" position to anot>
her gear .
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Starting the engine with the flame glow preheating system

The travel motor (engine) is equipped with a flame glow system and a flame start control unit.
Description of function
The flame start control unit supplies the current to the indicator light (50), the flame glow plugs in both intake
pipes and the solenoid valve for the fuel supply for the flame glow plugs.
At a lube oil temperature below the glow stop temperature (e+20∞C ), the preglow phase begins when the igni>
tion is turned on.
Preglow time
The preglow time depends on the system voltage .
When the ignition is turned on, the indicator light (50) lights up , the flame glow plugs are energized.
After completion of the preglow time, the indicator light (50) starts to blink (approx. 0.8 Hz), the STARTING
READINESS phase of the flame start system begins.
If the engine is not started during this time, the flame start control unit turns the flame glow plugs and the indi>
cator light (50) off.
If the engine is started during the starting readiness phase, then the flame start control unit opens the solenoid
valve for the fuel supply for the flame glow plugs.
After glow operation

The after glow operation starts when the starting procedure has been completed, the flame glow plugs continue
to be energized, the solenoid valve opens, the indicator light (50) turns off.
If the starting procedure was not successful, then the solenoid valve and the flame glow plugs are turned off.
> Return the ignition key to the stop before restarting the ignition.
At a lube oil temperature above the glow stop temperature (f+20∞C), the flame glow system is not functio>
ning, the indicator light !(50) blinks as soon as the ignition key is turned from the 1st notch and the engine is
ready to start.
Preglow time After glow time Glow stop
Volt sec ∞C sec ∞C
e19 35 +20 120 +25 (±5)

20 28 +10 120
21 26 0 120
22 24 $10 150
23 20 $20 180
32 10 $30 180
<$30 180
The flame start control unit recognizes errors on the flame start system and indicates the same, the indicator
light (50) will blink rapidly (approx. 1.6Hz) .
The following errors are recognized:

> Interruption of the flame glow plug > heating wire,
> Missing current supply on terminal 30,
> Defective fuse of flame start control uni t.
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Starting the engine at a lube oil temperature above the glow stop temperature (f+20∞ C)
CAUTION : The engine may only be started if:

> the alternator warning light (51) is on ,
> the flame start system indicator light (50) blinks.
If the engine does not start after max. 10 seconds, then wait for 1 minute.
The starter should only be cranked three times for 10 seconds per starting procedu>
re, with a 1 minute break in between.
At a lube oil temperature above the glow stop temperature (f+20∞C) , the flame glow system is not in opera>
tion, the indicator light !(50) blinks as soon as the ignition is turned on.
> Continue to turn the ignition key in clockwise direction to position "2" , slowly press down the gas pedal (5)
and start the engine.
Note: At every starting procedure, the starter will start to turn after about 1 second after the igni>
tion key is turned to position !"2"!.
This delay prevents a failure of the electric engine shut off system.
> Release the ignition key as soon as the engine turns over and release the gas pedal!(5) .
> If the engine does not start after approx. 5 seconds, slowly press down the gas pedal (5) and turn the starter
again.
> Return the ignition key all the way to the stop before restarting.
When the engine is warm, start the engine without pressing on the gas pedal (5) to prevent unnecessary ex>
haust emission.
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Starting the engine at a lube oil temperature below the glow stop temperature (e+20∞ C)

1. Preglow
> Turn the ignition key to (30) position ∫1∫ ,
the preglow time begins, the indicator light (50) will turn on.
If you try to start the engine during the preglow time, then the preglow phase is automatically interrupted. In
this case, return the ignition key to the stop and repeat the preglow phase.
2. Start the engine

The starting readiness starts as soon as the indicator light !(50) blinks.
> Turn the ignition key (30) to position ∫2∫ and start the crane engine without pressing down the gas pedal
(5).
Note: The starter turns over after approx. 0.6 seconds after the ignition key is in position !∫2∫ .
If the engine is not started during the starting readiness time, then the starting readiness will automatically
stop.
In this case, repeat point 1. and 2.
> If the engine does not start after approx. 5 seconds, return the ignition key to the stop and repeat the preglow
phase.
> slowly press down the gas pedal (5) or pull the gas lever (160) lightly and start again, engine RPM max. 1000
RPM.
If the engine still does not start after max. 10 seconds, then wait for 1 minute. The starter should only be
cranked three times for 10 seconds per starting procedure, with a 1 minute break in between.
During the cold season, pay special attention to the batteries.

The starting capacity is significantly reduced during cold temperatures, for example at >10 ∞C, it is only about
66% of its normal capacity.
For that reason, after the engine has been turned off, the batteries should be removed and stored in a heated
room .
CAUTION : As long as the engine is running, DO NOT loosen either the cable on the alternator,
nor any one of the battery terminals, do not unplug the regulator or change any of
these item.
The alternator must be connected with the batteries during operation .
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Starting procedure at ambient temperatures below >20 ∞C
To assure that the crane starts in extreme low temperatures, and that the engine is supplied with sufficient lu>
brication, the engine and the oil pan for the engine and the oil pan for the automatic transmission must be pre>
heated.
Preheating the engine *

Prerequisite: All components must be filled with service fluids for winter operation, according to the lu>
brication chart.
The preheat procedure * occurs via the coolant circuit through two* in>line, Diesel fuel operated heating units.
To preheat the oil pan for the engine*

The oil is preheated via the exhaust from the heating unit for engine preheating.
To preheat the oil pan for the automatic transmission *

The oil is preheated via the exhaust from the Diesel engine operated cab heater.
Preheat time
depends on ambient temperatures
Ambient temperature Preheat time

[∞C] [min]
> 40 to > 35 120

> 35 to > 30 90
> 30 to > 25 60
> 25 to > 20 30
> 20 and warmer no preheating required
Turn on the engine preheater

> Turn on the battery master switch (25) .
> Move the sliding regulator (12 > not shown) for the temperature selection to "cold" .
> Depending on the ambient temperature, turn on the two* heating units via switch (137) about 30 to 120 minu>
tes before starting the engine. It is functioning properly when the indicator light (81) turns on.
After about 15 seconds, the combustion procedure will start and the heating unit will run in automatic regula>
tion .
To turn the heaters off after the preheat time

Turn both* heaters off via switch (137) , the indicator lights (81) will turn off.
The fuel supply is interrupted and the combustion procedure is ended.
The combustion blower and the heater pumps will continue to run to cool down the heating units and will turn
off after about 150 seconds.
*Optional
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The engine runs > check instruments

Observe the oil pressure gauge (35) and the warning light (53) immediately after starting the engine.
CAUTION: If no oil pressure is shown or if the warning light (53) does not turn off, turn the
engine off immediately, to prevent engine damage due to insufficient lubrication.
The engine must be turned off immediately if:

> the oil pressure drops or fluctuates greatly
> the power and engine speed drops without a change of the throttle control lever
> there is a lot of smoke coming from the exhaust
> the coolant and oil temperature increases
> you can hear sudden abnormal noise coming from the engine or turbo charger.
Do not put a full load onto the engine until it is at operating temperature.
When starting a warm engine, do not press down on the gas pedal (5) to prevent unnecessary exhaust emis>
sion.
The following indicator lights must turn off when the engine is running:
> Battery charge indicator (51)
> The oil pressure in the torque converter / automatic transmission is too low (54)
> Steering circuit I (57)
> Steering circuit II (75)
NOTE : The indicator lights for the steering circuit II (75) will turn off after driving at a speed of
about 10 km/ hr.
> Brake circuit I (58)

> Brake circuit II (59)
> Brake circuit III (60)
NOTE: The indicator lights for the brake circuits will turn off when the pressure in the brake sy>
stem has built up to approximately 5 bar .
The cut off pressure is at approx. 8.5 bar.
The parking brake (158) may be released once the air pressure in brake circuit III has rea>
ched approximately 5.2 bar . At that point, indicator light (34) will turn off.
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Check the function of the brake system

> Slowly push the foot pedal (4) for the service brake down, the red needle in the duplex air pressure gauges !(44,
45) must move in proportion to the pedal stroke, until it reaches the position of the white needle (reserve pres>
sure).
3. Turn the engine off

> Relieve the engine load by slowly decreasing the engine RPM, let the engine run for a short time at idle speed
to give the turbo charger time to run out.
This is especially important for turbo charged engines, the turbocharger runs at high speeds and must have ti>
me to run out. If the engine is turned off suddenly, the turbocharger would run for some time without suffi>
cient oil supply.
> Turn the engine off by turning the ignition key (30) to the left.
> Remove the ignition key.
CAUTION: If tghe engine is at a standstill and the ignition is left "on", the batteries may
discharge, depending on their current charge.
Low level discharge can cause the following damage:
> reduced capacity

> white layer on batteries and terminals
> short battery life expectancy
> defective batteries
To turn the engine off in an emergency*

In dangerous situations, the engine can be turned off by pushing the emergency ∫OFF∫ button* (26) .
> The engine will be shut down immediately by pushing the button (26), at the same time, the knob of the button
will lock down.
> To restart the engine, turn the ignition key (30) all the way to the left, then release the knob of the button (26)
by turning it to the ∫right∫ .
The engine may now be restarted.
CAUTION: The emergency "OFF" button* (26) may only be used in absolute emergency
situations.
It is not permitted to use the emergency ∫OFF∫ button (26) operationally!
*Optional
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Adjust the axle suspension

The switch (154) must be turned off , the indicator light in the switch is not on.
In this position, all axles are suspended.
Note: For a description of the "AXLE SUSPENSION / LOCKING SYSTEM ", refer to chapter
3.03.
Automatic leveling > travel height adjustment

The automatic and manual travel height or level adjustment must be made while the vehicle is parked on a firm
and level road surface.
> Start the engine, as described in chapter 1. and 2.
CAUTION : Before actuating the axle suspension / locking system, make sure that there are no
persons within the danger range of the crane.
> Push button (142) for automatic level adjustment until the indicator light (143) lights up. The level (travel
height) is now adjusted correctly. The indicator light (143) will light up as long as button (142) is depressed.
Manual leveling
C A U T I O N: When driving on public roads, manual level adjustment is only permissible under
special circumstances, for example if the crane must be lowered in order to impro>
ve its vertical clearance, allowing it to pass under a bridge.
The vehicle may only be leveled manually if the vehicle is at a standstill!
Carry out the manual travel height adjustment as described in "AXLE SUSPENSION / LOCKING SYSTEM ",
chapter 3.03, paragraph 1.2 .
Ready to travel > engine runs in low idle speed

> Select the desired range on the gear selector switch (161). A slight drop in engine RPM shows that the selected
gear is shifted.
Release the parking brake

Pull the manual brake lever (158) straight out and push it forward , indicator light (34) turns off.
C A U T I O N: As long as the necessary brake release pressure of approx. 5.2 bar is not available
in brake circuit III > and the warning light (60) is on > the parking brake will not re>
lease, even if the brake lever has been moved forward.
Move the manual brake lever back again and recharge the brake circuit III until
the warning light (60) turns off.
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Service brake (4)

> Increase the engine RPM by pressing the gas pedal (5) down , the crane will begin to move.
C A U T I O N: Check the brake function immediately after the crane starts to move.
Engine brake (1)*

Use the foot button (1) to apply the wear free engine brake.
DANGER: When going downhill, use only the engine brake.

If the braking action is insufficient, slow down the vehicle with the service brake
until the transmission can down shift to next lower gear.
Eddy current brake (6)*

With the 5>stage steering column switch (6), the Eddy current brake can be actuated as needed. Brake function
is indicated on indicator light (63).
CAUTION: The steering column switch (5) must be switched back to ZERO (towards the front)
as soon as the vehicle has come to a stop or as soon the braking function is no
longer necessary.
Emergency release valve* (159) for parking brake (manual brake)

If the parking brake is blocked due to a defect in the air pressure system, then the brake can be vented (relea>
sed) by pressing the button (159)* and the vehicle can be moved from the danger zone.
DANGER: DO NOT CONTINUE to drive with a defective air pressure system!
Driving downhill
Use the engine and the Eddy current brake* to slow the driving speed, in order to take it easy on the service
brake.
A simple rule of thumb:
Drive downhill in the same gear as you used to drive uphill.
C A U T I O N: If you go downhill too fast, the engine brake can be overworked and it can no
longer hold a constant travel speed, at the same time, the oil temperature will
exceed its upper limit of 120∞C .
In this case, use the service brake to slow the vehicle and shift to the next lower
gear.
If the travel speed is adapted to the incline, as previously described, the engine
brake can slow the vehicle speed without the danger of overheating.
* Optional
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Getting ready to drive

The engine is running at low idle RPM.
On the gear selector switch (161) , select stage 1 (forward or reverse, as needed).
Release the parking brake, the manual brake lever points to the front when the brake is released.
The crane will already start to move off slowly .
Shifting, driving
Six forward gears and 2 reverse gears are available to drive the crane.
The travel speed is regulated via the pedal (5) and the gear selector switch (161) for the automatic
transmission.
The individual shift stages can be shifted under load.
To protect the engine from overspeeding, do not shift back until the highest speed of the next lower gear has
been reached. If necessary, slow the crane down with the operating brake until this speed has been obtained.
CAUT ION : If the vehicle is not moving, the engine must be running at low idle speed to shift
from ∫N∫ to another gear .
DO NOT press the gas pedal during or shortly before shifting from "N" to another
gear.
The various positions of the gear selector switch (161)

With the gear selector switch (161) , various shift programs can be selected or set .
CAUTION : It is important that the range is selected correctly .
R Reverse travel
1 Inching gear
2 Slow
N Neutral
Required gear to start the engine .
V Forward travel
1 Inching gear
2 Slow
3 City driving
4 Continuous driving at limited top speed
5 Continuous driving at limited top speed
D Continuous driving
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Driving, shift programs

Use switch (155) to preselect between two different travel programs , ∫FP 1∫ and ∫FP 2∫ . The change over
from ∫FP 1∫ to ∫FP 2∫ or reverse is also possible while driving.
C AU T I O N : It is important to select the correct range.
FP 1 :
For predominantly level routes.
This travel program is designed as an economy program, the gear shifts up to ta higher gear at approx. 1900
RPMs.
FP 2 :
For uphill routes.
This travel program is more powerful (with higher fuel consumption).
The gear shifts up at approx. 2100 RPMs.
The travel program ∫FP 2∫ should only be used before driving uphill.
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The different positions of the gear selector switch (161), their meaning and use is as follows:
N (Neutral)
The gear selector switch must be in this position to start the engine.
CAUT ION: For safety reasons, before starting the engine, apply the parking brake.
Never let the vehicle roll out in idle ( gear selector switch on ∫N∫ ) , because this
cancels out the engine braking effect, making the transmission lubrication insuffi>
cient.
D (Continuous drive )
In this gear selection, four forward gears are available, since the transmission starts out in 3rd gear and then
shifts to 4th, 5th and 6th gear.
At the appropriate RPM and speed, in all forward gears, the torque converter is turned off (bypassed) and a
simply mechanical transfer of power from the engine to the gear is established.
Down shifting is done in reverse order.
5 (Continuous drive with limited top speed )

In this gear selection, the change from 3rd to 4th gear occurs automatically. The 5th and 6th gear is blocked.
This gear selection is recommended for routes where the automatic would constantly switch between the 4th
and 5th gear or when driving down a slight hill, to prevent from shifting up to the 6th gear.
4 (Continuous drive with limited top speed )

In this gear selection, the change from 3rd to 4th gear occurs automatically.
The 5th and 6th gear is blocked.
This gear selection is also recommended for routes where the automatic would constantly switch between the
4th and 5th gear or when driving down a slight hill, to prevent from shifting up to the 6th gear.
3 Slow gear
In this gear selection, only the 3rd gear is used. Upward shifting is suppressed.
This is advantageous when driving uphill or downhill.
2 Slow gear
In this gear selection, only the 2nd gear is used. Upward shifting is suppressed.
This is advantageous when driving uphill or downhill, the 2nd gear should be preselected in time.
1 (Inching / creeper gear)

All other gears are blocked.
This gear selection is recommended whenever extremely low speeds must be used or when load and terrain or
off road conditions require you to drive extremely slow.
R (Reverse gear)
DO NOT shift from neutral to reverse, or from reverse to forward or vice versa, unless the vehicle is at a
standstill, the manual brake is engaged, and the engine is running at low idle speed!
After shifting, wait approximately 1 to 2 seconds before accelerating
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Shifting gears and driving

Even if the vehicle is at a standstill, always apply the service or parking brake before shifting from ∫N∫ to
another gear, to prevent the vehicle from "creeping away" .
Shifting gears manually

While driving along in forward direction, the gear lever can be used to change gears and to transfer to another
gear range even at full speed, in order to get the transmission to automatically shift to a higher or lower gear.
For example. select the 2nd gear before driving uphill, even though you could still drive in "D" .
The automatic transmission will shift back to the 2nd gear by itself.
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Keep an eye on the following important instruments while driving: :
1. Warning light > engine oil pressure (53),

2. Warning light > coolant temperature (71)
CAUTIO N : If one of the warning lights (53, 71) comes on during travel, then the crane must be
stopped immediately and the engine must be turned off.
Low engine oil pressure or high coolant temperature can cause serious engine
damage.
3. Coolant temperature gauge (32)

If the temperature increases too much while driving, try to lower the temperature to a permissible range of 85∞C
to 90∞C ( 185∞ F to 194∞ F) by decreasing the engine load or by increasing the engine speed.
C A U T I O N: If the coolant temperature does not drop to within the permissible range, then the
crane must be stopped immediately and the engine must be turned off.
Increased engine coolant temperature can cause serious engine damage.
4. Warning light > steering circuit ¬ (75)

At a driving speed of approximately 10 km/h (6 miles per hour) , the warning light (75) for the hydraulic stee>
ring circuit II must turn off.
C A U T I O N: If the warning light does not turn off, then the steering circuit II is not functioning
properly. The crane must be stopped immediately and the cause must be found and
remedied.
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5. Warning light > brake circuit ¡, ¬, √ (58, 59, 60)

At a driving speed of approximately 10 km/h (6 miles per hour) , these warning lights must turn off.
C A U T I O N: If one of these warning lights does not turn off, then the brake system is not
functioning properly. The crane must be stopped immediately and the cause must
be found and remedied.
6. Warning lights
Automatic brake block prevention * > vehicle (83)
Automatic brake block prevention * > trailer (85)
At a driving speed of approximately 10 km/h (6 miles per hour) , these warning lights must turn off.
C A U T I O N: If one of these warning lights (83) or (85) with trailer operation,does not turn off or
lights up while driving, then there is a problem in the electronic ABV control. The
automatic brake block prevention is no longer functioning.
The crane can be driven, but it must be noted that it now can be slowed down only ∫normally∫, i.e. without ABV
support.
The cause of the error must be found and remedied as soon as possible by a trained expert mechanic.
*Optional
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7. Warning light > insufficient oil pressure in the hydraulic circuit of the torque converter > automatic
transmission (54)
If this warning light lights up during travel, stop the crane and lower the engine RPM to !1500 RPMs. If the
warning light does not turn off within a short time, then turn the engine off.
If the warning light lights up momentarily during a shifting procedure, then no measures are needed.
CAUTION: If the warning light (54) lights up during travel, then the crane must be stopped im>
mediately .
Lower the engine RPM to approx. 1500!RPM, and watch the warning light (54) .
If the warning light does not turn off within a short period of time, then turn the en>
gine off.
Low engine oil pressure can cause serious gear or converter damage.
8. Torque converter oil pressure gauge (40)
Shifting program Oil pressure

approx. [bar]
Forward travel 17 to 18
∫Neutral∫ 17 to 18
Reverse travel 17 to 18
CAUTION : If the torque converter oil pressure drops dramatically, turn the Diesel engine off
immediately. Insufficient oil pressure can cause gear or converter damage.
9. Warning light > oil temperature > torque converter / automatic transmission (72)
If this warning light lights up during travel, stop the crane and lower the engine RPM to !1500 RPMs. If the
warning light does not turn off within a short time, then turn the engine off.
10. Temperature gauge > torque converter oil (41)

During normal travel operation, the needle of the temperature gauge (41) must be within the permissible range
(green area).
C A U T I O N: If the needle goes into the red range, stop the crane immediately.
Shift the automatic transmission into neutral position "N" and let the engine run at
approximately 1500 RPM. The oil temperature must drop to the permissible
temperature range within a short period of time.
If the oil temperature does not drop into the permissible temperature range, then
the crane must be stopped immediately and the engine must be turned off.
Increased oil temperature can cause serious damage to the transmission.
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11. Warning light > problem in the electrical system / electronic gear control (55)
If this warning light lights up during operation, then there is a problem in the electronic gear control system.
The gear shifts back to neutral, and no other gears can be selected.
CAUTION: If this happens while driving, then the crane cannot be driven any longer, and it
must be towed off.
A trained mechanic must be called to check out and remedy the problem .
12. Fuel gauge (33)

The fuel gauge shows when it becomes necessary to add fuel.
C A U T I O N: Do not let the fuel tank get completely empty, because contaminants in the fuel tank
can be drawn into the fuel system and it will become necessary to clean and bleed
the entire fuel system .
Do not drive until the fuel level warning light (69) comes on, refuel before.
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Off>road driving
For off>road driving, driving on unpaved surfaces and during winter or cold weather conditions, additional
gears are provided, which may only be selected in the following order:
CAUTION : The vehicle must be at a standstill and the gear selector switch must be in neutral
position before adding gears.
1. Off road gear

The off road gear reduces the travel speed of the individual gears and increases the drive power, which is
transferred by the wheels to the ground surface.
The off road gear can be shifted separately.
2. Front axle drive ,

Drive for 1st axle , (for 6¥4 drive).
Drive for 1st and 2nd axle, (for 6¥6* drive).
The front axle drive requires off road gear.
If one or more wheels slip when driving in off>road gear, the 1st (or 1st and 2nd*) axle drive and the can be
added .
3. Transverse differential lock

The transverse differential lock requires off road gear and front axle drive.
If the addition of the 1st (or the 1st and 2nd*) axle drive is not enough to prevent the wheels from spinning,
then the transverse differential locks of the driven axles can be added .
4. To raise the non >driven 2nd axle (for 6¥4 drive)

On machines with 6¥4 drive, this gear facilitates off road driving.
5. Oscillation * of 1st axle , (for 6¥4 drive, 2nd axle raised)

Oscillation * of 1st + 2nd axle , (for 6¥6* drive)
This gear is used to drive the crane on jobsites and can only be carried out from the crane operatorπs cab.
1.1 To add the off >road gear:

> Bring the crane to a standstill.
> Move the gear selector switch (161) to neutral position ∫N∫ .
> Add the off>road gear via switch (116).
> On the gear selector switch (161), select the desired travel range.
As soon as indicator light (76) lights up, the off road gear is engaged.
If the indicator light does not turn on, then return the gear selector switch (161) to neutral position, and
repeat the procedure.
2.1 Add front axle drive (drive for 1st or 1st and 2nd * axle ) zuschalten
> Add the drive for the 1st (or 1st and 2nd*) axle via switch (117).
CAUTION : Drive off carefully, the drive for the 1st (or the 1st and 2nd)* axle is only ad>
ded if the indicator light (77) is on.
* Optional
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3.1 Turn on the transverse differential lock

> Change the gear selector switch (161) to neutral position ∫ N ∫.
> Turn on the transverse differential lock for the driven axles via switch (118).
C A U T I O N: Move off carefully. The transverse differential locks are not engaged until the
indicator light (78) turns on.
4.1 Raise the (non>driven*) 2nd axle
DANGER: Before raising or lowering the 2nd axle, it must be assured that there are no
persons in the danger range of the crane.
In case of erroneous control, the raised 2nd axle can drop ∫down∫ .
> Before entering off road terrain, lower the vehicle in suspended condition on firm and level ground by
pushing the button (146, 147, 150, 151) ,
> On the switch (119), release the shift lock and turn on the switch (119) , the suspension of the 2nd axle
is hereby blocked, the axles 1 and 3 remain suspended.
> Press the button (142) until the indicator light (143) lights up, the 2nd axle is now raised.
4.2 Lower the 2nd axle

> Lower the vehicle in suspended condition, on firm and level ground, by pushing button !(146, 147, 150,
151),
> on the switch (119), release the shift lock and turn on the switch (119) , the suspension of the 2nd axle is
hereby released.
> Press the button (142) until the indicator light (143) lights up, the vehicle is now raised to travel
height.
Turn off added gears
CAUTION : Turn the the transverse differential locks as well as front axle drive off as
soon as the ground becomes harder and provides sufficient traction and they
are no longer required to drive.
Continued driving on solid ground with sufficient traction with the front axle
drive as well as the transverse differential locks engaged can cause signifi>
cant damage on the axles as well as the complete drive train !
*Optional
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Rear axle steering

The rear axle steering makes it possible to turn the wheels of the 3rd axle into the same direction for offset mo>
vement of the crane ( for the so > called dog or crab walk) and tight turning radii.
CAUTION : The rear axle steering may not be used while driving on public roads.
The functional warning lights (62 and 80) for the rear axle steering must be off for
on road travel.
Check the rear wheels to make sure they are positioned correctly.
To put the rear axle steering in operation

When using the rear axle steering , after turning on the switch (114), the upward shift lock is actuated, i.e. only
the 1st and 2nd forward and the 1st reverse gear are available.
> Bring the vehicle to a standstill on level ground.

> Apply the parking brake ,
> shift the gear selector switch (161) to neutral ∫N™ position.
> with switch (114), open (lock) the rear axle steering lock.
N o t e: The release is only possible if the automatic transmission is in neutral position, in 1st and
2nd forward gear and in reverse gear.
> Move the steering button (141) lightly to the left and right, until the yellow indicator light (80) lights up.
If the red warning light (62) comes on instead of the yellow indicator light (80), the steering lock / release is in
an intermediate position.
In this case, turn the switch (114) off and on again and move the steering button (141) lightly to the left and
right until the indicator light (80) lights up.
> With the steering button (141), the rear axle can now be moved to the left or right, independent from the front
axle.
To take the rear axle steering out of operation
CAUTION: If the rear axle steering is no longer needed, then it must be locked again in straight
away direction on level ground before continuing to drive!
> Bring the vehicle to a standstill on level ground .

> Turn the wheels for straight travel.
> Apply the parking brake .
> Via switch (114) , apply the steering lock for the rear axle .
> Move the steering button (141) for the rear axle steering slightly to the left and right until the yellow indica>
tor light (80) turns off. .
CAUTION: The red warning light (62) may not be on.
> Make sure that the rear axle steering is locked by actuating the rear axle steering again via the steering but>
ton (141) while watching the wheels of the 4th and 5th axle, these wheels may no longer steer to the right or
left .
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To stop the vehicle in traffic

> Bring the crane to a stillstand by applying the service brake.
> The travel range on the gear selector switch (161) can remain engaged.
To interrupt travel with the engine running

> Bring the crane to a stillstand by applying the service brake (4).
> Before leaving the driverπs seat, switch the gear selector switch (161) into neutral position ∫N∫ .
> Use the manual brake lever (158) to apply the parking brake, the indicator light (34) must turn on.
To end travel
> Bring the crane to a stillstand by applying the service brake ,
> Before leaving the driverπs seat, switch the gear selector switch (161) into neutral position ∫N∫ .
> Use the manual brake lever (158) to apply the parking brake, the indicator light (34) must turn on.
Turn the engine off

> Turn the engine off with the ignition key (30) by turning it counterclockwise to position ∫0∫.
Turn the ignition off

> Turn the ignition off with the ignition key (30) by turning it counterclockwise to position ∫0∫ and remove the
key.
> Turn the battery master switch (25) off by pulling the switch cam .
> Lock the cab.

> Place chocks under the wheels to prevent the crane from rolling away.
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142
Towing
In case the mobile crane must be towed, a pressurized air supply coupling is provided on the right front
underneath the bumper. This connection must be coupled with the air pressure system of the tow truck to
maintain the pressurized air supply for the crane.
CAUTION: For towing, the reserve pressure of the air pressure brake system of the vehicle
to be towed must be at least 6 bar .
During the towing procedure, the parking brake must be released to prevent da>
mage to the brake system .
As a matter of principle, the towing speed may not exceed 10 km/h ( 6.2 miles per
hour) .
To tow the crane, use the rangier coupling with pins in the bumper.
The crane may only be towed with a tow bar.
1. In the event of automatic transmission damage

> Disconnect the drive shaft from the transmission to the drive axles, flange off on the drive axles and secure
it.
> With the gear selector switch (161) in neutral position ∫N∫ , let the Diesel engine run in low idle .
> The air pressure system must be continually supplied with pressurized air (at least 6 bar) via an external
air pressure system.
2. In the event of engine damage:

If the towing distance is less than 10 km (6 miles):
> Do not flange off the gear shaft from the transmission.
> supply the air pressure system with pressurized air (at least 6 bar) via an external air pressure system.
3. In the event of engine and transmission damage
CAUTION : The crane may not be towed. Due to lack of steering support, the crane can no
longer be steered.
4. In the event of damage to the drive axles

Allow only trained personnel to carry out the towing procedures if there is any damage to the drive axles.
> Remove the drive shaft to the defective axle.

> Remove the half shaft from the defective axle.
143
3.05 THE CRANE AT THE JOBSITE 023221>00
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SELECT THE SITE

Choose the site carefully to assure that the outriggers can be extended to the support base specified in the load
capacity chart and that the crane can be aligned horizontally.
DANGER: The safety guidelines in chapter 2.04 must be strictly observed and adhered to, as
they prevent personal injury or death to yourself and others and possible damage to
the crane and equipment!
Changing from driving to crane operation

Prerequisites :
> The crane must be parked on even ground,
> the parking brake lever in the driverπs cab (158) and in the crane cab (263) is applied,
> the gear selector switch in the cab (98) and in the crane cab (208) is in neutral position ∫N∫,
> the switch (42**) is set to the vehicle symbol,
> the switch (154) is turned off (in position ™Axles suspended∫),
> the vehicle and crane engine is running,
Note: You should also refer to chapter 4.03, STARTING THE CRANE.
Lock the axle suspension

> Align the crane via the manual leveling control (button 146, 147, 150, 151) as level as possible.
> Turn on switch (154) to ™lock the axle suspension™.
> Turn the engine off with the ignition key (30) by turning it counterclockwise to position ∫0∫.
> Turn the ignition off.
To change over to superstructure operation
CAUTION: The switch (42**) may only be actuated when the engine is not running and the
If this is not observed,the coupling for the hydraulic pump will be damaged.
Note: When the switch (42**) is actuated, the gear selector switch in the driverπs cab (161) as well
as in the crane operatorπs cab (208) must be in neutral position ∫N∫.
If this is not the case, the warning light (55) lights up in the driverπs cab.
If the switch (42**) is actuated when the engine is running, the engine and ignition turns off
automatically.
In addition, for safety reasons, always turn the switch (154) to ∫AXLE SUSPENSION
LOCKED∫.
> Turn the switch (42**) ∫to the right∫ to the crane symbol to automatically lock the axle suspension.
The functions of the electrical system, steering, gear selection control, parking and foot brake are now changed
over to superstructure operation .
** Version with wide driver's cab: Fig. 1

Version with narrow* driver's cab: Fig. 2
* Optional
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146
Support the crane from the chassis

The crane can be supported from the chassis as well as from the crane cab.
CAUTION: The crane operator is obligated to set the appropriate load capacity chart for the
actual supporting width in the LICCON overload safety device.
The vertical support cylinders must be supported properly and may not be
extended as far as the lower stop.
The crane operator must assure, by measuring, that the extended cylinder stroke is
less than the maximum cylinder stroke.
If there is any doubt, all vertical support cylinders must be retracted a couple of
millimeters [mm] .
Bring the outrigger pads from transporting to operating position
Fig. 2:
> Turn the handle of the retaining pin (C) ∫upward∫ and pull the pin from the bore (4).
> Pull the outrigger pads on the handle until the stop (2) on the head of the outrigger cylinder (5).
> Insert the pin (C) into bore hole (3).
Fig. 3:
> Turn the handle of the pin (C) downward to secure it.
Fig. 1 and 4:
> Loosen the mechanical lock (pin A) on the four sliding arms and take them out,
> Open the control box for the outriggers, on the left or right hand side of the vehicle.
On both sides of the vehicle is a control box, Fig. 1 with control buttons to operate the support system.
Control box functions on the left side of the vehicle

a) Sliding arms left front > extend / retract
b) Outrigger cylinder left front > down / up
c) Outrigger cylinder right front > down / up
d) Outrigger cylinder right rear > down / up

e) Outrigger cylinder left rear > down / up
f ) Sliding arms left rear > extend / retract
Control box functions on the right side of the vehicle

a1) Sliding arms right front > extend / retract
b1) Outrigger cylinder right front > down / up
c1) Outrigger cylinder left front > down / up
d1) Outrigger cylinder left rear > down / up

e1) Outrigger cylinder right rear > down / up
f 1) Sliding arms right rear > extend / retract.
147
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148
Support the crane from the chassis

> Start the travel and crane engine, as described in chapter 3.04 ,
> Increase the engine RPM via the throttle control lever (160) to about 1500 RPM, otherwise let it run at low
idle.
Extend the sliding arms
DANGER: From the control box, the operator must carefully observe the sliding arms while he
extends or retracts them.
While the sliding arms are extended or retracted, the operator must make sure that
there are no persons or objects within the danger zone.
> Extend all four sliding arms to the support base specified on the load capacity chart.
> Check if support surfaces (E1 or E2) match.
Note: E1 = wide support base

E2 = reduced support base
Check marks (F) can be used by the crane operator to check the extension, if the extension is correct, they are
located just before the edge of the outer part of the sliding arm (D).
Secure all 4 sliding arms with 2 pins (A+B) per arm.
DANGER: The sliding arms MUST be secured with pins to prevent any subsequent movement
of the support surface. If this is not done, it could cause a serious a c c i d e n t !
The pins (A) must be completely inserted and the handle must point downward. If
this point is not adhered to, the crane could topple or tip over and cause a serious
a c c i d e n t.
Check the outriggers
Note: At this point, make sure to check the site again to assure that the outriggers can be placed
properly and securely and assure that all safety regulation and guidelines are strictly
adhered to, otherwise there is a serious risk of accidental injury or death!
DANGER: All 4 sliding arms for the outriggers must be extended, including those on the
opposite side of the load.
If only the sliding arms on the load side are extended, it can have serious
consequences, because :
1. Due to the load hanging on the hook, the hoist cable and the telescopic boom (this
also applies to the auxiliary boom and the guy ropes, if they are used) are under
great tension and stress.
If, in this situation, the load were to drop from the lifting cables and tackle, or if
the hoisting cable were to break, the sudden loss of the load and resulting relief
would cause the boom to jerk up, which in turn might cause the crane to topple
over.
2. Despite previous assumption, it might become necessary to swing the load to the
opposite side. If this happens, it could cause the crane to topple over.
3. When slewing from the lengthwise or longitudinal direction, the center of gravity
changes due to the boom or counterweight momentum, which might be sufficient
for the crane to topple over.
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150
Supports
The outrigger pads must be set on a foundation or base, its size depends on the ground conditions, the
foundation must be made of strong material, such as wood, steel or concrete slabs.
Note: Read and observe the safety guidelines and observe the permissible ground bearing load
(chapter 2.04).
Outrigger pad area = 2500 cm2
DANGER: Use only suitable material for making the foundation.

The foundation must be placed in the center beneath the outrigger pads.
If this point is not observed, there is a serious risk of accidents.
To extend and / or retract the outrigger cylinders from the chassis

> Go to one of the control boxes and extend the outrigger cylinders and raise the crane until the wheels are off
the ground.
DANGER: If this point is not observed, the axles may be damaged during crane operation.
When you move the outrigger cylinders from the control box, move only those
outrigger cylinders you can see directly !
When the outrigger cylinders are extended or retracted, the operator must make
sure that there are no persons or objects within the danger zone.
Align the crane horizontally

On both sides of the vehicle and in the crane operatorπs cab are sight gauges to level the crane.
> Align the crane horizontally by extending or retracting the individual outrigger cylinders.
This is achieved when the air bubbles in the sight gauges are between the innermost rings.
DANGER: If the crane is not aligned horizontally, there is an increased risk of causing a
serious accident.
Note : The maximum permissible deviation from the horizontal crane position is ± 0,5% (± 0.3∞).
The air bubble in the sight gauges must be between the innermost ring (in the center).
If the sight gauges have been damaged by external forces and become maladjusted, then
they must be recalibrated.
To do so, place a level on the slewing ring of the vehicle, and align the crane horizontally in
a longitudinal and lateral direction. Then reset the sight gauges by adjusting the
adjustment screws and secure them in this position with lock nuts. During normal travel
and crane operation, the adjustment of the sight gauges should remain unchanged.
> Once the crane is aligned, reduce the engine speed via the engine regulation (160) to idle speed and turn the
engine off by turning the ignition key (30) to the ∫left∫.
> Turn the ignition off and remove the ignition key.
To put the crane into service

Refer to chapter 4.03, STARTING THE CRANE.
151
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152
To retract the outrigger cylinders from the crane chassis

> Start the travel and crane engine, as described in chapter 3.04 and move the throttle control lever (160) to
increase the engine RPM to about 1500 RPM, then let it run at low idle.
Retract the outrigger cylinders

> Open the control box on the left or right hand side of the vehicle, fig 1
> Evenly retract the outrigger cylinders by pressing the buttons (b / c / d / f or b1 / c1 / d1 / f1) and lower the crane
until the wheels touch the ground.
> Then continue to retract all four outrigger cylinders fully.
> Turn the switch (154) to the position for ∫Axles suspended∫.
CAUTION: Make sure all wheels touch the ground before changing the switch for the axle
suspension (154) .
If this point is not observed, it can cause damage to the axle suspension due to the
sudden release of the axle lock.
Bring the outrigger pads from operating to transport position Fig. 2

> Move the handle of pin (C) ∫upward∫ and pull the pin from bore (3),
> Push the outrigger pad into the retainer (1) and push the handle in until the stop on the head of the outrigger
cylinder!(5).
> Insert the pins (C) into the bore hole (4) and turn the handle downward to secure them, Fig. 3.
CAUTION: Before retracting the sliding arms, you must bring the outrigger pads in transport
position and secure them.
When you push the outrigger pads into the retainer, push back with your hand to
create some counterpressure to prevent the outrigger pads from dropping!
Retract the sliding arms fig. 4.

> Release and remove the mechanical lock >pins (A) on all four sliding arms.
DANGER: The operator may only move those sliding arms he can see directly.
> Fully retract the sliding arms by pressing the button (a + e or a1 + e1) and secure them with the four pins (A)
to prevent them from falling out, fig. 1 + 5.
> Return the engine speed to idle and turn the engine off via the keyed switch (30),
> turn the ignition off and remove the key.
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154
Change over to control from the crane operatorπs cab
General prerequisites
> The crane must be positioned on level ground of sufficient load carrying capacity,
> The parking brake lever in the driverπs cab (158) as well as in the crane operator's cab (263) is applied,
> the outrigger pads are in operating position and secured,
> the safety pins on all four sliding arms are pulled out.
> the engine is turned off,
> the battery master switch of crane chassis is turned on .
Change over
> In the driverπs cab, start the travel and crane engine, as described in chapter 3.04.
> Align the crane via the manual leveling (button 146, 147, 150, 151) as horizontally as possible.
> Turn off the travel motor (engine) and turn the ignition off.
> Change the switch (42**) to the ∫crane operation∫ symbol, the axle suspension is automatically locked.
> Pull the ignition key.
CAUTION : The switch (42**) may only be actuated when the engine is not running and the
Note: If the switch (42**) is actuated, the gear selector switch in the driverπs cab (161) as well as in
the crane operatorπs cab (208) must be in neutral position ∫N∫.
If the switch (42**) is actuated when the engine is running, the engine will turn off
automatically.
In addition, for safety reasons, always turn the switch (154) to ∫AXLE SUSPENSION
LOCKED∫.
The following functions are now changed over to superstructure operation:

steering, gear selection control, parking and service brake, and the electrical system.
To put the crane into service

Refer to chapter 4.03, STARTING THE CRANE.

* Optional
155
185276
156
Support the crane from the crane operatorπs cab
CAUTION: If the crane is to be supported from the crane operatorπs cab, then all guidelines and
preventative measures already given in the chapter describing SUPPORT THE
CRANE FROM THE CHASSIS must be observed.
If the crane is to be supported from the crane operatorπs cab, the desired movement (sliding arm or outrigger
cylinder) must be preselected via the preselector switch (319).
The button (319) must always be held down, when one of the buttons (295, 296, 308, 309) is actuated.
This safety measure is installed to prevent that the crane gets into a dangerous incline position due to
inadvertent actuation of one of the support function buttons.
Always give a warning signal (horn) before extending or retracting the sliding arms.
DANGER: The operator must carefully observe the sliding arms while he extends or retracts
them. If he must extend or retract outriggers without visually being able to seem the
outrigger cylinder or sliding arm, then he must use an assistant to guide him.
there no persons or objects within the danger zone.
If the crane is not properly horizontally aligned, there is a danger of accidents.
All 4 sliding arms and outrigger cylinders must be extended, even those on the
opposite side of the load.
Prerequisites
On the crane:
> The parking brake is applied,
> the crane is parked on level ground of sufficient load carrying capacity and has been aligned horizontally via
the manual leveling system.
> the safety pins on all four sliding arms are pulled out ,
> the outrigger pads are in operating position and secured,
> the battery master switch is turned on.
In the driverπs cab:

> The parking brake is applied,
> the axle suspension is locked, which means
the switch (42**) is set to ∫crane operation∫ ,
the switch (154) is turned on, (in position axle suspension ∫locked∫).
> The travel and crane engine is turned off,

> the ignition key has been pulled.

* Optional
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158
Support the crane from the crane operatorπs cab, continuation

> In the crane cab, insert the ignition key into the key operated switch (283), and start the travel engine as
described in chapter 4.10.
During the support procedure, the Diesel engine speed may be increased from idle to max. 1500 RPM via the
throttle control lever (160) in the driverπs cab.
Return the lever (160) to ZERO position as soon as the increased engine is speed is no longer needed.
> Via the control release preselector button (319), preselect the desired movement (either sliding arm or
outrigger cylinder).
The buttons (295, 296, 308, 309) have four functions each, depending on the symbols.
Extend the sliding arms from the crane operatorπs cab
DANGER: All 4 sliding arms on the outriggers must be extended, including the sliding arms on
the side opposite the load .
> Button (319) hold the button in ∫bottom∫ position and at the same time
> Button (295) push ∫down∫ > left front sliding arm extends,
> Button (296) push ∫down∫ > right front sliding arm extends,
> Button (308) push ∫down∫ > left rear sliding arm extends,
> Button (309) push ∫down∫ > right rear sliding arm extends.
Extend the outrigger cylinders from the crane operatorπs cab:

> Button (319) hold the button in ∫top∫ position and at the same time
> Button (295) push ∫down∫ > left front outrigger cylinder extends,
> Button (296) push ∫down∫ > right front outrigger cylinder extends,
> Button (308) push ∫down∫ > left rear outrigger cylinder extends,
> Button (309) push ∫down∫ > right rear outrigger cylinder extends.
Align the crane horizontally

> Align the crane horizontally by extending or retracting the individual outrigger cylinders.
This is achieved when the air bubbles of both sight gauges (206) are between the innermost rings.
The maximum permissible deviation from the horizontal crane position is ± 0.5% (± 0.3∞ ).
DANGER: If the crane is not aligned horizontally, there is an increased risk of causing a
serious accident.
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160
To retract the outrigger cylinders from the crane operatorπs cab :

> Push button (295, 296, 308, 309) to evenly retract all outrigger cylinders and lower the crane until the wheels
touch the ground.
> Retract all four outrigger cylinders fully.
> Change over the switch for the axle suspension (154)
CAUTION: Make sure all wheels touch the ground before changing the switch for the axle
suspension (154) .
Retract the outrigger cylinders

> Button (319) hold the button in ∫top∫ position and at the same time
> Button (295) push ∫up∫ > left front outrigger cylinder retracts ,
> Button (296) push ∫up∫ > right front outrigger cylinder retracts ,
> Button (308) push ∫up∫ > left rear outrigger cylinder retracts
> Button (309) push ∫up∫ > right rear outrigger cylinder retracts .
Bring the outrigger pads to transport position and secure them.
Retract the sliding arms
CAUTION: Before retracting the sliding arms, return the outrigger pads to transport position
and secure them.
When you push the outrigger pads into the retainer, create a counterpressure to
prevent the outrigger pads from dropping!
> Button (316) hold the button in ∫down∫ position and at the same time
> Button (295) push ∫up∫ > left front sliding arm retracts,
> Button (296) push ∫up∫ > right front sliding arm retracts,
> Button (308) push ∫up∫ > left rear sliding arm retracts,
> Button (309) push ∫up∫ > right rear sliding arm retracts.
DANGER: The operator may only move those sliding arms he can see directly.
If he is not able to observe any of the outrigger cylinders or sliding arms, then he
must be guided by another person.
If the crane is not aligned horizontally, there is an increased risk of causing a
serious accident.
All four sliding arms must be extended, including the ones opposite of the load.
Turn the travel and crane engine off

> Let the engine run for a short time at low idle speed, then turn the ignition key (283) to the left hand side to
turn the engine off.
> Turn the ignition off with the ignition key (283) by turning the key counterclockwise to ∫0∫ and then pull it off.
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162
Changing over from crane operation to travel operation
Prerequisites
In the crane operatorπs cab:
> The manual brake is applied,
> the gear selector switch is in neutral position ∫N∫,
> the ignition is turned off,
> the ignition key has been pulled.
Prerequisites
In the driverπs cab :
> The travel motor is turned off,
> the ignition key has been pulled,
> the main battery switch (25) is turned on,
> the parking brake is applied ,
> the gear selector switch is in neutral position ∫N∫ ,
> the axle suspension is locked, which means switch (154) is turned on ,
> the switch (42**) is turned ∫to the right∫ (to the crane symbol).
Prerequisites
On the crane:
> The battery master switch (25) is turned on,
> the crane is supported ,
> the crane is aligned horizontally by the outrigger cylinders on the outrigger pads,
> the wheels are off the ground ,
> the telescopic boom is locked in forward position in the boom retainer and secured,
> the telescopic sections are retracted,
> the telescopic boom is locked in forward position in the boom retainer and secured,
> the hook block is secured, as described in chapter 3.04 ,
> the counterweight plates are distributed as described in chapter 3.04.
Note: For transport on public roads transport the counterweight plates and the hook block as
described in chapter 3.04 DRIVING ON PUBLIC ROADS.
Changeover
> Turn the switch (42**) ∫to the left∫ (to the vehicle symbol).
CAUTION: The switch (42**) may only be turned if the engine is not running and the ignition is
off.
If this is not observed, the coupling for the hydraulic pump will be damaged.

* Optional
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164
Retract the outrigger cylinders and sliding arms

> Insert the ignition key into the keyed switch (30) and turn it one notch in clockwise direction and start the
travel and crane engine, as described in chapter 3.04,
> Move the throttle control lever (160) to increase engine speed to approx. 1500 RPM.
> Proceed as described in this chapter in paragraph Retract outriggers from the crane chassis,
> lower the crane until all wheels are again in contact with the ground,
> retract outrigger cylinders and sliding arms,
> secure the sliding arms and outrigger pads with pins.
Actuate the axle suspension

> Turn switch (154) off , the axle suspension is automatically active.
CAUTION : Make sure all wheels touch the ground before changing the switch for the axle
suspension (154) .
Turn the travel and crane engine off

> Let the engine run for a short time at low idle, then push the engine Stop button (91) to turn it off.
> Turn the ignition off and pull the ignition key.
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Check the following items before leaving the jobsite :
In the crane operatorπs cab

> Is the crane superstructure locked to the crane chassis?
> Is the gear selector switch in position ∫N∫?
> Is the parking brake applied?
> Is the rear axle steering locked in ™straight position∫?
> Are the windows and doors closed?
In the driverπs cab:

> Is the rear axle steering locked in ™straight position∫?
> Is the switch ∫axle suspension locked∫ turned off?
On the crane
> Are the sliding arms fully retracted and secured with pins?
> Are the outrigger cylinders fully retracted?
> Are the outrigger pads inserted and secured?
> Are the lock pins secured, with the handle pointing downward?
> Are the lock pins in their retainers and secured so they cannot fall out?
> Is the installation ladder* secured (under the front bumper)?

> Are the travel motor and the converter box covered ?
> Is the mounting cover for the removal and installation of the transfer gearbox tightly secured?
> Are the locks and retainer bars of the covers on the crane superstructure closed?
> Are the wheel chocks in their retainers and secured so they cannot fall out?
> Are the control boxes on both sides of the vehicle closed and locked?
> Is the spare tire mounted properly and is it secured with a retaining pin?
> Is the telescopic boom fully retracted and secured in its retainer?
> Is the hoist cable fastened on the pin of the towing coupling and secured, so that it cannot fall out?
> Are the counterweight plates distributed and secured as described in chapter 3.04?
DANGER: All locks, spring retainers and pins must be attached and secured in such a way,
that they cannot loosen up by themselves and thus cause damage.
If these checks and measures are not performed, chances of having an accident will
increase.
Note: After an extended period on a jobsite, before driving off, make sure to complete all checks
described in chapter 3.02 ∫BEFORE VEHICLE START UP ∫.
* Optional
167
4.00 OPERATION OF THE SUPERSTRUCTURE 021677>00
168
021677>00
Chapter 4
Operation of the Superstructure
169
4.01 CONTROLS AND INSTRUMENTS 023222>00
183648
170
Pos.:
200 Pedal > Engine regulation > travel and crane engine
201 Pedal > Service brake
202 Pedal > Slewing brake
203 Not installed
204 Foot button > Horn
205 Switch > Travel direction indicator
206 Sight gauge > To check horizontal leveling of crane
207 Dome light with switch
208 Rotary switch > Gear selection
209 Reserved
210 * Switch > Beacon
211 * Switch > Beacon
212 * Switch > Seat heater
213 Not installed
214 Not installed
215 Not installed
216 Not installed
217 * Switch > Working floodlight, roof or boom head
218 Not installed
219 Switch > Illumination of hoist gears
220 * Switch > Windshield washer > roof window,
221 Switch > Windshield wiper > roof window > 2 stage,
Stage 1 > intermittent, Stage 2 > wipe
222 * Switch > Windshield washer system > front window,
223 Switch > Windshield wiper > front window, 2stage
Stage 1 > intermittent, Stage 2 > wipe
224 * Switch > Air conditioner system
225 * Indicator light > Air conditioner system
226 * Indicator light > Auxiliary heater
227 * Switch > Auxiliary heater
228 Reserved
229 Reserved
230 Reserved
231 Reserved
232 Reserved
233 * Digital clock with the following indicators:

> Time of day and day of the week,
> problem in auxiliary heater,
> air temperature,
> Preselection of heater operation with 3 preselection times,
every preselection time can be preprogrammed up to 7 days in advance.
234 * Gauge > Tank level, fuel for travel and crane engine
235 Hour meter > Crane operating hours
* Optional
171
183648
172
Pos.:
236 * Keyed switch > Working platform

237 * Indicator light > (red) lights up if the keyed switch (236) is set to ∫crane operation∫
238 * Indicator light > (green) lights up if the keyed switch (236) is set to ∫working platform∫
239 Switch > Working floodlights
240 * Switch > Working floodlights, roof or boom head
241 Not installed
242 Not installed
243 Not installed
244 Reserved
245 Reserved
246 Control box > contains control element for emergency control. among other items
248 Rotary knob > To change armrest incline

249 Manual lever >To change armrest and control panel incline
250 Manual lever > To release lock for horizontal seat adjustment
251 Rotary switch > Fan (3> stage)
252 Turn regulator > Temperature > cab heat
253 Sliding regulator > Change between recirculated air /ventilation, air flow
254 Turn regulator > Temperature > air conditioning system
255 Air vents > Control > air flow ∫up∫ or ∫down∫
256 Turn regulator > Adjustment of seat height and suspension (set the approximate operatorπs
weight on the window)
257 Button > Back support in the upper area of the backrest
258 Button > Back support in the lower area of the backrest
259 Manual lever > Change of seat surface incline
260 Reserved
261 Manual lever > Mechanical crane superstructure lock
262 Seat contact switch
264 Reserved
265 Reserved
Trumatic>e Gas heater *
247 * Control unit with thermostat for gas heater

— Indicator light > (red), lights up in case of problem
“ Sliding switch > for full power (large flame symbol), for half power (small flame symbol)
” Sliding switch > Heater > OFF > Ventilation
‘ Rotary knob > Temperature selection with green indicator light
* Optional
173
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174
Machines with one hoist gear
Pos.:
266 * Button > ∫Deadman ∫ > bypass of seat contact switch (262)
267 Manual control lever > Slewing gear and telescoping gear
268 Button > Shut off bypass when telescoping out
269 ` Button > Rapid gear cut in for hoist gear, luffing gear and telescoping gear
270 Button > Rear axle steering
271 Button > Bypass of LICCON Overload safety device, to luff up at overload
DANGER: The bypass may only be actuated in the limit range when the LICCON safe load in>
dicator has not reported an overload for a suspended load.
It is also prohibited to use the bypass function for the LICCON safe load indicator at
a radius of more than e3.5 m .
272 Switch > Slewing brake ∫open / closed∫

273 Reserved
274 Reserved
275 Reserved
276 * Button > ∫Deadman∫ > bypass of seat contact switch (262)
277 Manual control lever >Hoist gear and luffing gear
278 ` Button > Rapid gear cut in for hoist gear, luffing gear and telescoping gear
279 Reserved
280 Rotary switch > Preselection of operating mode for manual control lever (277)
Switch position (Fig. 1) Tele 1 telescope out / in + hoist gear
Switch position (Fig. 2) Tele 2, 3 and 4 synchronized telescope out / in + hoist gear
` Rapid gear cut in for: Hoist gear lifting and lowering

Telescopic boom to luff up only
Telescopic boom telescoping out
* Optional
175
185280
176
Machines with one hoist gear *
Pos.:
266 * Button > ∫Deadman ∫ / bypass of seat contact switch (262)

267 Manual control lever > Slewing gear and hoist gear 2
268 not used
269 ` Button > Rapid gear cut in
270 Button > Rear axle steering
271 Button > Bypassing the LICCON safe load indicator , to luff at overload
CAUTION : The bypass in the limit range may only be used if the LICCON safe
load indicator system did not report overload with freely suspended
load.
In addition, the LICCON safe load indicator system may not be by>
passed at working radii of e3,5 m.
272 Switch > Slewing brake ∫open / closed ∫

273 not used
274 not used
275 not used
276 * Button > ∫Deadman∫ / bypass of seat contact switch (262)
277 Manual control lever > Hoist gear 1 and luffing gear or telescoping gear, depending on switch
position of switch!(280)
278 ` Button > Rapid gear cut in
279 Button > Shut off bypass when telescoping out
280 Rotary switch > Preselection of operating mode for manual control lever (277)
Switch position: (Fig. 1) Tele 1 telescoping out / telescoping in

+ Hoist gear 1
(Fig. 2) Tele 2, 3 and 4 telescoping out / telescoping in (syn>

chronously)
+ Hoist gear 1
(Fig. 3) Luffing gear to luff up / to luff down

+ Hoist gear 1
Rapid gear cut in for: Hoist gear 1 lifting and lowering

Hoist gear 2 lifting and lowering
Telescopic boom telescoping out and telescoping in
Telescopic boom to luff up only
* Optional
177
182983
178
Pos.:
281 EMERGENCY
OFF Button > To turn the travel and crane engine off, and also the total crane electrical sy>
stem
282 Reserved
283 Keyed switch > Ignition / starter, travel and crane engine
284 Indicator light > Auxiliary drive, crane hydraulic turned on
285 Reserved
286 Reserved
287 Indicator light > Position of crane superstructure to the front
288 Indicator light > Travel direction indicator > Crane
289 Warning light > Fuel level >Travel and crane engine
290 Warning light > Insufficient oil pressure > Travel and crane engine
291 Indicator light > Preglow > Travel and crane engine
292 Reserved
293 Reserved
294 Reserved
295 Button > Extend / retract front left sliding arms or outrigger cylinders
296 Button > Extend / retract front right sliding arms or outrigger cylinders
297 Indicator light > Position of crane superstructure to the rear
298 Warning light > Parking brake (manuel brake)
299 Warning light > Alternator, travel and crane engine
300 Warning light > Increased coolant temperature > Travel and crane engine
301 Warning light > This warning light combines three warnings (54, 55 and 72) for the crane
chassis
1. Oil pressure too low or oil temperature too high in oil circuit for torque
converter / automatic transmission,
2. Error in electrical system for gear control
3. Increased oil temperature in oil circuit for torque converter / automatic
transmission
302 Reserved
303 Reserved
304 Reserved
305 * Switch > Preheat crane hydraulic
306 Indicator light > Crane superstructure locked with chassis
307 Reserved
308 Button > Extend / retract left rear sliding arms or outrigger cylinders
309 Button > Extend / retract right rear sliding arms or outrigger cylinders
310 Switch > Low beam head light
311 Switch > Emergency blinker system
312 * Switch > Release / lock rear axle steering
313 Switch > All wheel drive, drive of 1st (or 1st+2nd*) axle
314 Reserved
315 Switch > Instrument panel illumination
316 Button > Raise / lower counterweight
317 Button > Lock / release counterweight
318 Reserved
319 Button > Preselection > sliding arms or outrigger cylinder retract / extend
320 Reserved
321 Reserved
322 Switch > Off road gear
* Optional
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Pos.:
323 Reserved
324 Reserved
325 Reserved
326 Control and indicator unit for LICCON safe load indicator
(see separate , more detailed operating instructions)
A > Alpha numerical data input

B > Program keys
C > Input key to confirm changes
D > Keyed switch Bypassing the LICCON safe load indicator system
E > Function keys > > Page forward

< > Page backward
{ > Brightness adjustment
F > Function keys Screen program
327 * High voltage warning device

328 Reserved
* Optional
181
4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE 022634>00
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Operation:
See separately issued Operating Manual.
The LICCON overload safety device can be operated with the following control elements:
A $ Alpha numerical keyboard

With the alpha numerical keyboard (A), numerical values can be entered and a coded equipment
configuration view (load capacity chart) can be recalled on the screen.
The equipment configuration views are marked with a two digit number code.
If the entered code is confirmed with the button (C) ENTER, then the equipment configuration view (load
capacity chart) appears on the monitor.
If the equipment configuration view is confirmed with button (F8) O.K., then it is taken on by the
LICCON overload safety device and transferred to the ™OPERATION∫ program. The operating view
appears on the monitor .
B $ Program keys
With the program keys (B), various LICCON programs can be recalled.
By pushing program key (B1), for example, the equipment configuration view can be called up, and with
program key (B2), the operating view can be chosen.
During crane operation, various programs can be called up on the screen.
However, the crane operator is also able to view different equipment configurations, but he may not
confirm them with the key (F8) O.K.
By pushing the program key (B2), the operating view returns to the view, with which the crane works.
The equipment configuration view may only be selected if no crane movements are initiated.
F $ Function keys
With the function keys, operating conditions and functions, which are visible in the lower part of the
screen as symbols, can be changed.
The function keys (F1 to F8) are always to be viewed in connection with the symbols above, since they
have different meanings in different LICCON programs.
C $ The (C) ENTER key is an input confirmation key.

If there is a function in the operating mode and / or the equipment configuration is being changed, than
this change can only be confirmed with the key (C) ENTER and the load capacity chart can be called up
on the screen.
If the change in operating mode and / or the equipment configuration is confirmed with the key (C)
ENTER and an acoustical signal sounds, then the change has not been accepted. This means that the
chosen operating mode or the chosen equipment configuration has not been programmed into the
system.
D $ The installation key (D) is used to bypass either the LICCON overload safety device or the hoist top
limit switch.
On some cranes, the functions of this switch have been replaced by a switch on the instrument panel.
E $ The keys (E1) and (E2) < > are used for horizontal paging and are needed when a load capacity chart
is too wide to be viewed on one screen .
If keys (E1) and (E3) are pushed at the same time, the screen changes from light to dark.
When keys (E2) and (E3) are pushed at the same time, you can choose between 4 light levels.
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Description
The LICCON safe load indicator or overload safety device (Liebherr Computed Controlling) consists of an
electronic module with power pack and micro processor central unit, the monitor with controls, pressure
sensors, incline angle and length sensors.
As an overload safety device, the LICCON works according to the principle of a comparison of ∫should be∫ and
∫actual∫ values.
The ∫actual∫ values coming from length,angle and pressure sensors are compared with the ∫should be∫ values,
which are stored in the central data processor, and then are calculated by the microprocessor.
The crane data values, such as the load capacity charts, boom weights, center of gravity and measurements,
have been stored on data chips in the central data bank. This data is the reference information used to calculate
any overload conditions.
The system functions are either controlled by automatic components such as boom length and angle sensors or
by direct input into the dialogue functions on the monitor .
The prewarning symbol blinks when the load on the crane is 90 % or higher than the maximum load carrying
capacity.
If the overload safety device recognizes a sensor problem, for example, which could lead to a dangerous
situation, then it shuts down and displays a STOP symbol, even though the maximum permissible load carrying
capacity has not been exceeded. The STOP symbol remains on and blinks as soon as the load on the crane
exceeds the maximum permissible load carrying capacity.
An acoustical signal sounds with the blinking prewarning and STOP symbol.
If the crane shuts off due to overload, movements must be carried out which will reduce the load momentum,
such as:
> setting the load down
> retracting the telescope
> luffing up while pushing the button ™Luffing up at overload∫
Load momentum increasing movements are:

> luffing down
> telescoping out
> taking on a load by luffing up.
The central unit recognizes ground problems, broken lines and short circuits after (+).
When the hoist top limit switch is triggered, the overload safety device is also triggered.
The movement ∫hoist gear up∫ and all load momentum increasing movements are shut off, the warning symbol
hoist limit switch and the STOP symbol appear and blink on the monitor.
DANGER: The proper function of the load moment limiter is only assured if the adjusted
operating mode, the equipment configuration and the hoist cable reeving actually
match the condition of the crane.
If this is not observed, it can cause a serious accident!
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To weigh a load
The overload safety device makes it possible to determine the weight of a raised load (net load). This
calculation, however, is only permitted if the approximate weight of the load is known and it can be assured
that the crane is not overload.
With a free hanging hook block (with tackle), press the Tare button (F7) in the operating view. The ∫actual load
capacity∫ is automatically reset to zero.
In the ∫actual load carrying capacity indicator symbol∫, the NET description will appear in addition.
If the load is now being raised via the hoist gear, then the net weight of the load will be indicated.
If the working radius is being changed, the indicator returns to indicate the gross weight.
Functions check for control and indicator unit

The status of the monitor and the controller is shown via four luminous diodes, which are located on the front
behind the front windshield.
LED 1 (yellow) 24 V power supply available

LED 2 (red) Error in controller (watchdog error)
LED 3 (green) Self test of controller (Self test o.k.)
LED 4 (yellow) Power supply for controller available
187
4.03 STARTING THE CRANE 023223>00
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Checks before starting operation

Before operation, complete the following checks:
Note: For detailed description of the below listed checks,

refer to chapter 7.05, ∫MAINTENANCE GUIDELINES > CRANE SUPERSTRUCTURE∫.
Checks on the travel and crane engine

Check coolant level (fig. 1 )
> The coolant reservoir must be filled to the rim on the filler neck.
DANGER: NEVER check the coolant level if the engine is still warm! The engine must be
completely cooled off, then open the cap slowly to relieve pressure, otherwise you
could suffer serious injury and severe burns!
Check oil level (fig. 2)

The oil level must be between the minimum and maximum (MIN and MAX) mark on the dipstick.
The oil level must be checked with the engine turned off and the vehicle in horizontal position.
> If necessary, add oil as specified on the lubrication chart.
Check the fuel level

> Check how much fuel is remaining in the tank by checking the fuel gauge in the crane cab and in the driverπs
cab.
Checks on the hydraulic tank for the crane hydraulic

Breather filter (fig. 5)
> Open the rotary cover and visually check the filter for contamination.
Oil filter (fig. 6)

> Service the two filters according to guidelines in chapter 7.02 and 7.03.
Oil level (fig. 4)

> The oil level must be in the center of the center sight gauge.
If necessary, as specified on add oil as specified on the lubrication chart.
CAUTION: The oil level must be checked :

> with the vehicle in level, horizontal position,
> with the telescopic boom placed down,
> with the folding jib folded in,
> with fully retracted sliding arms and outrigger cylinders.
* Optional
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Warning light > fuel level (Fig. 7)

> Do not wait until the fuel level warning light (289) lights up before adding fuel.
If necessary, add fuel as specified on the lubrication chart.
CAUTION: Do not wait until the fuel tank is completely empty before adding fuel, otherwise it
must be bled before continued operation.
Central lubrication system (Fig. 8 )

> Make sure that the grease containers is always filled with grease, as specified to the lubrication chart.
Check the general crane condition

Before operating the crane, the crane operator must ensure that the following conditions are met:
> The crane must be properly supported and aligned horizontally,

> The slewing gear of the slewing ring must be clean and greased,
> The air supply for the oil cooler and radiator must be clear and unobstructed,
> The side covers must be closed and locked,
> There are no other persons or objects within the craneπs slewing range or danger range ,
> The cable and rope drums as well as the limit switch are free of snow and ice,
> There are no loose parts and objects on the crane superstructure, telescopic boom and folding jib*.
Make sure to observe all safety guidelines and danger warnings in chapter 5.02 FOLDING JIB .
DANGER: Before lifting the boom, it must be assured that there are no loose parts on the
boom, such as pins, spring retainers, etc. and that is is free and clear of any ice
formation.
If this point is not observed, there is an increased risk of accidents and severe
injuries due to falling objects, which might strike persons or objects and equipment
on the ground.
Before telescoping or luffing up the telescopic boom with side mounted folding jib*,
you must check that the folding jib * is pinned in both transport retainers on the
telescopic boom pivot section!
* Optional
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To change over to superstructure operation

> Change from travel to crane operation (superstructure operation) as described in chapter 3.05 .
Adjust the seat

The hydraulic>mechanically cushioned crane operatorπs seat can be adjusted to any body size and weight.
> Adjust the arm rest incline (248),
> Adjust the back rest incline, including the incline of the two control consoles (249).
> Release the lock for horizontal seat adjustment (250).
> Adjust the height of the seat (256)

by entering the approximate weight of the crane operator on the window of the rotary regulator.
> Adjust the back support in the upper area of the backrest (257),
> Adjust the back support in the lower area of the backrest (258)
> Adjust the incline of the complete seat including the two control consoles (259).
Seat heater *
The seat can be heated by turning on the switch (212).
* Optional
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Heater / ventilation / air conditioner *

For a more detailed description, refer to chapter 6.01 HEATER.
The crane operatorπs cab can be heated, ventilated or cooled* as ambient temperatures require.
The controls for the heater / ventilation and air conditioner are located below the crane operatorπs seat.
To heat the cab with the engine independent, Diesel fuel operated heater 1) *
> Set the desired turn on time and length of operation on the digital clock* (233) .
> Turn on the heater with switch (227), the indicator light (226) turns on to show the heater is operational.
> Close / open the top / bottom air vents (255),to preselect air flow, as desired,
> turn the pull switch (253) to ventilation,
> turn the rotary switch (251) to turn on the blower,
> regulate the temperature via the regulator valve (252) .
To heat the cab with the engine independent, fluid gas operated Truma 2800 heater 2) *
> turn the pull switch (253) to ventilation,
> select the desired output via the sliding switch “,
> set the desired room temperature on the knob ‘ of the control unit (247) ,
> Turn on the blower via the sliding switch ”.
To ventilate the cab

> Open or close the top or bottom air vents (255), to preselect air flow, as desired,
> turn the pull switch (253) to fresh air operation,
> turn the rotary switch (251) to turn on the blower.
To use the air conditioning system 3) *

> Turn the air conditioner on via switch (224), the system in operational as soon as the indicator light (225) in
the instrument panel lights up.
> turn the pull switch (253) to recirculate the air ,
> turn the rotary switch (251) to turn on the blower .
> Regulate the temperature via the regulator knob (254).
1) 2) 3) Also refer to the separately issued, more detailed manufacturerπs operation manual.
* Optional
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Windshield wiper
The windshield wipers on the front window as well as on the overhead window in the roof can be operated with
the 2 stage switch (223, 221).
Windshield wiper on front window > switch (223)

Windshield wiper on roof window > switch (221)
1. Stage > Intermittent operation
2. Stage > Standard wipe operation.
Windshield washer system *

The windshield wipers on the front window as well as on the roof window can be supported with an optional
windshield washer system *.
Windshield washer on front window > button (222)
Windshield washer on roof window > button (220)
Front window
The front window may be opened from the inside by simply pushing on it. A pair of nitrogen cylinders helps to
raise the window.
If you want to open the window only partially, you can secure the window on the perforated belt at any angle.
D A N G E R : Be very careful when you close the front window, make sure that your HANDS ARE
OUT OF THE WAY so you donπt jam them in the window and injure yourself!
Horn
Before you start working, make sure to check the horn by pressing down the foot operated button (204) to check
its function.
D A N G E R : The horn should be used ONLY in dangerous situations to warn others, to preserve its
warning effectiveness.
Lighting
The working flood lights in front of the crane cab are turned on by pressing switch (239).
The working floodlights on the roof of the cab * and on the boom head * are turned on by pressing switch (217).
The winch illumination* can be turned on via switch (219).

The interior is illuminated with a dome light, which can be turned on with switch (207) .
* Optional
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Instrument panel illumination

The instrument panel illumination can be turned on or off with switch (315).
Preheat the crane hydraulic *

Version to >40 ∞C.
Before the crane hydraulic system can be preheated, the crane engine must be warm and running.
In order to assure proper function of the crane hydraulics in extremely low temperatures, the engine and the
hydraulic system must be preheated before using the crane.
CAUTION: The engine must be preheated and the hydraulic system must be ∫run to warm up∫.
The cylinders, which are especially stressed in crane operation, such as those for
vertical support,
boom luffing cylinders and
boom telescoping cylinders,
must be controlled in such a way that the cold oil in the cylinders is displaced and
replaced with warm oil.
Refer to the end of this chapter for preheating the engine and the crane hydraulic > Crane operation at
ambient temperatures below >20 ∞C.
* Optional
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Turn on the crane ignition > check the instruments

> Insert the key into the ignition (283) and turn it one notch in clockwise direction.
The indicator light for the added crane hydraulic pump (284) must light up.
The following indicator and warning lights come on when the crane ignition is on:
> Battery charge indictor (299)
> Oil pressure in automatic transmission too low (300)
> Position of crane superstructure to the front (287) or to the rear (297).
The indicator light (291) first lights up for about 50 seconds (= preglow period) and then blinks for 30 seconds
(= starting period).
DANGER: NEVER operate the crane with defective warning lights. Any defective lights and
bulbs MUST BE REPLACED before operating the crane.
If the crane is operated without a functioning warning system, it can cause serious
accidents, injury and death.
Starting and stopping the craneπs engine
Gear selector switch

Set the gear selector switch (161) to neutral position ∫N∫.
The engine can be started only in ∫N∫ position.
CAUTION : When the vehicle is at a standstill, the engine must be running at low idle and the
gear must be in neutral "N" position before shifting into another gear.
Do not give gas during or shortly before shifting from neutral "N" position to anot>
her gear.
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Starting the engine with the flame glow preheating system

The travel motor (engine) is equipped with a flame glow system and a flame start control unit.
Description of function
The flame start control unit supplies the current to the indicator light (291), the flame glow plugs in both inta>
ke pipes and the solenoid valve for the fuel supply for the flame glow plugs.
At a lube oil temperature below the glow stop temperature (e+20∞C ), the preglow phase begins when the igni>
tion is turned on.
Preglow time
The preglow time depends on the system voltage .
When the ignition is turned on, the indicator light (291) lights up , the flame glow plugs are energized.
After completion of the preglow time, the indicator light (291) starts to blink (approx. 0.8 Hz), the STARTING
READINESS phase of the flame start system begins.
If the engine is not started during this time, the flame start control unit turns the flame glow plugs and the indi>
cator light (291) off.
If the engine is started during the starting readiness phase, then the flame start control unit opens the solenoid
valve for the fuel supply for the flame glow plugs.
After glow operation

The after glow operation starts when the starting procedure has been completed, the flame glow plugs continue
to be energized, the solenoid valve opens, the indicator light (291) turns off.
If the starting procedure was not successful, then the solenoid valve and the flame glow plugs are turned off.
> Return the ignition key to the stop before restarting the ignition.
At a lube oil temperature above the glow stop temperature (f+20∞C), the flame glow system is not functio>
ning, the indicator light !(291) blinks as soon as the ignition key is turned from the 1st notch and the engine is
ready to start.
Preglow time After glow time Glow stop
Volt sec ∞C sec ∞C
e19 35 +20 120 +25 (±5)

20 28 +10 120
21 26 0 120
22 24 $10 150
23 20 $20 180
32 10 $30 180
<$30 180
The flame start control unit recognizes errors on the flame start system and indicates the same, the indicator
light (291) will blink rapidly (approx. 1.6Hz) .
The following errors are recognized:

> Interruption of the flame glow plug > heating wire,
> Missing current supply on terminal 30,
> Defective fuse of flame start control uni t.
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Starting the engine at a lube oil temperature above the glow stop temperature (f+20∞ C)

At a lube oil temperature above the glow stop temperature (f+20∞C) , the flame glow system is not in opera>
tion, the indicator light !(291) blinks as soon as the ignition is turned on.
> Continue to turn the ignition key in clockwise direction to position "2" , slowly press down the gas pedal (200)
and start the engine.
Note: At every starting procedure, the starter will start to turn after about 1 second after the igni>
tion key is turned to position !"2"!.
This delay prevents a failure of the electric engine shut off system.
> Release the ignition key as soon as the engine turns over and release the gas pedal!(200) .
> If the engine does not start after approx. 5 seconds, slowly press down the gas pedal (200) and turn the starter
again.
> Return the ignition key all the way to the stop before restarting.
When the engine is warm, start the engine without pressing on the gas pedal (200) to prevent unnecessary ex>
haust emission.
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Starting the engine at a lube oil temperature below the glow stop temperature (e+20∞ C)

1. Preglow
> Turn the ignition key to (283) position ∫1∫ ,
the preglow time begins, the indicator light (291) will turn on.
If you try to start the engine during the preglow time, then the preglow phase is automatically interrupted. In
this case, return the ignition key to the stop and repeat the preglow phase.
2. Start the engine

The starting readiness starts as soon as the indicator light !(291) blinks.
> Turn the ignition key (283) to position ∫2∫ and start the crane engine without pressing down the gas pedal
(200).
Note: The starter turns over after approx. 0.6 seconds after the ignition key is in position !∫2∫ .
If the engine is not started during the starting readiness time, then the starting readiness will automatically
stop.
In this case, repeat point 1. and 2.
> If the engine does not start after approx. 5 seconds, return the ignition key to the stop and repeat the preglow
phase.
> slowly press down the gas pedal (200) and start again, engine RPM max. 1000 RPM.
If the engine still does not start after max. 10 seconds, then wait for 1 minute. The starter should only be
cranked three times for 10 seconds per starting procedure, with a 1 minute break in between.
During the cold season, pay special attention to the batteries.

The starting capacity is significantly reduced during cold temperatures, for example at >10 ∞C, it is only about
66% of its normal capacity.
For that reason, after the engine has been turned off, the batteries should be removed and stored in a heated
room .
CAUTION : As long as the engine is running, DO NOT loosen either the cable on the alternator,
nor any one of the battery terminals, do not unplug the regulator or change any of
these item.
The alternator must be connected with the batteries during operation .
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3. Starting procedure at ambient temperatures of less than >20 ∞C
At extreme temperatures, to make sure the engine starts properly and is supplied with sufficient lubrication,
the engine and the oil pan should be preheated.
Preheating the engine *

Prerequisite: All components must be filled with service fluids for winter operation, as specified in the
lubrication chart.
The engine is preheated * via the coolant circuit with a Diesel fuel operated heater.
To preheat the engine oil in the oil pan *

The oil is preheated by the engine heater exhaust.
Preheat time
depends on ambient temperatures
Ambient temperature Preheat time

[∞C] [min]
> 40 to > 35 120
> 35 to > 30 90
> 30 to > 25 60
> 25 to > 20 30
> 20 and above no preheating
Preheating
> Turn on the battery master switch (on the battery box) ,
> Depending on the ambient temperature, turn the heater for the preheat system on via switch (137) about 30 to
120 minutes before starting the engine in the driverπs cab, the indicator light (81) will light up to indicate
proper function .
After about 15 seconds, the heater will turn on and will run automatically.
To turn the heater off after the preheat time

> Turn the heater off via switch (137), the indicator lights (81) turn off.
This interrupts the flow of fuel and the combustion stops.
The fan and the heater pump will continue to run to cool the heater off and both will turn off after about
150!seconds.
*Optional
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The crane engine runs, check instruments

Observe the oil pressure warning light (290) immediately after starting the crane engine.
CAU TION: If the warning light (290) does not turn off, turn the engine off immediately.
If you do not turn the engine off, it will be severely damaged due to insufficient or
lack of oil pressure.
The engine must be turned off immediately :

> if the oil pressure drops or fluctuates significantly,
> if the power and engine speed drops without a change of the throttle control lever,
> if the exhaust is very smoky as well as if the exhaust temperature increases,
> if the coolant and oil temperature increases,
> if sudden abnormal noise can be heard coming from the engine or turbo charger.
Do not place a full load on the engine until it is at operating temperature.
The following warning and indicator lights must turn off when the crane engine is running:
> Engine oil pressure > crane engine (290)
> Preglow indicator light > crane engine (291)
> Battery charge indicator light > crane engine (301).
The following indicators and gauges should be observed during crane operation:
> Engine oil pressure > crane engine (290)
> Coolant temperature > crane engine (300)
> Battery charge indicator light > crane engine (299),
CAUTION: If the crane engineπs coolant temperature light (300) lights up during crane opera>
tion, turn the engine off immediately.
Increased coolant temperature can cause damage to the engine.
Stop the crane engine by turning the ignition key (283) to the left.
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212
The crane engine runs
As soon as the batteries are charged up by the alternator and the voltage remains stable, the electrical crane
control and the ∫LICCON∫ safe load indicator turn on automatically.
The microprocessor system will perform a self test.
Do not move any one of the two manual control levers during this boot up period.
CAUT ION: If one of the two manual control levers is being moved during this boot up period,
>an error message ∫ERROR 013∫ will appear. However, this warning message will
not shut off crane operation .
In order to delete this error message, the crane engine must be turned off and the
ignition must be turned off.
When the system is turned on again properly, the ∫ERROR 013∫ error message is
deleted.
If no problem is found, the first picture (EQUIPMENT CONFIGURATION VIEW) will appear after a few se>
conds.
The last equipment configuration view, which was used to work during the last job cycle will always appear on
the monitor.
If the ªINSTALLATION (!) ´ symbol blinks (Fig. 5) DO NOT operate the crane, because the LICCON safe
load indicator system is being bypassed through the keyed switch (16) .
If the crane is operated, the keyed switch (16) must be turned OFF (switch position ∫VERTICAL∫) and the
key must be pulled.
DANGER: If the switch (16) is in ∫ON∫ position,

> the working speeds can no longer be regulated via the manual control levers,
> the LICCON safe load indicator system is no longer effective,
> the hoist limit switch is bypassed.
The crane MAY NOT BE OPERATED with the switch (16) turned ON.
This may cause a serious A C C I D E N T !
The actual equipment configuration must be entered into the LICCON system. Recheck the configuration and
confirm the entry with the F8 key, at the same time, the OPERATING VIEW will appear.
The battery charge can be read via the ∫LICCON∫ monitor (326) , as needed, by pressing the function key F3).
Also refer to the separately issued, more detailed ∫LICCON∫ operating instruction manual .
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Crane operation at ambient temperatures of less than >20 ∞C

Preheat the hydraulic system *
CAUTION: The preheat time takes max. 30 minutes.
> Start the engine, as described at the beginning of this chapter.
> Turn on switch (305 *), the green indicator light in the switch must light up.
> After 30 minutes preheat time, turn the switch (305*) off again.
By turning on the switch (305) the hydraulic system is switched to ∫Block∫.
The hydraulic system is warmed up within about 30 minutes from >40 ∞C to +10 ∞C.
> After the 30 minute preheat time period, turn the switch (305*) off again.
> Actuate the boom luffing cylinders and the boom telescoping cylinders for about 10 minutes (extend / retract)
to displace the cold oil in the cylinders, replacing it with warm oil.
Turn the crane engine off

This is especially important for turbo charged engines, the turbocharger runs at high speeds and must have ti>
me to run out. If the engine is turned off suddenly, the turbocharger would run for some time without suffi>
cient oil supply.
> Turn the engine off by turning the ignition key (283) to the left.
> Remove the ignition key.
CAUTION: If tghe engine is at a standstill and the ignition is left "on", the batteries may
discharge, depending on their current charge.
Low level discharge can cause the following damage:
> reduced capacity

> white layer on batteries and terminals
> short battery life expectancy
> defective batteries
To turn the crane engine off in an emergency

In case of danger, turn the travel and crane engine off by pushing the emergency OFF button (281) .
The engine will be turned off immediately, when the button is being pushed, the alternator will supply no more
current, which causes the relay to drop off, turning off the electric crane control. At the same time, the button
knob locks down.
To restart the crane engine, turn the ignition key (282) to the left stop, then release the knob of button (281) by
turning it to the ∫right∫ .
The travel and crane engine can now be restarted.
CAUTION : The emergency ∫OFF ∫ button (281) may only be used in true emergency situations.
It is not permitted to use the emergency ∫OFF∫ button (281) operationally!
*Optional
215
4.04 SAFETY DEVICES 023217>00
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216
Check the safety devices

The crane operator MUST CHECK EVERY TIME before he operates the crane, that all safety devices function
properly.
DANGER: DO NOT OPERATE THE CRANE WITH DEFECTIVE WARNING DEVICES , this
can lead to serious accidents, causing injury or death.
LIEBHERR COMPUTED CONTROLLING ( LICCON )
Safe load indicator

The electronic safe load indicator turns all load moment increasing crane movement off as soon as the permis>
sible load moment is exceeded.
Only load moment decreasing movements can then still be carried out.
However, the fact that the crane is equipped with this load moment limiter does not absolve the operator from
his responsibility with regard to operating safety.
For that reason, before lifting a load, he must know the approximate weight of the load and decide, by checking
the load capacity table, if the crane is able to lift such a load.
DANGER: The safe load indicator is a safety device, it may not be used as an operational shut
off control when telescoping out or luffing up with a suspended load .
Before operating the crane, the load moment limiter must be adjusted to the actual
equipment configuration according to the load capacity chart, only this way will it
be able to fulfill its protective duty.
If the crane operator does not observe this safety obligation, then there is a great
danger that the crane overturns and is damaged beyond repair, despite a
functioning safe load indicator.
The safe load indicator cannot monitor and control all possible operating
conditions, this is still primarily the responsibility of the operator.
Leveling instruments
(Sight gauges)
In order to assure the safety while working with the crane, the crane must be horizontally aligned.
DANGER: If the crane is not aligned horizontally, there is an increased risk of accidents.
The air bubbles in the sight gauges on the left and right of the vehicle frame as well as in the crane operatorπs
cab (207) must always be within the inner rings..
The maximum permissible deviation from the horizontal line is ± 0.5% (± 0,3∞ ).
If the sight gauges have been damaged by external forces and become maladjusted, then they must be recali>
brated.
To do so, place a level on the slewing ring or as close as possible to the slewing ring onto the frame of the
vehicle, and align the crane horizontally in a longitudinal and lateral direction.
Then reset the sight gauges by adjusting the adjustment screws and secure them in this position with lock nuts.
During normal travel and crane operation, the adjustment of the sight gauges should remain unchanged.
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Emergency ™OFF" button (281)

Pressing the button will turn off the crane engine and the electric crane control .
This can immediately stop every movement.
DANGER: The emergency ™OFF" button may only be used in true emergency situations.
It is not permitted to use the emergency ∫OFF∫ button operationally!
"Control release" * button (266 / 276 )

If the operators intends to work from a standing position, he must hold down one of three buttons (266 / 276) .
When working in a seated position, the three buttons are bypassed by the seat contact switch (262) .
Note: This safety control is installed to prevent any inadvertent crane movement when entering
or leaving the cab through unintended movement of the manual control levers (267 / 277) .
Seat contact switch (262)

When working in a seated position, the crane control is released by the seat contact switch .
Button "luffing up at overload" (271)

In overload, the ™luffing™ crane movement is also turned off, even though it is a load reducing crane movement
with a freely suspended load.
If the button (271) "luffing at overload" is held down and the manual control lever (277) is moved in ∫luffing
up∫ direction, then this crane movement can be carried out.
DANGER: IT IS NOT PERMITTED to lift a load with the hoist gear, when it has already trigge>
red the load moment limiter and therefore shut off the crane movement, by ∫luffing
the boom ™ .
This could lead to overload and cause the crane to topple over.
The system may be bypassed in the limit range only if the LICCON safe load indica>
tor did not report an overload condition for a freely suspended load.
It is also prohibited to bypass the LICCON safe load indicator at a radius of more
than e3,5 m .
Contact switch * on the crane superstructure locking mechanism

In crane operation ∫only to the rear∫ the crane superstructure must be mechanically locked with the chassis.
The lever (261) must be positioned ∫downward∫.
CAUT ION: The indicator light (306) must be on.
Due to a contact switch, which is installed on the locking mechanism, the LICCON safe load indicator can be
released in the locked condition.
* Optional
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Bypass keyed switch (D )

The key operated switch (D) on the monitor of the LICCON control unit has 2 different functions.
It can be used to bypass:

1. the LICCON safe load indicator system or
2. the shut off for hoist ∫top∫ limit.
Hold the keyed switch (D) to the ™right™ position to bypass the LICCON safe load indicator.
CAUTION : The bypass is only permitted and necessary for installation purposes.
Select the shut off cause to be bypassed with function key F5,
> push the key for the next shut off cause to appear in the symbol >
and then hold the key in this position to the ∫right∫ . The symbol begins to blink and the warning light in front
of the cab changes from YELLOW to RED .
2 different shut off causes can be selected for bypass:
1.1 Shut off of LICCON (100%)

In the symbol, the text ∫100%∫ is crossed out.
2.1 Shut off of hoist ∫top∫ limit

In the symbol appears a crossed out load hook with arrow on ∫upper stop∫.
1.1.1 Bypassing the LICCON safe load indicator
DANGER: The LICCON safe load indicator system is not effective as long as the keyed button
is operated.
2.1.1 Bypass of the ∫upper™ hoist limit switch
DANGER: The hoist limit > hoist ∫top∫ is bypassed as long as the keyed button is operated.
The hoist limit switch may only be bypassed during crane operation, if another
person carefully observes the distance between the hook block and the boom pulley
head.
The observer must be in direct contact with the crane operator.
The hoist movement must be carried out with utmost care and at the lowest possible
speed.
Bypassing the hoist limit switch is only permitted in an emergency by authorized
personnel only!
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Sliding arms monitor*

For detailed description refer to chapter 6.04 SLIDING ARM MONITOR.
The LICCON sliding arm monitor checks the data of the crane operator , who has set it according to the suppor>
ting width to select the load capacity chart on the LICCON panel** .
CAUTION : It does not monitor proper crane support and if the sliding arms are pinned proper>
ly on the intended positions.
Support force monitor*, Fig. 1

See also chapter 6.04 SLIDING ARM MONITOR.
The support force is monitored via the LICCON safe load indicator **.
During crane operation, he LICCON support force monitor constantly determines the support force in all 4 out>
rigger cylinders.
The maximum and minimum values , when the alarm is triggered have been entered at the factory, depending
on crane type.
In equipment configuration crane supported, these support forces are automatically shown, either on crane ope>
rator request or when a critical situation occurs.
CAUTION : Blinking question marks ( ??? ) instead of a value, with the error number !062/063 in
the ERROR symbol FK6 indicate an error in the corresponding pressure sensor or
in the connection.
1. Indication of current support force**

With function key F3, the symbol support force monitor , Fig. 1 is shown next to the crane symbol, the sup>
port force for every support is shown in tons [t] .
The symbol appears automatically, including the alarm signal ªSHORT HORN´, if a support has reached or
exceeded the maximum force or if it has reached or fallen below the minimum force. However, the crane mo>
vements are NOT shut off.
The value (s), which trigger the warning are shown blinking.
DANGER: The crane movements are NOT shut off if the permissible support force is being ex>
ceeded / fallen below. Under no circumstances may the LICCON support force mo>
nitor be used to utilize the crane to the tipping limit!
If this is not observed, it can result in a serious accident.
2. Programming maximum and minimum support forces**

The same maximum and minimum support force values for each support have been entered at the factory, de>
pending on crane type.
The operator can change these 5 values in the SUPPORT FORCE LIMIT VALUE MODIFICATION program,
depending on the situation at hand.
* Optional
** Refer to the separately issued LICCON Operation Manual for more details about the LICCON system.
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Limitation of slewing speed*, Fig. 2

To prevent that a slewing movement is carried out too quickly by mistake, the slewing speed must be limited
via the LICCON safe load indicator* in the CONTROL program.
> When starting the program via the program key B2, preprogrammed percentage values are listed under the
∫Vmax symbol∫ .
> Use function key F8 (or program key B2) to return to the CRANE OPERATING VIEW.
Locking the hoist gear*, Fig. 3

To prevent an inadvertent movement by mistakenly touching the manual control lever when operating the cra>
ne with only one cable winch, this cable winch can also be turned off via the !CONTROL program.
By pushing the F4 function key, the cursor arrow is brought to the symbol for the cable winch, which is to be
turned off, and it is being turned off by pushing the F5 function key.
The winch symbol view changes and the ™cable winch is crossed out".
Wind velocity warning device *, Fig. 1

The wind velocity warning device is integrated into the ∫LICCON∫ system . *
As soon as the max. permissible wind speed is exceeded, the symbol begins to blink and an acoustical signal
sounds ªSHORT HORN´ . However, the crane movements are NOT TURNED OFF.
DANGER: If the permissible wind speed is exceeded, the crane movements are NOT shut down
automatically. This is only a warning system!
YOU YOURSELF MUST cease crane operation and lower the boom.
If you do not adhere to this rule, the risk of causing a serious accident is
significantly increased.
CAUTION: When operating the crane with the folding jib, the removable wind sensor must
always be installed and properly connected and fully functional, otherwise the
∫LICCON∫ safe load indicator will indicate a malfunction.
* Refer to the separately issued LICCON Operation Manual for more details about the LICCON system.
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Indication of direction of rotation of winch and hook path

Integrated into the LICCON system *
The rotation and hook path indicator on the screen shows if the winch spools in or out, even if the actual
movement of the hook block is hard to detect due to multiple reeving or due to slow speed.
CAUTION: When the cable is spooled in /out, keep watching the winch to make sure that there
is no excess loose cable spooling up on the winch (visually inspect the winch).
Loose cable can damage the winch cable.
Limit switch > winch spooled in / out

A cam limit switch is installed in the hoist winches and turns off the ™ down / lower ™ crane movement , if the>
re are at least 3 safety loops remaining on the drum.
This switch also stops the movement when the winch is full.
DANGER: If the hoist cable is spooled up during installation, make sure that the end of the ca>
ble still remains in front of the winch and is not spooled up over the winch, because
if the end of the cable is then pulled over the winch by another turn, the shut off
could no longer be guaranteed when the cable gets to the three safety loops.
In this case, the cam limit switch must be reset.
In addition, if the hoist cable is replaced with a new one, then the cam limit switch
must be reset, so it shuts off when it gets to the point when there are still three
safety loops on the drum.
If this point is not observed, the cable mount can be torn out, causing the load to
fall.
Hoist limit switch ª Hoist top´

The hoist limit switch monitors the distance of the hook block to the boom pulley head, it is installed to prevent
the hook block from hitting the boom pulley head.
It must be checked before every crane operation by running the hook block up to the top weight to check the
switch function.
The ∫hoist∫, ∫luffing down ∫ and ∫ telescoping out∫ crane movements must shut off if the switch is
functioning properly.
DANGER: The hoist limit switch may only be bypassed during crane operation with the keyed
button (D), if another person carefully observes the distance between the hook
block and the boom pulley head.
The observer must be in direct contact with the crane operator.
The hoist limit switch may not be used as a regular shut off system .
If this point is not observed, in case of malfunction, various crane components can
be severely damaged.
Bypassing the hoist limit switch is only permitted in an emergency by authorized
personnel only!
Hydraulic safety valves

Pressure relief valves against broken pipes and hoses.
Shut off valves in luffing, telescopic and outrigger cylinders.
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Pressure switch > Hoist gear 1 and hoist gear 2* "down" = 'CLEAR'
The pressure switch is installed to prevent a lowering movement of the hoist gear in case of a defective control
valve (for example: if the piston seizes in the spool). This can prevent the load falling down in case of a defective
control valve. One pressure switch is installed for each hoist gear.
Checking the function or the pressure switch:
1. Manual check
If the control valve is without pressure (i. e.: both manual control levers are in neutral position), a voltage of
24V must be on each pressure swicht. This can be measured with a suitable voltage meter.
2. Checking the function with the LICCON control and indicator unit:
The realease conditions for "hoist gear down"can be shown
> by checking system inputs of CPU 2 or
> via the 'Special view' ("i" key) and 'System special' (F4 key).
If the control valve is without pressure, the LICCON indicator unit must show the number "1" to indicate
that the hoist gear down movement is "clear". This means, that the pressure switch is functioning properly.
Note: If the pressure switch is defective, it must be replaced (refer to the spare parts manual).
DANGER: The pressure switch may not be bypassed manually! This is strictly prohibited!
High voltage warning device* HSW 40

The high voltage warning device* (327) monitors the safe distance between the crane boom and the high voltage
wires, if they are ( high ) alternating voltage.
CAUTION : This device is not suitable for overhead wiring for street cars.
DANGER: The warning device does not shut the crane movement off!
Safe crane operation is only assured if all adjustments are made, as described in chapter 4.08 ∫Working near
electrical overhead wires∫ .
A test box on the boom sends test values via a cable to the high voltage warning device in the crane operatorπs
cab.
The monitoring range is limited; for that reason, no warning can be given for wires outside the monitoring
range.
Note: Note also chapter 2.04 SAFETY TECHNICAL NOTES.
If the voltage in the overhead wires is known :

The appropriate voltage value must be set on the high voltage warning device.
If you fall within the minimum distance, the warning is given.
If the voltage in the overhead wires is unknown :

The high voltage warning device * must be adjusted.
* Optional
229
4.05 CRANE OPERATION 023224>00
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230
Prerequisites:
> The crane is properly supported as noted in the load capacity chart and horizontally aligned,
> the counterweight is installed and secured, as noted on the load capacity chart ,
> the crane engine is running,
> the hook block is properly reeved according to the reeving chart ,
> all safety devices are set in accordance with the load capacity chart.
> the danger zone is free of personnel and objects.
CAUTION : Move the manual control lever always slowly and and sensitively to take it easy on
the crane and prevents accidents.
DANGER: For all crane movement, make sure that there are no obstacles in the working range
of the crane and that the danger zone is free of any personnel.
Before initiating a crane movement, sound the horn (foot button 204) as a warning
signal.
The engine is running
As soon as the batteries are charged up by the alternator and the voltage remains stable, the electrical crane
control and the LICCON safe load indicator system turn on automatically.
The microprocessor will run through a self test.
Do not move either one of the two manual control levers (267, 277) during this process.
CAUTION : If one of the two control levers has been moved during this period,
> an error message ∫ERROR 013∫ will appear. However this will not put the crane out
of service .
In order to delete the error message, turn the crane engine off immediately and turn
the ignition off.
When you repeat the starting procedure properly, the error message ∫ERROR 13∫
will disappear.
If no error has been found, the EQUIPMENT CONFIGURATION VIEW will appear on the monitor .
The last EQUIPMENT CONFIGURATION VIEW, which was used to before you turned the crane off, will
always reappear.
Release the crane control

The crane control is released when the seat contact switch (262) is pushed down.
Note: In order to prevent any unintentional crane movement when entering or exiting the cab by
inadvertently moving the manual control lever (267, 277), the crane control is shut off by
the seat contact switch (262) as soon as the crane operator gets up from his seat.
If the crane operator must work while standing up, the seat contact switch can be bypassed
by one of the buttons (266, 276).
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Before beginning to work, the telescopic boom must be extended to the correct extension according to the
current load capacity chart.
Extension length of telescopic sections
without folding jib

Telescopic boom: T=10.5 m bis 40 m
Boom length [m]
10.5 17.1 17.1 23.8 23.8 30.4 30.4 37 40
Extension condition of telescopic sections [ % ]
Tele 1 0 90 0 90 0 90 0 90 100
Tele 2 0 0 30 30 60 60 90 90 100
Tele 3 0 0 30 30 60 60 90 90 100
Tele 4 0 0 30 30 60 60 90 90 100
Code No.:
See current load z z z z z z z z z
capacity chart
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Before beginning to work, the telescopic boom must be extended to the correct extension according to the
current load capacity chart.
Extension length of telescopic sections
with folding jib *

Telescopic boom: T=30.4 m bis 40 m
folding jib: K=9.6 m bis 16 m
Boom length [m]
T=30.4 T=33.7 T=37.0 T=40.0 T=30.4 T=37.4 T=40.0

K=9.6 K=9.6 K=9.6 K=9.6 K=16.0 K=16.0 K=16.0
Extension condition of telescopic sections [ % ]
Tele 1 0 90 90 100 0 90 100
Tele 2 90 75 90 100 90 90 100
Tele 3 90 75 90 100 90 90 100
Tele 4 90 75 90 100 90 90 100
Code No.:
See current load z z z z z z z
capacity chart
D AN G E R : In steep boom positions, for which no load capacities are given on load capacity
charts, there is a great danger of tipping over to the rear, to the counterweight side,
if the crane superstructure is turned.
This danger is especially acute
> if the support base is reduced,
> if the crane is supported, but the sliding arms are retracted or
> if the crane is freestanding on its tires.
Before luffing up with side mounted folding jib *, is must be assured that the folding
jib is mounted for transport on the telescopic boom pivot section.
If this is not observed, the folding jib can fall down when luffing it up.
This could cause a serious accident.
Note: Please note guidelines in chapter 5.02 FOLDING JIB .
* Optional
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VERSION WITH ONE HOIST GEAR

Control of crane movements
Operating mode switch (280)

When telescoping out telescopic sections 1, 2, and 3 with 4, the telescoping movement is automatically shut off
when a programmed extension length has been reached and the ™telescope STOP∫ symbol will appear on the
screen.
The shut off points are at :

Telescopic
[%] [%] [%] [%]
section
1 90 100
2, 3 + 4 30 60 90 100
By pushing the button (268) and simultaneously deflecting the manual control lever (267) forward, the shut off
function can be bypassed and the section can continue to telescope out.
The ∫telescope STOP∫ symbol turns off.
Fig. 1 In this position, only telescopic section 1 is extended and retracted with the manual control lever (267).
Hoist gear, telescoping gear, luffing gear and the slewing gear are operational.
The rapid gear can be added
for hoist gear , lifting and lowering
to telescope out and in
to luff up the boom only
Fig. 2 In this position, the telescopic sections 2, 3 + 4 are telescoped out and in simultaneously with the
manual control lever (267). Hoist gear, telescoping gear, luffing gear and the slewing gear are
operational.
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Version with one hoist gear
Control of crane movement "lifting / lowering (up / down) "

> With the B2 program key, turn on the OPERATING VIEW.
Please also note chapter 4.02 LICCON SAFE LOAD INDICATOR and 5.10 MAST STUB*.
No t e : For operation of LICCON system, please refer to the more detailed LICCON operation
manual.
DANGER: At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (button 269, 278),
if the crane is loaded with more than 50% of its maximum permissible load carrying
capacity at the corresponding reach.
CAUTION: When spooling the cable of hoist gear 1 out, keep watching the winch to make sure
that there is no excess loose cable on the winch. Keep an eye on the winch!
Hoist gear up / down

> Move the manual control lever (277) forward = hoist down (lowering)
> Move the manual control lever (277) backward = hoist up (lifting)
The speed of the crane movement is controlled by the deflection of the manual control lever and via the engine
regulation (gas pedal) .
Further increase of speed can be reached by adding the rapid gear:

> Push one of the "Rapid gear" buttons (269 or 278) once, the ∫Rapid Gear™ symbol will appear on the monitor.
The rapid gear is now retained until the rapid gear button (269 or 278) is pushed again and the ∫Rapid Gear™
symbol turns off.
> Initiate the hoisting or lowering movement be deflecting the manual control lever (277) .
Note: The rotary indicator on the screen shows that the winch is running, even if it is not always
possible to detect a hook movement , due to the number of rope runs and slow speed.
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Control of crane movement ªluffing´ the telescopic boom
> Move the manual control lever (277) to the left = to luff up the boom .
> Move the manual control lever (277) to the right = to luff down the telescopic boom .
The speed of the ∫luffing∫ crane movement is controlled by the deflection of the manual control lever (277) and
via the pedal for the engine regulation.
DANGER: The load on the telescopic boom may not be lifted from the ground by luffing up the
boom.
It must be lifted from the ground via the hoist gear.
To further increase the luff up speed, add the rapid gear :

> Initiate the rapid gear by pushing the button (269 or 278) once, the ªrapid gear´ symbol will appear on the
screen .
The rapid gear is now retained until the button (269 or 278) is pushed again and the ªrapid gear´ symbol
turns off.
> Initiate the luffing movement by deflecting the manual control lever (277),
Preselect the luffing speed
> Turn on the OPERATING VIEW via program key B2 .

> With program button C , select the CONTROL program.
On the screen (326) appear from left to right the vmax > symbol of the slewing gear, the symbol for hoist gear 1
and 2, the vmax > symbol of the luffing gear and underneath the preprogrammed speed values in
percentages![%].
> With program key E1 and E2, the double arrow will be moved over the vmax > symbol for the luffing gear.
> With function key F7, the desired or maximum permissible luffing speed can be selected in percentages [%]..
> Confirm this entry by pressing the ENTER key. The new value is now shown in the vmax!> symbol for the
luffing gear.
> Press function key F8 (or the B2 program key) to change back to the OPERATING VIEW.
> Use function key F3 to show the selected luffing speed in the OPERATING VIEW.
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Control of crane movement ªtelescoping´ the telescopic boom
Description
The telescopic section 1 is hydraulically extended and retracted individually, after preselection via the
operating mode switch (280), by actuating the manual control lever (267) .
The telescopic sections 2, 3 and 4 are mechanically extended the retracted synchronously, after preselection
via the operating mode switch(280), by actuating the manual control lever (267) .
Every extension condition has been assigned a 2 digit code number.

Take the code number from the current load capacity chart and enter it via the keyboard into the LICCON
control unit.
The telescoping procedure is shown optically on the ∫LICCON∫ monitor.
The current extension condition of the various telescopic sections is shown in percentages [%], the individual
values are separated by diagonal lines.
Note: Please also refer to the separately issued, more detailed ∫LICCON∫ operation manual!
CAUTION: The telescopic boom should normally be extended to the necessary length when it
is not loaded and should be loaded only after is has been extended.
However, it is possible to extend the boom under partial load.
This maximum permissible partial load capacity depends on the lubrication of the
bearing pads as well as on the length of the telescopic section, which is still
available for extension.
The maximum permissible partial load is limited by the pressure adjustment on the
pressure valve of the telescopic cylinder.
DANGER: When telescoping loads in and out, the equipment configuration, working radius
and instructions given on the load capacity charts MUST be adhered to!
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Control of crane movement ªtelescoping out´ the telescopic boom

The speed of the ∫telescoping∫ crane movement is controlled via the deflection of the manual control lever (267)
and via the pedal for the engine regulation.
Further increase of speed of the telescoping out crane movement can be reached by adding the rapid gear:
> Add the rapid gear by pushing one of the buttons (269 or 278) once, the ªrapid gear´ symbol will appear on the
screen.
The rapid gear remains operational until the button (269 or 278) is pushed again and the ªrapid gear´ symbol
turns off.
Telescope the telescopic section 1 out

> Turn the operating mode switch (280) to telescopic section 1 (Fig. 1).
> Deflect the manual control lever (267) forward and telescope the telescopic section 1 out to the 1st shut off
(=90 %).
If the 90 % extension condition is not required, but the 100 % position, after the shut off, actuate the bypass
button (268) in the manual control lever (267) !
> Continue to deflect the manual control lever (267) forward and telescope the telescopic section 1 out to the
desired extension length.
Telescope the telescopic section 2, 3 and 4 out

> Deflect the manual control lever (267) forward and telescope the telescopic section 2 (with 3 and 4) out to the
1st shut off (=30 %).
If the 30 % extension condition is not required, but the 60 %, 90 % or 100 % position, after the shut off, actuate
the bypass button (268) in the manual control lever (267) !
> Continue to deflect the manual control lever (267) forward and telescope the telescopic section 2 (with 3 and 4)
out to the desired extension length.
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Control of crane movement ªtelescoping in´ the telescopic boom

The speed of the ∫telescoping in∫ crane movement is controlled via the deflection of the manual control
lever!(267) and via the pedal for the engine regulation!(200) .
Note: When telescoping the various telescopic sections in, there is no shut off.
Telescope the telescopic section 2, 3 + 4 in

> Deflect the manual control lever (267) backward and telescope the telescopic section 2, 3 + 4 in.
Telescope the telescopic section 1 in

> Deflect the manual control lever (275) backward and telescope the telescopic section 1 in.
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Control of ∫slewing™ crane movement

> Before initiating the crane movement, the mechanical slewing platform lock must be released. Move the
manual lever (261) down, the indicator light (306) turns off.
> Release the slewing brake via switch (272) , switch position ∫up™.
Preselect the slewing speed

In the load capacity manual, the maximum permissible slewing speeds are given in percentages (%). These
values, which depend on boom length and operating mode,may never be exceeded in crane operating with a
load.
DANGER: Safe crane operation is only assured if all adjustments and entries have been made
according to the load capacity chart.

percentages![%].
> With program key E1 and E2, the double arrow will be moved over the vmax > symbol for the slewing gear.
> With function key F7, the desired or maximum permissible slewing speed can be selected in percentages [%]..
slewing gear.
> Use function key F3 to show the selected slewing speed in the OPERATING VIEW.
DANGER: If the maximum slewing speed, as noted on the load capacity chart, is not
preselected, the crane can be damaged severely.
Before initiating the ∫slewing∫ crane movement , the crane operator must assure
that there are no persons or obstacles within the slewing range.
If this point is not observed, there is an increased risk of accidents.
In addition, before any slewing crane movement, an audible warning signal must be
given by pressing the horn.
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Control of ∫slewing™ crane movement Continuation
The speed of the crane movement is controlled by the deflection of the manual control lever (267) and via the
engine regulation (200).
> Move the manual control lever (267) to the right = to turn to the right
> Move the manual control lever (267) to the left = to turn to the left.
To slow down the slewing movement

The slewing movement is slowed down two ways:
> by countering with the manual control lever (267)
> or by pressing the foot pedal (202)
Note : Normally, the movement should be slowed by countering with the lever, as this can be done
much more sensitively.
CAUTION : When carrying loads with a large surface exposed to winds and if there is wind
blowing from the side, than it can happen that the slewing movement ªruns after´.
The same can happen when positioning loads exactly, if there is a side wind, the
load can ªrun to the side´.
To prevent this, slow down the slewing movement of the load via the pedal (203) and
hold it.
If it needs to be retained in a certain position for a longer period of time, then the slewing brake should be
applied via switch (272) .
In general, the following rule applies:
Longer boom
more load } slower speed
DANGER: When slewing with a load, initiate the slewing movement and / or braking
movement very carefully and very gently.
Jerky, irregular movements and braking the slewing movement too suddenly can
cause the load to swing.
A swinging load can cause the boom to break off and could cause the crane to
topple over.
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VERSION WITH TWO HOIST GEARS *

Control of crane movements
Operating mode switch (280)

When telescoping out telescopic sections 1, 2, and 3 with 4, the telescoping movement is automatically shut off
when a programmed extension length has been reached and the ™telescope STOP∫ symbol will appear on the
screen.
The shut off points are at :

Telescopic
[%] [%] [%] [%]
section
1 90 100
2, 3 + 4 30 60 90 100
By pushing the button (279) and simultaneously deflecting the manual control lever (277) forward, the shut off
function can be bypassed and the section can continue to telescope out.
The ∫telescope STOP∫ symbol turns off.
Fig. 1 In this position, only telescopic section 1 is extended and retracted with the manual control lever (277),
hoist gear 1 or hoist gear 2, the telescoping gear and the slewing gear are operational.
for hoist gear 1, lifting and lowering
Fig. 2 In this position, the telescopic sections 2, 3 + 4 are telescoped out and in simultaneously with the
manual control lever (277). Hoist gear 1 or hoist gear 2, the luffing gear and the slewing gear are
operational.
Fig. 3 In this position, the telescopic boom can be luffed up and down with the manual control lever (277).
Hoist gear 1, hoist gear 2, the luffing gear and the slewing gear are operational.
* Optional
253
185280
254
Version with two hoist gears*
Control of crane movement "lifting / lowering (up / down) "

> With the B2 program key, turn on the OPERATING VIEW.
Please also note chapter 4.02 LICCON SAFE LOAD INDICATOR and 5.10 MAST STUB*.
No t e : For operation of LICCON system, please refer to the more detailed LICCON operation
manual.
DANGER: At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (button 269, 278),
if the crane is loaded with more than 50% of its maximum permissible load carrying
CAUTION: When spooling the cable of hoist gear 1 or 2 out, keep watching the winch to make
sure that there is no excess loose cable on the winch. Keep an eye on the winch!
Hoist gear 1 up / down

Move the manual control lever (277) backward = hoist up (lifting)
Hoist gear 2 up / down

Move the manual control lever (267) backward = hoist up (lifting)
The speed of the crane movement is controlled by the deflection of the manual control lever and via the engine
regulation (gas pedal) .
Further increase of speed can be reached by adding the rapid gear:
Hoist gear 1
> Push one of the "Rapid gear" buttons (269 or 278) once, the ∫Rapid Gear™ symbol will appear on the monitor .
symbol turns off.
Hoist gear 2
> Push one of the "Rapid gear " buttons (269 or 278) once, the ∫Rapid Gear™ symbol will appear on the monitor .
symbol turns off.
Note: The rotary indicator on the screen shows that the winch is running, even if it is not always
possible to detect a hook movement , due to the number of rope runs and slow speed.
* Optional
255
185283
256
Control of crane movement ªluffing´ the telescopic boom

> Turn the operating mode switch (280) to ªluffing´ the telescopic boom (Fig. 3)
> Move the manual control lever (277) to the left = to luff up the boom .
> Move the manual control lever (277) to the right = to luff down the telescopic boom .
The speed of the ∫luffing∫ crane movement is controlled by the deflection of the manual control lever (277) and
via the pedal for the engine regulation.
DANGER: The load on the telescopic boom may not be lifted from the ground by luffing up the
boom.
It must be lifted from the ground via the hoist gear.
To further increase the luff up speed, add the rapid gear :

> Initiate the rapid gear by pushing the button (269 or 278) once, the ªrapid gear´ symbol will appear on the
screen .
The rapid gear is now retained until the button (269 or 278) is pushed again and the ªrapid gear´ symbol
turns off.
> Initiate the luffing movement by deflecting the manual control lever (277),
Preselect the luffing speed, Fig 11

percentages![%].
> With program key E1 and E2, the double arrow will be moved over the vmax > symbol for the luffing gear.
> With function key F7, the desired or maximum permissible luffing speed can be selected in percentages [%]..
luffing gear.
> Use function key F3 to show the selected luffing speed in the OPERATING VIEW.
* Optional
257
185280
258
Control of crane movement ªtelescoping´ the telescopic boom
Description
The telescopic section 1 is hydraulically extended and retracted individually, after preselection via the
operating mode switch (280), by actuating the manual control lever (277) .
The telescopic sections 2, 3 and 4 are mechanically extended the retracted synchronously, after preselection
via the operating mode switch(280), by actuating the manual control lever (277) .
Every extension condition has been assigned a 2 digit code number.

Take the code number from the current load capacity chart and enter it via the keyboard into the LICCON
control unit.
The telescoping procedure is shown optically on the ∫LICCON∫ monitor.
The current extension condition of the various telescopic sections is shown in percentages [%], the individual
values are separated by diagonal lines.
Note: Please also refer to the separately issued, more detailed ∫LICCON∫ operation manual!
CAUTION : The telescopic boom should normally be extended to the necessary length when it
is not loaded and should be loaded only after is has been extended.
However, it is possible to extend the boom under partial load.
This maximum permissible partial load capacity depends on the lubrication of the
bearing pads as well as on the length of the telescopic section, which is still
available for extension.
The maximum permissible partial load is limited by the pressure adjustment on the
pressure valve of the telescopic cylinder.
DANGER: When telescoping loads in and out, the equipment configuration, working radius
and instructions given on the load capacity charts MUST be adhered to!
* Optional
259
185280
260
Control of crane movement ªtelescoping out´ the telescopic boom

The speed of the ∫telescoping∫ crane movement is controlled via the deflection of the manual control lever (277)
and via the pedal for the engine regulation.
Further increase of speed of the telescoping out crane movement can be reached by adding the rapid gear:
> Add the rapid gear by pushing one of the buttons (269 or 278) once, the ªrapid gear´ symbol will appear on the
screen.
The rapid gear remains operational until the button (269 or 278) is pushed again and the ªrapid gear´ symbol
turns off.
Telescope the telescopic section 1 out

> Deflect the manual control lever (277) forward and telescope the telescopic section 1 out to the 1st shut off
(=90 %).
If the 90 % extension condition is not required, but the 100 % position, after the shut off, actuate the bypass
button (279) in the manual control lever (277) !
> Continue to deflect the manual control lever (277) forward and telescope the telescopic section 1 out to the
desired extension length.
Telescope the telescopic section 2, 3 and 4 out

> Deflect the manual control lever (277) forward and telescope the telescopic section 2 (with 3 and 4) out to the
1st shut off (=30 %).
If the 30 % extension condition is not required, but the 60 %, 90 % or 100 % position, after the shut off, actuate
the bypass button (279) in the manual control lever (277) !
> Continue to deflect the manual control lever (277) forward and telescope the telescopic section 2 (with 3 and 4)
out to the desired extension length.
* Optional
261
185280
262
Control of crane movement ªtelescoping in´ the telescopic boom

The speed of the ∫telescoping in∫ crane movement is controlled via the deflection of the manual control
lever!(277) and via the pedal for the engine regulation!(200) .
Note: When telescoping the various telescopic sections in, there is no shut off.
Telescope the telescopic section 2, 3 + 4 in

> Deflect the manual control lever (277) backward and telescope the telescopic section 2, 3 + 4 in.
Telescope the telescopic section 1 in

> Deflect the manual control lever (277) upward and telescope the telescopic section 1 in.
CAUTION: When the telescoping procedure is finished, make sure to change the operating
mode switch (280) to luffing gear (Fig. 3) !
* Optional
263
185282
264
Control of ∫slewing™ crane movement

> Before initiating the crane movement, the mechanical slewing platform lock must be released. Move the
manual lever (261) down, the indicator light (306) turns off.
> Release the slewing brake via switch (272) , switch position ∫up™.
Preselect the slewing speed

In the load capacity manual, the maximum permissible slewing speeds are given in percentages (%). These
values, which depend on boom length and operating mode,may never be exceeded in crane operating with a
load.
DANGER: Safe crane operation is only assured if all adjustments and entries have been made
according to the load capacity chart.

percentages![%].
> With program key E1 and E2, the double arrow will be moved over the vmax > symbol for the slewing gear.
> With function key F7, the desired or maximum permissible slewing speed can be selected in percentages [%]..
slewing gear.
> Use function key F3 to show the selected slewing speed in the OPERATING VIEW.
DANGER: If the maximum slewing speed, as noted on the load capacity chart, is not
preselected, the crane can be damaged severely.
Before initiating the ∫slewing∫ crane movement , the crane operator must assure
that there are no persons or obstacles within the slewing range.
If this point is not observed, there is an increased risk of accidents.
In addition, before any slewing crane movement, an audible warning signal must be
given by pressing the horn.
* Optional
265
185282
266
Control of ∫slewing™ crane movement Continuation
The speed of the crane movement is controlled by the deflection of the manual control lever (267) and via the
engine regulation (200).
> Move the manual control lever (267) to the right = to turn to the right
> Move the manual control lever (267) to the left = to turn to the left.
To slow down the slewing movement

The slewing movement is slowed down two ways:
> by countering with the manual control lever (267)
> or by pressing the foot pedal (202)
Note : Normally, the movement should be slowed by countering with the lever, as this can be done
much more sensitively.
CAUTION : When carrying loads with a large surface exposed to winds and if there is wind
blowing from the side, than it can happen that the slewing movement ªruns after´.
The same can happen when positioning loads exactly, if there is a side wind, the
load can ªrun to the side´.
To prevent this, slow down the slewing movement of the load via the pedal (203) and
hold it.
If it needs to be retained in a certain position for a longer period of time, then the slewing brake should be
applied via switch (272) .
In general, the following rule applies:
Longer boom
more load } slower speed
DANGER: When slewing with a load, initiate the slewing movement and / or braking
movement very carefully and very gently.
Jerky, irregular movements and braking the slewing movement too suddenly can
cause the load to swing.
A swinging load can cause the boom to break off and could cause the crane to
topple over.
* Optional
267
4.06 REEVING 022413>02
183074
268
4.06 REEVING 022413>02
Reeving an d unreeving the hook block
Reeving
Prerequisite:
> The crane is properly supported and horizontally aligned.
> The travel and crane is running, and
> an assistant is present to guide the cable.
Installation procedure:
> Place the required hook block under the pulley head of the telescopic boom.
> On the hook block (19), remove the spring retainers (2 x folding pins) on both sides of the cable retaining bar
(18) and pull out both cable retaining bars.
> On the pulley head, remove the spring retainer and pull out both cable retaining bars (14 and 15) and pull out
the 3 cable retainer bars.
> Guide the hoist cable over the telescopic boom to the pulley head.
Note: While the assistant guides the hoist cable to the pulley head, the crane operator must
operate the winch. This procedure must be done in such a manner, that the cable does not
slacken up on the cable drum.
DANGER: This work should be completed while standing on a secure base.

If it is unavoidable that the cable must be hand guided on the telescopic boom to the
pulley head, use utmost caution when walking on the telescopic boom.
There is a great danger of causing a serious accident if the crane function is not
operated properly and the person guiding the cable slips on the telescoping boom.
> Lay the hoist cable over the top cable pulley (13) and reeve the hoist cable between the pulley head and the
hook block as shown on the reeving plan for the appropriate load capacity chart.
> Reinsert the cable retaining bars (14 and 15 ) and secure them with spring retainers.
Fig. 1
> On the cable lock (1), pull the spring retainer (2) and remove the pin (3) ,
> depending on the reeving, bolt the cable lock either to the pulley head or to the hook block and secure with the
spring retainer.
Note : The pin must always be placed from the inside to the outside and secured from the outside,
to prevent the hoist cable from rubbing against the pin (3) or the spring retainer (2).
Fig. 2
> On the cable lock (1) , push in the retainer pin (6) , move the lever (4) ∫downward∫ and hold it in this position,
this causes the lock lever (5) to swing downward.
CAUTION : The safety mechanism (4, 5 and 6) on the cable lock must move freely.
> Hang the end of the cable with the press fitting (8) into the cable lock and pull the cable ∫down∫, in direction of
the arrow until the cable fitting (8) touches the cone (7) .
CAUT ION : The cable fitting (8) must touch the cone (7) in the cable lock, the lever (4) must be
locked with the retainer pin (6) .
269
4.06 REEVING 022413>02
183074
270
4.06 REEVING 022413>02
Install the hoist limit switch weight
Fig. 4
> Open the chain lock (9) on the hoist limit switch weight (A) .
> Using a 13 mm wide (SW 13) open end wrench, loosen the hex head nut (10) and turn it ∫up∫ by hand.
> Release the hoist limit switch weight (A) ..
CAUTION: The hoist limit switch weight (A) consists of two interconnected parts (11 and 12) .
When releasing or attaching the weight, make sure that the two parts do not slide
apart and cause the weight (11) to fall out.
Danger of foot injuries!
> Push the weight (11) by hand onto the cable and hold it,
> with the other hand, guide the carrying part (12) behind the cable, underneath the weight (11) .
Note: With multiple reeving, the hoist limit switch weight (A) must always be routed around the
∫fixed cable∫, meaning around the cable, whose end makes up the cable fixed point.
Fig. 5
> Push the weight (11) over the carrying part (12) ,
> Hang the hoist limit switch weight (A) again into the chain lock (9) ,
> Turn the lock nut (10) down and tighten with a SW 13 open end wrench.
DANGER: The chain lock (10) serves at the same time to secure the weight (11).
It may not be replaced with another part, such as a shackle, snap etc.
The chain lock (10) must always be attached in such a way that the lock nut (10) is
on ∫top∫, meaning on the chain (17) and the chain lock is closed by turning the lock
nut (10) ∫downward∫ .
This procedure assures that the lock nut (10) does not loosen up by itself, causing
the chain lock to open.
Visual inspection:Is the chain lock (10) fully closed?

Is the hoist limit switch weight (A) attached to the ∫fixed or stationary cable∫?
> Enter the number of reeves into the ∫LICCON∫ safe load moment indicator or recheck it.
DANGER: The crane operator must make sure that the reeving process has been done proper>
ly and that the safe load indicator has been set correctly.
Incorrect reeving or entering an incorrect number of reeves can lead to serious
accidents.
271
4.06 REEVING 022413>02
183074
272
4.06 REEVING 022413>02
Unreeving the hook block
> Lower the hook block to the ground .
CAUTION: Make sure the hook block is positioned securely and stable.
If this is not observed, injuries can result if the hook block tips over during unree>
ving.
Release the hoist cable
Fig. 2
> On the cable lock (1) , push in the retainer pin (6) , move the lever (4) ∫down∫ and hold it in this position, this
moves the lock lever (5) to the side and releases the cable fitting(8) .
Fig. 3
> Push the hoist cable ∫up∫ and unfasten the fitting (8) .
> Slowly rewind the hoist cable.
DANGER: The area around the hook block must be free and clear of any personnel .
During the rewinding procedure, the cable can lash out like a whip .
Have another person observe the rewinding procedure to make sure that the cable
does not rewind loosely.
> Mount the hoist cable with the cable lock to the front tow coupling and tighten it slightly or rewind the cable
without the cable lock fully onto the winch.
CAUTION: Rewind the hoist cable up to the point where there are at least 2 m of remaining ca>
ble .
Do not pull the cable end under the winch!
273
4.06 REEVING 022413>02
184489
274
4.06 REEVING 022413>02
To place the single sheave hook block into the transport retainer*
> Telescope the telescopic boom with reeved single sheave hoock block (16) fully in, luff up to stop and pull up
the hook block.
> Turn the crane superstructure in vehicle lengthwise direction to the fornt™.
Fig. 6
> On both pins (28, 29) remove the retaining springs and pull out both pins from the transport retainer (27).
> Slowly lower the hook block (16) into the transport retainer (27).
Note: The transport retainer (27) is not placed centered to the telescopic boom.
Setting the crane at a slight sideways ineline via the support evlinders facilitales placement
of the hook block into the transport retainer.
Fig. 7
> Attach the hook block (16) in the transport retainer (27) with the pin (28) and secure the pin with the retaining
spring.
> Carefully and sensitively luff down the telescopic boom with the reeved in single sheave hook block (16), the
hook block will slowly swing downward into the transport retainer.
CAUTION: Fig. 8
When luffing up, make sure that the holst cable is placed on the two pulleys (31) on
the bracket (30).
> Luff down the telescopic boom into the boom retainer and mechanically lock the crane superstructure to the
chassis.
Fig. 7
> Secure the hook block (16) into the transport retainer (27) with the pin (29) and secure the pin with the
retaining spring.
CAUTION: After the hook block is secured with both pins (28, 29) in the transport retainer (27),
tighten the hoist cable slightly to prevent the telescopic boom form running out by
itself.
* Optional
275
4.06 REEVING 022413>02
183075
276
4.06 REEVING 022413>02
Attach and remove the load hook (26) *
Installation procedure:
> Lay the load hook under the pulley head of the telescopic boom,
> On the pulley head, remove the spring slips on the cable retainer bars (14 and 15) and pull our the 3 cable re>
tainer bars,
> Guide the hoist cable over the telescopic boom to the pulley head.
Note: While the assistant guides the hoist cable to the pulley head, the crane operator must con>
trol the winch. Proceed in such a way that the cable does not slacken up on the cable drum.
DANGER: This work must be completed from a stable area.

If it is necessary to route the cable on the telescopic boom to the pulley head, then
proceed with utmost caution when walking on the telescopic boom.
There is a great danger of causing an accident if the crane is controlled improperly
or if the persons slips on the telescopic boom.
> Lay the hoist cable over the upper cable pulley (13) ,
> Reinsert the cable retainer bars (14 and 15 ) and secure with spring clips.
Fig. 3
> Pin the cable lock (1) in the load hook (26) and secure with spring clip.
Fig. 1
> Hang the hoist cable into the cable lock,
on the cable lock (1) , push in the retainer pin (6), move the lever (4) to the side and hold it in this position, this
causes the lock lever (5) to swing to the side.
CAUTION : The safety mechanism (4, 5 and 6) on the cable lock must move freely.
> Hang the end of the cable with the press fitting (8) into the cable lock and pull the cable ∫down∫, in direction of
the arrow until the cable fitting (8) touches the cone (7) .
CAUT ION : The cable fitting (8) must touch the cone (7) in the cable lock, the lever (5) must be
locked with the retainer pin (6) .
> Hang in the hoist limit switch weight (A), as described at the beginning of this chapter.
Visual inspection: Is the chain lock (10) fully closed?
> Enter the number of reeves into the ∫LICCON∫ safe load moment indicator or recheck it.
DANGER: The crane operator must make sure that the reeving process has been done proper>
ly and that the safe load indicator has been set correctly.
Incorrect reeving or entering an incorrect number of reeves can lead to serious
accidents.
*Optional
277
4.06 REEVING 022413>02
183075
278
4.06 REEVING 022413>02
To remove the load hook (26)*

> Lay the load hook on the ground,
> Remove the hoist limit switch weight (A), as described at the beginning of this chapter.
Fig. 2
> Release the hoist cable on the cable lock ,
On the cable lock, push in the retainer pin (7), swing the lever (6) to the side and hold it in this position.
Note: This causes the lock lever (5) to swing to the side and releases the cable fitting (8) .
> Push the hoist cable in the direction of the hook and release the fitting (8) .
> Slowly pull up the hoist cable .
DANGER: The area around the load hook must be clear of any persons.
The cable can whip out when it is spooled back.
An assistant should check to make sure that the cable rolls up tightly, and there is
no loose cable on the winch.
> Reattach the hoist cable in the cable lock and attach it on the front tow coupling,
> Tighten the hoist cable slightly to secure the telescopic boom and prevent it from running out inadvertently.
If you do not attach the hoist cable to the front tow coupling, then the cable (without cable lock) must be com>
pletely spooled up on the winch.
CAUTION : Rewind the hoist cable up to the point where there are at least 2 m of remaining ca>
ble .
Do not pull the cable end under the winch!
*Optional
279
4.06 REEVING 022413>02
184490
280
4.06 REEVING 022413>02
Lower the load hook into the load hook receptacle (26)*
> Fully telescope the telescopic boom with attached load hook (26) in, luff it up to the stop and raise the load
hook.
> Turn the crane superstructure in vehicle lengthwise direction ∫to the rear∫ and position the load hook (26)
over the load hook receptacle (27)*.
> Carefully and sensitively lower the load hook (26) into the load hook receptacle (27) until the hoist cable is no
longer tensioned.
CAUTION: When lowering the load hook, make sure that the cable on the winch does not
slacken up (check the winch visually).
Slack cable can cause damage to the cable
> Release the hoist cable from the cable lock (1) as described in this chapter, in paragraph ∫Remove the load
hook∫.
* Optional
281
4.06 REEVING 022413>02
183076
282
4.06 REEVING 022413>02
Reeving plan
Reeving > 12 fold, Fig. 10

Fixed point on the side of the pulley head
Reeving > 11 fold , Fig. 11

Fixed point on the side of the hook block
Hook block 7 > sheave *

T
Hook block 5 > sheave
Added hanger 1 > sheave *
In order to be able to reeve the 7>sheave hook block (12) , hang the 1>sheave added hanger (20) into the
suspension (23) .
To install the added hanger (20)

> On the added hanger, remove the retainer spring (22) from the pin (21) .
> Guide the added hanger into the suspension (23) under the pivot section of the telescopic boom,insert
the pin (21) through the bore holes in the suspension and in the added hanger.
> Secure the pin (21) with the retainer spring (22) .
Reeve the hoist cable

> Reeve the hoist cable according to the illustration, Fig. 11 or Fig. 10.
*Optional
283
4.06 REEVING 022413>02
183077
284
4.06 REEVING 022413>02
Reeving plans
Reeving > 10 fold,

Reeving > 8 fold
T
Reeving > 9 fold ,

∫Normal reeving∫ for

5 > sheave hook bloc
3 > sheave hook bloc
1 > sheave hook block
285
4.06 REEVING 022413>02
183078
286
4.06 REEVING 022413>02
Reeving plans
Reeving > 7 fold,

Reeving > 5 fold,
T
Reeving > 3 fold
Reeving > 6 fold ,

Reeving > 4 fold,
Reeving > 2 fold
∫Normal reeving∫ for

287
4.06 REEVING 022413>02
183079
288
4.06 REEVING 022413>02
Fig. 1
Reeving plan for single pulley hook block on mast stub (or folding jib)
Fixed point on the side of the mast stub (or folding jib)
max. 2 sheave reeving T

Fig. 2
Reeving plan for load hook on mast stub (or folding jib)
Fixed point on load hook (or on folding jib)
Single reeving
T
Operation with mast stub*

The mast stub is generally used in ∫T™ telescopic operation.
The LICCON safe load indicator must be set to smaller reeving of both hooks, and the appropriate CODE
number for the corresponding boom length must be entered.
CAUTION: In this case, the LICCON safe load indicator system will not show the exact radius
and load indication, because the mast stub has not been considered in the boom
geometry.
Operation with folding jib*

For two hook operation, the ∫LICCON∫ safe load indicator must be adjusted as described in guidelines given in
chapter 4.12, TWO HOOK OPERATION.
The auxiliary hoist (winch 2) may only be operated with a maximum of two reeves, the main hoist (winch 1)
may be operated with multiple reeves.
TWO HOOK OPERATION *
DANGER: The reeving on the telescopic boom must be the same or larger than the reeving on
the mast stub or folding jib.
If this is not assured, the hoist gear 1 or the hoist cable can be overloaded.
The LICCON safe load indicator system must be set to the smaller reeving number
of both hooks.
* Optional
289
4.07 COUNTERWEIGHT 022431>00
183072
290
Counterweight plates
The counterweight plates are marked with their own weight.
DANGER: The mounted counterweight must correspond to the data given in the load ca>
pacity chart
If this is not followed, it could cause a serious accident!
To place the counterweight plate (1)

The 2.1 ton counterweight is attached with 2 hex head screws M 30 ¥ 140 (Pos. 11) and nuts with washers to
the counterweight frame.
DANGER: The two hex head screws (11) of the plate (1) may only be removed if the
counterweight plate (1) is held by counterweight plate (6) via the ballasting
cylinders (8) or by an auxiliary crane.

The 0.5 ton counterweight is attached with 2 hex head screws M 30 ¥ 200 (Pos. 10) to the counterweight frame.

The 1.0 ton counterweight is attached with 2 hex head screws M 30 ¥ 240 (Pos. 11) to the counterweight
frame.
To take on counterweight plates (1, 2 and 3)

The plate (6) is held by the locking mechanism of both ballasting cylinders (8) and serves as the carrier plate for
the remaining counterweight plates.
First,the plate (1) must be raised over the carrier plate (6) to the counterweight frame and attached with both
hex head screws M 30 ¥ 140 (Pos. 11) and nuts and washers on the counterweight frame.
Then the plates 2 and 3 can be raised together over the carrier plate (6) on the counterweight frame and
plate (2) can be attached with two screws (10),
plate (3) can be attached with two screws (9) on the counterweight frame.
CAUTION : The tightening torque of the hex head screws (9, 10 and 11) is 1000 Nm.
291
183072
292
The following combinations are possible :
with one hoist gear
Counterweight
Indiv.
Combination
weights
4.1 t Plate 1 2.1 t

Plate 6 2.0 t
6.5 t Plate 1 2.1 t

Plate 2 0.5 t
Plate 5 1.9 t
Plate 6 2.0 t
9.7 t Plate 1 2.1 t

Plate 2 0.5 t
Plate 3 1.0 t
Plate 4 2.2 t
Plate 5 1.9 t
Plate 6 2.0 t
Installation / removal
Prerequisite:
> The crane is supported in accordance with specifications on the load capacity chart and horizontally aligned,
> the transport vehicle with the counterweight plates is positioned close to the supported crane,
> the hook block is reeved properly in accordance with the reeving chart.
CAUTION: The ballasting cylinders (8) must be fully retracted, otherwise they could collide
with the counterweight plates, which are stacked on the vehicle!
DANGER: The slewing range must be free and clear of personnel and objects.
For steep boom positions, for which no load capacities are given on the load capaci>
ty chart, there is the danger that the crane topples over to the rear, the counter>
weight side, when the swing platform is turned .
This danger is specially acute,
> if the support base is reduced or
> if the crane is supported, but with retracted sliding arms.
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Installation procedure
> Start the travel and crane engine, as described in chapter 4.03.
> Set the LICCON safe load indicator according to the load capacity chart to reflect the weights installed on the
counterweight frame.
DANGER: Before lifting the boom from the transport position, the crane must be supported as
noted on the load capacity chart and the LICCON safe load indicator must be adju>
sted according to a valid load capacity chart.
If this point is not observed, it could cause a serious accident due to the crane topp>
ling over.
Note: The base plate (6) , as the carrier plate for the other plates, must always be placed first on
the vehicle frame.
> Release the crane superstructure lock, moving the lever (261) ∫up∫ .
> Turn the crane superstructure (telescopic boom in travel direction to the rear) until the ballasting cylinders (8)
are above the counterweights.
> Mechanically lock the crane superstructure to the chassis by moving the lever (261) ∫down∫ , the indicator
light (306) must light up .
To take on the counterweight

Fig. 2
> Hold the button (316) ∫down∫until the green indicator light in the button lights up,
the ballasting cylinders are extended and have entered the recesses in the counterweight plate (6).
Fig. 3
> Hold the button (317) ∫down∫ until the red indicator light in the button turns off, the ballasting cylinders are
now locked to the counterweight plate (6) .
DANGER: If the button (317) is actuated and the red indicator light in the button lights up con>
stantly , then both ballasting cylinders are not locked or released, and no movement
(such as raising / lowering the counterweight)may be carried out via the button
(316)!
Fig. 4
> Hold the button (316) ∫up∫until the green indicator light in the button lights up,
the ballasting cylinders are retracted and the plates placed on the counterweight plate (6) have been raised
until they stop on the counterweight frame.
> Set the LICCON safe load indicator to the operating mode and the existing equipment configuration.
DANGER: Before crane operation, the new ballasting condition must be entered again into the
∫LICCON∫ overload warning system.
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296
To remove the counterweight

> Turn the crane superstructure (with the telescopic boom in travel direction to the rear) until the counter>
weight is positioned above the vehicle receiving area (13).
DANGER: Before initiating a slewing movement and before lowering the counterweight, the
crane operator must be sure that there are no obstacles in the working range and
that there is no personnel with in the danger range.
> Lock the crane superstructure to the crane chassis by moving the lever (261) ∫down™, the indicator light (306)
must light up.
CAUTION: The superstructure must be locked with the vehicle frame, so that the counter>
weight can be placed onto the centering (12) and attached.
DANGER: Make sure the area is clear, that no foreign objects are under the counterweight
when the counterweight is placed on the vehicle frame (13).
If this is not the case, the counterweight cannot be locked down properly and
therefore cannot be secured properly and safely on the vehicle.
Lower the counterweight

Fig. 3
> Push the button (316) ∫down∫ until the green indicator light in the switch lights up, the counterweight plate
(6) is placed on the counterweight seating (13) on the vehicle.
CAUTION: Lower the counterweight slowly and assure exact placement .
Fig. 2
> Push button (317) ∫up∫ until the red indicator light in the switch turns off, the ballasting cylinders are re>
leased.
Fig. 1
> Pushbutton (316) ∫up∫ until the green indicator light in the switch lights up. The ballasting cylinders are re>
tracted.
Driving with the counterweight on the vehicle

In transport condition, the counterweight plates must be distributes as described in chapter 3.04 ∫DRIVING
ON PUBLIC ROADS ∫ .
Depending on permissible axle load, up to 3 plates can be placed on the vehicle.
DAUTION : Before driving the crane on public roads, the ballast plates 1 .... 3) on the vehicle
must be secured by lowering the telescopic boom into the boom retainer.
DANGER: Before every trip, make sure to visually check the counterweight plates for damage.
Damaged counterweight plates must be replaced. Any distortions on the mounting
area must be corrected.
297
4.08 WORKING WITH A LOAD 022958>00
Safety technical guidelines for working with a load
Note: Refer also to the safety technical guidelines in chapter 2.04!
> Always maintain the maximum load as specified in the load capacity chart.
> Always maintain the working radius as specified in the load capacity chart.
DANGER: For steep boom positions, for which no load capacities are given on the load
capacity chart, there is the danger that the crane topples over to the rear, the
counterweight side, when the slewing platform is turned .
This danger is specially acute,

if the support base is reduced or
if the crane is supported, but with retracted sliding arms.
Operating the crane with a smaller working radius than specified on the load
capacity chart is not permitted.
This also applies if there is no load on the hook.
Doing so increases the risk of accidents!
> Always maintain the number of reevings corresponding to the maximum load capacity as specified in the
load capacity chart.
DANGER: If this rule is not observed, the cable could snap and cause a serious accident and
injury or death.
> Always initiate any crane movement and braking movement very slowly and carefully, to prevent the load
hanging on the hook from swinging.
> As soon as the lowest layer of a winch drum is reached, another person must make sure that there are always
at least three coils remaining on the winch drum.
DANGER: If this rule is not observed, it could cause a serious accident and injury or death.
> It is not permitted to use larger hook blocks than the size specified to hoist the maximum load as stated on
the load capacity chart. If this rule is not observed, the hook cannot be lowered to the ground, because the
hoist cable is too short.
298
Inspection
Before beginning any crane operation, the crane operator must carry out a thorough inspection to ensure the
operating safety of the crane once more.
> Is the crane properly supported and horizontally aligned?

> Are all applicable values from the load capacity chart entered and adjusted to reflect the current equipment
configuration?
> Is the danger range of the crane free of any persons and objects?
DANGER: Before beginning any slewing movements, the operator must always
> give an audible warning signal by pressing the horn.
> The crane operator must make sure, especially when working on tight
construction sites,
> that there are no persons or objects within the slewing range, in the rear area
behind the counterweight and close to the vehicle chassis.
There is always a risk of accidents!
Visual inspection for damage.

The crane operator must report any problems he found on the crane to his supervisor, the designated person in
charge, including to his relieve person or assistant.
DANGER: The crane operator must immediately stop crane operation if any malfunctions are
found or should occur, which could endanger the operational safety of the crane
operation, particularly the following:
> if there is any damage to the load carrying parts of the crane structure, such as
boom, outriggers, etc.
> any time the load slips due to hoist brake failure,
> any time there is a functional problem in the crane control,
> any time any of the indicator and/or warning lights are not functioning properly,
> if there is any damage to the hoist cable,
> if any of the safety devices are not functioning properly,
> if there is a leakage anywhere on the craneπs hydraulic system.
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300
Setting the safety devices

> Start the travel and crane engine, as described in chapter 4.03.
As soon as the Diesel engine runs, check:

> the engine oil pressure warning light (290)
As soon as the Diesel engine runs, and the alternator has taken over the electrical supply, the ∫LICCON∫ safe
load indicator turns on automatically and after a few seconds, the configuration image appears on the screen
(326) .
The configuration image is always the last configuration used during the previous working cycle.
Check the following instruments during crane operation

> Gauge Fuel level > crane engine (234)
> Warning light Battery charge, engine (299)
> Warning light Engine oil pressure > engine (290)
> Warning light Coolant temperature > engine (300)
CAUTION : If the warning light (290) does not turn off right after the engine starts, or if one of
the other two warning light (290) or (300) light up during crane operation, turn the
engine off immediately.
If this is not done, the engine can be severely damaged due to insufficient oil
pressure or overheating.
DANGER: For safety reasons, during crane operation, do not allow any other personnel in the
crane operatorπs cab or step onto the frame of the crane to enter the cab.
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302
Setting the safety devices, Continuation
Enter the operating mode and equipment configuration into the ∫LICCON∫ system
The operating mode and the equipment configuration must be reentered before starting to work or any time the
equipment or attachment has been changed according to the load capacity chart into the ∫LICCON∫ safe load
indicator.
Note: If a function in the operating mode and (or) in the equipment configuration is changed, then
this change must be confirmed with the ENTER key.
If an acoustical signal sounds after entering the information via the ENTER key , then this
change has not been accepted.
In this case it must be checked which one of the adjusted function is not correct.
Refer to the added, more detailed operating manual for the ∫LICCON∫ safe load indicator
was well as the control and indicator unit of the safe load indicator in the chapter 4.02.
DANGER: The function of the safe load indicator is only then assured if the data from the load
capacity chart has been entered correctly and matches the actual equipment
configuration.
The crane operator is obligated to recheck the correct setting on the safe load
indicator before beginning any new crane operation, (even if he leaves the cab
briefly) !
Preselect the slewing speed and the luffing speed

The slewing speed must be limited via the LICCON safe load indicator system .
The luffing speed may be limited via the LICCON safe load indicator system .
CAUTION: In the load capacity chart, the maximum permissible slewing speeds are given in
percentages.
These values, which depend on boom length and operating mode, may NEVER be
exceeded when operating the crane with a load.
DANGER: Safe crane operation is only assured if all settings have been made according to the
load capacity chart.
If the given maximum slewing speed is not preselected, the crane can be severely
damaged.
> With the !B2 program key, turn on the CRANE OPERATING VIEW,
”
> With program key! , select the ªCONTROL´ program.
percentages![%].
> With program key E1 and E2, the double arrow can be moved over the vmax > symbol, which needs to be set.
> With the F7 function key, set the cursor to the permissible slewing speed value, according to the load capacity
chart.
> Push the ENTER key to confirm the speed value. The new value appears now in the selected vmax symbol .
> With the F8 function key (or the B2 program key), return to the CRANE OPERATING VIEW.
> Push the F3 function key to show the selected slewing speed in the CRANE OPERATING VIEW.
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304
Sliding arm monitor*

The sliding arms are monitored via the LICCON safe load indicator system. For operation of the LICCON
system, refer to the more detailed LICCON operation manual.
The LICCON sliding arm monitor checks the supporting width data, which the crane operator has entered on
the LICCON panel according to the load capacity chart.
CAUTION : The LICCON safe load indicator system does not monitor if the crane is supported
properly and if the sliding arms are pinned correctly in the intended positions.
Support force monitor* Fig. 1

The support force is monitored via the LICCON safe load indicator system.
Prerequisite:
> the crane must be operated in supported condition,
> the installation keyed switch ( D ) may not be actuated.
CAUTION : To assure that the LICCON support force monitoring system works properly, do not
move the support cylinders to ∫lower block ∫ nor ∫upper block!∫ .
1. Indication of current support force

Press function key F3 to view the support force monitoring symbol, Fig. 1, which shows the support force
for every support in tons [t] next to the crane symbol.
The symbol appears automatically with the alarm signal ªSHORT HORN´, if a support has either exceeded
the maximum force or if it has fallen below it. However, the crane movements are NOT shut off.
The values, which triggered the warning are blinking.
DANGER: The crane movements are NOT shut off when the permissible support force is being
exceeded or fallen below. The LICCON support force monitor may NEVER be used
to utilize the crane to its tipping limit!
If this is not observed, it can cause a serious accident.
2. Programming the maximum and minimum support forces
Program the support forces as described in the LICCON operation manual, chapter !4.4. THE SUPPORT
FORCE LIMIT VALUE MODIFICATION PROGRAM.
Push the P3 program key, and the ∫SUPPORT FORCE LIMIT VALUE MODIFICATION ∫ program will
appear. The right display window, fig. 3shows the current support force values. If one or more of these values
are below the adjusted minimum or above the adjusted maximum values, then they will blink. The left
window (EDIT window, Fig. 2) shows the programmed maximum / minimum values.
* Optional
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306
Wind velocity warning device *

The wind velocity warning device is integrated into the LICCON safe load indicator.
> Turn the unit on via the B2 program key to show the CRANE OPERATING VIEW. Fig. 2
The wind speed will appear on the screen, it is depicted in meters [m/s] or foot [ft/s], depending on the unit of
measurement used in the load capacity chart.
The maximum permissible wind velocity (same unit of measurement) shown below depends on the operating
mode, the equipment configuration and the boom length.
If the current value exceeds the maximum value, an acoustical signal ªSHORT HORN´ will sound and the
symbol will blink. However, the crane movement is NOT shut off.
DANGER: This safety device does NOT turn the crane off if the permissible wind velocity is
being exceeded.
The operator must cease crane operation and lower the boom.
If this is not done, a serious accident can occur.
C A U T I O N: When operating the crane with the folding fly jib*, the removable wind sensor must
always be installed and properly connected and fully functional, otherwise the
∫LICCON™ safe load indicator will indicate a malfunction.
* Optional
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184420
308
Working near overhead electrical wires

If there are any overhead electrical wires close to the job site, they must be disconnected by trained electricians.
If this is not possible, the danger zone must be covered or blocked off.
If these measures are not permitted or possible, the following safe distances must always be kept between the
crane / boom and any wires:
Minimum Minimum
Rated Voltage
distance in meters distance in feet
up to 1 kV 1 3
if rated voltage is 5 16
unknown
Note : If, despite all precautionary measures, a flashover occurs, proceed as follows:
> Keep calm,
> DO NOT leave the cab,
> Warn all those around the crane to remain standing where they are and not to touch the
crane,
> Move the crane from the danger zone.
DANGER: If this is not observed, serious injury or damage can occur!
High voltage warning device * HSW 40

The high voltage warning device monitors the safety distance between the boom and the overhead wires, as
long as they are high voltage (AC current) wires.
If the voltage in the wires is known :

Set the voltage value on the high voltage warning device.
As soon as a minimum distance is exceeded, a warning will sound.
If the voltage in the wires is unknown :

The high voltage warning device must be adjusted.
DANGER: This safety device does not turn the crane off.
A safe crane operation is only assured if all data and adjustments have been
entered and set correctly as noted in the separately issued warning device
operating manual* .
* Optional
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310
Taking on a load
The crane must always be operated in such a manner that the load bearing parts are not damaged and the
stability is guaranteed.
Pulling a load at an angle is prohibited!

The crane is designed to lift loads vertically.
Pulling at an angle causes horizontal stress in addition to the vertical stress, which the crane has been designed
to handle. It makes no differences if the load is pulled in direction of the boom or crosswise to it, the crane is
simply not designed to handle loads which are pulled at an angle.
Since forces are transferred via the hoist cable to the boom jib, they have a stress effect which is above the
permitted stress level for the height of the boom head pulley.
DANGER: DO NOT pull a load at an angle!

Pulling a load at an angle can damage the crane and cause it to topple over.
Pulling a stuck or jammed load free is prohibited!

NEVER pull stuck or jammed loads free by using the crane, this is strictly prohibited!
DANGER: DO NOT pull stuck or jammed loads free with the crane !
This can cause the crane to topple over.
Hoisting the load

When hoisting a load, utmost care must be taken.
It can be very dangerous, there is always the danger that a load may fall and any persons, which are close to the
area of the load to be hoisted, can be crushed.
If the hoisting tackle is manually placed on the load by another person, the crane operator must assure :
> that the hands of this persons placing the tackle are not crushed between the tackle and the load when the
cable tightens,
> that arms and legs are not crushed by a swinging load while hoisting it .
DANGER: If there are any persons in the area where the load is being hoisted, they are in
danger of being crushed! Utmost care must be taken.
At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (269, 278), if the
crane is loaded with more than 50% of its maximum permissible load carrying
It is strictly prohibited to lift a load by luffing the boom, after the LICCON safe load
indicator has shut off the system after an attempt was made to lift the load by the
hoist gear.
This would overload the crane and/or cause the crane to topple over.
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312
Crane operation
A swinging load must always be kept under control.
Only a safe, sensitive control of the crane functions can guarantee this.
All crane movements must always be initiated and slowed down slowly to prevent the load from swinging.
DANGER: A swinging load can damage the crane or cause it to topple over.
It could cause a serious accident!
Tag lines
To aid the crane operator to accurately guide the load, we recommend to use tag or guiding lines.
This can prevent unintentional movement of the load and resulting damage.
Moving persons
This crane is NOT designed to move any personnel.
It is prohibited to move or let anybody ride along on the load being lifted.
DANGER: Moving or letting any persons ride along on the load or load tackle is strictly
PROHIBITED.
It could cause a serious accident.
Danger of being crushed

When lowering the load, utmost care must be taken.
It can be very dangerous, there is always the danger that persons, which are close to the area of the load to be
lowered, can be crushed.
DANGER: When lowering the load, no personnel or objects may be below the load!
It could cause a serious accident!
313
4.09 DRIVING WITH ATTACHMENT IN PLACE 023225>00
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314
General Guidelines
The crane may be driven on level ground with a blocked axle suspension system and raised telescopic boom with
the attachment installed .
DANGER: When driving with the attachment in place, it is imperative that the values given
in the following charts and all guidelines are adhered to.
If this is not done, there is the danger of causing a serious accident, as the crane
can topple over.
Planning of the movement

When planning to move the crane to an another place on the site, it must be assured that the following measu>
res are taken after the crane operation and before placing the supports of the crane:
1. Before travel, the travel route must be checked to see if it is level throughout, and to assure that
there are no uneven areas.
D A N G E R: The travel route may not slope by more than 3∞, even within the permissible to>
lerance range of ± 0.10 m over 10 m!
2. Before supporting the crane, the vehicle must be aligned in horizontal direction via the manual leveling
control (buttom 142) until the indicator light (143) lights up.
Then the axle suspension must be changed from ∫suspended∫ to ∫locked∫ by actuating switch (154). These
measures are the prerequistes for the following driving with attachment.
Then support procedure must be carried out as described in chapter 3.05 THE CRANE AT THE JOB SITE
3. After crane operation

> Telescope in the telescopic boom completely.
> Turn the crane superstructure to the position given in the charts, either to the front or rear.
> Lock the crane superstructure to the crane chassis.
Turn the manual lever down, the indicator light !(306) must be on.
> Luff the telescopic boom or the telescopic boom with folding jib* to the angle given on the corresponding lo>
ad capacity chart.
DANGER: Before turning the superstructure, make sure the crane is properly supported
and horizontally aligned.
The sliding arms must be secured with pins.
The crane superstructure must be locked to the chassis after it has been turned
into lengthwise direction.
4. To lower the crane on the blocked axles

Carefully lower the crane onto the blocked axles by retracting the outrigger cylinders.
DANGER: The horizontal position of the crane must be constantly monitored during this
lowering procedure!
CAUTION: All wheels must touch the ground evenly, or the axle suspension system will be
damaged!
The travel route must be even and horizontal, and must have sufficient load
carrying capacity to withstand the axle load.
* Optional
315
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316
Prerequisites for driving with attachment:

> The crane superstructure must be positioned in lengthwise direction, with the boom either to the front or to
the rear, and it must be mechanically locked to the chassis.
DANGER: Before turning the superstructure, make sure the crane is properly supported and
horizontally aligned.
> The hydro>pneumatic suspension of the axles 1 to 3 must be locked.
> The sliding arms must be extended and pinned.
DANGER: The sliding arms must be secured with pins.
> The outriggers cylinders with pads must be set about 10 > 15 cm above ground level, so that the crane can be
supported in case the base gives.
> All tires must be inflated to the correct tire pressure.
> The crane may only be driven with utmost care, in 1st gear and with added 1st axle drive (at step by step
pace), with only the slightest acceleration and with careful braking action.
> The base must be even and horizontal, and must offer sufficient load carrying capacity to support the axle load
(see chart).
> There may be no persons or obstacles in the travel range.
> During travel, another person must observe the luffed boom as well as the outriggers to assure that they will
not collide with anything.
> It is only permitted to move the crane if there is NO load on the hook.
CAUTION : These prerequisites must be observed and assured when traveling with the
attachment in place. If this is not done, there is the danger of causing a serious
accident, as the crane can topple over!
*Optional
317
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318
Charts for driving with the attachment in place

Chart 1: Fully retract the telescopic boom (T > 10.5 m) (0 / 0 / 0 / 0)
Chart 2: Fully retract the telescopic boom (T > 10,5 m) (0 / 0 / 0 / 0) with folding jib * 0∞, 15∞ and 30∞
CAUTION: The charts 1 and 2 are valid only for travel with attachment without a load on the
hook.
The hydro pneumatic suspension for axles 1 to 3 must be blocked.
The support pads must be held closely above the ground.
DANGER: The travel route must be checked before driving off to see if it is level throughout,
and to assure that there are no uneven areas.
The terrain may not slope by more than 3∞, even within the permissible tolerance
range of ± 0.10 m over 10 m !
The given telescopic boom angles must be adhered to.
You may only drive the crane with raised boom on even ground of sufficient load
carrying capacity, without a load and if the counterweights and their distribution
are kept as noted in charts 1+2 !
You may only drive the crane with locked axle suspension. If the axles are
suspended the cran can topple over.
Driving the crane with the attachment in place

Driving with fully retracted telescopic boom (T>10.5 m) (0 / 0 / 0 / 0)
Chart 1
In the chart, a pulley weight of 330kg has been considered.
Slight axle load increase with folding jib installed on the side of the telescopic boom.
Counterweight Telescopic boom maximum axle

Boom on the crane angle a to the load
direction superstructure horizontal [t]
[t] 1 2 3
Boom to the 9.7 0∞ > 50∞ 8 8 29

front 6.5 0∞ > 80∞ 9 9 30
4.1 0∞ > 80∞ 10 10 26
Boom to the 9.7 0∞ > 80∞ 17 17 19

rear 6.5 0∞ > 80∞ 15 15 19
4.1 0∞ > 80∞ 13 13 19
* Optional
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320
Driving the crane with the attachment in place

Driving with fully retracted telescopic boom (T>10.5 m) (0 / 0 / 0 / 0) with folding jib* 0∞, 15∞ and 30∞
Chart 2
In the chart, a pulley weight of 110kg has been considered.
Counterweight Telescopic boom maximum axle

Boom on the crane angle a to the load
Folding jib
direction superstructure horizontal [t]
[t] 1 2 3
K > 9,6 9.7 10∞ > 60∞ 9 9 30

6.5 10∞ > 80∞ 10 10 30
4.1 10∞ > 80∞ 11 11 26
to the front
K > 16,0 9.7 10∞ > 60∞ 10 10 29

6.5 10∞ > 70∞ 11 11 29
4.1 10∞ > 80∞ 12 12 26
K > 9,6 9.7 10∞ > 80∞ 17 17 20

6.5 10∞ > 80∞ 15 15 21
4.1 10∞ > 80∞ 13 13 21
to the rear
K > 16,0 9.7 10∞ > 80∞ 16 16 22

6.5 10∞ > 80∞ 15 15 23
4.1 10∞ > 80∞ 13 13 23
> The given distribution of the counterweights and the telescopic boom angle must be retained.
> Driving with raised boom is only permissible on even ground of sufficient load carrying capacity
and without a suspended load!
> The hydro>pneumatic suspension of axles 1 to 3 must be blocked.
> The outriggers must be extended at least to the minimum support width .
> The outrigger pads must be held close to the ground.
* Optional
321
4.10 DRIVING FROM THE CRANE OPERATORπS CAB 023226>00
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322
∫Driving from the crane operatorπs cab ∫

If the crane is to be driven from the crane operatorπs cab and steered via the added hydrostatic rear axle stee>
ring, all checks and measures described in chapters
3.02 ∫BEFORE VEHICLE START UP∫
3.05∫THE CRANE AT THE JOBSITE∫ and
4.03 ∫STARTING THE CRANE∫
must be observed.
On machines with 6¥4 drive, the non>driven 2nd axle may be raised*, this facilitates driving in off road ter>
rain.
However, the axle can only be raided * from the driverπs cab and must be done before changing over to ∫driving
the crane form the crane operatorπs cab∫ .
Raising * the (non>driven) 2nd axle

> Before driving into off road terrain, stop the vehicle in suspended condition, while still on firm and level
ground, and raise the 2nd axle, as described in chapter 3.04 ∫Off road driving∫.
Lower the 2nd axle
> Stop the vehicle on firm and level ground and lower the 2nd axle, as described in chapter 3.04 .
Change over to ∫Driving from the crane operatorπs cab∫

> In the driverπs cab, apply the parking brake, turn off the travel and crane engine and the ignition by turning
the ignition key (30) to the ∫left∫ .
> In the driverπs cab, turn switch (42**) ∫to the left∫ to ∫crane superstructure ∫ symbol, the axle suspension is au>
tomatically locked .
In addition, for safety reasons, switch (154) must be shifted to AXLE SUSPENSION LOCKED .
CAUTION: The switch (42**) may only be actuated when the engine is not running and the igni>
tion is turned off.
If this is not assured, the cut in coupling for the hydraulic pump can be damaged.
N o t e: If the switch (42**) is actuated, the gear selector switch in the driverπs cab (161) as well as in
the crane operatorπs cab (208) must be in neutral ∫N™ position.
If the switch (42**) is actuated with the engine running, the travel motor (engine) will turn
off automatically .
The following functions are now changed over to the crane operator πs cab:
Electrical system, steering, gear shift, engine regulation for travel and crane engine, parking and service bra>
ke.
> Turn the ignition key (30) one notch in clockwise direction and turn on the ignition for the travel and crane
engine.
> Turn on switch (154), to AXLE SUSPENSION LOCKED .
> Turn the ignition off again and remove the ignition key (30).
DANGER: For safety reasons, do not remain or step into the driverπs cab (crane chassis) during
crane operation.
Danger of injury due to turning steering wheel.

* Optional
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324
In the crane cab, turn on the ignition for the travel motor (engine)
> Set the gear selector switch (208) to neutral ∫N™position.
N o t e: The engine can only be started if both gear selector switches (in the driverπs cab and in the
crane operatorπs cab) are in neutral position ∫N∫.
Check the instruments

> Insert the ignition key into the ignition lock (283) and turn in one notch in clockwise direction.
The following warning (indicator ) lights light up if the ignition is turned on:
> Oil pressure (290)
> Indicator light > frame glow system (291)
> Alternator , battery voltage (299)
> Position of the crane superstructure to the front (287) or
> Position of the crane superstructure to the rear (297),
> Combi warning light (301): > insufficient oil pressure in in the hydr. circuit torque converter / automatic
transmission
> error in electronic gear shift in automatic transmission
> increased oil temperature in hydr. circuit torque converter / automatic trans>
mission.
To start the travel and crane motor

> Continue to turn the ignition key (283) in clockwise direction and
> start the travel and crane motor, as described in chapter 3.04 ∫DRIVING ON PUBLIC ROADS ∫ in paragraph
∫Starting the engine with the flame glow system™.
The travel motor runs, check the instruments

As soon as the engine starts, watch the oil pressure gauge (290) .
CAUTION : If the warning light (290) does not turn off, stop the engine immediately by pushing
the engine stop button (281) to prevent engine damage due to insufficient lubrica>
tion .
The engine must be turned off immediately in case of:

> dropping or fluctuating oil pressure
> a drop in performance or speed without changing the regulator > throttle control
lever (200)
> heavily smoking exhaust
> increasing coolant and oil temperature
> sudden abnormal noise coming from the engine or turbocharger.
Do not put a full load on the engine until it has reached operating temperature.
The following warning (indicator ) lights must turn off when the engine is running:
> Oil pressure (290),
> Indicator light > flame glow system (291),
> Alternator , battery voltage (299),
> Combi warning light (301)
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Travel readiness > the engine runs at low idle RPM
Driving / shifting
To drive the crane from the crane operatorπs cab, 2 forward gears and 2 reverse gears are available.
CAUTION : Changing from neutral to reverse, reverse to forward or vice versa is only permitted
when the vehicle is at a standstill, the parking brake is applied and if the travel and
crane engine runs at low idle RPM!
After changing gears, wait for 1 to 2 seconds before giving gas.
The shift stages V1Æ V2 (forward), V2Æ V1 or R1Æ R2, R2Æ R1 (reverse) can be shifted under load.
The travel speed can be regulated via the gas pedal (200) and the gear selector switch (208) for the automatic
transmission.
Gear selection switch (208)

The various positions for the gear selector switch (208), their meaning and use are as follows:
N (Neutral)
Required shift position to start the travel motor (engine).
CAUTION : Do not let the vehicle run out in neutral (gear selector switch ∫N∫ ) , this eliminates
the engine braking action ,and the gear lubrication is insufficient.
V1
Creeper / inching gear, forward
The shift position is the same as the 1st gear in the driverπs cab
Use this gear if you must drive extremely slow.
V2
Slow driving, forward
The shift position is the same as the 3rd gear in the driverπs cab.
R1
Creeper / inching gear , reverse
The shift position is the same as the 1st gear in the driverπs cab.
R2
Slow driving, reverse
The shift position is the same as the 3rd gear in the driverπs cab.
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Travel readiness > the engine runs at low idle RPM

On the gear selector switch (208) , select the desired travel direction (V / forward or R /reverse) and the travel
stage 1 or 2.
A slight decrease in engine RPM signals that the transmission has shifted to the selected gear .
Release the parking brake

Pull the manual brake lever (263) straight out and push it forward , indicator light (298) turns off.
Note: When the parking brake is released, the manual brake lever (263) points forward.
As long as the required brake release pressure of approx. 5.2 bar is not available in
brake circuit III, the parking brake is not released even if the brake lever is in
forward position.
Move the brake lever (263) back again, increase the engine RPM with the gas pedal
(200) to charge the brake circuit III.
C A U T I O N: Check the brakes immediately after the crane starts to move.
Keep an eye on the following important instruments while driving:

> Oil pressure (290)
> Coolant temperature (300)
> Combi warning light (301)
If warning light (301) lights up, then the crane must be brought to a standstill immediately and the warning
lights (54, 55, 72*) must be checked in the driverπs cab to see which one of the three lights is on.
Then the travel motor (engine) must be turned off.
CAUTION: If the warning lights (290, 300 or 301) light up during travel, then the crane must be
stopped immediately, and the engine must be turned off via the engine Stop button
(281).
Low engine oil pressure or high coolant temperature can cause serious engine da>
mage.
Low oil pressure and (or) high oil temperature in the circuit for the torque conver>
ter / automatic transmission can cause serious transmission damage.
> Add Diesel fuel as soon as warning light (289) lights up.
C A U T I O N: Do not let the fuel tank get completely empty, because contaminants in the fuel tank
can be drawn into the fuel system and it will become necessary to clean and bleed
the entire fuel system .
* Optional
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Off road driving

For driving in off road terrain, on unpaved roads or in winter conditions, additional shift stages are available,
which may only be added when the vehicle is at a standstill and when the gear selector switch is in neutral posi>
tion.
1. Off road gear

The off road gear reduces the travel speed of the individual gears and increases the drive power, which is
transferred by the wheels to the ground surface.
The off road gear can be shifted separately.
2. Front axle drive ,

Drive for 1st axle , (for 6¥4 drive)
Drive for 1st and 2nd axle, (for 6¥6* drive)
The front axle drive requires off road gear.
If one or more wheels slip when driving in off>road gear, the 1st (or 1st and 2nd*) axle drive and the can be
added .
3. To raise the non >driven 2nd axle (for 6¥4 drive)

On machines with 6¥4 drive, this gear facilitates off road driving.
4. Oscillation * of 1st axle , (for 6¥4 drive, 2nd axle raised)

Oscillation * of 1st + 2nd axle , (for 6¥6* drive)
This gear is used to drive the crane on jobsites and can only be carried out from the crane operatorπs cab.
DANGER : Driving with axle oscillation is only permitted on firm and level ground .
1.1 To add the off >road gear:

> Add the off>road gear via switch (322).
As soon as indicator light (322) lights up, the off road gear is engaged.
If the indicator light does not turn on, then return the gear selector switch (208) to neutral position, and
repeat the procedure.
2.1 Add front axle drive (drive for 1st or 1st and 2nd * axle ) zuschalten
> Add the drive for the 1st (or 1st and 2nd*) axle via switch (313).
> On the gear selector switch (208), select the desired travel range (1, 2 or R).
CAUTION : Drive off carefully, the drive for the 1st (or the 1st and 2nd)* axle is only added
if the indicator light (313) is on.
* Optional
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3.1 Raise the (non>driven*) 2nd axle

The non>driven 2nd axle must be raised from the crane driverπs cab.
DANGER: Before raising or lowering the 2nd axle, it must be assured that there are no
persons in the danger range of the crane.
In case of erroneous control, the raised 2nd axle can drop ∫down∫ .
> Before entering off road terrain, lower the vehicle in suspended condition on firm and level ground by
pushing the button (146, 147, 150, 151) ,
> On the switch (133), release the shift lock and turn on the switch (133) , the suspension of the 2nd axle is
hereby blocked, the axles 1 and 3 remain suspended.
> Press the button (142) until the indicator light (143) lights up, the 2nd axle is now raised.
3.2 Lower the 2nd axle

> Lower the vehicle in suspended condition, on firm and level ground, by pushing button !(146, 147, 150,
151),
> on the switch (133), release the shift lock and turn on the switch (133) , the suspension of the 2nd axle is
hereby released.
> Press the button (142) until the indicator light (143) lights up, the vehicle is now raised to travel
height.
4.1 "Oscillating "* the 1st and 2nd axle

Prerequisite:
> The corresponding load chart is programmed,
> the boom is positioned to the rear ,
> the crane superstructure is mechanically locked to the crane chassis,
> the axle suspension is "LOCKED".
CAUTION : Oscillation is only possible if the boom is positioned to the rear and the crane
superstructure is mechanically locked to the crane chassis, the indicator light
(306) must light up, the lever position!(261) must be positioned ∫downward ∫.
After entering the corresponding CODE No. into the LICCON system and after confirming the entry, the
1st and 2nd axle is automatically changed to ∫oscillation∫ , with axle suspension "LOCKED" , indicated
by symbol (Fig. 1), the 3rd axle remains "LOCKED."
As long as the crane is operated with the load chart in a safe operating range , the 1st and 2nd axle are
shifted to oscillation.
If you leave the safe operating area or switch to another load chart, the LICCON safe load indicator system
shifts automatically back to axle suspension "LOCKED" , indicated by the symbol !(Fig. 2).
Turn off added selections
CAUTION : Turn the transverse differential locks as well as front axle drive (s) off as soon
as the ground becomes harder and provides sufficient traction and they are no
longer required to drive.
Continued driving on solid ground with sufficient traction with the front axle
drive as well as the transverse differential locks engaged can cause significant
damage on the axles as well as the complete drive train !
* Optional
333
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Hydraulic rear axle steering

The rear axle steering makes it possible to turn the wheels of the 3rd axle into the same direction for offset mo>
vement of the crane ( for the so > called dog or crab walk) and tight turning radii.
CAUTION : The rear axle steering may not be used while driving on public roads.
To offset the wheels for dog or crab walk, all wheels must be turned into the desired travel direction.
For tight turning radii, the wheels of the front axle must be turned in travel direction and the wheels of the rear
axle must be turned opposite the travel direction.
The turning angle of the rear axle should be in about same as that of the front axles to prevent ∫ tire chafing∫.
To put the hydraulic rear axle steering in operation

> Bring the vehicle to a standstill on level ground, turn the wheels of the front axle to ∫straight forward travel ∫
and apply the parking brake .
> Switch the gear selector switch (208) to neutral position "N" .
> Turn the crane superstructure in ∫vehicle lengthwise direction∫ to the front or rear and lock to the chassis,
> Move the manual lever (261) ∫downward∫ , the indicator light (306) must light up .
Note : When the crane superstructure is positioned in ∫vehicle lengthwise direction∫ to the front,
the indicator light !(287) must be on.
When the crane superstructure is positioned in ∫vehicle lengthwise direction∫ to the rear,
the indicator light !(297) must be on.
> With switch (312) , release the steering lock for the rear axle.
Note : The steering lock can be released in neutral position, in 1st and 2nd gear as well as in re>
verse gear.
> Move the steering button (270) slightly to the left and right.
If the rear axle wheels do not steer , then the steering lock / release is in intermediate position.
In this case, turn the switch (312) off and on again and then move the steering button (270) slightly to the left
and right .
> Via steering button (270), , the rear axle can now be steered to the right or left independently from the two
front axles.
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To take the rear axle steering out of operation
CAUTION: If the rear axle steering is no longer needed, then it must be locked again in straight
away direction on level ground before continuing to drive!
> Bring the vehicle to a standstill on level ground. Turn the wheels of both rear axles for straight travel and ap>
ply the parking brake.
> Set the gear selector switch (208) to neutral position "N".
> Via switch (312) lock the steering lock for the rear axle.
> Move the steering button (270) for the rear axle steering slightly to the left and right to make sure that the re>
ar axle steering is locked, while watching the wheels of the rear axle; these wheels may no longer steer to the
right or left .
> Turn the travel motor off by turning the ignition key (283) to the πleftπ.
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Other features for the travel operation

> The front windshield wiper is turned on via switch (223) .
> The windshield washer system* for the front window can be turned on via button (222)*.
> The windshield wiper for the roof window is turned on via switch (221) .
> The windshield washer system* for the roof window can be turned on via button (220)*.
> The parking and low beam lights can be turned on via the 2>stage switch (310) .
> The emergency blinker system can be turned on via switch (311) , the blinker in the switch shows that the sy>
stem is functioning.
> The instrument panel can be illuminated via switch (315).
> The crane operatorπs cab features interior lighting (207), it can be turned on or off with a switch.
> The travel direction indicator is set via switch (205), the blinker in the indicator light (288) shows that the sy>
stem is functioning.
> The horn (warning signal) can be triggered via the foot switch (204).
Note: The horn will only work if the crane electrical system and the ignition of the crane engine
are turned on.
To end travel
> Bring the crane to a stop by applying the service brake (201) ,
> apply the parking brake with the manual brake lever (263).
> Switch the gear selector switch (208) into neutral position ∫N∫ .
Stop the travel and crane engine

> Reduce the engine speed, let the engine run at low idle for a short time to cool off,
> then turn the engine off via the ignition key (283) by turning it counterclockwise.
Turn off the ignition for the travel and crane engine
> Turn off the ignition with the ignition key (283) by turning it counterclockwise to ∫0∫ position and
remove the key.
> Lock the crane operatorπs cab.
> Secure the crane with wedges to prevent it from rolling off.
> Turn the main battery switch (in the battery box, on the left side, behind the driverπs cab) off and pull
the cam.
* Optional
339
4.11 CRANE OPERATION ∫FREESTANDING ∫ 023227>00
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4.11 CRANE OPERATION ∫FREESTANDING∫ 023227>00
Crane operation ∫freestanding *, on tires∫

The crane can be operated freestanding on tires if the following notes are observed:
DANGER: The crane may only be operated ∫freestanding on tires∫ and with attached load if
the required load capacity charts for this operation have been programmed and
entered on the LICCON safe load indicator system.
The instructions of the appropriate load capacity chart MUST be followed!
Non > adherence can cause serious accidents!
1. Crane operation freestanding * on tires

1.1 The boom may be moved, even without a load, only in ranges where load capacity values are available,
otherwise there is a danger that the crane will tip over.
1.2 All tires must be inflated to the specified air pressure (see load capacity charts).
1.3 The telescopic boom may be telescoped out to a length of no more than 17.1 m .
1.4 The ground must be able to securely support the maximum operating weigh t of the crane and the weight
of the suspended load.
1.5 The ground must be level and without any slopes.
1.6 The suspension of all axles must be locked via switch (106).
1.7 If possible, the 4 sliding arms should be extended and the outrigger cylinders with the installed pads
should be lowered close to the ground, so the crane can catch itself in case the ground should give.
For safety reasons, if possible, and even in cases when freestanding crane operation would be possible,
always work with the crane properly supported.
2. Driving with a load*

The crane may be driven with an attached load if the notes in paragraph 1. are strictly observed.
In addition, the following applies:

2.1 Drive only with utmost care, in 1st gear, with added off road gear, at the least possible increase in
speed and careful braking action.
2.2 Avoid jerky travel movements.
2.3 The attached load must be carried as close as possible near the ground and must be secured to prevent it
from swinging.
3. Crane operation, freestanding * on tires ,

Working range ªonly to the rear´
The crane can be operated freestanding on tires and attached load ∫to the rear∫, if the notes in paragraph
1 and 2 are strictly observed.

3.1 The crane superstructure must be in lengthwise direction to the rear and mechanically locked to the
chassis.
To do so, move the locking lever (261) ∫forward∫ until the indicator light (306) lights up.
3.2 The slewing brake (switch 272) must be applied.
3.3 On machines with axle oscillation*, the load capacity chart for axle oscillation must be selected.
See also chapter 4.10 ∫DRIVING THE CRANE FROM THE CRANE OPERATORπS CAB™, paragraph 4.1
∫Oscillating∫ the 1st and 2nd axle.
* Optional
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4. Driving the crane with an attached load,

Working range ªonly to the rear´
The crane can be moved with an attached load ∫to the rear∫, if the notes in paragraph 1, 2 and 3 are
strictly observed.

4.1 The attached load must be carried as close as possible to the ground and must be secured to prevent it
from swinging.
4.2 Drive only :

> in 1st gear with added off road gear,
> with utmost case and in step by step speed.
> the least possible increase in speed and careful braking action.
> Avoid jerky travel movements.
4.3 The crane superstructure must be positioned to the rear, in lengthwise vehicle direction, and ist must
be mechanically locked to the chassis via locking lever (261).
The slewing brake must be applied.
5. There is a danger of tipping over or a danger of overload, if:
5.1 if the crane superstructure is not positioned in lengthwise travel direction to the rear.
5.2 if the boom is telescoped out to a length of more than 17.1 m and the crane superstructure is turned from
the lengthwise direction.
5.3 if the axle suspension is not blocked.
5.4 if the ground is not able to securely carry the maximum operating weight and the weight of the suspended
load.
5.5 if the ground is not level and without slope.
5.6 if you drive too quickly with a load or if you start out or slow down jerkily.
5.7 the outrigger cylinders with installed outrigger pads are not held close to the ground,
5.8 if you exceed or fall under the load values and/or radii values for the corresponding boom length, as noted
in the load capacity chart,
5.9 if insufficient distance is kept to ditches, pits and / or slopes,
5.10 the attached load starts to swing, due to improper control of crane movements ,
5.11 or if a load is being pulled at an angle. The most dangerous is pulling a load transverse to the lengthwise
direction of the boom . IT IS NOT PERMITTED to pull a load diagonally or at an angle.
343
4.12 TWO>HOOK OPERATIONS 021688>04
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344
Description
In two>hook operations, a distinction must be made between
1. Operation with mast stub, for which no load capacity charts are available, and
2. Operation with boom extension (auxiliary boom, folding jib, luffing jib).
1. Operation with mast stub *

This operating mode makes quick lifts via the mast stub (hoist gear 2) possible; the reeved in hook block (hoist
gear 1) remains fully reeved on the telescopic boom.
The mast stub is generally operated in the (T) tele operation mode.
DANGER: The overload safety device ist only effective if the reeving on the telescopic boom is
the same or larger than the reeving on the mast stub. If this is not assured, the hoist
gear 1 or the hoist cable can be overloaded.
The LICCON safe load indicator system must be set to the smaller reeving of
both hooks.
> Set operating mode "T" on the LICCON safe load indicator system.
> Enter the cable reeving to reflect the actual reeving on the mast stub.
CAUTION: For crane operation with mast stub, be aware that the radius and load indicator of
the safe load indicator system is not exact, because the mast stub is not being
cosidered in the boom geometry.
The safe load indicator system must be set to the actual reeving on the mast stub
annd the corresponding CODE No. for the appropriate boom length must be
entered.
In addition, the counterweight, the support base, etc. must also be cosidered.
By setting the smaller reeving number of the two hooks, it is assured that the crane ist not overloaded.
Add the weight of the hook block (load hook) and the tackle to the weight of the load, which is to be lifted.
* Special equipment
345
180647
346
2. Operations with the folding fly jib or with the auxiliary boom *
This capability is provided for turning the load while simultaneously operating both hoisting gears.
DANGER: The load must always be raised or lowered to 100% with the weakest component (fly
jib or auxiliary boom*).
> Enter the reeving in the LICCON in accordance with the reeving present (folding fly jib or auxiliary
boom*).
DANGER: The reeving on the main hook (telescopic boom) must be equal to or larger than the
reeving on the jib (folding fly jib or auxiliary boom *).
If this is not observed, hoisting gear 1 or the hoisting cable could be overloaded.
> For operations with the folding fly jib or the auxiliary boom *, the LICCON must be set to the operating
mode "Folding fly jib".
> Enter the cable reeving in the equipment mode diagram of the LICCON in accordance with the reeving
present on the jib.
In this case the maximum total load corresponds to the maximum permissible load on the folding fly jib given
in the corresponding load capacity table for jib operations.
The weight of the hook block and the slinging tackle must be added to the loads to be hoisted.
CAUTION: The radius display is given corresponding to the entered folding fly jib.
The individual loading capacity per hook during two> hook operations corresponds
to the permissible load given in the appropriate load capacity table for operations
with folding fly jib.
The sum loading capacity corresponds during two>hook operations to the

permissible load given in the appropriated load capacity table for operations with
folding fly jib.
DANGER: Hoisting a load with 2 hooks is only permissible in accordance with diagrams Va.1
and Va.2.
If this is not observed, there is a danger of accidents due to the overloading of the
individual crane components.
Protection via the overload safety device is then no longer provided.
If a load is hoisted in accordance with Va.1, the load must first be completely hoisted to 100% with the most
outer hook.
Note: As soon as the inner hook is drawn, the load display in the overload safety device is
incorrect!.
DANGER: If both hook are loaded, luffing the boom is prohibited!

Protection via the overload safety device is then no longer provided.
For this reason, the load must always be taken up at the maximum radius.
* Special equipment
347
5.00 EQUIPMENT 021678>00
348
021678>00
Chapter 5
Equipment
349
350
Notes on assembly:
> The hoisting cable must be reeved in between the pulley head and hook block in accordance with the
reeving plans in Chap. 4.06, for the respective load capacity table.
> The ballast must be mounted in accordance with the specifications in the load capacity tables.
> Combining and mounting the ballast must be carried out in accordance with Chap. 4.07.
DANGER: For assembly works on the crane, an operationally safe assembly scaffold / working
platform must be used > improvisations are prohibited. Otherwise, there is a danger
of falling.
Assembly / disassembly
If lattice sections are not touching the ground during assembly and / or disassembly, then they must be
supported from below with suitable, stable materials.
DANGER: Make sure that nobody is underneath the lattice jib, especially during when pinning
and unpinning the lattice sections. This is strictly prohibited!
Transport of lattice sections

If the lattice sections are pushed into each other for transport, then they must be secured with 2 chains each.
DANGER: If the lattice sections are not secured, there is a danger of causing a serious
accident, because the inner lattice sections may fall out.
Checking the safety measures
> Is axle suspension / axle floating locked?
> Is the load bearing capacity of the foundation sufficient?
> Are all four sliding arms and support cylinders extended to the support base as indicated in the load
capacity table?
> Are the sliding arms secured with pins?
> Are the support pads secured?
> Is the crane horizontally aligned?
> Is the crane at a safe distance from slopes and trenches?
> Are the axles relieved; i.e., no contact between the tires and the ground?
> Has it been absolutely established that there are not electrical wires and lines within the operating range of
the crane?
> Has the operating site been selected so that operations can be carried out with the smallest possible working
radius?
> Are there any obstacles which would block necessary crane movements?
351
Bypassing the safety devices with the assembly key>operated switch
Parts of the safety device equipment can be bypassed with the assembly key>operated switch. For certain
assembly procedures, this is necessary and permissible.
DANGER: Using the assembly key>operated switch during crane operations is prohibited.
Only those persons may use the key>operated switch who are fully familiar with the
entire operation of the crane and who are aware of the effects of bypassing the
system.
After all assembly work has been carried out, the key must be removed immediately
and handed over to an authorized person.
If the load torque limiter is bypassed during crane operations, there is the danger of
accidents.
Checking the cables
Before assembly and at regular intervals, the cables must be subjected to expert inspection in order to recognize
possible damage and signs of wear.
DANGER: The cables must be taken off the crane immediately if any of the following defects
are found:
> broken strand
> broken wires
> groups of broken wires
> cable diameter 10% or more narrower than the nominal value
> cable deformation
New cables must be of the same design, strength rating and diameter as the old ones.
DANGER: If the hoist cable is spooled up during installation, make sure that the end of the
cable still remains in front of the winch and is not spooled up over the winch,
because if the end of the cable is then pulled over the winch by another turn, the
shut off could no longer be guaranteed when the cable gets to the three safety loops.
In this case, the cam limit switch must be reset.
In addition, if the hoist cable is replaced with a new one, then the cam limit switch
must be reset, so it shuts off when it gets to the point when there are still three safety
loops on the drum.
If this point is not observed, the cable mount can be torn out, causing the load to
fall.
CAUTION: If the cable pulleys are rewound, they must be wound out or replaced before
replacing an old cable with a new one. Otherwise, the new cable can be damaged.
352
Connecting or removing hydraulic lines with quick>release couplings
DANGER: When connecting or removing hydraulic lines by means of the quick>couplers, it

must always be ensured that the coupling procedure is carried out properly.
Requirement for a correct coupling connection is:

> Before any connections are made or loosened,there must be no pressure in the entire pressure system.
(Bring engine to a standstill > wait 5 minutes)
> Assemble the coupler parts (socket and plug) and tighten with hand nut.
> Turn the hand nut until a noticeable, fixed stop is reached.
> The couplers must only be attached and detached by hands > do not use tools as this could damage the
couplers.
DANGER: Improperly connected couplers could lead to a loss of pressure or sudden leaks and
thus lead to an accident.
Raising / Lowering
Before raising or lowering a boom combination, the following requirements must be fulfilled:
Requirements:
> The crane is properly supported and horizontally aligned.
> The ballast is attached to the slewing platform in accordance with the load capacity table.
> The telescopic boom is completely retracted.
> The jib is assembled in accordance with the load capacity tables and instruction manual.
> All limit switches are correctly mounted and properly functioning.
> All pinned connections are secured.
> The hoist cable is properly placed in the cable pulleys and is secured with cable retaining pins against
jumping out.
> There are no loose parts on the telescopic boom or jib.
In winter:
> The telescopic boom and the jib and its components (limit switch, cable drum, aircraft warning light, wind
speed gauge, etc.) are free of snow and ice.
DANGER: Incorrectly mounted or nonfunctioning limit switches as well as falling parts (pins,
spring keepers, ice, etc.) are dangerous and can cause serious injury.
353
5.02 FOLDING JIB > TK 022490>00
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354
5.02 FOLDING JIB > TK 022490>00
Short description
This crane can be equipped with one of two different folding jibs , as desired.
1. Two part folding jib * weighs about 790 kg

Working length 16.0 m
Consists of:
Adapter 2.6 m
Pivot section
End section
2. One part folding jib * weighs about 535 kg

Working length9.6 m
Consists of:
Adapter 2.6 m
Pivot section
The folding jibs can be installed either as a straight extension or at an angle of 15∞ or 30∞ to the telescopic boom
and can be operated on the 30.4 m . . . 40 m extended telescopic boom.
For the installation of the two folding jibs, an hydraulic mechanical installation aid is installed.
For driving on public roads, the folding fly jib is folded on the telescopic boom and mechanically secured.
Angle adjustment (15∞ or 30∞ to the telescopic boom ) for the

two part folding jib (working length 16.0m)
two part folding jib (working length 9.6m) as a short extension,
one part folding jib (working length 9.6m)
The folding jib angle can only be done via the hoist gear with the aid of the special hook block* (Fig. 1) or the
load hook* (Fig. 2) and through sensitive movement of the corresponding manual control lever.
CAUTION : Angle adjustment and crane operation via the folding jib with other hook blocks or
load hooks is not permitted.
*Optional
355
5.02 FOLDING JIB > TK 022490>00
183138
356
5.02 FOLDING JIB > TK 022490>00
Component overview for the two part * folding jib
Pos.:
1 Pin with retainer clip > Swing pin and mount of end section on pivot section of folding jib at(A)
2 Pivot section of folding jib
3 End pulley > on pivot section of folding jib
4 End section of folding jib
5 End pulley > on end section of folding jib
6 Cable guide pulley > Cable guide over folding jib
7 Pin with retainer clip > Swing pin and mount of end section on pivot section (2) of folding jib at te>
lescopic boom head at (C)
8 Pin with spring retainer > Mounting of folding jib on telescopic boom head at (E)
9 . . . 14 > Installation aid for installation of upper pin (E)

9 Bore > (Installation receptacle of pin 11)
10 Bore > (Transport receptacle of pin 11)
11 Pin with spring retainer
12 Hydraulic cylinder
13 Valve
14 Manual pump
15 Pin with spring retainer > Swing pin and lock between folding jib and telescopic boom pivot section at
(D)
16 Lever > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
17 Sleeve > on end section of lever (15)
(to insert installation rod)
18 Bracket > To secure the lever (15) in transport condition
19 Link > To secure the lever (15) when swinging out folding jib
20 Pin with spring retainer > To secure the end section (4) of the folding jib on the pivot section of the
telescopic boom
21 Bore > To take up the pin (20), if the folding jib is installed in a working length
of !8.1m and the end section (4) remains secured on the pivot section of the
telescopic boom.
22 Bore > To take up the pin (20), if the folding jib is installed in a working length
of !14.5m and the end section (4) is folded out together with the pivot sec>
tion (2) of the folding jib .
23 Plastic rope > To release the lock (26) between end and pivot section of the folding jib
24 Pin with spring retainer > Lock for folding jib rest (25) in appropriate end position (in our out)
25 Folding jib rest > at the same time transport retainer (bracket X) of folding jib
26 Lock > To secure the end section (2) on pivot section!(4) of folding jib.
X Bracket > Transport retainer for folding jib
>> Installation rod > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
*Optional
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Installation procedure
DANGER: For the installation, a safe installation base (working platform) must be used, DO
NOT improvise!
There is a danger of falling down and causing a serious accident!.
Prerequisites for the installation of all folding jibs:

> The crane is properly supported and horizontally aligned,
> the counterweight is installed on the counterweight frame, according to the corresponding load capacity chart,
> the telescopic boom is fully telescoped in (retracted) ,
> the folding jib is mounted for transport on the telescopic boom pivot section ,
> the travel and crane engine is running.
> the telescopic boom is positioned to the rear or to the side, luffed down to 0∞ position,
angle indicator is at 0∞, see control and indicator unit of LICCON system.
DANGER: The telescopic boom must be in 0∞ position, otherwise there is a danger of causing a
serious accident because the folding jib might swing out by itself when the locks are
released!
If the folding jib is to be used for work for a longer period of time, then the hook block on the telescopic boom
should be unreeved and the hoist cable for winch 1 should be used when operating the folding jib .
This simplifies work with the folding jib, in addition, this will eliminate the load reduction for the reeved in
hook block on the telescopic boom .
If the hoist cable of winch 2* is used for work with the folding jib, then the hook block on the telescopic boom do>
es not have to be unreeved.
CAUTION : In this case, the load carrying capacities of the folding jib are reduced by the weight
of the reeved in hook block.
Unreeve the hoist cable on the telescopic boom head

> Wind up the hoist cable from hoist gear 2 * all the way onto the cable drum.
DANGER: This work must be done from a stable base.

Extreme caution must be exercised when walking on the telescopic boom.
There is a danger of causing a serious accident due to erroneous control of crane
functions and slipping on the telescopic boom.
> Lock hoist gear 2 via the LICCON system.

> Extend the telescopic boom to about 9.8 m (depending on the length of the folding jib in use) and place the
hook block on the ground,
> on the pulley head of the telescopic boom, release the hoist limit switch weight and the hoist cable on the lock
(cable fixed point).
> Remove the cable retainer bars on the pulley head of the telescopic boom and pull the hoist cable from the pla>
ced down hook block,
> Reinsert the cable retainer bars, secure them with spring clips and telescope the telescopic boom in all the
way.
* Optional
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1.1 Installation of the two part * folding jib with a working length of 9.6 m
The not needed end section (4) of the folding jib remains secured by the retainer pin (20) on the telescopic boom
pivot section.
DANGER: The retainer pin (20) may not be removed.

If this is not observed, the unsecured end section will fall down when the folding jib
swings out, causing a danger to LIFE and DEATH!
Make sure there are no persons or objects within the swing range as well as the fol>
ding range of the telescopic boom and folding jib .
There is a potential danger of causing a serious accident.
> Adjust the LICCON system according to the load capacity chart by entering the CODE number and hoist ca>
ble reeving number for crane operation ∫Crane supported∫, with 9.6 m folding jib, (see separate LICCON
Operation Manual)
Take the two digit CODE number from the load capacity chart.
> Mount an auxiliary rope on the folding point on the pivot section (2) of the folding jib .
> Roll out the wound up plastic rope (23, which is used to release the lock (26) and let it hang down.
Swing out the folding jib rest (25)
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the pi>
vot sections(2) on the telescopic boom pivot section.
> Remove the spring retainer on the pin (24) , hold the ball joint of the pin (24) with one hand, pull it ∫down∫ and
swing the folding jib rest (25) out by hand,
> release the ball joint and continue to swing out the folding jib rest until the pin (24) notches in,
> secure the pin (24) again with the spring retainer.
Swing out the pivot section (2) to the side by 180∞

> Remove the spring clips on both swing pins (A), pull both swing pins (A) out and keep them in the installed
retainers, securing them with spring clips.
> Pull the plastic rope (23) in direction of the arrow Ø to release the lock (26) between the end section (4) and
the pivot section of the folding jib (2) .
CAUTION: During the release procedure at (26), you must hold the folding jib with an auxiliary
rope to prevent it from swinging out by itself.
> Swing the pivot section (2) with the auxiliary rope around its pivot point (D) onto the telescopic boom head un>
til it can be pinned at (C) on top and bottom.
* Optional
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Pin the pivot section (2) on the telescopic boom head

> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secu>
re both pins with retainer clips (7) .
CAUTION : To secure the swing pins on the pivot points ( C) , you MUST USE the special retai>
ner clips (7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!(A and C) is not permitted!
Release the lock (15) on the pivot point (D) between the pivot section (2) and the telescopic boom pivot
section
DANGER: Before releasing the lock, make sure that at (C) both pins are pinned and secured
with the special retainers clips!(7) .
During the release procedure of the folding jib from the telescopic boom, you must
hold the folding jib with the auxiliary rope to prevent it from swinging out by itself.
> Insert the supplied installation rod into the retainer bracket (18) and swing it to the side,
> insert the installation rod into the sleeve (17), push the lever (16) upward and notch it to the left into the brac>
ket !(19) to secure, the link (15) between the folding jib and the telescopic boom pivot section is released.
Swing the pivot section (2) forward

The end section (4) of the folding jib, which is not used, remains pinned (20) to the telescopic boom pivot
section.
DANGER: Make sure there are no persons or objects within the swing range as well as the fol>
> Swing the pivot section (2) with the auxiliary rope by 180∞ around the pivot point (C) to the front, until it can
be pinned at (E) on the bottom.
> Insert a pin at (E) on the bottom and secure with a spring retainer.
Pin the pivot section (2) at (E) on top

The upper pin (E) can only be pinned with the hydraulic > mechanical installation aid!(9 . . . 14) .
> After removing the spring retainer, change the pin (11) over to bore (9) and secure it again with the spring re>
tainer,
> on the manual pump (14) , close the valve (13) and actuate the pump until the fork of the adapter touches the
stop and the upper pin (E) can be inserted.
> Insert the upper pin (E) and secure it with spring retainers.
> Roll the plastic rope (23) up again and remove the auxiliary cable for storage.
CAUTION : When all pins ( 2¥ at C and 2¥ at E) are inserted and secured, the pin (11) in the bo>
re hole (9) must now be relieved on the installation aid by opening the valve (13).
*Optional
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Swing the cable guide pulley (6) "upward"

> After removing the spring retainer, take the retainer pin (32) for the cable guide pulley (6) from its transport
retainer, swing the cable guide pulley from its transport position into operating position ∫upward∫, hold it and
> insert the retainer pin for the cable guide pulley (6) into the bore hole at (31) and secure with spring retainer.
Guide the hoist cable to the pulley head of the folding jib
> Remove the spring retainers and pull out the cable retainer pins (34 and 36) .
> Guide the hoist cable from winch 1 to the end pulley (3)
over the cable guide pulley (6),
through the cable guide (35),
over the end pulley (3)
and between the end pulley (3) and cable guide pulley (37) to the hook block * (to the load hook*).
> Reinsert the cable retainer pins (34 and 36) and secure with spring retainers.
> Reeve the hook block * (load hook *) according to the load carrying capacity chart for operation with 9.6 m fol>
ding jib and hang the end of the cable on the cable fixed point into the cable lock,
> Reinstall the hoist limit switch weight and chain, as described in chapter 4.06 and hang the hoist limit switch
weight onto the hoist cable.
Connect the hoist limit switch

See paragraph 1.5 in this chapter
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1.2 Installation of the two part * folding jib with a working length of 16 m
DANGER: DO NOT REMOVE the two swing pins (A)!.

If this is not observed, the unsecured end section (4) will fall down when the folding
jib swings out, causing a danger to LIFE and DEATH!
ble reeving number for crane operation ∫Crane supported∫, with 16 m folding jib, (see separate LICCON
Operation Manual)
Unreeve the hoist cable on the telescopic boom head

> Wind up the hoist cable from hoist gear 2 * all the way onto the cable drum.
DANGER: This work must be done from a stable base.

Extreme caution must be exercised when walking on the telescopic boom.
There is a danger of a serious accident due to erroneous control of crane functions
and slipping on the telescopic boom.
> Lock hoist gear 2 via the LICCON system.

> Extend the telescopic boom to about 16 m (depending on the length of the folding jib in use) and place the hook
block on the ground,
> on the pulley head of the telescopic boom, release the hoist limit switch weight and the hoist cable on the lock
(cable fixed point).
> Remove the cable retainer bars on the pulley head of the telescopic boom and pull the hoist cable from the pla>
ced down hook block,
> Reinsert the cable retainer bars, secure them with spring clips and telescope the telescopic boom in all the
way.
> Install an auxiliary rope on the folding point on the pivot section (2) of the folding jib,
> install a second auxiliary rope at (5) on the end section of the folding jib ,
> roll out the rolled up plastic rope (23) and let it hang down.
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the fol>
ding jib on the telescopic boom pivot section.
*Optional
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Swing the folding jib (pivot section with end section) to the side by 180∞
> Remove the spring retainer and then pull the retainer pin (20) of the transport retainer, change the pin over to
bore (22) and secure it again with the spring retainer.
CAUTION: When removing the retainer pin (20), make sure to hold the folding jib with the auxi>
liary rope to prevent it from swinging out by itself.
> Swing the folding jib (pivot section with end section) with the auxiliary rope,which is attached to the pivot sec>
tion of the folding jib around its pivot point (D) onto the telescopic boom head, so that it can be pinned at (C) on
the top and bottom.
Pin the folding jib (pivot section with end section) on the telescopic boom head
> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secure
both pins with retainer clips (7).
CAUTION : To secure the swing pins on the pivot points ( A and C) , you MUST USE the special
retainer clips (1 and 7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!(A and C) is not permitted!
Release the lock (15) on the pivot point (D) between the pivot section and the telescopic boom pivot
section.
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Swing the pivot section with end section forward
ding range on the telescopic boom and folding jib .
> Swing the pivot section with the auxiliary rope by 180∞ around the pivot point (C) to the front, until it can be
pinned at (E) on the bottom.
Pin the pivot section at (E) on top

tainer,
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Swing the end section (4) forward
DANGER: During the release procedure of the end section (4) from the pivot section (2), you
must hold the end section with a second auxiliary rope to prevent it from swinging
out by itself.
> Pull the plastic rope (23) in direction of the arrow Ø to release the lock (26) between the end section (4) and
the pivot section of the folding jib (2) .
> Swing the end section with the second auxiliary rope by 180∞ around its pivot point (A) , until it can be pinned
at (B) on top and bottom.
> Insert a pin at (B) on top and bottom and secure both pins with spring retainers.
D A N G E R: All pins must be secured.

If this is not assured, a serious accident can be caused by falling crane sections.
> Remove both auxiliary ropes and roll up the plastic rope (14) .
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Guide the hoist cable to the pulley head of the end section
> Remove the spring retainers and pull out three cable retainer pins (34, 36, and 39) .
CAUTION : The cable retainer pin (36) may not be inserted again.
If this is not observed, the hanging hoist cable will scrape on the pin (36), and be da>
maged.
> Reeve the hook block * (load hook *) according to the load carrying capacity chart for operation with 16 m fol>

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1.3 Installation of the two part * folding jib at an angle of 15∞ to the telescopic boom
Prerequisite:
> The folding jib is installed as a straight extension (0∞ position) , as described in paragraph 1.1 or 1.2 ,
> the crane is properly supported and horizontally aligned,
> the telescopic boom is positioned to the rear or to the side ,
> the hook block * (the load hook *) is reeved according to the load capacity chart,
Installation at an angle of 15∞

> Luff down the telescopic boom to 0∞ , while holding the hook block at about 1 m above the ground.
> Remove the hoist limit switch weight with chain and unhook the hoist cable from the cable lock (cable fixed
point).
CAUTION : The hoist limit switch weight and the chain must be removed to install the folding
jib at an angle.
> Bypass the LICCON overload system by holding the keyed switch in.
> Deflect the corresponding manual control lever very sensitively to bring the hook block * (or the load hook*)
carefully to the stop (38 or 41) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 or 41) of the folding jib, do not teles>
cope the telescopic boom out nor luff it down!
Only if the hook block has been lowered by at least one meter can be telescopic
boom be telescoped out or luffed down.
If this is not observed,the sections of the folding jib and the hoist cable will be over>
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) and raise the bracket (30) a little.
DANGER: The pin (33) may only be unpinned if the end section or the pivot section of the fol>
ding jib is held by the hoist cable.
If this is not observed,there is a danger of causing an accident, as the folding jib will
suddenly ªfold down´ !
> Insert the pin (33) into the corresponding bore for 15∞ and secure it with spring retainers.
*Optional
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> Carefully luff up the telescopic boom to about 10∞ , while simultaneously luffing down the folding jib by lowe>
ring the hook block* (the load hook*), until the bracket (30) is on the pin for the bore for 15∞ (Fig. 5).
> Lower the hook block until it is about 1 m above the ground,
> Luff down the telescopic boom .
D ANGER: When luffing down,

> the hook block may not run up on the pulley head,
> the telescopic boom may not be telescoped out!
onto the hoist cable.
To erect the folding jib, see paragraph 1.6

> Luff up the telescopic boom and telescope it out according to the load capacity chart.
* Optional
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1.4 Installation of the two part * folding jib at an angle of 30∞ to the telescopic boom
Prerequisite:

point).
jib at an angle.
carefully to the stop (38 or 41) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 or 41) of the folding jib, do not teles>
cope the telescopic boom out nor luff it down!
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) , insert it in the transport retainer and secure it with the
spring retainer.
*Optional
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ring the hook block* (the load hook*) (fig. 4),
until the length slot of bracket (30) is on the pin for the bore for 30∞ (Fig. 5).

*Optional
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1.5 Connect the hoist limit switch (HES)
One hook operation

> On the connector box X (on the left hand side of the telescopic boom head), loosen the union nut and then re>
move the plug for the telescopic boom hoist limit switch cable from the socket X 451 .
> Change the dummy plug X 552 from socket X 500 to socket X 451 and tighten the union nut.
> Insert the plug of the hoist limit switch cable of the folding jib into socket X 500 and tighten the union nut.
> Attach the hoist limit switch weight.
Two hook operation
CAUTION : In two hook operation, the dummy plug X 552 must be removed and the plug of the
cable for the host limit switch for the folding jib must be connected to socket X 500 .
To remove the hoist limit switch

> Change the dummy plug X 552 again to socket X 500 and insert the hoist limit switch of the telescopic boom
into socket X 451 , tighten the union nut.
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1.6 To erect the two part * folding jib
Prerequisites:
> the telescopic boom is fully telescoped in (retracted) ,
> the folding jib is mounted according to the load capacity chart and the operating manual,
> all limit switches are correctly installed and are fully functioning.
> the hoist cable has been inserted correctly into the cable pulleys and is secured with cable retainer pins to pre>
vent it from jumping out.
> There are no loose parts on the telescopic boom and folding jib,
In Winter:
> The telescopic boom, the folding jib and their components, such as limit switch, cable drums, airplane war>
ning light*, wind velocity sensor* etc.) must be free of ice and slow.
DANGER: Improperly installed on non>functioning limit switches as well as falling parts, such
as pins, spring retainers, ice, etc. can cause accidents!
To erect
> Enter and confirm the operating mode >TK>, according to the installed folding jib (length 16.0m or 9.6m
and the installation angle !(0∞,!15∞!or!30∞) as well corresponding data from the load capacity chart into
the LICCON system.
> Luff up the telescopic boom with installed folding jib to the steepest telescopic boom position (fig.!3) and
> telescope the telescopic boom out to the telescopic boom length given in the load capacity chart.
DANGER: Telescoping in and out with installed folding jib is only permitted if the telescopic
boom is at its steepest position.
If this is not observed, it can cause an accident !
The radii given in the load capacity chart may not be exceeded or fallen below ,
even if there is no load on the hook!
If this is not observed, then the crane can tip over!
* Optional
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1.7 Crane operation with 16 m long two part * folding jib
The folding jib may be operated on the following boom lengths:
Telescopic boom length [m] 30,4 33,7 37 40 30,4 37 40

Folding jib length [m] 9,6 9,6 9,6 9,6 16 16 16
Telescopic section 1 extended [ % ] 0 90 90 100 0 90 100
Telescopic section 2 extended[ % ] 90 75 90 100 90 90 100
CAUTION : The guidelines given in the load capacity chart for crane operation with
folding jib must be observed.
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1.8 Removal procedure of the two part * folding jib
Prerequisites :
> the folding jib is installed at an angle of 15∞ or 30 to the telescopic boom ,
> the telescopic boom is luffed up to 80∞ position,
> the folding jib rest is folded out and secured,
First, the folding jib must be changed over again to a straight extension in 0∞ position to the telescopic boom he>
ad.
DANGER: For the installation, a safe installation base (working platform) must be used, do not
improvise!
To change the folding jib from 15∞ to 0∞

> In the LICCON program TK, 15∞, telescope the telescopic boom with installed folding jib fully in.
> Luff down the telescopic boom until the hoist limit switch weight can be removed on the end section of the fol>
ding jib, to do so, hold the hook block * (the load hook*) about 1m to 1.5m above the ground,
> On the hoist limit switch, take off the weight and chain and store it in the toolbox .
> Bypass the LICCON overload safety device by holding in the keyed switch,
> through sensitive movement of the corresponding manual control lever, carefully bring the hook block* (the
load hook *) to the stop (38 or 41) on the end section of the folding jib and pull it up via the hoist gear, while
luffing the telescopic boom down at the same time, until the folding jib is at 0∞ position (stops on the bracket
30) (Fig. 2)
CAUTION : As soon as the folding jib is at 0∞, stop the ªup´ and ªluffing´ movement immediate>
ly.
> Remove the spring retainer and take the pin (33) from the 15∞ bore hole, pin it into the (0∞) bore hole and secu>
re it with the spring retainer. (Fig. 3)
*Optional
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To change the two part* folding jib from 30∞ to 0∞
> Luff down the telescopic boom until the hoist limit switch weight can be removed, to do so, hold the hook block
* (the load hook*) about 1 m to 1.5 m above the ground,
> On the hoist limit switch, remove the weight and chain and store it in the tool box.
load hook *) to the stop (38 or 41) on the end section of the folding jib and pull it up via the hoist gear, while
luffing the telescopic boom down at the same time, until the folding jib is at 0∞ position (stops on the bracket
30) (Fig. 6)
ly.
> Remove the spring retainer and take the pin (33) from the transport retainers, pin it into the (0∞) bore hole and
secure it with the spring retainer. (Fig. 5)
*Optional
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Changing the two part * folding jib from 0∞ into transport position
> Luff down the telescopic boom to 0∞, check LICCON operating and control unit for angle indicator for 0.
> Lower the hook block * (load hook *) and place it on the ground,
> Unhook the hoist cable from the cable lock (cable fixed point) .
DANGER : The telescopic boom must be in 0∞ position, otherwise there is a danger of accidents
because the folding jib can swing in by itself when the pins are released!
> Remove the spring retainers and pull out the cable retainer pins (39) on the end pulley and (34) on the cable
guide pulley (6),
> lift the hoist cable from the pulleys (5 and 6) and let it hang down next to the folding jib .
> Insert the cable retainer pins (34, 36, and 39) and secure with spring retainers.
Swing the cable guide pulley (6) into transport position ªdownward´
> On the retainer pin (32) , remove the spring, slightly lift the cable guide pulley (6) with one hand and pull out
the pin (32) ,
> swing the cable guide pulley (6) all the way ∫down∫ to the stop, insert the pin (32) into the bore hole!(31) and
secure with the spring retainer.
*Optional
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To change the two part * folding jib from 0∞ to transport position
Swing the end section (4) to the rear
DANGER: The two swing pins (A) ) may not be removed.

If this is not observed, the unsecured end section (4) will fall down when the folding
jib swings in, causing a danger to LIFE and DEATH!
> Attach an auxiliary rope to the pivot section of the folding jib ,
> attach a second auxiliary rope to the end section of the folding jib .
> At (B) on the top and bottom unpin both pins after removing the spring retainers, and insert both pins into the
installed transport retainers and secure with spring retainers.
DANGER: While unpinning the two pins (B), hold the end section with an auxiliary rope to pre>
vent it from swinging by itself.
> Swing the end section (4) with the auxiliary rope by 180∞ around the pivot point (A) to the rear onto the pivot
section (2) until the lock (26) engages.
*Optional
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5.02 FOLDING JIB > TK 022490>00
Swing the two part folding jib (pivot section with end section ) to the side by 180∞ to the rear
DANGER: The two swing pins (C) may not yet be removed.
If this is not observed, the unsecured folding jib will fall down when it is moved,
causing a danger to LIFE and DEATH!
Release the pin between the pivot section (2) and the end section of the telescopic boom at (E)
Note: The upper pin (E) can only be unpinned with the hydraulic >mechanical installation aid (9 . .
. 14) .
> On the manual pump (14) , close the valve (13) and actuate the pump until the upper pin (E) can be removed
by hand.
> Remove the spring retainer and take out the upper pin (E) , insert it into the transport retainer and secure it
with spring retainer.
> On the installation aid, remove the spring retainer and pull the pin (11) from the bore (9), reinsert it in bore
(10) and secure again with the spring retainer,
> on the hand pump (14), open valve (13) .
DANGER: The lower pin (E) may only be unpinned, if the folding jib is being held with an au>
xiliary rope, to prevent it from swinging by itself.
> Hold the folding jib with the auxiliary rope and
> at (E) on the bottom, remove the pin after removing the spring retainer,insert the pin into the installed trans>
port retainer and secure with spring retainer.
> Insert the installation rod into the retaining bracket (18) , swing it to the side until the snub is on the retai>
ning bracket next to the lever (16) ,
> place the installation rod down .
> Swing the folding jib with the auxiliary rope by 180∞ around the pivot point (C) to the rear onto the pivot sec>
tion , until the lock (15) engages at the pivot point (D) .
> Insert the installation rod into the retaining bracket (18) , swing the retaining bracket to the center to the
snub of the retaining bracket is over the lever and secure it.
> Store the installation rod in the tool box.
399
5.02 FOLDING JIB > TK 022490>00
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400
5.02 FOLDING JIB > TK 022490>00
Release the folding jib from the telescopic boom head

Release the pin between the pivot section (2) and the end section of the telescopic boom at (C) .
DANGER: Before unpinning the two pins (C) it must be assured that the lock (15) is engaged .
causing a serious ACCIDENT!
> At (C), unpin both pins after removing the retainer clips, insert them into the transport receptacles and secu>
re them with the retainer clips .
> Pull the folding jib with the auxiliary rope to the pivot section and secure the end section of the folding jib on
the telescopic boom pivot section ( in transport retainer. )
> Remove the spring retainer and remove the pin (20) from its retainer (22) and insert it into the bore hole for
the transport retainer (21) , secure with spring retainer.
Secure the folding jib on the telescopic boom pivot section (transport retainer X)
> Swing in the folding jib rest (25) .
Note: Due to the folded front section of the folding jib rest, (25) the retainer bracket(X) , which is
welded onto the folding jib is ªtensioned´ , securing the folding jib for transport.
swing the folding jib rest (25) in by hand,
> release the ball joint and continue to swing in the folding jib rest until the pin (24) notches in,
DANGER: The pin (24) must be notched in and secured with the spring retainer. If this is not
assured, the the folding jib is unsecured and can swing out by itself, causing an AC>
CIDENT.
> Remove both auxiliary ropes and store them.

> Telescope the telescopic boom out to the hook block,
> remove the spring retainers and pull out the cable retainer bars on the telescopic boom head and on the hook
block and reeve the hook block,
> on the telescopic boom head and on the hook block, reinsert the cable retaining bars and secure with spring re>
tainers.
> Hang the cable end on the cable fixed point in the cable lock and the hoist limit switch weight on the hoist ca>
ble, as described in chapter 4.06 .

Refer to paragraph 1.5 in this chapter
Secure the hook block for transport

> Telescope the telescopic boom in, while holding the hook block about 1 m to 1.5 m above the ground and
> attach the hook block, as described in chapter 2.04 , to the front bumper.
401
5.02 FOLDING JIB > TK 022490>00
183409
402
5.02 FOLDING JIB > TK 022490>00
Component overview for the one part * folding jib
Pos.:
1 Reserved
2 Folding jib
3 End pulley
4 Reserved
5 Reserved
6 Cable guide pulley > Cable guide over folding jib
7 Pin with retainer clip > Swing pin and mount of folding jib at telescopic boom head at (C)
8 Pin with spring retainer > Mounting of folding jib on telescopic boom head at (E)
9 . . . 14 > Installation aid for installation of upper pin (E)

9 Bore > (Installation receptacle of pin 11)
10 Bore > (Transport receptacle of pin 11)
11 Pin with spring retainer
12 Hydraulic cylinder
13 Valve
14 Manual pump
15 Pin with spring retainer > Swing pin and lock between folding jib and telescopic boom pivot section at
(D)
16 Lever > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
17 Sleeve > on end section of lever (15)
(to insert installation rod)
18 Bracket > To secure the lever i (15) in transport condition
19 Link > To secure the lever (15) when swinging out folding jib
20 Reserved
21 Reserved
22 Reserved
23 Reserved
24 Pin with spring retainer >Lock for folding jib rest (25) in appropriate end position (in our out)
25 Folding jib rest > at the same time transport retainer (bracket X) of folding jib
26 Reserved
>> Installation rod > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
*Optional
403
5.02 FOLDING JIB > TK 022490>00
183409
404
5.02 FOLDING JIB > TK 022490>00
2.1 Installation of the one part * folding jib with a working length of 9.6 m
ble reeving number for crane operation ∫Crane supported∫, with 9.6 m folding jib, (see separate LICCON
Operation Manual)
> Mount an auxiliary rope on the folding point on the pivot section (2) of the folding jib .
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the pi>
vot sections(2) on the telescopic boom pivot section.
During the release procedure of the folding jib rest (25), you must hold the folding
jib with an auxiliary rope to prevent it from swinging out by itself.
Swing out the pivot section to the side by 180∞
D A N G E R: Make sure there are no persons or objects within the folding range of the telescopic
boom and the folding jib, or it can cause a serious accident .
> Swing the pivot section (2) with the auxiliary rope around its pivot point (D) onto the telescopic boom head un>
til it can be pinned at (C) on top and bottom.
Pin the folding jib on the telescopic boom head

> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secu>
re both pins with retainer clips (7) .
CAUTION : To secure the swing pins on the pivot points ( C) , you MUST USE the special retai>
ner clips (7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!( C) is not permitted!
* Optional
405
5.02 FOLDING JIB > TK 022490>00
183409
406
5.02 FOLDING JIB > TK 022490>00
Release the lock (15) on the pivot point (D) between the pivot section (2) and the telescopic boom pivot
section
Swing the pivot section (2) forward
> Swing the pivot section (2) with the auxiliary rope by 180∞ around the pivot point (C) to the front, until it can
be pinned at (E) on the bottom.
Pin the pivot section (2) at (E) on top

tainer,
*Optional
407
5.02 FOLDING JIB > TK 022490>00
183466
408
5.02 FOLDING JIB > TK 022490>00

Guide the hoist cable to the pulley head of the folding jib
> Remove the spring retainers and pull out the cable retainer pins (34 and 36) .
> Reeve the hook block * (load hook *) according to the load carrying capacity chart for operation with 9.6 m fol>

409
5.02 FOLDING JIB > TK 022490>00
183467
410
5.02 FOLDING JIB > TK 022490>00
2.3 Installation of the one part * 8.1 m long folding jib at an angle of 15∞ to the telescopic boom
Prerequisite:
> The folding jib is installed as a straight extension (0∞ position) , as described in paragraph 2.1 ,

point).
jib at an angle.
carefully to the stop (38 ) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 ) of the folding jib, do not telescope
the telescopic boom out nor luff it down!
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) and raise the bracket (30) a little.
> Insert the pin (33) into the corresponding bore for 15∞ and secure it with spring retainers.
*Optional
411
5.02 FOLDING JIB > TK 022490>00
183468
412
5.02 FOLDING JIB > TK 022490>00
ring the hook block* (the load hook*), until the bracket (30) is on the pin for the bore for 15∞ (Fig. 5).


> Luff up the telescopic boom and telescope it out according to the load capacity chart.
* Optional
413
5.02 FOLDING JIB > TK 022490>00
183469
414
5.02 FOLDING JIB > TK 022490>00
2.4 Installation of the one part *, 8.1 m long folding jib at an angle of 30∞ to the telescopic boom
Prerequisite:

point).
jib at an angle.
carefully to the stop (38 ) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 ) of the folding jib, do not telescope
the telescopic boom out nor luff it down!
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) , insert it in the transport retainer and secure it with the
spring retainer.
*Optional
415
5.02 FOLDING JIB > TK 022490>00
183470
416
5.02 FOLDING JIB > TK 022490>00
> Carefully luff up the telescopic boom to about 20∞, while simultaneously luffing down the folding jib by lowe>
ring the hook block* (the load hook*) (fig. 4),
until the length slot of bracket (30) is on the pin for the bore for 30∞ (Fig. 5).

2.5 Connect the hoist limit switch (see paragraph 1.5)
2.6 Erect the folding jib, see paragraph 1.6
*Optional
417
5.02 FOLDING JIB > TK 022490>00
183407
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5.02 FOLDING JIB > TK 022490>00
2.7 Crane operation with 9.6 m long one part * folding jib
The folding jib may be operated on the following boom lengths
Telescopic boom length [m] 30,4 33,7 37 40 30,4 37 40

Folding jib length [m] 9,6 9,6 9,6 9,6 16 16 16
Telescopic section 1 extended[ % ] 0 90 90 100 0 90 100
CAUTION : The guidelines given in the load capacity chart for crane operation with
folding jib must be observed.
419
5.02 FOLDING JIB > TK 022490>00
183471
420
5.02 FOLDING JIB > TK 022490>00
2.8 Removal procedure of the one part folding jib
Prerequisites :
> the folding jib is installed at an angle of 15∞ or 30 to the telescopic boom ,
> the telescopic boom is luffed up to 80∞ position,
> the folding jib rest is folded out and secured,
First, the folding jib must be changed over again to a straight extension in 0∞ position to the telescopic boom he>
ad.
DANGER: For the installation, a safe installation base (working platform) must be used, do not
improvise!
To change the one part folding jib from 15∞ to 0∞
> Luff down the telescopic boom until the hoist limit switch weight can be removed on the end section of the fol>
ding jib, to do so, hold the hook block * (the load hook*) about 1m to 1.5m above the ground,
> On the hoist limit switch, take off the weight and chain and store it in the toolbox .
load hook *) to the stop (38) on the end section of the folding jib and pull it up via the hoist gear, while luffing
the telescopic boom down at the same time, until the folding jib is at 0∞ position (stops on the bracket 30) (Fig.
2)
ly.
> Remove the spring retainer and take the pin (33) from the 15∞ bore hole, pin it into the (0∞) bore hole and secu>
re it with the spring retainer. (Fig. 3)
*Optional
421
5.02 FOLDING JIB > TK 022490>00
183472
422
5.02 FOLDING JIB > TK 022490>00
To change the one part folding jib from 30∞ to 0∞
> Luff down the telescopic boom until the hoist limit switch weight can be removed, to do so, hold the hook block
* (the load hook*) about 1 m to 1.5 m above the ground,
> On the hoist limit switch, remove the weight and chain and store it in the tool box.
load hook *) to the stop (38) on the end section of the folding jib and pull it up via the hoist gear, while luffing
the telescopic boom down at the same time, until the folding jib is at 0∞ position (stops on the bracket 30) (Fig.
6)
ly.
> Remove the spring retainer and take the pin (33) from the transport retainers, pin it into the (0∞) bore hole and
secure it with the spring retainer. (Fig. 5)
*Optional
423
5.02 FOLDING JIB > TK 022490>00
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424
5.02 FOLDING JIB > TK 022490>00
Changing the one part, 8.1 m long folding jib from 0∞ into transport position
> Luff down the telescopic boom to 0∞, check LICCON operating and control unit for angle indicator for 0.
> Lower the hook block * (load hook *) and place it on the ground,
> Unhook the hoist cable from the cable lock (cable fixed point) .
DANGER : The telescopic boom must be in 0∞ position, otherwise there is a danger of accidents
because the folding jib can swing in by itself when the pins are released!
> Remove the spring retainers and pull out the cable retainer pins (36) on the end pulley and (34) on the cable
guide pulley (6),
> lift the hoist cable from the pulleys (3 and 6) and let it hang down next to the folding jib .
> Insert the cable retainer pins (34 and 36) and secure with spring retainers.
Swing the cable guide pulley (6) into transport position ªdownward´
> On the retainer pin (32) , remove the spring, slightly lift the cable guide pulley (6) with one hand and pull out
the pin (32) ,
> swing the cable guide pulley (6) all the way ∫down∫ to the stop, insert the pin (32) into the bore hole!(31) and
secure with the spring retainer.
425
5.02 FOLDING JIB > TK 022490>00
183474
426
5.02 FOLDING JIB > TK 022490>00
Swing the one part folding jib to the side by 180∞ to the rear
DANGER: The two swing pins (C) may not yet be removed.
causing a danger to LIFE and DEATH!
Release the pin between the folding jib (2) and the end section of the telescopic boom at (E) (fig. 7).
Note: The upper pin (E) can only be unpinned with the hydraulic >mechanical installation aid (9 . .
. 14) .
> Attach an auxiliary rope to the end section of the folding jib.
> On the manual pump (14) , close the valve (13) and actuate the pump until the upper pin (E) can be removed
by hand.
> Remove the spring retainer and take out the upper pin (E) , insert it into the transport retainer and secure it
with spring retainer.
> On the installation aid, remove the spring retainer and pull the pin (11) from the bore (9), reinsert it in bore
(10) and secure again with the spring retainer,
> on the hand pump (14), open valve (13) .
DANGER: The lower pin (E) may only be unpinned, if the folding jib is being held with an au>
xiliary rope, to prevent it from swinging by itself.
> Hold the folding jib with the auxiliary rope and
> at (E) on the bottom, remove the pin after removing the spring retainer,insert the pin into the installed trans>
port retainer and secure with spring retainer.
> Insert the installation rod into the retaining bracket (18) , swing it to the side until the snub is on the retai>
ning bracket next to the lever (16) ,
> place the installation rod down .
> Swing the folding jib with the auxiliary rope by 180∞ around the pivot point (C) to the rear onto the pivot sec>
tion , until the lock (15) engages at the pivot point (D) .
> Insert the installation rod into the retaining bracket (18) , swing the retaining bracket to the center to the
snub of the retaining bracket is over the lever and secure it.
> Store the installation rod in the tool box.
Release the pin between the folding jib (2) and the end section of the telescopic boom at (C) (fig. 8)
DANGER: Before unpinning the two pins (C) it must be assured that the lock (15) is engaged .
causing a serious ACCIDENT!
> At (C), unpin both pins after removing the retainer clips, insert them into the transport receptacles and secu>
re them with the retainer clips .
> Pull the folding jib with the auxiliary rope to the pivot section .
427
5.02 FOLDING JIB > TK 022490>00
183474
428
5.02 FOLDING JIB > TK 022490>00
Secure the folding jib on the telescopic boom pivot section (transport retainer X)
> Swing in the folding jib rest (25) .
Note: Due to the folded front section of the folding jib rest, (25) the retainer bracket(X) , which is
welded onto the folding jib is ªtensioned´ , securing the folding jib for transport.
swing the folding jib rest (25) in by hand,
> release the ball joint and continue to swing in the folding jib rest until the pin (24) notches in,
DANGER: The pin (24) must be notched in and secured with the spring retainer. If this is not
assured, the the folding jib is unsecured and can swing out by itself, causing an AC>
CIDENT.
> Remove the auxiliary rope and store it.

> Telescope the telescopic boom out to the hook block,
> remove the spring retainers and pull out the cable retainer bars on the telescopic boom head and on the hook
block and reeve the hook block,
> on the telescopic boom head and on the hook block, reinsert the cable retaining bars and secure with spring re>
tainers.
> Hang the cable end on the cable fixed point in the the cable lock and the hoist limit switch weight on the hoist
cable, as described in chapter 4.06 .

Refer to paragraph 1.5 in this chapter
Secure the hook block for transport

> Telescope the telescopic boom in, while holding the hook block about 1 m to 1.5 m above the ground and
> attach the hook block, as described in chapter 2.04 beschrieben, on the front bumper.
429
5.10 MAST STUB 022959>00
184479
430
5.10 MAST STUB 022959>00
Operation with mast stub* on telescopic boom head

This function is available for quick lifts (with winch 2) via the mast stub, the hook block (winch 1) remains ree>
ved on the telescopic boom head.
CAUTION : You may work maximum 2sheeve with the mast stub.
The radius and load indication by the LICCON safe load indicator is not exact in
this case, because the mast stub is not taken into account in the boom geometry.
DANGER: The reeving on the telescopic boom must be the same or higher than the reeving on
the mast stub.
If this is not assured, than the hoist gear 1 or the hoist cable can be overloa>
ded.
The LICCON safe load indicator must be set to the smaller reeving of the two
hooks, and the CODE NO. for the corresponding boom length must be entered.
The hoist limit switch on the mast stub must be connected.
The load on the mast stub may not be raised from the ground by luffing
up the telescopic boom .
It must be raised from the ground via the hoist gear.
Component overview, Fig. 1
Pos.:
1 Mast stub
2 Hoist limit switch on mast stub
3 Cable retainer pin with spring clip on the mast stub
4 Hoist limit switch weight with chain on the mast stub
5 Adapter
6 Screw coupling for hoist limit switch electric system
7 Bore to take on the retaining pin (9) in operating position
8 Bore to take on the spring clip (9) in transport position
9 Bore to take on the swing pin (12)
10 Retaining pin
11 Spring clip for retaining pin (10)
12 Swing pin with shim and cotter pin
13 Hoist limit switch on telescopic boom head

14 Connector box for hoist limit switch (2) on mast stub and hoist limit switch (13) on telescopic boom head
15 Cable retaining pin on telescopic boom head
*Optional
431
5.10 MAST STUB 022959>00
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5.10 MAST STUB 022959>00
1. Installation of mast stub on telescopic boom head
1.1 Swing mast stub (1) from transport position into operating position , Fig. 2
CAUTION : The swing pin (12) may not be unpinned.
> On the retaining pin (10), remove the spring clip (11) ,
> Support the mast stub (1) with one hand, hold the retaining pin (10) on the handle, pull it from the bore
(8) and swing the mast stub downward.
1.2 Secure the mast stub in operating position , Fig. 3

> Insert the retaining pin (10) into the bore hole (7) and secure it with the spring clip (11) .
1.3 For hoist cable guide and reeving on the mast stub, see chapter 4.06, CABLE REEVING.
CAUTION : Work from a safe and stable place. Be extremely careful when walking on the te>
lescopic boom .
There is a great danger of having an accident due to erroneous crane control
and due to slipping on the telescopic boom .
> On the telescopic boom head, remove the spring clip and pull the cable retaining pin (15) and the cable
retaining pin !(3) on the mast stub,
> guide the hoist cable from the auxiliary hoist gear (winch 2) via the 2nd pulley on the telescopic boom he>
ad and via the cable pulley of the mast stub, Fig. 3
> reinsert the two cable retaining pins (3, 15) and secure them with spring clips.
> Attach the load hook and the host limit switch weight (4) with chain, as described in chapter 4.06, CA>
BLE REEVING.
*Optional
433
5.10 MAST STUB 022959>00
184480
434
5.10 MAST STUB 022959>00
2. Connect the hoist limit switch (HES)
> On the mast stub, insert the plug on the cable from the hoist limit switch (2) into the socket (6) and
tighten the screw connection on the union nut.
> On the connector box X , remove the dummy plug X 552 , Fig. 4.
> Insert the plug of the hoist limit switch cable of the mast stub into the socket X 500 and tighten the screw
connection on the union nut.
DANGER: The hoist limit switch (2) on the mast stub must be connected to the socket X552.
Incorrectly mounted or malfunctioning limit switches can cause accidents.
2.1 To remove the hoist limit switch

> On the plug of the hoist limit switch cable on the mast stub, loosen the screw connection on the union nut
and remove the plug from the socket X 500 .
> Reinsert the dummy plug X 552 into the socket X 500 and tighten the screw connection on the union nut.
3. Erect the telescopic boom with the mast stub
> Enter the operating mode > T >, the cable reeving, according to the reeving on the mast stub and the CO>
DE!No. according to the current boom length into the LICCON safe load indicator system and confirm the
entries.
For details about the operation of the LICCON safe load indicator system, refer to the separate, more de>
tailed LICCON!Operation manual.
> Luff up the telescopic boom with the installed mast stub and telescope it out to the length given in the lo>
ad capacity chart.
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5.10 MAST STUB 022959>00
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5.10 MAST STUB 022959>00
3. Turn the mast stub into transport position, Fig. 5
CAUTION : DO NOT unpin the swing pin (12) !
> On the mast stub, remove the load hook, as described in chapter 4.06 CABLE REEVING,
> remove the hoist limit switch weight (4) with chain and store it in the tool box.
> Carefully spool up the hoist cable from the mast stub to winch 2 ,
> lock winch 2 via the LICCON safe load indicator system.
3.1 Secure the mast stub in transport position, Fig. 5 and 6
> On the retaining pin (10), remove the spring clip (11) ,
> Grasp the retaining pin (10) on the handle, pull it from the bore !(7) , swing the mast stub upward and
hold it in this position ,
> now reinsert the retaining pin (10) into the bore (8) and secure it with the spring clip (11) .
> Change over the hoist limit switch, as described in paragraph 2.1 in this chapter.
437
6.00 ADDITIONAL EQUIPMENT 021679>00
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021679>00
Chapter 6
Additional Equipment
439
6.01 HEATER / ENGINE PREHEAT SYSTEM * 023228>00
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6.01 HEATER / ENGINE PREHEAT SYSTEM* 023228>00
1. Heater > driverπs cab

The driverπs cab can be heated with two* separate heater systems.
1.1 Engine dependent heater system

The heat for the driverπs cab is supplied by the engine coolant, it can be regulated via the temperature
regulator (12) and used to heat the cab.
Via regulator (13) , you can chose between fresh air or air circulation.
The air distribution to the top or bottom can be preselected via the regulator (14) .
Via a 3$stage blower switch (15), the heated air flow can be regulated.
Both doors and the side windows must remain closed.
1.2 Engine independent WEBASTO added heater*

For detailed description of the WEBASTO added heater, refer to the manufacturerπs operation manual.
The engine independent heater is used to preheat the travel motor as well as to heat the driverπs cab
when the engine is not running, and as a auxiliary heating system in extremely low ambient
temperatures, when the engine dependent heater is not sufficient.
D A N G E R : The heater may not be operated in closed areas (such as garages or workshops),
that includes timer operation* or telestart*.
If this rule is not observed, there is a danger of poisoning and suffocation!
On gas stations and refueling stations, the heater must be turned off.
If this rule is not observed, there is a danger of EXPLOSION!
1.2.1 Added heater* used as heater when the travel motor is not running.
> Turn the blower switch (15) to stage 1, set the temperature regulator (12) to ∫WARM∫ and turn on
the added heater with switch (137) , the indicator light (81) lights up.
Use the sliding regulator (12) to regulate the amount of coolant and the blower switch (15) to regulate
the air flow.
1.2.2 Preheating the engine* with the WEBASTO added heater

In temperatures below $15 ∞C, the travel motor can be preheated with the added heater.
> Turn the cab heater to ∫COLD∫ with the sliding regulator (12) .
> With switch (137) , turn on the added heater, the indicator light (81) lights up.
Now the coolant fluid of the travel motor is being preheated via the added heater.
In low temperatures, this engine preheating process can take an hour or more.
* Optional
441
185295
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1.2.3 To bleed the system
When draining the engine coolant fluid, the contents of the heating system must also be drained,
because the engine coolant system and heater system are part of the same single circuit.
When refilling the system, it must be bled carefully. This can be done quickly if the system is bled via
the engine.
> Add coolant via the expansion tank for the engine cooling system, according to the lubrication chart.
> Open the bleeder valve on the bleeder line of the added heater.
> Start the engine as described in chapter 3.04 "Driving", paragraph 1 and 2.
> Move the temperature regulator (12) to ™WARM™ .
> Watch the expansion tank if air bubbles rise up.

> If no more air bubbles are visible in the expansion tank, then move the temperature regulator (12) to
™COLD∫, now the heating circuit is being bled.
If now no more air bubbles are visible in the expansion tank, then this circuit is also bled properly.
CAUTION : The valve on the bleeder line must always be closed during operation!
The battery master switch (25) may only be turned off after the heater has
stopped running !
If arc welding must be done on the crane, remove the negative and positive
battery cable from the vehicle and the crane superstructure batteries to
protect the heater controls. Attach the positive cable to the vehicle ground.
Note:
During the summer months, run the added heater system (s)* once a month for about 15 to 20 minutes.
For details about the WEBASTO added heater maintenance, refer to the separately issued
manufacturerπs operation manual.
* Optional
443
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1.3 Air conditioning system > driverπs cab*

The driverπs cab can be cooled with an air conditioner.
Refer to the Operating Manual supplied by the air conditioner manufacturer for detailed information.
To put the system into service

> Turn on the main battery switch on (25) and also turn on the ignition.
> Move the sliding regulator (12) to ∫COLD™.
> Close the sliding regulator (13) for fresh air / circulation.
> Turn on the air conditioning system via switch (109) , the illuminated indicator light (67) shows that
the system is operational.
> Preselect the air flow to the top or bottom via regulator (14) ,
> Turn the blower on via rotary switch (15) ,
> Close the doors and windows.
> Regulate the temperature with the rotary knob (140) .
Maintenance of air conditioning system*

* Optional
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2. Heater > crane cab

The crane cab can be heated with two* separate heater systems.
2.1 Engine independent with Diesel fuel working WEBASTO heater*

For detailed description of the WEBASTO added heater, refer to the manufacturerπs operation manual.
The crane operatorπs cab is heated with a water circulation, the amount of heat for the cab heater is
regulated via a temperature regulator (252) .
The amount of air coming into the cab can be regulated via a 3$ stage blower switch (251).
Via switch (232), the driver can choose between fresh air and air circulation.
Upward or downward air flow can be adjusted by opening or closing the air vents (255).
2.2 Engine independent with fluid gas working TRUMATIK heater*

Please refer to the more detailed manufacturer's operation manual.
The crane operatorπs cab is heated with a water circulation, the amount of heat for the cab heater is
regulated via the thermostat (4) .
2.1.1 Operation:
> Turn the blower switch (251) to stage 1.
> move the temperature regulator (252) to ∫WARM∫ and turn the auxiliary heater on via switch (227),
indicator light (226) will light up.
By moving the sliding regulator (252), the amount of water can be regulated and via the blower
switch!(251) the air flow amount can be regulated.
DANGER: The heater may not be operated in closed areas, such as garages or
workshops, not even with timer operation* or Tele start*.
If this rule is not followed, there is a danger of poison or suffocation!
The heater must be turned off at gasoline stations.

If this rule is not followed, there is a danger of causing an EXPLOSION!
2.1.2 Thermostat*
The desired temperature in the cab can be preselected on the thermostat .
To do so, set the temperature regulating valve (252) to ∫WARM∫ .
* Optional
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2.2.1 The TRUMATIC* auxiliary heater

For detailed information about the TRUMATIC auxiliary heater, refer to the manufacturerπs
operation manual .
DANGER: The gas operated heater MAY NOT BE OPERATED at gasoline stations and
in closed areas, such as garages and workshops.
If this rule is not followed, there is a danger of causing an EXPLOSION!
2.2.2 Operation
> On the crane chassis, turn the main battery switch (25) on.
> In the cran cab, turn on the ignition for the crane engine
> Remove the chimney cover for the auxiliary heater.
> Open the valve on the gas bottle and the quick closure valve in the gas line (rear right, below the
crane operatorπs cab).
> Preselect the air flow direction (upward or downward) by closing or opening the air vents (255) .
> Switch the knob (253) to air circulation.
> Close both windows and the cab door.
Note: Make sure that the air intake for air circulation is free and clear of any obstructions.
> Set the desired room temperature on the rotary knob ‘ and turn the temperature regulator valve
(252) to ªWARM´ (open it all the way),
> turn the switch ” to ªHEAT´ and turn switch “ to the desired power.
At low ambient temperatures, run the heater at full power.
Note: If the indicator light — stays on all the time, then there might be a problem, such as
lack of gas, air in the gas line, dirty fan, or defect of a safety item.
Turn the switch ” off and turn the heater on again to check if there is still a
problem .
The temperature can be regulated via the temperature regulator valve (4) and the air flow can be
regulated via the blower switch (3) .
Maintenance of the TRUMATIC* auxiliary heater

Carry out maintenance according to the manufacturerπs instructions. For detailed information, refer
to the manufacturer's operation manual .
C A U T I O N : In Germany, the gas system must be rechecked every 2 years by a DVFG

expert.
The operator is responsible to initiate and schedule this service and system
check up.
In other countries, always make sure to adhere to and observe any rules and
regulations applicable to the locality, state or country.
For your safety, make sure that the gas installation system and the unit is
checked by an expert in regular intervals, but at least every 2 years .
*Optional
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To bleed the system .

When refilling the system, it must be bled carefully.
> Add coolant via the expansion tank for the crane engine cooling system, according to the lubrication chart.
> Open the bleeder valve on the bleeder line of the added heater and turn the heater on.
> Move the temperature regulator (252) to ™WARM™ .
> Watch the expansion tank of the crane engine cooling system if air bubbles rise up.
> If now no more air bubbles are visible in the expansion tank, then this circuit is also bled properly.
CAUTION: The battery master switch (25) may only be turned off after the heater has stopped
running !
If arc welding must be done on the crane, remove the negative and positive battery
cable from the vehicle and the crane superstructure batteries to protect the heater
controls. Attach the positive cable to the vehicle ground.
Note:
During the summer months, run the added heater system * once a month for about 15 to 20 minutes.
* Optional
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3. Air conditioning system* > crane cab

The crane cab can be cooled with an air conditioner .
To put the system into service

> Turn on the main battery switch on (20) and also turn on the ignition.
> In the crane cab, turn on the ignition of the crane engine.
> Close both windows and the cab door.
> Close the regulator (253) for fresh air / air circulation (253).
N o t e: The air intake for air circulation must be free and clear of any obstructions.
> Turn on the air conditioning system via switch (224) , the illuminated indicator light (225) shows that
the system is operational.
> Select the air flow to the top or bottom by opening or closing the air vent (255).
> Turn the blower on via rotary switch (251) ,
> Regulate the temperature with the rotary knob (254) .
CAUTION: The main battery switch (25) may only be turned off after the heater has
stopped running!
If arc welding must be done on the crane, remove the negative and positive
battery cable from the vehicle and the crane superstructure batteries to
protect the heater control units*. Attach the positive cable to the vehicle
ground.
Maintenance of air conditioning system *

Refer to the Operating Manual supplied by the air conditioner manufacturer for maintenance
guidelines.
*Optional
453
6.02 EMERGENCY CRANE CONTROL 023229>01
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Prerequisite for emergency operation:

> The travel and crane engine is running and the hydraulic system in the crane superstructure is operational,
> the hydraulic system in the crane chassis is operational.
> Two persons are available to control the solenoids on the directional valves ( 1 . . . . 11 )
or
> one person and two emergency control union nuts* for the directional valves (1 and 2) are available.
GEFAHR: In emergency operation, the crane superstructure must always be taken care first.
1. Emergency operation > crane superstructure, Fig. 2

In case of a failure of the LICCON monitor or the LICCON safe load indicator system, the crane can still be
taken down via the emergency control keyed switch (16) with the two manual control levers in the crane
operatorπs cab.
DANGER: The keyed switch (16) bypasses the LICCON safe load indictor system and may
only be turned on in emergency situations!
Crane operation with the switch (16) turned on is strictly prohibited.
There is a great danger of LIFE AND DEATH!
2. Emergency control > crane chassis

Retract the outriggers
To control the various movements, 2 directional valves for the support system ( 4 . . . . 11 ) are located on all 4
sliding arm boxes.
In case of a failure of the electrical control for these directional valves, the hydraulic supports can also be
retracted manually by controlling the solenoids on the directional valves.
3. Emergency operation > rear axle steering

To control the hydrostatic rear axle steering, an additional directional valve (12) is located on the left rear
sliding arm box.
In case of a failure of the electrical control for this directional valve, the rear axle steering can also be
controlled manually by controlling the two solenoids on the directional valve (12).
The emergency control for the rear axle steering is used to straighten the rear wheels , in case a problem
had occurred when the rear wheels had been turned, which would prevent them from being returned to
straight forward position.
Note: The emergency control for the rear axle steering can be handled by one person.
*Optional
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1.1 Emergency operation on crane superstructure
The emergency control is possible in case of :

> a problem or failure of the LICCON monitor or
> a problem or failure of the LICCON safe load indicator system.
The monitor on the control and indicator unit of the LICCON is not functioning,
The working procedures are no longer displayed optically on the monitor.
DANGER: The crane may be operated in emergency operation only to take care of an
emergency situation.
Since the monitor is not functioning in case of problems or failure of the LICCON
system and the telescoping procedure and angle indicators are no longer displayed
optically, every step must be done with extreme caution and care and must be
checked visually.
In emergency operation, ALL IMPORTANT safety devices are bypassed .
The emergency crane control may only be performed by authorized personnel, who
are aware of the effects of these bypasses.
Keyed switch (16)
DANGER: The keyed switch (16) bypasses the LICCON safe load indictor system and may only
be turned on in emergency situations by personnel, who are aware of the effects of
this bypass!
Crane operation with the switch (16) turned on is strictly prohibited.

After completion of emergency operation and repair of the LICCON safe load
indicator system, the keyed switch (16) must be turned OFF again, switch position
∫VERTICAL∫.
When the keyed switch (16) is in ∫ON∫ position,

> the working speeds can no longer be regulated via the manual control lever,
> the LICCON system is no longer effective,
> the hoist limit switch is bypassed.
> the ªINSTALLATION´ symbol, (Fig. 5) blinks on the LICCON monitor , and an exclamation mark ( ! )
appears in the symbol. In this case, the operating view is not locked.
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1.2 To take down the crane
CAUTION : First, the load which is suspended on the hook must be set down.
In order to lower the load safety, the crane superstructure might have to be turned or the telescopic boom might
have to be luffed up .
DANGER: All crane movements must be carried out with utmost care and at the slowest
possible speed.
Only load reducing movements may be carried out.
If this is not observed, there is a danger of causing a serious accident.
Emergency control procedure
On the crane cab , Fig. 2

> Open both locks on the cover of the control box by turning the control box key to the left, and remove the cover.
> Turn the keyed switch (16) to ∫ON∫ position.
DANGER: Crane operation with the switch (16) turned on is strictly prohibited.
1.3 Emergency control for machines with one hoist gear
1.3.1
Luff the telescopic boom up
> Carefully and sensitively move the manual control lever (277) to the left and luff the telescopic boom up to the
required position.
1.3.2
Turn crane superstructure
DANGER: Before initiating a ªslewing´ crane movement, the operator must make sure that
there are no persons or obstacles within the slewing range.
> Carefully and sensitively move the left manual control lever (267) to the right or left and turn the crane
superstructure to the desired direction.
> Release the left manual control lever.
1.3.3
Set down the load
> Carefully and sensitively move the manual control lever (277) to the front and set down the load.
> Move the manual control lever (277) to the rear and raise the hook block,
> Release the manual control lever (277).
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Emergency control for machines with one hoist gear continuation
1.3.4
Telescope the telescopic boom in
Telescope telescopic section 2, 3+4 in

> Switch the operating mode switch (280) to position ªTelescopic section 2´, Fig. 4
> Carefully and sensitively move the manual control lever (267) to the rear and telescope the telescopic sections
2, 3+4 all the way in.
> Release the manual control lever (267) .
Telescope telescopic section 1 in

> Switch the operating mode switch (280) to position ªTelescopic section 1´.
> Carefully and sensitively move the left manual control lever (275) to the rear and telescope telescopic section 1
all the way in.
1.4 Turn the crane superstructure forward into travel direction
1.4.1
Turn the crane superstructure
> See paragraph 1.3.2
1.5 Luff down the telescopic boom into the transport retainer
> Carefully and sensitively move the manual control lever (277) to the right and luff down the telescope
telescopic boom carefully into the transport retainer .
> Turn the keyed switch (16) off and pull the key.
CAUTION: After completing the emergency operation and repairing the LICCON system,
return the keyed switch (16) again to the ∫OFF∫ position.
Switch position ∫VERTICAL∫.
If the keyed switch (16) is in ∫ON∫ position

> the LICCON system does NOT TURN OFF any functions,
> the hoist limit switch is bypassed,
> working speeds cannot be regulated via the manual control levers.
On the crane cab, Fig.2

> Reinstall the cover on the control box and close the lock by turning the control box key to the right.
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1.6 Emergency control for machines with two hoist gears *
1.6.1
Luff the telescopic boom up
> Turn the operating mode switch (280) to ª luffing the telescopic boom ´ position, Fig. 4
> Carefully and sensitively move the manual control lever (277) to the left and luff the telescopic boom up to the
required position.
1.6.2
Turn crane superstructure
> Carefully and sensitively move the left manual control lever to the right or left and turn the crane
superstructure to the desired direction.
> Release the left manual control lever .
1.6.3
Set down the load hoist gear 1
1.6.4
Set down the load hoist gear 2
> Release the manual control lever (267).
* Optional
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1.6 Emergency control for machines with two hoist gears* continuation
1.6.4
Telescope the telescopic boom in
Telescope telescopic section 2, 3+4 in

> Carefully and sensitively move the manual control lever (277) to the left and telescope the telescopic sections
2, 3+4 all the way in.
Telescope telescopic section 1 in

> Carefully and sensitively move the manual control lever (277) to the left and telescope telescopic section 1 all
the way in.
1.7 Turn the crane superstructure forward into travel direction
1.7.1
Turn the crane superstructure
> See paragraph 1.6.2
1.8 Luff down the telescopic boom into the transport retainer
Switch the operating mode switch (280) to position ªLuffing the telescopic boom´, Fig.7
> Carefully and sensitively move the manual control lever (277) to the right and luff down the telescope
telescopic boom carefully into the transport retainer .
> Turn the keyed switch (16) off and pull the key.
CAUTION : After completing the emergency operation and repairing the LICCON system,
return the keyed switch (16) again to the ∫OFF∫ position.
Switch position ∫VERTICAL∫.
If the keyed switch (16) is in ∫ON∫ position

> the LICCON system does NOT TURN OFF any functions,
> the hoist limit switch is bypassed,
> working speeds cannot be regulated via the manual control levers.
On the crane cab, Fig.2

> Reinstall the cover on the control box and close the lock by turning the control box key to the right.
* Optional
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1.9 Bypassing the electric crane control via the self>locking button (17)
If the crane engine is not running or in case of alternator failure, the electric crane control can be turned on by
actuating the bypass button (17).
In this case, the battery voltage may not drop below 20 Volt .
To bypass the electric crane control, fig. 2

> Turn the ignition on.
> Move the bypass button (17) to ∫ON∫ position (to the right).
> If the bypass function is not longer required turn the ignition off.
The bypass turns off automatically.
CAUTION: After bypassing the crane control with button (17), make sure to release the bypass
function by turning the ignition off.
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2.1 Emergency control on chassis, with two persons
Retract the outriggers ∫by hand∫
> On the front covering of the fuel tank, remove the four mounting screws and take off the cover.
> On both directional valves (1 and 2) , push in the solenoids ∫by hand∫ and hold them down, this establishes the
oil pressure supply from the crane hydraulic to the directional valves !( 4 . . . . 11 ) .
> On the corresponding solenoid of directional valves!( 4 . . . . 11 ) push in the piston in direction of the arrow ∫by
hand∫.
As soon as the pressure which is applied onto the piston stops, the movement will stop.
left side function right side function
Push in piston Push in piston
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2.2 Emergency control on chassis, with one person

This requires two union nuts (S)*
Retract the outriggers ∫by hand∫

> On the front covering of the fuel tank, remove the four mounting screws and take off the cover.
> On both directional valves (1 and 2) , on the solenoids, unscrew both union nuts (a) with dust caps (b) and
actuator pins (c), (see illustration).
> Screw both union nuts (S) onto the solenoids on the directions valves (1 and 2).
This establishes the oil pressure supply from the crane hydraulic to the directional valves !( 4 . . . . 11 ) .
> On the corresponding solenoid of directional valves!( 4 . . . . 11 ) push in the piston in direction of the arrow ∫by
hand∫. As soon as the pressure which is applied onto the piston stops, the movement will stop.
> After completing the emergency control, remove both union nuts (s) and store them in the tool box.
> Reinstall union nuts (a) with dust caps (b) and actuator pins (c) in their original position.
left side function right side function
Push in piston Push in piston
183566
*Optional
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2.3 Lower the crane
The outrigger cylinders on the right hand side of the vehicle are extended and retracted individually via the
directional valves installed on the right hand side.
The outrigger cylinders on the left hand side of the vehicle are extended and retracted individually via the
directional valves installed on the left hand side.
> By actuating the directional valves 4, 6, 9 and 10, retract all outrigger cylinders evenly and carefully lower
the crane until all tires are in contact with the ground,
> then retract all outrigger cylinders all the way.
2.4 Retract and secure the sliding arms
The four sliding arms are individually pushed in and out via the directional valves on the opposite side of the
vehicle.
> By actuating the directional valves, 5, 7, 8 and 11, fully retract all sliding arms,
> then secure the sliding arms by inserting the pins into the sliding arm boxes to prevent them from moving out
by themselves.
DANGER: An assistant must observe the in and out movement of the sliding arms.
It must be assured that there are no persons or objects within the danger range.
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3.1 Emergency control of the rear axle steering
For the emergency control of the rear axle steering, only the right or left solenoid on the directional valve (12)
needs to be pushed, as shown on the illustration.
Letting the crane roll back slowly makes it easier to return the rear wheels into ∫straight forward∫ position.
CAUTION : Before driving the crane, lock the rear axle steering in ∫straight forward∫ position.
Note: Read the paragraph covering the rear axle steering in chapter 3.04 DRIVING THE CRANE
ON PUBLIC ROADS.
left side of vehicle right side of vehicle
Push in solenoid Push in solenoid
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6.04 SLIDING ARM MONITOR 022961>00
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476
General
The LICCON sliding arm monitor checks the support width data entered by the crane operator to select the load
capacity chart on the LICCON panel.
However, it does NOT monitor if the crane is properly supported and if the sliding arms have been pinned
properly in their intended positions.
The support base for the LTM 1050/1

The LTM 1050/1 can be operated in 3 different support widths :
* wide 7.1 m
* reduced 4.5 m
* retracted 2.3 m
CAUTION: The support bases have no tolerances and the sliding arms must be pinned on these
support bases.
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Working with the sliding arm monitor

Preparation of the crane
When the crane is utilized on the job site, the sliding arms are to be extended to the planned width for the
application, they are to be pinned and supported according to the operation manual. Then the load capacity
chart, which corresponds to the desired working range, the utilized ballast and the support width of the crane,
must be set on the LICCON panel. If this load capacity chart corresponds to the support base the sliding arm
monitor recognizes, then the crane operator is shows the load capacity chart on the monitor, pushes the "OK"
button and the operating view appears, the crane is operational.
Function and error indication of sliding arm monitor when setting the load capacity chart
If the selected support base and the sliding arm length of all sliding arms do not match, and the operator pushes
the "OK" button, an error message will appear ( "ERROR 155" ) and the crane cannot be equipped according to
the preselected chart. In this case, the operator must either select a sliding arm length which matches the
chart or he must extend all four sliding arms to a length, which matches the preselected chart. It is not possible,
for example, to select a chart with a reduced base, if the supports are retracted; it is also not possible to select a
reduced or retracted support base chart if the crane is actually operated with a wide support base.
Function and error indication of sliding arm monitor during operation

If a valid load capacity chart has been set, and it was checked by the sliding arm monitor, then the crane can be
operated according to the appropriate guidelines in the operation manual and according to the load capacity
charts.
Monitoring the sliding arm lengths

Just as when setting the load capacity chart, the position of the sliding arms is constantly being checked during
crane operation, and it is constantly being compared with the entered load capacity chart. If any deviations are
found, the system will also report "ERROR 155" , the LICCON safe load indicator system reports overload and
the crane can only be operated by bypassing the LICCON safe load indicator system. In addition, the slewing
gear will be turned off when at standstill, and cannot be restarted if not in ∫installation∫ mode. The slewing
gear can also be shut off during rotation.
Monitoring the support forces

In addition to the sliding arm length, the support forces are monitored. The system constantly checks if their
sum exceeds a minimum crane weight without attachment. If this is not the case, the error message "ERROR
155" is shown, the LICCON safe load indicator system reports overload and the crane can only be operated by
bypassing the LICCON safe load indicator system. In addition, the slewing gear will be turned off when at
standstill, and cannot be restarted if not in ∫installation∫ mode. The slewing gear is not shut off during
rotation. The support force monitor has no influence on the load capacity chart adjustment in the configuration
program.
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Interpretation of extension condition by the sliding arm monitor

The sliding arm monitor measures the length of the various sliding arms and checks, if they are in the
preset,permissible intervals. If at least one sliding arm is not within such an interval, then the crane cannot be
equipped with a load capacity chart in the configuration program, as the crane must be supported and operated
with the proper sliding arm lengths.
If all sliding arms are extended to permissible, but different lengths, then that sliding arm, which shows the
smallest value, is taken as the basis for selecting the load capacity chart. The numbering sequence corresponds
to the sequence of support bases, as they are shown in the configuration program, when one pushes the F5
button several times.
As an example, the illustration on the opposite page shows in which extension condition which support is
permitted when selecting the load capacity chart. The last case shows a situation, where a sliding arm is
between two permissible extension conditions.
Error procedure
It must always be differentiated between an operational error by the crane operator and a problem due to a total
sensor failure or an erroneous sensor function.
If a sensor fails completely, then the monitor recognizes a length for this sliding arm, which corresponds to the
retracted condition. Automatically only a chart with retracted supports can be selected. However, as a result, it
is possible that no chart can be selected because in this operating mode, for example "TK" operation, the crane
cannot even be operated with retracted supports.
If a sensor does send a signal, which is within the permissible test range, but it is wrong, then the incorrect
sensor value can be deducted, and the retracted condition will be simulated. An incorrect length value can also
be given if the length sensor cable of a sliding arm is twisted up in the sliding arm box.
C A U T I O N: If a sensor fails completely or the retracted condition is simulated, it must be

assured that no sliding arm is between two pinable positions, because this could
cause a dangerous situation even for load capacities for retracted conditions.
The sliding arms must always be pinned.
481
7.00 SERVICE AND MAINTENANCE 021680>00
482
021680>00
Chapter 7
Service and Maintenance
483
7.01 SERVICING AND MAINTENANCE 021681>04
484
Liebherr After Sales Service > what it means for you
Liebherr truck>mounted, mobile and crawler cranes are products incorporating mature engineering which is
able to cope day in, day out with the roughest operating conditions to which a crane may be subjected.
The high standards of engineering embodied in these cranes are reflected in their operation reliability, their
insusceptibility to faults and in their ease of servicing and maintenance.
Liebherr is constantly further developing their drive and control elements. The combination of tried and tested
components and modern production methods produces cranes which are reliable operating partners with a
range of convenient operating features.
We build many hundreds of cranes each year for the international market and provide the backup services for
them worldwise, too. For ∫After Sales Service∫ ranks high at Liebherr to ensure that your crane is always
available and operational.
Service at Liebherr begins from the moment the crane is handed over to you, the customer. We will provide your
crane operators with the specialist training tailored to their particular needs.
Also we will train your maintenace personnel in all questions relating to crane servicing and repairs because
we know that you are able not only to deal with all their minor repairs, but often have the specialists who can
quickly and reliably perform major crane repairs.
A further benefit of our After Sales Service are our special Service Advisors who are only a telephone call away
whenever a problem arises. This immediate contact saves you time and money and you should always take
advantage of it whenever your crane is ∫down∫.
Our Fild Technicians are also specialists with many year's experience who operate from strategically located
bases. They bring with them their specialist knowledge and a range of special tools for the job. They are at your
disposal as the last link in the range of Liebherr After Sales Services, although in most cases, your technical
problems can be solved by contacting our Service Advisors.
Note: The buyer may submit warranty claims and receive possible reimbursement only if Original
Liebherr spare parts are used in the Liebherr mobile crane.
Original Liebherr spare parts have been tested and are designed specifically for crane
operation and can be utilized without any safety concerns.
DANGER: LIEBHERR>WERK EHINGEN GMBH, accept no liability for utilisation of

replacement parts not manufactured originally by Liebherr. This applies to the
functioning capability as well as to the actual parts!
485
Cleaning and upkeep of crane
The areas covered with sound absorbing mats may only be cleand with a non>flammable cleaning fluid. It may
not be corrosive or chemically agressive.
Do not use steam to clean the sound absorbing mats!
DANGER: If sound absorbing mats are contaminated with oil and / or fuel, then they must be
removed, because they have become flammable and are no longer flame retardent!
Wash the crane with water.
Note: If a steam cleaner / power washer is used, keep a distance of at least 80 cm (2' 7'' ) from paint
and decals.
After washing the crane, especially with steam, lubricate the crane (drive shaft, slewing connections).
The steering wheel, center console, control panel cover, floor covering and dirty upholstery in the driver's and
crane operator's cab should be cleaned with warm water mixed with dish detergent.
Do not use scouring pads!
486
The scope of maintenance works are described in the following chapters.
7.02 MAINTENANCE INTERVALS CRANE CHASSIS
7.03 MAINTENANCE INTERVALS CRANE SUPERSTRUCTURE
Maintenance work must carried out according the crane.
The following chapters describe maintenance work in more detail.
7.04 MAINTENANCE INSTRUCTIONS CRANE CHASSIS
7.05 MAINTENANCE INSTRUCTIONS CRANE SUPERSTRUCTURE
For individual assemblies note manufacturers instructions.
Maintenance work on the crane chassis is carried out according to the number of operating hours or
kilometres covered.
Maintenance work on the crane superstructure is carried out according to the number of operating hours
only.
487
7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS 021691>06
regular maintenance every minimum inspections

1st main>
main>
tenance
200 hrs. 400 hrs. 800 hrs. tenance
after
5000 km 10000 km 20000 km annually daily weekly
" Diesel engine
¥
> Check oil level
For all further maintenance

work, observe
manufacturer's instructions
> Check coolant level in

¥
equalizing reservoir
every
> Change coolant liquid
2 years
" Air filter
> Observe monitoring device ¥

> Clean the filter element
(Observe the guidelines If
issued by the engine necessary
manufacturer!)
> change the filter element every

(and after having it cleaned
2 years
5¥.)
" Steering
> Check the steering hydraulic

¥
oil level
> Test steering rod and tie rod

tightness and split pin ¥
keepers
> Check hydraulic system for ¥

proper seals
> Test tie rod setting, test if

¥*
necessary
> Oil change ¥

> Replace oil filter 100 hrs. ¥
> Test hydraulic steering stop,
¥
test if necessary
> Check hydraulic pressure, set

¥
if necessary
* If used heavily off>road, at least 1¥per year.
488

1st main>
main>
tenance
after
" Automatic transmission
> Check oil level ¥

> Check oil pressure ¥
> Check operating temperature ¥
> check for proper seals ¥
> Check / tighten fastening
screws
¥
> Oil change 100 hrs. ¥ ¥

> Replace oil filter 100 hrs. ¥ ¥
" Power shift gearbox

> Oil change 100 hrs. ¥ ¥
> Replace oil filter 100 hrs. ¥ ¥
489

1st main>
main>
tenance
after
" Displacement gear

> check fastenings ¥
> oil change 1000 km ¥ ¥
" Distribution gearbox
> Oil change 1000 km ¥ ¥

> Check for proper seals ¥
> Check/tighten fastening ¥
screws
> Check road/off>road gear

¥
switchover function
> Check all>wheel drive switch>

¥
on function
> Check tachometer connection ¥

> Clean ventilation nipple ¥ ¥
" Pump distributor gearbox

> check fastenings ¥
> oil change 200 h ¥ ¥
490
regular maintenance everyminimum inspections

1st main>
main>
tenance
after
" Drive shafts (universal

drive shafts) and bearing
bracket
every
> Grease 25000 km
2 years *
> Check flange screws, tighten

100 km 2500 km
if necessary
" Driven axles
> Test for proper seals ¥

> Oil level check at axle
housing, differential housing ¥
and wheel hubs
> Grease steering knuckle 25000 km

every
bearings 2 years **
> Check mounting tightness ¥

every
> Oil change 1000 km ¥ 2 years
> Replace grease filling in

every
wheel bearings
2 years
(if lubricated with grease)
> Clean ventilation on axle

¥ ¥
housing
" Axle drive DK>7
every
> Oil change 1000 km ¥
2 years
" Non>driven axles
> Grease steering knuckle every

25000 km
bearings 2 years **
> Check mounting tightness ¥

> Change wheel hub grease
¥ ¥
filling
> Set wheel bearings ¥ ¥
* Maximum grease pressure: 15 bar. If used heavily off>road, at least 1¥per year.
** If used heavily off>road, at least 1¥per year.
491

1st main>
main>
tenance
after
" Electrical system
> Check vehicle lighting

¥
system for function
> Check cable connections and

¥
battery acid level
" Fuel system
> Check for leaks ¥

> Check condition and
¥ ¥
mounting
> Drain off water and

¥ ¥
contamination
> Clean pre>filter for fuel

¥ ¥
auxiliary pump
" Tires
> Check lug nut tightness,

tighten if nec.
100 km ¥
> Check tire pressure ¥

" Brake system
> Check function of service ¥

brake and parking brake
> Check brake lining wear ¥

> Adjust brakes,
¥
if necessary, replace linings
> Grease ¥
> Oil fork head connections ¥
> Check service brake and
¥
hand brake functioning
" Eddy current retarder
> Check mechanical and

electrical sections
(Observe manufacturer's
5000 km ¥
guidelines)
492

1st main>
main>
tenance
after
" Compressed air system
> Test for proper seals ¥

> Check brake system
¥
operating pressure
> Check shutdown pressure ¥

> Check pressurized air
reservoir automatic water ¥
bleeder valve functioning
> Replace air dryer granulate

cartridges
¥
> Clean air dryer

pre>filter
¥
" Axle suspension
> Check hydraulic tank oil

¥
pressure
> Check hydraulic system seals ¥

> Blocking cylinder function ¥
test
> Replace oil filter 100 h ¥

> Check hydraulic pressure, set
¥
if necessary
> Check pressure reservoir

¥* ¥*
priming pressure (nitrogen)
> Oil change ¥ ¥

" Outrigger support plates
with equalizer
> Replace grease supply ¥

> Complete funktion test ¥
* refer to chapter 7.04, MAINTENANCE INSTRUCTIONS CRANE CHASSIS
493

1st main>
main>
tenance
after
" Hydraulic
supports
> Check hydraulic system seals ¥

> Check hydraulic tank oil
¥
pressure
> Check sliding arm

¥
movement / oil
> Grease fleyer chains ¥

> Oil sliding arm keeper pins ¥
> Oil operating level fork heads ¥
> Check level, adjust if nec. ¥
> Oil change (oil sample) ¥ ¥
> Replace hydraulic filter 100 hrs. ¥
> Replace bleeder filter on 100 hrs. ¥
hydraulic tank
> Check hydraulic system

¥
operating pressure
" Hydraulic accessories,

e.g. ventilator, ballasting
cylinders
> Check hydraulic operating ¥

pressure, set if necessary
" Driver's cab
> Check armature function ¥

> Check indicator light
¥
function
> Check motor brake

¥
activation
> Check retarder activation ¥

" Emergency control
> Check emergency control

¥
function
494
regular maintenance every minimum

main>
For crawler cranes only
tenance
10 hrs. 100 hrs. 800 hrs. annually
" Running gear
> Oil change ¥ ¥

> Check seals ¥
> Grease tumbler bearing ¥
" Track carrier
> Check seals on track rollers

¥
(with oil lubrication)
> Grease track rollers (with oil

¥
lubrication)
> Grease support rollers ¥

> Grease guide rails on sliding
¥
piece
" Track shoes
> Check shoe tension, tighten if ¥

necessary
> Inspect for fastening and

¥
damage
495
7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE 021933>07
496

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
hrs. hrs. hrs. hrs. annually
" Diesel engine
> check oil level ¥
for further inspections please

refer to manufacturers
maintenance instructions
> check cooling water level in
the extension tank
¥
every
> change cooling water
2 years
" Air filter
> check dust indicator ¥
> clean resp. change
according to manufacturers
maintenance instructions
" Slewing ring
every 3
> lubricate
months *
> inspect and check bolts for
200 hrs. ¥ ¥
tightness
> check tilt play ¥ ¥
" Rope winches
> inspect for leaks ¥
> check fastening bolts for
200 hrs. ¥ ¥
tightness
3 000 every
> oil change
hrs. 4 years
" Propeller shafts
> check flange bolts ¥
> lubricate ¥ ¥
* if the crane is not moved
497

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Tension rods
> check condition ¥
" Overtopping guard struts
> lubricate pivots ¥ ¥
" Fall back cylinders
> inspect for leaks ¥*
> check preload pressure
¥ ¥
(nitrogen gas)
> check oil quantity ¥ ¥
" A bracket mounting
> lubricate ¥
" Counterweight
or
> check tightening torque of
1 000 km 10 000 ¥
fastening bolts
km
" Ballasting system
" Rope drum contact rollers
> grease guides ¥ ¥
" Rope pulleys
> inspect and lubricate ¥ ¥
" Ropes
> inspect, grease if necessary ¥ ¥
" Hook blocks
> lubricate ¥ ¥
* visual check before starting up the crane
498

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Crane cab
> check operation of
¥
instruments
> check operation of tell>tale
warning lights
¥
> check liquid level in the
reservoir of the engine speed ¥
control
" Extending crane cab
> check operation ¥
" Load moment limiter
" Electrical system
> check cable connections and
¥
battery acid level
" Fuel system
> check for leaks ¥
> check condition and
¥ ¥
mounting
> drain off water and
¥ ¥
contamination
" Slewing gear transmission
> check fastening bolts for
200 hrs. ¥ ¥
tightness
4 000 every
> change oil
hrs. 4 years
" Locking of the slewing
brake
> lubricate ¥ ¥
499

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Pump distributor gearbox
> oil change 400 hrs. ¥ ¥
" Hydraulic system
> check for leaks ¥
> replace control and feed
circuit pressure filter ¥
200 hrs.
element
> replace returnline filter
element (cranes with open 200 hrs. ¥
hydraulik circuit only)
> replace bleeder filter on

200 hrs. ¥
hydraulic tank
> check hydraulic oil
(oil sample test)
400 hrs. ¥ ¥
" Hydraulic cylinders

" Hydraulic pressure
reservoirs (nitrogen gas)
> check preload pressure ¥* ¥*
" Emergency control
> check emergency control
¥
function
* refer to chapter 7.05, MAINTENANCE INSTRUCTIONS CRANE SUPERSTRUCTURE
500

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Telescopic boom with
cable mechanism
> lubricate the telescopic boom ¥ ¥
pivots
> lubricate change over pulley
¥ ¥
for push out mechanism
> check cable mechanism,
200 hrs. ¥
adjust if necessary
> disassemble boom and 20 000 every
inspect it hrs. 10 years
" Pneumatic boom locking
> clear the air filter for
¥ ¥
compressed air
> check boom locking holes ¥ ¥
> lubricate boom locking bolts ¥ ¥
" Telescopic boom system
TELEMATIC
> check telescopic boom for
¥
distortion, cracks and leaks
> check telescopic cylinder for
¥ ¥
proper condition
> check push out tong for
¥ ¥
proper condition
> check locking pins and
locking bores for proper ¥ ¥
condition
> check inner and outer glide
surfaces for proper condition
¥ ¥
> lubricate glide surfaces ¥*
* and as necessary
501
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE 023230>01
185298
502
Check oil level and filters on travel and crane engine

To check the oil level in the engine, the crane must be in horizontal position.
Turn the engine off and wait until the oil has drained into the oil pan.
CAUTION : For all maintenance work, make sure you assure utmost cleanliness, so no dirt or
contaminants enter the internal engine areas.
Check the engine oil level (fig. 1)

The oil must be between the minimum and maximum ( MINI and MAXI ) mark on the dipstick.
CAUTION : If the oil level has dropped below the minimum mark, you must add engine oil as
specified on the lubrication chart until the oil level is again between the minimum
and maximum mark.
If no oil is added, the engine can be severely damaged.
Reinsert the dipstick after checking the oil, pushing it in tightly.
Check engine air filter on the travel and crane engine

The air filters are electronically monitored.
If a vacuum is created in the air intake line due to contaminated filter elements, the corresponding warning
light (52) on the instrument panel in the driverπs cab will light up.
In that case, clean or replace the filter elements.
Note: All maintenance on the engine and air filter must be completed as noted in the separate
engine manual .
When performing maintenance and repairs in the engine area, observe the following::
Never step on the fuel lines.
When changing the filter, especially on the V>area of the engine,spread out a layer of absorbent material before
loosing the filter to absorb any fuel which might drain out.
DANGER: You must make sure that no Diesel fuel is spilled in the engine area and it remains
free of Diesel fuel, otherwise there is a risk of causing a
FIRE!
When you change the filters and bleed the system, you must assure utmost
cleanliness. Any fuel spills must be dried up. Dispose of the absorbent material
properly.
Note : When changing filters or when working on the fuel system in the V>area of the engine, we
recommend to support the crane from the rear so there is a slight drop towards the front.
Any fuel spill can then flow toward the front away from the V>area.
503
185298
504
Check the oil level in the automatic transmission (fig. 2)
Check the oil level

> with the crane standing in horizontal position
> with the gear in neutral position ∫N∫
> with the engine running at approximately 1000 RPM.
> Turn the dipstick in counterclockwise direction to loosen it and pull it out.
> Wipe off the dipstick, reinsert it and pull it out again.
Note: If the oil is cold, it must be between the MIN and MAX mark for cold oil, or if the oil is at
80!∞C, the oil must be between the MIN and MAX mark for warm oil on the dipstick.
CAUTION: If the oil level is below the minimum mark for the temperature, oil must be added
according to the lubrication chart, until the oil level is again between the MIN and
MAX mark.
If no oil is added, the transmission can be severely damaged.
> Reinsert the dipstick and turn it in clockwise direction to tighten.
To change the oil

> When the gear is at operating temperature, the engine is turned off and the crane is in level position, remove
the drain plug (magnetic plug with seal ring) and drain the old oil into an appropriate container.
> Change the oil filter.
N o t e: All maintenance must be done according to the separate gear operation manual issued by
the manufacturer.
> Add oil as specified on the lubrication chart.

> Clean the magnetic plug and sealing surface on the housing, reinsert he magnetic plug with new seal ring and
tighten it by hand.
> Start the engine, let it run at low idle .
> Move the gear to neutral position ∫N∫ ,
> Add oil until it reaches the MIN (minimum) mark .
> Apply the brakes.
> Actuate all switch positions .
> Recheck the oil level, if necessary, add oil to the MIN (minimum) mark.
505
185298
506
For (6¥6)* drive

Check the oil level on the axle drive of the 2nd axle (DK>7, Fig. 3)
Check the oil level

> with the crane in horizontal position, remove the plug ( a3 ) on the gear, the oil level must reach the lower edge
of the inspection port ( a3 ) .
> Add oil, if necessary.
CAUTION : The oil level should be at (a3 ) .

If the oil level has dropped, you must add oil according to the lubrication chart until
it runs over on the inspection port ( a3 ).
If no oil is added, it will damage the gear .
> Clean the sealing surfaces on the housing and clean the plug.
> Reinsert the plug with new seal ring into the inspection port ( a3 ) and tighten it by hand.
To change the oil in the axle drive for the 2nd axle
CAUTION: For all maintenance work, make sure you assure utmost cleanliness, so no dirt or
contaminants enter the gear areas.
> With the crane in horizontal position, remove the plugs ( b1 b2 b3 ) with seal rings and drain the old oil.
> Clean the magnetic plugs (b1 b2 b3) and sealing surfaces on the housing, reinsert the magnetic plugs with new
seal rings and tighten them by hand.
> Remove plugs (a1 a2 a3) and clean the sealing surface.
> Add oil according to the lubrication chart at (a1 and a2) until it starts to run out at the inspection port!(a3) .
Note: When adding oil, keep the proper sequence:

1. add oil at ( a1 )
2. add oil at ( a2 )
> Reinsert the plugs (a3 a2 a1) with new seal rings and tighten them by hand.
*Optional
507
185298
508
Check the oil level in axles (axle casing)
Check the oil level

> With the crane in horizontal position.
> The oil level in axle casing for the first and third axle must be to the lower edge of the corresponding inspection
port. If necessary, add oil according to the lubrication chart.
Check the oil level in the planetary gears of the wheel hubs (Fig. 4)
Check the oil level

> With the axle suspension blocked, align the crane in horizontal position via the support cylinders and raise it
until all wheels are off the ground.
> Turn all driven wheels until the drain plug ( b ) is positioned at the lowest point. The mark ( c ) must be
exactly horizontal.
> Remove the plugs of the filler and inspection port ( a ), the oil level must reach the lower edge of the inspection
port, if necessary, add oil according to the lubrication chart.
> Install a new seal ring and reinsert the plug into the filler and inspection port ( a ) and tighten by hand.
CAUTION: For all maintenance work, make sure you assure utmost cleanliness, so no dirt or
contaminants enter the internal areas of the axles or planetary gears.
509
183157
510
Check the oil level on the hydraulic tank (Fig. 5) for:

Steering and fan drive ,
Support and axle suspension hydraulic,
Crane hydraulic
> With the crane in horizontal position, the oil level must be in the center of the sight gauge.
If no oil is visible in the sight gauge, add oil as specified on the lubrication chart, until the oil level is in the
center of the sight gauge.
CAUTION: When checking the oil,

the luffing and telescoping cylinders, the outrigger cylinders as well as the sliding
arms must be retracted and the vehicle must be brought down to the lowest axle
suspension level.
If you would check the oil with the outrigger cylinders extended and with the
vehicle at a high axle suspension level, you would run the risk of adding too much
oil and overfilling the system.
Do not retract the cylinders too quickly, this can cause damage to the oil tank.
D A N G E R: If the oil level has dropped below the minimum mark, oil must be added as specified
on the lubrication chart.
If the oil level is too low, the hydraulic pumps can be damaged, which increases the
risk of causing an accident, due to steering inability.
In addition, the outrigger cylinders cannot be fully extended and the vehicle cannot
be leveled.
Air intake and bleeder filter (Fig. 6)

> Turn the engine off.
> Open the turn cap and check the filter visually for contamination.
If the filter is very dirty, it must be replaced.
> Close the turn cap again.
> Start the travel and crane engine,
> slowly run through all crane movements,
> then recheck the oil level and add more oil, if necessary.
Check the return filter in the crane hydraulic system (Fig. 7)
The ∫rear∫ return filter is equipped with a maintenance indicator * .

If the red bar is visible when the oil is at operating temperature (check once a week), then both filter inserts
must be replaced.
Flush out the filter housing before inserting the new filter elements.
* Optional
511
183157
512
Check the engine coolant (fig. 8)
DANGER: Check the engine coolant only when the engine is cold!
The radiator cap must be cool enough to touch. Avoid contact with components
containing coolant, since it could cause SEVERE SKIN BURNS!
Add coolant to the reservoir only via the filler nozzle.
> Turn the radiator cap on the filling nozzle of the radiator tank / reservoir to the first notch to release the
pressure,
> remove the cap,
> if necessary, add coolant according to the lubrication chart until it runs over ,
> reinstall the radiator cap and tighten it .
CAUTION: If any coolant has been lost, the coolant must be replaced in the same ratio
according to the LUBRICATION CHART!
Mixture ratio: 50 Vol % Corrosion and antifreeze fluid

50 Vol % Fresh water
Air dryer > Air pressure and brake system (Fig. 9)

The air dryer for the air pressure and brake system is maintenenance free.
The cartridge should be replaced once a year.
Hydraulic hoses
The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in safe
working condition.
Changing hoses
The hoses and lines must be replaced periodically.
Due to our experiences with mobile cranes, we recommend the maximum usage:
> in severe operation

at high operating temperatures and frequent movements approximately 3 years
> in normal operation approximately 6 years
> in assembly operation with rare high output frequency approximately 12 years
CAUTION: The hoses on the intake lines of the oil reservoirs must be checked visually once a
month for cracks and damage, and, if necessary, they must be replaced
immediately!
513
185299
514
Axle suspension/Axle locking system

The pretension pressure in the diaphragm reservoirs of the axle suspension system must be 45 bar .
CAUTION: If ambient temperatures fluctuate, for example in countries with extremely warm
or cold temperatures as well as in countries with great differences between summer
and winter temperatures, the pretension pressures must be checked and corrected,
if necessary.
If the pretension pressure is too low, the diaphragms can be overstressed and
damaged.
If the pretension pressure is too high, the spring action in the axle suspension
system is no longer assured, which can cause damage to the travel gear.
The pretension pressure in each of the reservoirs must be checked individually, as follows**:
> Move the switch (154) to axle suspension ∫suspended∫ .

> Push button (146, 147, 150, 150) ªon front´ , until the oil has drained from the diaphragm reservoirs.
> Check the pretension pressure with a testing and inflation device and correct the pressure, if necessary.
DANGER: To fill the reservoirs, DO NOT use a i r or o x y g e n . This can cause an
EXPLOSION!
The pressure in the nitrogen cylinder may not exceed the maximum permissible
operating pressure of the reservoir or the pressure gauge. If the pressure is higher,
a pressure reducing device must be connected between the cylinder and the
inflating device.
After the test**:

> Press button (142) "LEVEL" , until the indicator light (143) lights up.
The vehicle is automatically raised via the axle suspension cylinders to the required height for on road travel.
Tires
DANGER: The risk of having an accident is greatly increased if you drive the vehicle and
there is any tire damage, if the tires are worn and the treads are too low, and if the
air pressure in the individual tires differs.
> Check the tires (including the spare tire) for damage.
The depth of the tire treads (including the spare tire) may not fall below the legal limit.
> The tire pressure, including the spare tire, must be correspond to the recommended pressure given for the
particular tires, which are installed on your vehicle.
Tire pressure refer to chapter 1.3, TECHNICAL DATA
The tire pressure must be checked when the tires are cold.
> Before adding air to the tires, make sure that the tire is seated properly on the rims and the end ring is seated
properly.
CAUTION: The highest permissible air pressure may not be exceeded!
DANGER: Before adding air to the tires on the vehicle, make sure that there are no other
persons within the danger zone. They could be hit by flying parts!
** Version with wide driver's cab: fig. 11

Version with narrow driver's cab: fig. 12
515
Wheel alignment
The wheel alignment must be checked in regular intervals.
If this is not done, the tires will wear prematurely.
Recheck the wheels if the tires had been subjected to greater than normal stress, for example, if they hit the
curb.
Note: The wheel alignment can only be checked by qualified and especially trained personnel.
To change a wheel
> Loosen the wheel hubs on the defective wheel and carefully support the crane.
Refer to chapter 3.05 THE CRANE AT THE JOBSITE.
> Use the crane to lift off the spare tire, set it next to the defective wheel and secure it from rolling off or tipping
over.
Note: Never lay tires down on their side, it is very difficult to raise them again.
> Remove the wheel lugs and replace the defective wheel with the spare, reinstall the wheel lugs and tighten
them in crosswise fashion.
CAUTION: Do not overtighten the wheel lugs!

The maximum permissible tightening torque is 600 Nm.
After the first 50 and 100 kilometers, recheck the wheel lugs for tightness.
Safety and maintenance guidelines for the wheels (rims)

The below listed safety and maintenance guidelines are recommendations made by the manufacturer, in order
to prevent any safety risks due to damaged wheels or rims.
In addition, the manufacturer states that the manufacturerπs warranty is only valid if the guidelines noted
below have been strictly observed and followed.
The wheel is one of the most important safety components of the vehicle. For this reasons, it is imperative that
the following guidelines are followed. When changing the tires, the wheels must be checked, the rim as well as
the complete dish, as follows:
> formation of excessive rust or corrosion
> bent rim flanges
> cracks in the rim
> cracks in the wheel dish
> damage on the side and lock rings
> damage to the lug nuts or bolts
> worn or damaged bolt holes
> rim components must match and fit.
If any damaged rim components are found, they must be replaced immediately with new components.
If chipped paint or minor rust is found, the rust layer should be removed and the area should be repaired with
commercially available paint. You must make sure that the surface is smooth, especially on the tire seating
surface.
DANGER: NEVER perform or allow any welding on the wheel rim or wheel dish. It is strictly
prohibited to repair deformed or worn bolt holes or to replace or repair the wheel
center .
Any wheels with these defects must be scrapped immediately and replaced with
new wheels.
Any repair to these highly stressed parts of the wheel causes structural changes in
the material, which can lead to sudden fractures.
516
Electrical System > Lighting System

The maintenance of the electrical system is basically limited to changing defective fuses and bulbs and to
battery maintenance.
CAUTION: Always replace defective fuses with fuses ob the same amperage. Never use a
different size or stronger fuse, than the original fuse. This could cause an electrical
fire! NEVER repair or short circuit a fuse. This could severely damage the entire
electrical system.
The batteries must be kept clean and dry.

The bleeder bore holes in the battery plugs must be clear and unobstructed.
Disconnect dirty battery terminals, clean them and apply acid free and acid resistant grease.
Make sure no oil or grease gets on the battery sealing compound.
CAUTION: DO NOT place any tools on the batteries and keep sparks and open flames at a great
distance away from the battery.
Never disconnect the batteries with the engine running, as this could destroy the
alternator.
The electrolyte level in the batteries must be checked once a month, in the summer and in warm climates it
must be checked at least once a week.
The battery acid (electrolyte) level must be checked at at approximately 15 mm (5/8∫) above the top edge of the
plates. Add distilled water, if necessary.
CAUTION: Do not use a metal funnel to add distilled water.
The vent holes in the cell plugs must always be kept clear.
If distilled water has been added, wait 1/2 hour and then check the specific gravity of the battery acid.
For this test, the temperature should be as close as possible to +20 ∞C (68∞ F) .
Specific gravity
Condition of battery charge
[kg/dm3]
1.28 well charged
1.20 half charged,recharge
1.12 dead, recharge immediately
The battery must be especially well charged before and during the cold season, since the electrical power
consumption increases as the battery performance decreases.
CAUTION: If the batteries must be recharged, use DC current only, the current may never be
higher than 1/10th of the battery capacity.
Example: To recharge a 143 Amp battery, the charging current may not be higher than 14,3 Amps.
CAUTION: When working on the electrical system of the crane, and any time any welding must
be done on any part of the crane, the battery MUST be disconnected from the
electrical circuit by turning the battery master switch off.
517
7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE 023231>01
185301
518
Central lubrication system (fig. 1)

The crane superstructure is equipped with a central lubrication system. It is permissible to clean the crane with
water or steam.
All grease points of the slewing gear, the bearing of the pivot section, the bearings of the luffing cylinder and
hoist winches are automatically supplied with the proper amount of grease according to the operating hours.
The lubrication procedure takes two minutes, every two hours.
CAUTION: The lubrication interval must be set to 2.0 hours.

If the crane is not being operated for longer than 3 months, then it must be
lubricated every 3 month with an external grease pump on the grease fitting
block!(3), until grease emerges from all lube points.
Then repeat the corresponding crane movement several times and repeat the
lubrication procedure.
Component in the system
Pos. Description
1 Grease container
2 Grease nipple > to refill the central lubrication pump
3 Grease nipple > to refill the grease lines
4 Pump outlet
5 Pressure relief valve
6 Pump element
7 Button
8 Control
9 Indicator light (yellow)
10 Switch > interval set for .. hours (hrs.)
11 Switch > lubrication time set for .. minutes (min)
To set the lubrication and interval time

> Turn on the ignition of the crane engine, when the ignition is turned on, the yellow indicator light (9) lights up
for approx. 2 seconds, it shows that the control (8) is functional .
During the lubrication procedure, the yellow indicator light (8) blinks, on the pump housing, in 0.5 second
intervals.
The lubrication and interval time has been set at the factory. If necessary, these times can be changed via
switches (10, 11).
Function check
> With the ignition turned on, trigger 2 to 3 additional lube impulses to check if lubricant emerges from all lube
points.
> With the system block, but with a functioning electric pump, lubricated emerges on the pressure relief
valve!(5).
This assures the safety of the system and allows for system monitoring.
Access to the automatic lubrication system (intermediate lubrication).

> With the ignition turned on, press the red button (7) on the pump housing to initiate intermediate lubrication
intervals, for example after washing the crane. or to refill the grease lines with grease after a repair.
519
185301
520
To refill the grease container (1)

> With a commercially available grease pump, fill the grease nipple (2) on the central lubrication pump.
CAUTION: Make sure that the grease container (1) is always filled with grease, according to the
lubrication chart.
When filling the grease container, observe utmost cleanliness!
To bleed the system

If one of the grease containers (1) has become empty, then it might be necessary to bleed the system.
> Fill the grease container.
> Remove the main line from the pump outlet (4) .
> Trigger the lubrication impulse until the grease emerging from the pump outlet (4) contains no more air
bubbles.
> Reconnect the main line.
> Trigger additional lubrication procedure.
To refill the grease lines

> With an external grease pump fill on the grease nipple (3) or
> with the ignition turned on, press the red button (7) on the pump housing
CAUTION: After any repair work on grease lubricated components, refill the grease lines to
prevent the components from running dry.
When filling the grease lines, observe utmost cleanliness!
521
185301
522
Troubleshooting on the central lubrication system
Problem Cause Remedy
Pump does not work integrated, electronic control is Replace the lower part of the motor
defective, housing
electr. line is interrupted, replace electrical lines,
pump is defective replace pump
Pump works, but does not put Air cushion in supply piston Bleed pump,
out Fallen below min. level fill grease container,
Pump elements are defective replace pump elements
No grease collar on all lube Pump is not working see (Pump is not working∫
points Stop time is too long or lubrication Reduce stop time or extend lubrication
time is too short time
System is blocked see (Grease emerges from pressure
relief valve∫
No grease collar on several lube Lines to auxiliary distributor are Change lines
points broken or leak,
fitting leaks Retighten fitting or change it
No grease collar on one lube Corresponding line is broken or Change line

point leaks
fitting leaks Retighten fitting or change it
Pump speed reduced High system pressure Check system / bearing points
low ambient temperature no damage
(if necessary, grease once or twice in
between)
Grease emerges from pressure System pressure too high Check system
relief valve Progressive distributor blocked replace distributor
System blocked plugged / tight bearing point
Valve spring is defective replace pressure relief valve
523
185302
524
Check max. tilt play on the rotary connection, fig. 2

The maximum tilt play is 2,5 mm + 0,1 mm.
If the play exceeds this measurement, change the slewing connection.
DANGER: If the maximum permissible play is being exceeded, there is the danger that the
slewing ring breaks and the crane topples over.
525
183638
526
Slewing gear
> Check for leaks (visually).
With the slewing gear not moving

> Check the oil level on the dipstick, Fig. 8 , the oil level must be between the two notches.
> After checking the oil, reinsert the dipstick into the test point.
CAUTION: If there is any loss of oil, check out the problem, it must be remedied immediately.
Hoist gear
> Check for leaks (visually).
With the hoist gear not moving

> Check the oil level on the dipstick, Fig. 9 , the oil level must be between the two notches.
> After checking the oil, reinsert the dipstick into the test point.
CAUTION: If there is any loss of oil on the hoist gear, check out the problem, it must be
remedied immediately.
Hydraulic hoses
The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in safe
working condition.
Changing hoses
The hoses and lines must be replaced periodically.
Due to our experiences with mobile cranes, we recommend the maximum usage:
> in severe operation

at high operating temperatures and frequent movements approximately 3 years
> in normal operation approximately 6years
> in assembly operation with rare high output frequency approximately 12 years
CAUTION: The hoses on the intake lines of the oil reservoirs must be checked visually once a
month for cracks and damage, and, if necessary, they must be replaced
immediately.
527
528
Membrane accumulator in the hydraulic system
The following membrane accumulators are installed in the hydraulic system:

> Control pressure on basic block 10 bar
> Ballasting system (2 accumulators) each 40 bar
It is important that the pretension pressure given in the hydraulic schematic and on the accumulators is
available.
The pretension pressure must be measured in every reservoir.
CAUTION : If ambient temperatures fluctuate , for example in countries with extremely warm
or cold temperatures as well as in countries with great differences between summer
and winter temperatures, the gas pressures must be checked and corrected, if
necessary.
Check pretension pressure

Prerequisite:
> The crane hydraulic (or travel and crane engine) is not running, which relieves the fluid side of the membrane
accumulators ( reservoirs) .
> Check the pretension pressure with a testing and inflation device and correct the pressure, if necessary.
DANGER: To fill the reservoirs, DO NOT use a i r or o x y g e n. This can cause an
EXPLOSION !
The pressure in the nitrogen cylinder may not exceed the maximum permissible
operating pressure of the reservoir or the pressure gauge. If the pressure is higher,
a pressure reducing device must be connected between the cylinder and the
inflating device.
Note: In addition, you must observe any applicable national or local regulations !
529
182006
530
Telescopic boom
The inner sliding surfaces of the telescopic sections are lubricated via grease fittings in the bearing shoes (3).
These grease fittings are accessible via inspection ports on both sides of the pivot section as well as the
telescopic sections, if the telescopic sections are moved out to 60% or 90% .
For the inner and outer sliding surfaces on the telescopic sections, use special grease, as specified on the
lubrication chart.
Telescoping cables
The telescopic sections — and “are extended and retracted individually with one hydraulic cylinder each.
The telescopic sections ” and ‘ are extended and retracted simultaneously when telescoping telescopic
section “ via a cable mechanism.
Push out telescopic sections ” and ‘ via two 5way flat band ropes (telescoping cables),
Retract telescopic sections ” and ‘ via two 2way flat band ropes (return cables).
The telescoping and return cables can be monitored without disassembling the boom via several inspection
ports on both sides of the telescopic sections .
CAUTION: If a new cable must be added, then it must be the same make and strength and the
same diameter than the original.
The telescopic cables (flat band ropes) must be replaced as a pair.
Maintenance
In addition, the telescopic boom should be dismantled after an operating period of 20 000 hrs. or 10 years to
check all bearings, telescopic and return cables, cable pulleys and telescoping cylinders.
The telescopic sections are held at pretension by the return cables.
If this pretension has been lost due to permanent stretching of the cables, then the return cables must be
retensioned.
To retension the return cables

Telescope telescopic sections “, ” and ‘ about 1 m out and retension the return cables evenly on both sides
with adjustment nuts (1) until the return cables are tensioned properly on both sides.
Check visually through the side inspection ports on the telescopic sections.
The return cables should not hang more than 10 cm over their total length.
C A UT I O N : 1. When tightening the nuts (1) make sure that the return cables are not twisted.
2. After every retension procedure, check if the telescopic sections “,!”!and!‘are
pushed in synchronously.
To check synchronization
Carefully telescope telescopic sections “, ” and ‘in, the stop of telescopic section “ must first touch.
If this is not the case, then the stop of telescopic section “ must be thickened by adding or welding on a plate or
the stop of telescopic section ” must be reduced by grinding it off to suit.
531
188524
532
Take down criteria for belt cables in telescopic booms

To ensure crane safety, with proper use, regular inspection and maintenance of the crane, the belt cables (3),
which are utilized according to drive gear group 1Bm and are used in normal industrial applications, must be
replaced after 16 years of operation or 1600 operating hours, even if no damage is visible.
Belt cables (3) must be replaced:
1. Discard due to broken wires

See chapter 8.04 INSPECTION OF CRANE CABLES
2. Cable sag
If the maximum sag of a cable exceeds that of the other cables by 2 x the nominal diameter.
3. Sleeve
If there is any damage, corrosion or deformation on the sleeve.
4. Settling of cone (2) in sleeve (1)

During the crane operating time, the tapered cones in the sleeves (1) may settle. This is called 'settling of the
cone' (2).
The settling of the cone (2) is influenced by the following factors:

> dynamic changes of casting volume during cool down period
> roughness of casting surface in the cable fitting
> stress which occurs during cable pull
The settling of the cone can be determined by:

> measuring the settling
Number of cable strands in Max. permissible cone settling (L max.) when cable
casting must be discarded
3>5 4 mm
> Imbedding of cable in casting material.
The cable is proper imbedded if the cable strands are covered all around with casting material. If there are any
points or areas where this is not the case, then the cable (3) must be changed.
533
183637
534
Slewing platform ballast (added weight, replacement weight)
After the first 1000 kilometers of driving, check the mounting screws on the slewing platform ballast!Pos.!1
and 2!or!Pos.!1 on the counterweight frame, to make sure they are tight.
Check for mounting tightness every 10 000 km or every 400 operating hours, however at least once a year.
DANGER: If this is not assured, the tight seating of the slewing platform ballast
(counterweight) is no longer assured.
Due to oscillating movements during travel, the screws can be fatigued sufficiently
to cause them to break, which could cause the slewing platform counterweight to
fall down.
For tightening torque of mounting screws, see chapter 4.07COUNTERWEIGHT.
535
7.06 LUBRICATION CHART, QUANTITIES 023188>00
183134
536
7.06 LUBRICATION CHART, QUANTITIES 023188>00
Quantities, crane chassis approx. liter
Diesel engine D 926 TI>E

Engine oil 19.0
Coolant 40.0
Fuel tank
Diesel fuel 300.0
Powershift transfer gear
Engine oil 28.0
Axle drive DK>7, for (6¥6) 1) drive
Gear oil 9.0
1. Axle
Gear oil in axle drive 15.0
per wheel side 1.5
1)
2. Axle driven, for (6¥6) drive
Gear oil per wheel side 1.5
2. Axle, non>driven, for (6¥4)drive
Grease per wheel side as needed
3. Axle
Gear oil in axle drive 15.0
per wheel side 1.5
Hydraulic tank *
ATF 630.0
Quantities, crane superstructure approx. liter
Slewing gear
synthetic gear oil 3.0
Hoist gear
synthetic gear oil 3.4
Central lubrication system
Special grease 2 kg
* When checking the oil level in the hydraulic tank, all hydraulic cylinder must be retracted.
The oil level may not exceed the ªcenter sight gauge´ .
CAUTION : The given quantities are approximate.

When adding service fluids, always refer to the marks on the dipstick, the inspec>
tion ports or sight gauges.
Synthetic oils may not be mixed with mineral oils!
Abbreviations :
1 Engine oil
2 Grease
3 Gear oil
4 ATF
5 automatic grease supply via central lubrication system
1) Optional
537
7.07 SCHMIERSTOFFTABELLE 013098>08
538
Vorgeschriebene Schmierstoffe fÂr LIEBHERR Krane

Approved lubricants for LIEBHERR cranes
Lubrifiants prescrits pour les grues LIEBHERR
Verwendungszweck Umgebungstemperatur fÂr den Fahr> und Kranbetrieb

Ambient temperature for travel and crane operation
Intended use Temp±rature ambiante pour le mode translation et le
mode grue
Application $ 25 ∞C Æ + 50 ∞C $ 50 ∞C Æ + 10 ∞C
1 Dieselmotor SAE 10W>40 SAE 10W>40
diesel engine API CG>4 API CG>4
moteur Diesel ACEA E3>96 ACEA E3>96
LWE>Identnr.: 861005408 LWE>Identnr.: 861005408
unter $ 20 ∞C mit unter $ 20 ∞C mit

Vorwßrmung Vorwßrmung
below $ 20 ∞C with preheating below $ 20 ∞C with preheating
en>dessous de $ 20 ∞C avec en>dessous de $ 20 ∞C avec
pr±chauffage pr±chauffage
2 Antriebsachse mit Differentialen, SAE 90 SAE 75W>80

Planetengetrieben und angebautem API GL 5 API GL 5
Verteilergetriebe LWE>Identnr.: 861901008 LWE>Identnr.: 861003508
driving axle with differential, planetary
gears and flanged transfer case
essieu moteur ° diff±rentiel, r±ducteurs
plan±taires et bo¿te transfert
ZF Achsantieb DK>7
axle drive ZF DK>7
entra¿nement des essieux ZF DK>7
Fahrzeug Verteilergetriebe
transfer box
bo¿te de transfert
KESSLER (VG 1800 / 2400)
STEYR PUCH (VG 1200 / 1600 / 2000)
STEYR PUCH Versatzgetriebe (drop box)

STEYR PUCH drop box
STEYR PUCH decaleur de bo¿te de
transfert
Pumpen>Verteilergetriebe
pump transfer cases
bo¿tes transfert de pompes
Bergewinde
recovery winch
treuil de remorquage
Fahrgetriebe fÂr Raupenkran

travel gear transmission for crawler crane
r±ducteur de translation pour grues sur
chenilles
539


mode grue
3 ZF Lastschaltgetriebe SAE 15W>40 ATF 86 (66M)
(WG 120 / 150 / 180 / 181 / 200 / 201) API CF>4 ALLISON C4
ZF power shift gears ACEA E2>96 ZF TE>ML 14
ZF bo¿tes de vitesse et d'inversion LWE>Identnr.: > LWE>Identnr.: 861900608
ALLISON Versatzgetriebe (drop box) unter $ 15 ∞C Warmfahren unter $ 35 ∞C mit

ALLISON drop box nach gesonderter Vorwßrmung
ALLISON decaleur de bo¿te de transfert Warmlaufvorschrift below $ 35 ∞C with preheating
below $ 15 ∞C warm up en>dessous de $ 35 ∞C avec
CLARK Lastschaltgetriebe according to special warm up pr±chauffage
CLARK power shift gears specifications
CLARK bo¿tes de vitesse et d'inversion en>dessous de $ 15 ∞C mise en
temp±rature d'apres les
consignes particuli∞res de
pr±chauffage
4 Automatikgetriebe ATF 86 (66M) ATF 86 (66M)

automatic transmissions ALLISON C4 ALLISON C4
bo¿tes de vitesses automatiques ZF TE>ML 14 ZF TE>ML 14
ALLISON
(CLBT 740 / 750 / 754 / 755)
(HT 755 / HD 4560) unter $ 35 ∞C mit
Vorwßrmung
ZF Wendegetriebe (WG 210 / 251 / 260) below $ 35 ∞C with preheating
ZF reversing transmission en>dessous de $ 35 ∞C avec
ZF bo¿tes d'inversion pr±chauffage
5 Seilwinde ISO VSG 220 ISO VSG 68

winch PGLP 220, DIN 51 502 PGLP 68, DIN 51 502
treuil LWE>Identnr.: 861901208 LWE>Identnr.: ohne
Drehwerksgetriebe nicht mischbar mit nicht mischbar mit

slewing gears Mineral‘len! Mineral‘len!
m±canismes d'orientation do not mix with mineral oils! do not mix with mineral oils!
non miscible avec des huiles non miscible avec des huiles
TA>Abspannwinde mit Klinkensperre min±rales! min±rales!
TA>pawl guy rope winch
TA>treuil de haubanage ° cliquet
540


mode grue
6 Kranhydraulik ATF 86 (66M) Sondervorschrift:
fÂr Kranfahrgestell und Kranoberwagen DEXRON II D special prescription:
crane hydraulics LWE>Identnr.: 861900608 prescription sp±ciale:
for crane carrier and crane superstructure ATF 44 M
hydrauliques LWE>Identnr.: 861902290
pour ch£ssis porteur et partie tournante
TA>Abspannwinde mit Lamellenbremse

TA>guy rope winch with multiple>disk
brake
TA>treuil de haubanage avec frein
multidisques
7 Scheibenbremsanlage DOT 4 Sondervorschrift:

disk brake system SAE J 1703e special prescription:
syst∞me de frein ° disque LWE>Identnr.: 861000108 prescription sp±ciale:
ATE Arktis 3.9901.5503.2
LWE>Identnr.: 861000190
8 Allgemeine Gleit> und Wßlzlagerungen Sondervorschrift: Sondervorschrift:

wßlzgelagerte Gelenke LIEBHERR LIEBHERR
general plain and roller bearings Spezialfett 9610 PLUS Spezialfett 1026
joints on rolling bearings LWE>Identnr.: 861301308 LWE>Identnr.: 861303708
paliers lisses et ° rouleaux courants
articulations ° palier special prescription: special prescription:
LIEBHERR LIEBHERR
Zentralschmieranlage Kranoberwagen special grease 9610 PLUS special grease 1026
centralized lubricating system crane
superstrcture prescription sp±ciale: prescription sp±ciale:
graissage central partie tournante LIEBHERR LIEBHERR
graisse sp±ciale 9610 PLUS graisse sp±ciale 1026
Auslegerverriegelung
boom locking
verrouillage de la fl∞che
Drehkranz>Wßlzlagerungerungen
slewing ring rolling bearings
paliers couronnes d'orientation
Gelenkwellen
cardan shafts
arbres articul±s
541


mode grue
9 Drehkranzschrauben (nur bei Montage) Sondervorschrift: Sondervorschrift:
slewing ring bolts (only at assembly) special prescription: special prescription:
boulons pour couronne d'orientation prescription sp±ciale: prescription sp±ciale:
(seulement lors montage) Gleitmo 100 S Gleitmo 100 S
10 Kunststoff>Gleitlagerungen der Sondervorschrift: Sondervorschrift:

Teleskopausleger LIEBHERR LIEBHERR
synthetic sliding bearings of the telescopic Spezialfett 9613 Spezialfett 1026 LS
boom LWE>Identnr.: 861303608 LWE>Identnr.: 861302608
paliers de guidage synth±tique de la fl∞che
t±lescopique special prescription: special prescription:
LIEBHERR LIEBHERR
Kunststoff>Gleitlagerungen der special grease 9613 special grease 1026 LS
Schiebeholme
synthetic sliding bearings of the prescription sp±ciale: prescription sp±ciale:
outriggers LIEBHERR LIEBHERR
paliers de guidage synth±tique des graisse sp±ciale 9613 graisse sp±ciale 1026 LS
stabilisateurs
AbstÂtzplatten mit Ausgleich

Outrigger plates with compensation
Patins de calage avec compensation
11 Innengleitlagerung der Teleskopausleger Sondervorschrift: Sondervorschrift:

(nur bei Montage) LIEBHERR Spezialfett 1336 LIEBHERR Spezialfett 1336
internal slide bearing application of mit L‘sungsmittel LM mit L‘sungsmittel LM
telescopic booms (only at assembly) (SprÂhfett) (SprÂhfett)
guidage ° glissement int±rieur des fl∞ches LWE>Identnr.: 861303308 LWE>Identnr.: 861303308
t±lescopiques (seulement lors du montage)
special prescription: special prescription:
LIEBHERR special LIEBHERR special
grease!1336 with LM carrier grease!9613 with LM carrier
(spray grease) (spray grease)
prescription sp±ciale: prescription sp±ciale:

LIEBHERR graisse LIEBHERR graisse
sp±ciale!1336 ° v±hicule LM sp±ciale!96103 ° v±hicule LM
(graisse ° pulv±riser) (graisse ° pulv±riser)
542


mode grue
12 Offene Verzahnung der Drehkrßnze Haftschmierstoff Haftschmierstoff
open toothing of slewing rings OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
denture des couronnes d'orientation (wasserbestßndig) (wasserbestßndig)
Laufende Seile
running ropes adhesive lubricant adhesive lubricant
c£bles d±roulants OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
(water resistant) (water resistant)
lubrifiant adh±sif lubrifiant adh±sif

OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
(r±sistant ° l'eau) (r±sistant ° l'eau)
13 Seil der Bergewinde Sondervorschrift: Sondervorschrift:

rope of the recovry winch special prescription: special prescription:
c£ble du treuil de remorquage prescription sp±ciale: prescription sp±ciale:
Motorex TW>Fluid Motorex TW>Fluid
14 KÂhlerfÂllung fÂr Dieselmotoren und KÂhlerschutzmittel KÂhlerschutzmittel

Heizanlagen LIEBHERR>Norm LIEBHERR>Norm
radiator filling for Diesel engines and 50 % Korrosions> / 60 % Korrosions> /
heatings Frostschutzmittel Frostschutzmittel
remplissage de radiateur pour moteurs LWE>Identnr.: 861600508 LWE>Identnr.: 861600508
Diesel et chauffages 50 % Wasser 40 % Wasser
radiator protective agent radiator protective agent

LIEBHERR standard LIEBHERR standard
50 % corrosion preventatives / 60 % corrosion preventatives /
antifreeze fluids antifreeze fluids
50 % water 40 % water
agent de protection de agent de protection de

radiateur radiateur
norme LIEBHERR norme LIEBHERR
50 % produit antigel / 60 % produit antigel /
anticorrosion anticorrosion
50 % eau 40 % eau
543
8.00 CRANE INSPECTIONS 022101>00
544
022101>00
Chapter 8
Crane inspections
545
8.01 REPEAT CRANE INSPECTIONS 021686>06
General
This crane has been inspected before delivery at the factory, according to the valid ISO, FEM and DIN
standards or VBG 9 (ZH 1/27).
During crane operation, deviation may occur from the safety standard, which had existed at initial delivery.
Such deviations can be the result of wear, corrosion, intentional force, environmental changes or application
changes.
The operator must take care of the required tasks to maintain the same initial standard of safety at all times.
For that reason, the crane must be inspected by an experienced technician, depending on conditions of
application and operational conditions, at least once a year, counting from the day of initial service. See also:
ISO 9927>1, EU machine guidelines (EWG Maschinenrichtlinie) 89/655, VBG 9.
The crane must be inspected by an expert engineer at least once every 4 years, counting from the day of initial
service .
After the 12th year in operation, an expert engineer must check the crane annually.
CAUTION : If significant changes had been made on the crane, or after repairs of load carrying
part , the operator must have the crane inspected by an experienced technician
before putting the crane back in service.
In addition, national and regional regulations apply.
Experienced technicians are persons who, due to their vocational background and experience, have sufficient
knowledge in the field of lifting appliances (cranes) and are sufficiently familiar with the relevant regulations,
such as labor laws, OSHA regulations, accident preventions regulations, to determine deviations from the
proper and safe conditions (they are specially trained personnel).
Expert engineers are engineers experienced in the design, construction and maintenance of lifting devices, such
as cranes, with sufficient knowledge of the relevant regulations and standards, who have equipment necessary
to carry out the inspection and are in a position to judge the safe condition of the lifting appliance (crane) and to
decide which measures have to be taken in order to ensure further and continued safe operation.
A repeat crane inspection is generally a visual inspection, where the experienced technician / expert engineer
inspects the condition of the crane and components. .
This inspection should prevent accidents through timely recognition of defects.
Any defects found by an experienced technician / expert engineer must be documents, remedied and
reinspected.
Below, as an example, we have listed certain important items, which must be checked especially during repeat
crane inspections. We note that the experienced technicians / expert engineers are solely responsible for
carrying out the crane inspection. For that reason, we cannot list the complete range of inspections in this
chapter.
Attached is a checklist for the inspector for repeat inspections of LIEBHERR mobile and crawler cranes.
If the inspector has any questions, they should be directed via our Service Dept. to the appropriate departments
at LIEBHERR>WERK EHINGEN GMBH.
DANGER: Non>observance of the following inspection guidelines or non>adherance of the

inspection intervals can lead to a serious accident !
546
1. Inspection of load bearing / load carrying steel constructions
The load bearing steel constructions, such as boom , slewing platform, chassis, support systems (sliding
arms or folding supports) must be part of a careful inspection at least once a year. Even though the
welding seams normally are not in high stress areas, it is nevertheless important to pay special
attention to them during this repeat inspection.
We refer to DIN 15018, part 3, point 1, which lists permissible stress figures for highly resilient steel.
They also determine the life expectancy of the steel frame work. It cannot only be calculated from the
stress figures alone, but also depends on the collective load figures during time of operation.
LIEBHERR cranes are designed and sized for installation operation, whereby the following design
calculations have been used as a basis (DIN 15018, part 3):
Load collective : SO (light)
Stress figure: 25 000
For that reason, the load bearing or load carrying parts of the steel construction and the welding seams
must be subjected to an especially intensive check during the repeat inspection by an expert engineer.
If the crane was subjected to excessive stress, for example an unusual shock or impact during its time in
operation , the inspection of load baring components must be carried out immediately.
If any damage, such as cracks, can be found at any point of the steel construction, then the extend of
damage must be determined by expert personnel with the aid of material analysis methods, such as
magnetic powder test, ultra sound or X>ray tests. Then it must be determined by expert personnel if the
defective section can be repaired by repair welding or by other means.
The following drawings show examples of load bearing welding constructions. For example, welding
seams which need to be checked can occur in multiple areas on the steel components and in a variety of
shapes. The connections or zones around the points marked by arrows must be checked.
CAUTION : We note that all crane inspections, as far as content and extend, are the sole
responsibility of the inspector. The following drawings are given only as an
aid for the inspector. The drawings are only examples, and we do not claim
that they are complete!
547
Vehicle fame
185046
548
Sliding arms
185047
549
Folding arm
185060
550
Slewing platform frame
185048
551
Slewing platform frame
185049
552
Telescopic boom
185050
553
Lattice jib
185051
554
NA / WA> bracket
185052
555
Installation unit with lattice jib
185053
556
Pulley head
185054
557
Guy rods
185055
558
Lattice boom
185056
559
Folding jib
185057
560
Folding jib
185058
561
TA> guying
185059
562
1.1 Check the rims
The wheel and the rim are one of the most important safety>related items on the vehicle. The rim is
designed as a welded steel construction, and must be checked as outlined in paragraph 1. ™Checking
load carrying steel constructions∫.
In addition, chapter 7.04 ™MAINTENANCE INSTRUCTIONS $ CRANE CHASSIS∫, paragraph ™Safety
and maintenance guidelines for rims∫.
In addition, at least once a year during the annual crane inspection, the rims should be checked for
cracks. We recommend a color penetration procedure. If any cracks or even the beginning of crack
formation is shown, then the rims must be replaced immediately.
After a service time of max. 40 000 km, irregardless of the actual driven load collective, the operator
must monitor the rims constantly.
The rims should be checked especially for cracks in the base material and in the areas marked by
arrows.
188019
2. Inspection of hoist and pull in winches
The hoist and pull in winches and slewing gears are closed planetary gear versions. These gears have
been designed for long service life, drive shafts and gear wheels are also long lasting.
Even though these gears have been designed for long service life, an external visual inspection is not
sufficient in this case, because the service life can be influenced by insufficient maintenance (lack of
oil), defective seals, improper operation or overuse. For that reason, the inspection must be made by
experienced technicians according to the following guidelines:
563
2.1 Inspections
2.1.1 Inspection intervals

Every 1000 operating hours, at least once a year (annually)
2.1.2 Inspection
Check oil level. On hoist and pull in winches, we recommend to drain the oil and compare the amount
with the stipulated oil quantity.
2.1.3 Check color of oil

If the oil is blackened and / or if the oil smells burnt, one can assume that the oil has been overheated. In
that case, the oil must be changed.
2.1.4 Check for foreign particles

This test should be done in a qualified lab. The used oil is dropped onto specified filter paper. The oil
sample is visually checked under a microscope for foreign particles. If any are found, then the oil must
be analyzed by a qualified lab to determine the make up of the particles.
2.1.5 Evaluation of foreign particles found in oil

Maximum permissible foreign particle parts are 0.15% of the total oil quantity, by weight.
Maximum permissible foreign particle size from fine shavings to 0.25 my.
If the above values have been exceeded, remove the gear and check out the cause of increased
contamination. Replace any damaged parts and fill the gear with new oil.
CAUTION: These repairs may only be made by expertly trained personnel.
2.1.6 Visual inspection

The gears must be checked for leaks, since any loss of oil > aside from environmental contamination >
can also lead to gear failure.
2.1.7 Check brakes in gears

Check the brakes at the same time you check the gears.
If the brakes should not hold the required test load of +33% cable pull increase on single line and fully
coiled drum, then they must be removed and the cause must be found. If the planetary gear is removed
due to increased oil contamination, check the brakes at the same time.
CAUTION: Only expertly trained personnel may inspect gears and brakes!
2.1.8 Document completed inspection

The result of annual inspections and repair / reconditioning work, including all completed tasks, must
be recorded by the expert or the trained service technician, if necessary, and signed off by the inspection
station or specialty shop.
This documentation must be enclosed in the crane inspection booklet and must be recorded in the repeat
inspection column.
564
2.2 Required measures to monitor the winches
2.2.1. Theoretical service life

When calculating and dimensioning the winches for your crane, the designer took certain operating
conditions and a calculated total service life time into account, which resulted in a theoretical service
life.
The winches in your crane are classified according to DIN report 1, ISO 4301/1 or FEM 9.511, as follows:
Drive group: M3 (1 Bm)
Load collective: Q1 (L1)
Factor of load collective km: 0.125
Theoretical service life D: 3200 hrs.
CAUTION: The "theoretical service life" may not be equated with the real (actual)
service life of a winch!
The real service life for a winch is influenced by many external matters, such as :
1. Overloads: because the crane was not utilized as intended
2. Insufficient maintenance: oil has not been changed at the proper intervals
3. Erroneous operation : extreme acceleration or deceleration of the load

Load fell into the cables
4. Maintenance errors: Use of wrong oil

Wrong quantity
Contamination during oil change
5. Installation errors during repair or maintenance
6. Leakages which were not taken care of
7. Improperly adjusted safety devices
8. Hidden accident damage
9. Extreme ambient conditions: Low or high temperatures

aggressive atmosphere
Dust and dirt
565
2.2.2 Used portion of theoretical service life

The crane operator is obligated to have the crane inspected at least once a year (ISO 9927>1 and VBG 8).
The used portion of the theoretical service life must also be determined. If necessary,the crane operator
must call in an expert.
When determining the used portion of the theoretical service life, the actual operating conditions (load
collective) and the operating hours of hoist gears per inspection interval must be determined. The user
is responsible to have it documented in the crane inspection booklet.
2.2.2.1 Determining the operating conditions (Load collective)

The load collective of the crane is divided into groups; see also DIN report 1, ISO!4301/1 or FEM 9.511.
From the determination of the actual operating conditions, choose one of the following load collectives
and enter them in the crane inspection book for the corresponding inspection interval.
Note: For mobile cranes in assembly operation, we normally use the load collective L1
(Q1), with the load collective factor km = 0.125.
566
Load Factor of
collective Definition Service life portion load Graphic view
Classification collective
Light Drive gear or parts 10 % of running time km=0,125 Load %

Q1 thereof, which run only with largest load
100
L1 at high utilization in (dead load + 1/1 load
exceptional cases , but capacity)
are subjected to 40 % of running time
constant, but only light with dead load + 1/3 50
40 %
duty load capacity)
50 % of running time 10 %
with only dead load 0
50 100
Running time %
Medium Drive gear or parts 1/6of running time with km = 0,25 Load %
Q2 thereof, which often largest load
100
L2 run at high utilization, (dead load + 1/1 load
but are subjected to capacity)
73 %
light duty 1/6 of running time
with dead load + 2/3 50 47 %
load capacity
20 %
1/6 of running time
with dead load + 1/3 0
load capacity 50 100
50 % of running time
only with dead load Running time %
Heavy Drive gear or parts 50 % of running time km = 0,5 Load %
Q3 thereof, which often with largest load
100
L3 run at high utilization, (dead load + 1/1 load
but are subjected to capacity)
constant medium duty 50 % of running time
only with dead load 50
40 %
0
50 100
Running time %
Very heavy Drive gear or parts 90 % of running time km = 1 Load %
Q4 thereof, which with largest load
100
L4 regularly run at high (dead load + 1/1 load
utilization, and are capacity) 80 %
subjected to constant 10 %of running time
heavy duty only with dead load 50
0
50 100
Running time %
567
2.2.2.2 Determining the effective operating hours Ti

The effective operating hours, as determined as follows, must be entered in the crane inspection
booklet for the corresponding inspection interval, differentiated by the following 4 points:
2.2.2.2.1 Hour meter is on every winch

If your crane is equipped with an hour meter on every winch, then the effective umber of operating
hours Ti per inspection interval can be read directly.
2.2.2.2.2 Hour meter for the total crane operation

The winch operation portion of the total operating hours of the superstructure must be guessed.
Note: For mobile cranes in assembly operation, normally, when hoist winches are used,
20% of the total superstructure operating hours can be contributed to winch
operation.
2.2.2.2.3 Hour meter for both travel and crane operation

The winch operation portion of the total operating hours of the superstructure must be guessed.
Note: For mobile cranes in assembly operation, normally, 60% of the total operating
hours can be contributed to superstructure operation. If 20% of the total
superstructure operating hours can be contributed to winch operation (see
paragraph 2.2.2.2.2), the result would be 12% of the total crane operating hours.
2.2.2.2.4 If there is no hour meter at all

In this case, the operator must guess and document the actual winch operating hours .
Note: The given percentage values apply normally for the main hoist winch. For
auxiliary hoist winches or adjustable boom winches, the actual share of total
operating hours can be significantly less and must therefore be guessed by the
operator.
568
2.2.2.3 To determine the used portion of the theoretical service life

For an inspection interval i (max. 1 year after ISO 9927>1 or VBG 8), the used portion Si of the
theoretical service life is determined according to the following formula:
kmi
Si = &&&&& ¥ Ti
km
km = Factor of load collective, which was the basis when calculating the winch. This factor can
be taken from the Operation Manual.
kmi = Factor of load collective in the inspection interval i according to paragraph 2.2.2.1
Ti = effective operating hours in the inspection interval i according to paragraph 2.2.2.2
This used portion is taken off after each inspection interval from the remaining theoretical service life
Di (see example).
If the remaining theoretical service life is insufficient for the next operating period, then the winch
must be reconditioned or overhauled.
When the theoretical service life D has been reached (see paragraph 2.2.1), then the winch may only be
operated again after it has been reconditioned or overhauled.
In any case, it must be reconditioned or overhauled at the latest after 10 years after putting the
crane into service.
The general reconditioning or overhaul must be initiated by the operator and must be done by the
manufacturer or by a person authorized by the manufacturer and the overhaul must be documented in
the inspection booklet.
After the general reconditioning or overhaul, the manufacturer or the person authorized by the
manufacturer will note a new theoretical service life D.
In any case, the maximum time frame to the next general overhaul is max. 10!years.
569
2.2.3. Example
According to the Operation Manual, a mobile crane with separate hour meter for travel drive and crane
operation is classified by the manufacturer as follows:
Drive gear group: M3

Load collective: light L1, km = 0.125
Theoretical service life: D = 3200 hrs.
The used part S of the theoretical service life can be calculated for the individual inspection intervals as
follows:
1st Inspection (1st year)
The crane has been utilized during the past year for assembly work:
Load collective L1, which means km1 = 0.125.
The superstructure hour meter read 800 hrs. Winch operation was about 20 % of that, which means
T1!= 160 hrs.
At the 1st inspection, the used part S of the theoretical service life is therefore as follows:
0.125
S1 = &&&&& ¥ 160 hrs = 160 hrs.
0.125
remaining theoretical service life:
D1 = 3200 hrs > 160 hrs. = 3040 hrs.
The above values are entered in the chart in the crane inspection booklet, see paragraph 2.2.4)
2nd Inspection (2nd year )
The crane has been utilized for unloading ships in the harbor:
Load collective: L3, which means km2 = 0.5
The superstructure hour meter read 2000 hrs, which means during this period:
2000 hrs. > 800 hrs. = 1200 hrs. (800 hrs. were used in the first year of operation)
Of that, the winch was used about 40 %, which means T2 = 480 hrs.
The used portion S2 of the theoretical service life can be calculated for the 2nd individual inspection
interval as follows:
0.5
S2 = &&&&& ¥ 480 hrs. = 1920 hrs.
0.125
D2 = 3040 hrs. > 1920 hrs. = 1120 hrs.
570
3rd Inspection (3rd year)
The crane has been used for assembly work and sometimes for unloading work in the harbor:
Load collective: L2,which means km3 = 0.25
The superstructure hour meter reads 3000 hrs, which means that during this period:
3000 hrs. > 2000 hrs. = 1000 hrs. (2000 hrs. were used up in the first two years of operation)
Of that, the winch was used about 30 %, which means T3 = 300 hrs.
The used portion S3 of the theoretical service life can be calculated for the 3rd individual inspection
interval as follows:
0.25
S3 = &&&&& ¥ 300 hrs. = 600 hrs.
0.125
D3 = 1120 hrs. > 600 hrs. = 520 hrs.
The above values are entered in the chart in the crane inspection booklet as shown in chart 1.
2.2.4. Addendum
Chart 1 shows an example.
Document the remaining theoretical service life on chart 2.
571
Chart to determine the remaining theoretical service life of winch No. 1 (Main hoist winch)
Crane type: LTM 1050
Fabrication No.: 0010 540 08
Put in service : 12345
Serial number of winch according to data tag: 0815 Si = Used part of theoretical service life since last inspection
Last general overhaul performed on: ................... Di = Remaining theoretical service life
Configuration data of winch (see Operating Manual): Di > 1 = Remaining theoretical service life after previous inspection
Drive gear group: M3 km = Factor of load collective, which was taken for calculation of winch.
Load collective: Q 1 (L1) This factor is to be taken from the Operating Manual
Factor of load collective km: 0.125 kmi = Factor of load collective in inspection interval i according to paragraph 2.2.2.1
Theoretical service life D: 3200 hrs. Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining
Name of Signa> Remarks
No. initial conditions since load operating hours of hours of hours of hours of winch theoretical theoretical service
inspector ture
service, last inspection connective hours super> super> winch since last service life D: life
data of (load collective) structure structure inspection Ti kmi
inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
0 10.06.90 > > > 0 0 3200
160
1 05.06.91 L1 0,125 > 800 800 > (20 % of 800) 160 3040 MÂller
480
2 20.05.92 L3 0,5 > 2000 1200 > (40 % of 1200) 1920 1120 Huber
300
3 18.05.93 L2 0,25 > 3000 1000 > (30 % of 1000) 600 520 Maier
CAUTION: Perform general overhaul at least once every 10 years.

General overhaul last performed on : .........................
Chart to determine the remaining theoretical service life of winch No. ....
Crane type: ...................
Fabrication No.: ...................
Put in service: ...................
Serial number of winch according to data tag: ................... Si = Used part of theoretical service life since last inspection
Last general overhaul performed on: ................... Di = Remaining theoretical service life
Configuration data of winch (see Operating Manual): ................... Di > 1 = Remaining theoretical service life after previous inspection
Drive gear group: M................ km = Factor of load collective, which was taken for calculation of winch.
Load collective: Q.......(L.....) This factor is to be taken from the Operating Manual
Factor of load collective km: ................... kmi = Factor of load collective in inspection interval i according to paragraph 2.2.2.1
Theoretical service life D: ................... Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining Name of Signa> Remarks
No. initial conditions since load operating hours of hours of hours of hours of winch theoretical theoretical service inspector ture
service, last inspection connective hours super> super> winch since last service life D: life
data of (load collective ) structure structure inspection Ti kmi
inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
CAUTION: Perform general overhaul at least once every 10 years.

General overhaul last performed on : .........................
180068
574
3. Inspection of load hook

The load hooks must be regularly checked by an expert.
These inspections are made to prevent accidents through early detection of problems.
Any problems found during these inspections must be documented, remedied and then reinspected .
3.1 Inspections and monitoring procedures
3.1.1 Distortion
Check for any distortions, for example on the open end of the hook, regularly, but at least on an annual
basis.
The open end of the hook may not have stretched by more than 10% in relation to the initial
measurement ∫y∫ or exceed ∫y1∫ and ∫y 2∫.
DANGER: If the hook opening is now wider by more than 10 % of the initial
measurement, then the load hook may no longer be used.
In that case, contact the Service Department at Liebherr Ehingen .
Note: The initial measurements ∫y∫ or ∫y1∫ and ∫y2∫ are noted on the load hook. Measure
from point to point, as shown.
3.1.2 Corrosion
For this test, the nut must be removed from the hook shaft, so that the threads can be checked for
corrosion and wear.
DANGER: In case corrosion and wear is found on the threads, the load hook may no
longer be used.
In that case, contact the Service Department at Liebherr Ehingen .
refer to chapter
4. Check the cable push out mechanism in the telescopic boom.

4.1 Inspection of pretension of pull back cables, see chapter 7.05
4.2 Life expectancy of cables according to DIN 15020, or ISO 4309, see chapter 8.04
5. Check the inner and outer locking systems on the telescopic boom for function.
For cranes with apneumatic locking system: pin set up, wear and safety control, refer to
chapter!8.11.
6. Check the safety control or the limit switch in the relapse support and the boom A>brackets,
refer to chapter 8.12.
7. Check the nitrogen reservoir for correct gas pressure, especially that of the relapse supports
and suspension accumulators (observe instructions).
refer to chapter 7.04, 7.05, 8.13, 8.14.
575
8. Check the cable pulleys

8.1 The cable pulleys must be checked once a year all around for damage and cracks.
If the cable pulleys have been hit during crane operation (for example on buildings, etc.) or if they were
subjected to any other stress factors, then they must be extensively checked for damage or cracks.
DANGER: If any damage or cracks are found, then the cable pulley must be replaced
immediately. If this is not observed, there is great danger of causing a
serious accident!
8.2 In addition, check the wear in the cable groove. If the cable groove base is run in by more than p of the
cable diameter, then the pulley must be replaced.
9. Check the safe load system for function.

9.1 With the longest boom, move to the minimum and maximum radius: Check the load indication, take the
hook block as a test weight.
The deviation may not be more than 10% of the load capacity in these two extreme positions.
9.2 The given radius must be measured again for the longest boom for the smallest radius and at a boom
angle of 45∞ .
The deviation may not be more than 10% of the measured radius.
10. Check the slewing ring connection

10.1 For tilt play measurement, see chapter 7.05
11. Check the mounting tightness of the load carrying components

Check the mounting screws of the pulley rotary connection, winches, slewing gears and tackle couplings
for tight seating.
11.1 The mounting screws of the rotary connections are pretensioned at the factory, and normally should not
loosen up during normal operation.
However, if the crane has been overloaded or if the load broke off, then it is possible that the screw
connection has been overloaded and the screw has been stretched.
For that reason, check these screws during the annual inspection or after an overload to make sure they
are seated tightly.
Any loose screws, as well the the two screws next to them on both the left and right hand side should be
completely removed and carefully checked for damage.
The screws must be especially inspected for cracks or distortion. If the screw has been stretched by more
than 0.2% (in relation to it original length) or if cracks or other damage can be seen, then the damaged
screws must be replaced. In case the screws were stretched or damaged, the screws next to the damaged
screw should also be replaced.
576
12. Check the oil and fuel tanks

Check the oil and fuel tanks at least once a year and in subsequent inspections every 4 years all around
for leaks.
Repairs may only be made by especially trained expert personnel.

Improper repairs, for example welding, brazing or soldering are not permitted without consulting the
Service Dept. at LIEBHERR Ehingen!
13. Check the reeving auxiliary winch, salvage and spare tire winch
Check the corresponding manufacturer for the life expectancy of the reeving auxiliary winch, salvage
and spare tire winch .
Addendum
To aid the inspector, attached find a check list for repeat inspections of LIEBHERR mobile and crawler cranes.
577
Inspection guidelines for repeat inspection of LIEBHERR mobile and crawler cranes according to
ß26(1) or (2) UV ™Cranes™ (VBG 9)
Company: . . . . . . . . . . . . . . . . . . . . . . . . Inspector: . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . . .
Crane manufacturer:LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . . .
Year: . . . . . . . . . . . Inventory number: . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature of inspector for No. 1 to 20: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Inspection group: Crane documentation

Item to be checked A B C D E Remarks
Crane inspection book
Operation> / installation manual
Crane control book
Load chart manual
Work planer
2. Inspection group:Decals / signs
Data tag
Load capacity data
Decal for operating instructions
Warning and safety decals
Other safety signs
3. Inspection group:Travel gear 1)
Frame 2)
Supports 2)
Axles
Wheels
Tires
Bearing
Gear
Universal drive shaft
Springs
Shock absorber
Steering
Brakes
Hydraulic axle suspension
A: existing / complete B: Condition / Maintenance C: Function

D: Repair / Replacement E: Reinspection required
done = ¥ not done = > not required = 0
578
Company: . . . . . . . . . . . . . . . . . . . . . . . Inspector: . . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . .
Crane manufacturer:LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
4. Inspection group: Chassis 1)

Covers
Steps
Counterweight retainers 2)
Tackle devices
Ladders
Retainer for hook block 2)
Boom receptacle 2)
5. Inspection group: Chassis > Driverπs cab 1)
Doors
Window / windshields
Windshield wiper
Mirror
Seat
Heater
Ventilation
Noise protection
Recorder
First aid kit
Spare bulbs
Warning triangle
Warning vest

579
6. Inspection group: Chassis > Drive 1)

Engine
Exhaust system
Fuel tank
Filter
Muffler
Engine suspension
Oil levels
Fuel lines
7. Inspection group: Chassis > Hydraulic system 1)
Oil tank
Filter
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure relief valves
8. Inspection group: Chassis > Air pressure system 1)
Compressor
Filter
Air tank
Valves
Lines
Hoses
Cylinder

580
9. Inspection group: Chassis > Electrical system 1)

Motors
Generators / Alternators
Battery
Schalter
Lines
Fuses
Resistors
Lighting
Brake lights
Blinkers
Tail lights
Floodlights
Signal devices
Indicator lights
Battery switch
Limit switch:
Gear, steering, drive
Support force indicator 2)

581
10. Inspection group: Chassis > Control systems 1)

Engine regulation
Gears
Couplings / clutches
Gear shifts
Brakes
Steering
Indicators
Engine stop line
Control of outrigger supports 2)
Axle suspension
Crane leveling control
Rear axle steering
11. Inspection group: Superstructure
Frame
Covers
Steps
Mounting
Counterweight
Relapse retainer
Slewing ring: tilt play
Slewing ring: mounting screws
Slewing ring: gear
Slewing gear: Mounting screws
Slewing gear: Gear

582
12. Inspection group: Superstructure > Crane operatorπs cab

Doors
Windows / windshields
Windshield wiper
Mirror
Seat
Heater
Ventilation
Shock absorber
Control lever for working functions
Gear controls
Retention: Scrapes / chafings/ kinks
13. Inspection group: Superstructure > Retention and protective devices
Handles and ladders / steps to the cab and to drive gears
Covers
Coverings
Flaps
14. Inspection group: Superstructure > Drive system
Engine
Exhaust system
Fuel tank
Filter
Muffler
Engine suspension
Fuel lines

583
15. Inspection group: Superstructure > Hydraulic system

Oil tank
Filter
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure relief valves
Brake lowering valves
Brake control: Hoist gear
Brake control: Slewing gear
16. Inspection group: Superstructure > Electrical System
Motors
Generators / Alternators
Batteries
Switches
Lines
Fuses
Resistors
Lighting

584
Crane manufacturer: LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
17. Inspection group: Superstructure > Control systems

Engine regulation
Gear
Elastic couplings
Controls
Engine stop line
Indicators
18. Inspection group: Superstructure > Cable drive systems
Winch I 3)
Winch II 3)
Winch III 3)
Winch IV 3)
Cable pulleys
Cable end mounting
Cable for winch I
Cable for winch II
Cable for winch III
Cable for winch IV
Guy ropes
19. Inspection group: Superstructure > Hook
Pulleys
Cable guide bar on pulleys
Axle retainer
Load hook
Load hook mounting
Hook retainer

585
Crane manufacturer: LIEBHERR . . . . Crane type: . . . . . . . . . . . . . . . . . . . . . . . S/N:
20. Inspection group: Superstructure > Safety and Control devices

Hoist limit switch I
Hoist limit switch II
Lowering limit switch I
Lowering limit switch II
Boom limit switch I
Boom limit switch II
Luffing jib: boom limit switch I
Luffing jib: boom limit switch II
Load moment limiter
Angle indicator: Boom
Angle indicator: Luffing jib
Angle indicator: Slewing gear
Safety devices: Steuerung
Working range limitation
Pressure sensor
Speed sensor
Wind velocity sensor
Sliding arm monitor
Support force monitor
Incline monitor
Length indicator:
radius, boom length
Emergency off
Engine stop

586
20. Inspection group: Boom

Welding construction
Cable pulleys
Luffing cylinder
Telescoping cylinder
Push out cables
Return pull cables
Boom bearing / mounting
Boom pinning
Guy rods
Relapse cylinder

Remarks:
1) The inspection of the road safe condition of the carrier vehicle is also recommended if an error free expert
inspection result according to highway safety regulations is available. For vehicle cranes, which are not
cleared for use on public highways, the experienced technician or expert inspector should also check the
vehicle for road safe condition (see also UVV ∫Vehicles∫ (VBG 112)).
2) These inspections must be made by an expert engineer even if an error free expert inspection result
according to highway safety regulations is available.
3) Inspection of winches regarding used part of theoretical utilization time.
587
8.04 INSPECTION OF CRANE CABLES 022422>03
Discard time for wire cables due to broken wires.
Torsion free cables
Hoist cable I, Hoist cable II
Number of Number of visible broken wires at

Cable a time of discard over a length of
Crane type Cable turn carrying wires in
[mm]
outer strands 6 ¥ Cable a 30 ¥ Cable a
LTM 1050/1 17 Even lay 105 2 5
Non torsion free cables
Telescoping cable I

[mm]
LTM 1050/1 12 Cross lay 208 9 18
Telescoping cable II

[mm]
LTM 1050/1 17 Cross lay 208 9 18
Back pull cable I

[mm]
LTM 1050/1 13 Cross lay 208 9 18
Back pull cable II

[mm]
LTM 1050/1 13 Cross lay 208 9 18
588
Monitoring
The cables must be checked regularly, especially strict during the first initial period after placing them, in
addition to the time after they have been exposed to unusual strains, if there might be any damage which is not
clearly visible or after the first signs of cable damage show up.
The operating safety of cables can be determined according to the following criteria:
> Type and number of broken wires (see chart)
> Position and time frame of broken wires
> Reduction of cable diameter during operating time
> Corrosion, chafing, cable distortion
> Heat effects
> Total placement time
In addition, cable end connections and cable suspension must be regularly checked for proper condition. The
individual elements of the cable drive, cable drums and pulleys must easily rotate in their mounts and they may
not show an impression of the cable profile in their tracks.
Note: The groove radius on drums and pulleys must be 0.595 ¥ rated cable diameter.
Any changes in cable behavior must be especially well monitored.
DANGER: As soon as the cable strands hit together above the hook block, there is a danger of
serious cable damage. The cause is always added revolution tension in a torsion
free hoist cable, which can be due to a variety of influences and problems, but also
due to special stress or extension of the hoist cable in severe applications.
Note: Refer to the paragraph describing ™Extension torsion in torsion free hoist cables and its
elimination™
589
180069
590
Discard time
DANGER: The cables must be discarded immediately if one of the following problems is found:
> Break of a strand
> Occurrence of wire break pockets
> Reaching the wire break numbers according to the chart
> Corkscrew type deformations by more than 1/3 of the cable diameter (fig. 1)
> >Arch formation (fig. 2)
> Hair pin shaped penetration of wires or wire strands from the cable (fig. 3)
> Reduction of cable diameter as compared to the nominal diameter by more than 15% or
> by 10% with simultaneous occurrence of corrosion and / or abrasion (fig. 4)
> Slackening of cable structure (fig. 4)
> Constriction (fig. 5)
> Kinks and compressions (fig. 6+8)
> Pulls or remaining distortions (fig. 7)
If particular cable damages occur, you must find the cause for these damages and remedy them before placing a
new cable.
The damages and grinding traces on the construction parts of the crane can provide important clues.
CAUTION: If there are doubts if the crane cable is still operational safe, then put it down or
consult an expert for an opinion.
591
180070
592
Place the cable
DANGER: If a cable is changed, you must use a cable of the same type and solidity with the
same diameter as the original cable had when it was new.
If another wire cable is to be used, you must first get the approval of the crane
manufacturer .
Cables are very susceptible to external damage. Be especially careful when placing them for transport and / or
when they are unloaded.
Any cables held in reserve must be stored in a clean, cool and dry area. Be sure that they donπt lay on soil.
Cables can only work properly without any problems if they are without any twists or other external damage.
Winding procedure
Cables must be pulled in winding direction from the reel or the ring (fig. 1).
Do not pull off the cable sideways, because that will cause the cable to twist and will cause pulls which will
destroy the cable.
The best procedure is to spool up the cable from a raised reel to the drum ( fig. 2).
Winding the cable in the same bending direction prevents additional cable tension and assures that the cable
lays better on the drum.
CAUTION: Make sure that the cable is not pulled over the ground to prevent it from getting
dirty.
A swivel must be interconnected to protect torsion free hoist cables from forced twists.
If multiple layers are wound, the lower layers must be wound tightly with a pretension of about 1 to 2% of the
minimum braking force of the cable. This pretension can be reached by slowing down (braking) the reel.
For multi>sheave reeving, the hoist cable should be reeved at the same direction as it has in the drum. If a
limited cable length to reeve the hook block must be laid on the ground, then it must be assured that the cable is
not twisted.
After placing the cable, test it first with low partial loads and then retract it in several hoists, switching
between a loaded and an unloaded hook block. This ensures that the cable adapts to the bending direction and
the bending radius of pulley and drum.
593
594
Maintenance and care

Regular cable maintenance assures the operating safety of the crane and significantly increases the service life
of the cable.
Wire cables must be lubricated in regular intervals, depending on the operating conditions, especially in the
area where the cable bends on drums and pulleys.
It was determined that under the same test conditions well lubricated cables provide 4 times more bending
flexure than unlubricated cables.
The lubricants must be compatible with the original cable lubricant .
Note: The cables must be lubricated with standard, commercially available lubricants, as
recommended by the crane manufacturer. Refer to the lubrication chart.
Dirty wire cables should be cleaned regularly, preferably with brushes.
If the lower cable layers on the drum are hardly used or used not at all, then they should be unwound from time
to time and rewound with pre>tension. A cable is most economical when it is used in its entire length. For that
reason, for longer lasting crane work, it is recommended to match the cable length to the task.
If certain section of the cable are more used than others then the cable should be turned over after a certain
time. Service life of the cable can be increased significantly by attaching the previously free end to the drum,
and sections which were previously spared are now used more severely and areas which were previously used
more will now not be used as much.
If wear is predominantly in multi>layers on the Lebus drum, then the service life of the cable can be increased
by shorting the drum end by a length which corresponds to 1/3 of the drum circumference.
Extension torsion in torsion free hoist cables and its elimination

A torsion compensation is not only required after a new cable has been placed, but also if extension torsion has
been building up after a longer working period, resulting from stretching and settling of the cable structure.
Torsion compensation can be noticed when the hook block turns in multi reeve operation and when the load is
set down and / or the outer strands seem to loosen up and if, in extreme cases, the cable shows an arch
formation.
Measures to take care of an elongation cable twist are noted below.

If a crane is operated for a longer period of time with the same reeving, without unreeving or changing the hoist
cable reeving, then we recommend installation of a cable twist catcher on the fixed point of the hoist cable.
CAUTION: If this is not observed, the cable can be damaged!
595
183627
596
Measures to eliminate torsion compensation:
1 Set down the hook block

Lower the hook block as much as possible, so that the greatest cable length between pulley head and hook
block is exposed to compensation (twist, point 4).
2 Determine the turning direction

First determine in which direction the hook block is twisted.
The turning directions are shown on the illustration with a continuously lined arrow.
Since this is difficult, especially in large hoisting heights, check it by turning in direction of the dashed
arrow. The ∫braid∫ must dissolve.
3 Loosen the cable on the fixed point

When the direction of rotation has been determined, release the cable on the fixed point on the hook block.
Note: It is advantageous if, for torsion compensation, the hook block has been reeved in an
uneven number or that such a number will be reeved.
In that case,the fixed point of the cable is easily accessible on the hook block and it can
easily be released.
4 Carefully turn the end of the cable by 180∞ to 360∞, to compensate for the turn of the hook block
To compensate for the turn, turn the separately shown end of the cable, as marked by the solid line arrow.
Note: It is important that the correct reference point is taken and that the crane operator holds
the cable in front of him .
The right moving cable (Z), as shown in fig. 1 and the left moving (S) cable, as shown in fig. 4, is turned in
for compensation, while the right moving cable (Z), as shown in fig. 2, and the left moving cable (S), as
shown in fig. 3, must be turned out.
The rule is that for torsion compensation, the end of the cable must be turned against the direction of
rotation, which caused the release of the ∫braid∫ in the above test.
CAUTION: The cable section should be as long as possible for the turn. Through a hoisting
movement without a load, this turn should be distributed over the complete
length of the cable.
Under no circumstances turn the cable by force over a short section, because this
would destroy the cable structure permanently.
5 Reattach the cable on the fixed point

The end of the cable must be reattached and secured on the fixed point after the turn.
6 Carefully lift the hook block, raise it without a load and repeat the procedure, if necessary
Since a non>stretch cable construction is relatively safe from torsion, the cable can only be stretched a little
(actually, the torsion does not continue over the cable pulley), so that the hoisting movements with out a
load must be repeated several times.
After getting the compensating turn to the end of the cable, reattach the cable end again to the fixed point
and repeat the hoisting movements with out a load one or several times so that the torsion compensation
can be distributed over the complete length of the cable past the cable pulley.
Note: If necessary, in case the stretch was especially severe (multiple twisting of the lower
pulley block and / or slackening of outer strands over a longer stretch, or at several
points) then repeat this procedure several times, depending on hoist cable length.
597
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM 022648>01
598
General
The pneumatic brake system in mobile cranes must be checked annually.
In Germany, this brake inspection must be made according to ß 29 STVZO.
For other countries, local and national regulations apply.
1. Visual inspection
To check the pneumatic brake system, the following requirements apply:
1.1 Pipe and hose lines are not damaged, not corroded and are properly routed.
1.2 Components are correctly installed and properly mounted.
1.3 Air tank is not damaged, no external corrosion can be seen.

The tank is marked properly.
CAUTION: No welding nor heat applications may ever be done on the tank walls .
1.4 Condensation is drained from the air tank.
1.5 Dust guards are not damaged.
1.6 Joints are secured, move easily and have not been knocked out.
1.7 Linkage has not been welded, is not bent, moves easily and is not damaged.
1.8 Brakes are adjusted properly (ventilation, brake cylinder stroke, pad thickness, linkage plate).
2. Function and action test
2.1. Function test
2.1.1 Pressure regulator , air compressor

Check cut in pressure, cut off pressure and output capacity.
2.1.2 Check seals and reservoir pressure in air pressure system.
2.1.3 Check multi circuit safety valve, overflow valves, warning device.
599
2.2 Brake action test

The brake function can be checked through the ports in the cover plates.
If the brake pedal is pressed down, both brake pads must touch the drum, when the brake pedal is relea>
sed, the brake pads must immediately return to starting position.
The brake action can be checked by measuring delay, brake path or by determining the braking action
on a brake test station.
2.2.1 Measure the delay with a declerometer

At a pressure of 6.5 bar, the measured median delay should be dm!>!4,5!m/s2 .
2.2.2 Measure the brake path

At a pressure of 6.5 bar, the brake path should be s!<!as the value given in the chart.
Test speed Brake path

v [km/h] s [m]
20 6.5
30 12.5
40 19.8
50 29.0
2.2.3 Determine braking action on a brake test station

To measure the brake power on the vehicle axles, calculate the braking action as follows:
F1¥i1+F2¥i2 ... Fn ¥ in
z = &&&&&&&&&&&&&&&&&&&&& ¥ 100 [%]
Gz
Gz = Permissible total weight of the vehicle [N]

z = Braking [%]
F1 = Brake power of first axle, which has been measured at p1 pressure [N]
F2 = Brake power of second axle, which has been measured at p2 pressure [N]
Fn = Brake power of last axle, which has been measured at pn pressure [N]
pN1 > 0,4
i1 = &&&&&&&
p1 > 0,4
pNn > 0,4

in = &&&&&&&
pn > 0,4
pN1 ... n = maximum brake pressure of corresponding axle [bar]

p1 ... n = Brake pressure, which is used [bar] at the brake test in the wheel cylinder of the correspon>
ding axle
600
3. Internal inspection of wheel brake

Independent of the function and action test, the following tests must be made:
3.1 Every 3 months, the brake pad condition should be checked through the ports in the cover plates.
Every 12 months, pull the brake drum to check the various, internal brake components .
CAUTION: The brake may not be actuated if the brake drum has been pulled.
3.2 Replace the pads when the pad thickness is 5.5 mm (new thickness = 18 mm), measured without ta>
king the thickness of the metal part of the brake pad into account; replace the pads if the pads are burnt,
slick or oily.
For replacement, only Jurid 546 and Bremskerl 6275 brake pads may be used.
Rivet and adhere these pads, as these asbestos free pads are not as rigid.
DANGER: Always replace the pads on both wheels of each axle.
3.3 The brake drums should also be turned.
Note: When turning the brake drums, do not exceed the permissible turning measurement
of 0.75 % of the nominal diameter!
Example: Nominal diameter: 500.00 mm

Permissible turning measurement: 3.75 mm
Permissible inside diameter: 503.75 mm
DANGER: If the inside diameter of the brake drum is larger than 503.75 mm, then the
brake drum must be replaced.
Otherwise there is a danger of causing a serious accident!
3.4 To correct the brake pad wear or to center the brake, it is equipped with an automatic adjustment devi>
ce, which is maintenance free.
DANGER: In case of damage to any parts, replace the automatic adjustment device
completely, using repair kit ∫adjustment device∫.
If this is not done, there is a danger of causing a serious accident!
3.5 The pressure and pull springs as well as seal rings, caps and dust covers must be replaced at least every
2 years.
DANGER: All maintenance and repairs on th brake system must be performed by aut>
horized and especially trained personnel.
Otherwise there is a danger of causing a serious accident!
3.6 After assembly, repeat visual, function and action test.
601
9.00 GENERAL NOTES 022102>00
602
022102>00
Chapter 9
General Notes
603
9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES 021687>00
Issued by: VDMA (association of german mechanical> and plant engineers) > January 1970
The telescopic boom crane which has been supplied to you is equipped in conformity with the Accident
Prevention Regulations Relating to Telescopic Boom Cranes with an overload safety device (overload motion
cut device) by means of which the hoist and the telescoping gear are switched off if the maximum permissible
load moment of the crane is exceeded. It must still be possible, after the overload safety equipment has been
activated, to perform the opposite movement in order to reduce the crane load, in other words, it must still be
possible to lower the load after the hoist has been switched off.
Installation of an overload safety device (overload motion cut device) is intended to prevent loads being lifted
with the crane which jeopardise the craneπs stability. The overload safety device (overload motion cut device) is
thus an emergency switch which switches off any movement which increases the load moment of the crane once
the crane has been overloaded and thus prevents a possible accident or damage or injury to persons or property.
It is essential to observe a number of points in order to ensure that the overload safety device is able to perform
its safety function:
1. Overload safety devices (overload motion cut devices) mut not be used in normal operations for switching off
the hoist or the telescoping gear. The crane operator is required to satisfy himself that lifting the load will
not exceed the specified maximum lifting capacity of the crane prior to performing the lifting operation.
Excessively heavy loads, which are in excess of the load lifting capacity of the crane, must not be lifted even
though an overload safety device is fitted. This safety device must not be used as a means of checking the
weight of the load to be lifted and the crane must not be loaded beyond its safe working load.
2. Duties involving freeing stuck loads may only be performed with the prior approval of the crane
manufacturer and only using such cranes as are properly equipped for such duties. If the crane is used for
such duties, the overload safety device (safe load limiter) must not be used as a means of measuring the
force.
3. The overload safety device fitted requires to be inspected and serviced at regular intervals and an
operational check should be performed each time before crane operations are commenced. A regular
inspection of the overload safety device is an integral part of the crane maintenance procedures in
conformity with the Accident Prevention Regulations for Telescopic Boom Cranes.
4. The overload safety device does not normally adjust automatically to the different operating states of the
crane. It is therefore the responsibility of the crane operator to also correctly set the overload safety device
to the altered lifting capacity or load moment range when the crane is to be used for different duties. The
instructions given in the manufacturerπs operating manual in this connection should be strictly observed.
Strict adherence to these instructions is essential to ensure proper operation of this safety device and to
ensure safe operation of the crane. An overload safety device which is incorrectly set, e.g. set to an
excessively large load moment with the outriggers retracted, is a far greater hazard than a crane not fitted
with such a device because this gives the crane operator a false sense of security, which in turn can be the
cause of a serious accident.
604
9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES 021687>00
5. The crane operator is required to set the overload safety device (overload motion cut device) which is fitted
to the crane to the altered lifting capacity or load moment range when the crane is to perform different
duties, for instance:
a) when extending or retracting the outriggers (switching over to large or small load moment)
b) when altering the boom length by
> manually extending or retracting (telescoping)
> fitting or dismantling intermediate sections
c) when turning or slewing the crane into the range of the greater or lesser moment of stability (changing
over to the large or small load moment)
d) when changing over to a different lifting capacity range by reeving the hoist or the telescopic gear with
several falls
6) Attention is expressly drawn to the fact that the overload safety device may not be activated or the gear
may not be switched off quickly enough if the crane is incorrectly operated. In such cases, it is not possible to
completely rule out an accident despite an overload safety device being fitted. This is particularly true for
> hooking the load or the lifting tackle from below
> excessive braking forces
> loads dropping into the rope
> pulling at an angle
> moving the crane to an area of ground with a greater slope
> ground which gives way
> wind load
7) If a device is provided which enables the overload safety device (safe load limiter) to be switched off or
overridden, this may only be used if special safety measures are taken and in the presence of a crane
supervisor, e.g. when conducting a test of the crane, and when performing the duties specifically authorised
by the crane manufacturer.
On no account may the overload safety device be switched off or overridden in order to lift a load which
exceeds the maximum permissible load lifting capacity of the crane.
Careful observance of the instructions contained in this Code of Practice and in the operating manual of the
crane manufacturer are essential requirements for safe and reliable operation of the overload safety device
(overload motion cut device). If there is any doubt, the manufacturerπs operating instructions should be
consulted. If the information contained therein is not sufficient, it is essential to contact the company
concerned. Unauthorized interference in the mechanism of the overload safety device will invalidate the
warranty provisions.
605
AND IMPORTANT SERVICE WORK TO BE PERFORMED 022103>03
1. Inspections
1.1 Check the engine area daily before starting the crane, and check all oil and fuel lines for leaks and make
sure they are dry. In addition, check the fuel and oil filter as well as the injection pump for leaks.
1.2 During the daily check up, also check all hydraulic components, the hydraulic motors for the fan drives
and corresponding hydraulic lines to assure that they are tight and that there are no leaks.
1.3 Check the exhaust system, especially the exhaust flange and the exhaust flap brakes to assure that they
are not leaking and are easily movable. The return springs to open the exhaust flaps must be
functioning properly, as stuck and therefore closed exhaust flaps during engine operation cause great
increases in temperatures and overheating.
1.4 Check if electrical lines are still routed and mounted properly, with sufficient distance to exhaust pipes,
and assure that they are not damaged and still properly insulated.
1.5 To reduce the noise emission, insulating mats are installed in the engine area (chassis > engine
covering) on some crane models. When the fiberglass mats with integrated noise reduction material are
are clean, they are not flammable and are flame retardant.
If engine compartments are is not cleaned regularly, oil and fuel may splash on the mats while
performing maintenance and repair work. Oil and fuel soaked noise reduction mats must be removed, as
they are now flammable. The same is true for insulating mats in the exhaust system area.
Clean the engine compartment only with nonflammable cleaning fluids. In addition, the fluid may not
be corrosive or chemically damaging to hoses and cables.
606
2. Care during repairs and maintenance work
2.1 When changing the fuel and oil filters, you must observe utmost cleanliness and carefully clean up any
spilled Diesel fuel or oil. Check the fuel and hydraulic system for leaks.
2.2 The V>area of the engine must be especially checked after repairs and service tasks, in addition to
regular intervals, to assure it is free of oil and fuel. Any fuel in the V>area can run throughout the
engine compartment during travel and cause a fire, if it hits hot engine parts.
2.3 We note again, that all electrical lines and wires must be properly routed and must be attached in their
harnesses, any chafings or defects of the insulation and wiring covers must be taken care off
immediately. Any improper installation lines must be replaced immediately.
2.4 Be aware that fuel and oil lines can become porous or brittle due to age. Any lines which look brittle or
porous must be replaced immediately. (See also Guidelines about the life expectancy of hoses and lines).
2.5 Please note, while carrying out repairs and service task, that you do not step on any pipe or hose lines in
the engine area. This applies especially to fuel injection lines. If you must step in that area during
installation, then the engine must be covered with a board or similar support plate.
3. Important service tasks
3.1 To prevent dry runs, the gear shafts must be lubricated regularly and properly with specified
LIEBHERR grease.
3.2 The gear shaft screws must be checked regularly to assure they are seated tightly.
3.3 Gear and engine oil levels must be checked regularly. Add oil to compensate for normal oil
consumption. However, if an unusual amount of oil must be added or has been lost, you must check for
and remedy the problem.
4. Maintenance guidelines for replacement components
4.1 When replacing drive components, such as Diesel engine, gear, axles, etc. you must observe the
following:
Before putting these components into service, make sure to add the specified oil to the max. mark; for
type of oil, check data tag and lubrication chart.
Perform the first maintenance check as noted in chapter MAINTENANCE INTERVALS; then carry out
all regular maintenance intervals as noted.
4.2 Make sure to follow initial operational instructions.
607
5. Notes for travel operation
CAUTION: DO NOT exceed the permissible engine speed in high gear, it could cause
engine damage!
6. Disposal
6.1 Engine, gear and hydraulic oils, grease, fuel:

To prevent pollution, these service fluids may not be spilled onto the ground, to prevent them from
getting into ground water, sewage, or drainage systems.
Observe all state and local regulations applicable to the disposal of these items.
6.2 Radiator fluids for Diesel engines and heater systems:

For disposal, undiluted antifreeze fluids / corrosion protective oils must be handled as special hazardous
material.
When disposing of used coolant fluids (mixture of antifreeze / corrosion protective oils and water,
observe all state and local regulations applicable to the disposal of these items.
7. Rotating wheels
7.1 Tires used on crane vehicles are exposed to different loads and stresses, depending on the location of the
wheels on the crane, such as:
> non > propelled steering and fixed axles.
> propelled steering and fixed axles and
> various wheel positions exposed to more or less load.
Depending on the type of the tire tread, tires often wear differently.
7.2 To assure that all tires wear equally, we recommend to rotate the tires as soon as a difference in tire
wear is visible. We recommend to rotate the tires after 5,000 to 10,000 km.
Rotate the tires in crosswise direction (see illustration). In addition, select the new tire positions in such
a way that tires with uneven tire wear are moved to positions where tires wore evenly.
These measures can influence driving comfort and tire wear in a positive way.
8. Tire change
8.1 The tires may only be changed by authorized expert personnel; this applies to the removal as well as to
the installation of tires onto the rims.
8.2 All sections on the rim must be cleaned and checked for damage! For the installation, use a new end ring
and a new O>ring.
Check tires, side ring and end ring to ensure they are seated correctly.
D A N G E R : If the end ring is not positioned all the way in the groove, it might explosively
release when the tire is pumped up!
If this is not observed, there is an increased risk of causing a serious accident!
608
182295
609
182296
610
182297
611

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LIEBHERR

TELESCOPIC BOOM MOBILE CRANE

BAL >No. 09708>02>02

The operating instructions are part of the crane!

Always keep on hand!

Comply with road travel and crane operating

LIEBHERR>WERK EHINGEN GmbH, Postfach 1361, D>89582 Ehingen / Donau

Using these instructions

> makes it easier to become familiar with the crane

Observing these instructions

> increases reliability in operations

1.00 DESCRIPTION OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602

Description of the Crane

Abbreviations for the boom system

TK = Telescopic boom with folding fly jib 0∞, 15∞ or 30∞

T > Boom combination T =10.5 m to 40.0 m

TK > Boom combination T =30.4 m to 40.0 m

2.1 Crane operatorπs cab

4 Folding fly jib

The crane carrier

Axles: All 3 axles are steerable.

Suspension: Hydro>pneumatic axle suspension system ∫Niveaumatic∫. Axle suspension can be

Tires: 6 wheels, all axles provided with single tires.

Driverπs cab: 1 man cab (small size cab) *

Electr. system: 24 V DC,

The crane superstructure

Tires: 6 tires, all axles with individual wheels.

6¥6 drive *: Additional drive of the 2nd axle.

Hoisting heights [m]

Max. supporting load per support:

Max. supporting load [t] Front Rear

according to load capacity

according to load capacity

according to load capacity

Emission values at the work place

Stationary sound LpAeq [db(A)]

Wide driver's cab, driver's side 69 69

Wide driver's cab, co>driver's side 71 72

Narrow driver's cab* 75 75

Crane operator's cab 74 74

A hook block may only be carried on the front if:

> it is reeved not more than 4 times,

Carrying passengers in the crane cab is not permitted.

CAUTION: The crane is not yet running>in

For this reason, the following instructions must be followed:

CAUTION: Do not overtighten wheel nuts!

> Check coolant and oil levels in the engine.

Breaking in the brake pads

> Nature of work

> Site location (journey distance)

> Route to be driven

> Height and side clearances