LTM 1030-2

LIEBHERR
TELESCOPIC BOOM MOBILE CRANE
LTM 1030/2
LTM 1030>2>006
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Operating instructions
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BAL>No. 10407>01>02
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pages : 1 up to 521
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Crane number
Date
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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
Telefon (07391) 5 02>0, Telefax (07391) 5 02>33 99
www.lwe.liebherr.de, E>mail: info@lwe.liebherr.com
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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
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plankings, may only be carried out in connection with attenuator pads and may
only be performed after consultation with the crane manufacturer.
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Any risks associated with unspecified or improper use are the sole responsibility of the crane's owner, operator
or user.
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Using these instructions
> makes it easier to become familiar with the crane

avoids malfunctions due to improper operation
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Observing these instructions

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> increases reliability in operations

> increases the operating life of the crane
> reduces repair costs and down>time
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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.
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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.
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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.
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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:
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"SAFETY FIRST"
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CONTENTS
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CONTENTS
1.00 DESCRIPTION OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.01 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.02 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.03 TECHNICAL DATA ..................................................................... 22
2.00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.01 ROAD TRAFFIC REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.02 INSTRUCTIONS ON RUNNING>IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.03 OPERATIONAL PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.04 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1. Requirements of the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2. Selecting an operating site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3. Slopes and trenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4. Permissible ground>bearing load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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5. Supporting the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6. Crane operation with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7. Safety guidelines for auxiliary power supply (230 V AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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8. Working near transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9. Hand signals for guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10. Observing wind conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.01 CONTROLS AND INSTRUMENTS > VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.02 BEFORE VEHICLE STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1. Pre>checks before start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2. General transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3. Driverπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4. Check the hazard warning flashers / emergency blinkers, blower,
windshield wipers and horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5. Check fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6. Check the lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7. Two part crane operatorπs cab * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.03 AXLE SUSPENSION / AXLE LOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2. Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3.04 DRIVING ON PUBLIC ROADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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1. Travel condition of crane for on road travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2. Travel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3. Important indictor instruments during travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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4. Off road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5. Hydraulic rear axle steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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3.05 THE CRANE AT THE JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1. Site selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2. Changing from driving to crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3. Support the crane from the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4. Supporting the crane from the crane operatorπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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5. Changing from crane to driving operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

6. Check the following items before leaving the job site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.01 CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE . . . . . . . . . . . 158
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2. The control elements of the LICCON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3. LICCON programs for crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4. Booting the LICCON system after turning it on (= Boot >up phase) . . . . . . . . . . . . . . . . . . . . . 167
5. The ∫SET UP∫ program > the equipment configuration view . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6. The ∫OPERATION∫ program > crane operation view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7. The ∫Support∫ program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.03 STARTING THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

1. Checks before starting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2. The crane operatorπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3. Change over to superstructure operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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4. Starting procedure > engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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4.04 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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1. Check the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2. Leveling instruments in the control box for the outrigger support system . . . . . . . . . . . . . . . . 225
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3. Hydraulic safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4. EMERGENCY OFF button * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5. LICCON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
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4.05 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1. Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2. Tilt the crane operatorπs indicator system * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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3. LICCON Safe load indicator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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4. Control of crane movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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4.06 CABLE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

1. Reeving the hook block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2. Unreeving the hook block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3. Reeving plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.07 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

1. Counterweight combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2. Installation / removal ............................................................. 261
3. Travel operation with added ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.08 WORKING WITH A LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

1. Safety technical guidelines for working with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3. Visual inspection for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4. Setting the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5. Working near overhead electrical wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
6. Taking on a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
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7. Crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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4.09 DRIVING WITH THE ATTACHMENT IN PLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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1. General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2. The following measures must be performed before driving: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
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3. Prerequisites for driving with the attachment in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4. Charts for driving with the attachment in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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4.10 DRIVING FROM THE CRANE OPERATORπS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1. Change over to ∫superstructure operation ∫ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2. Travel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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4.11 CRANE OPERATION ∫FREE STANDING∫ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

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5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.01 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.02 FOLDING JIB > TK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

1. Folding jib variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
2. Installation of the folding jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3. Hoist cable reeving on the 8.6 m and on the 15 m long folding jib . . . . . . . . . . . . . . . . . . . . . . . 335
4. Change over the 8.6 m long or the 15 m long folding jib from 0∞ to 20∞ / 40∞ . . . . . . . . . . . . . . . 337
5. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
6. Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
7. Changing the 8.6 m or the 15 m long folding jib from 20∞ / 40∞ to 0∞ . . . . . . . . . . . . . . . . . . . . . . 351
8. Removal of the folding jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
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6.01 HEATER / ENGINE PREHEAT SYSTEM * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
1. Heating system > driverπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
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2. Heater / crane operatorπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
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6.02 EMERGENCY CRANE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
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1. Crane chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
2. Crane superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
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CONTENTS
7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
7.01 SERVICING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 402
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

1. Maintenance and repairs in the engine area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
2. Check the oil level in the hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3. Air dryer, pressurized air and brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4. Check the oil level in the planetary gears of the wheel hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
5. Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
6. Axle suspension/Axle locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
7. Tires / wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
8. Tilt the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
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9. Safety and maintenance guidelines for the wheels (rims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
10. Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
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11. Electrical System > Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
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7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . 432
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1. Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
2. Check the maximum tilt play on the slewing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
3. Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
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4. Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

5. Hoist gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
6. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
7. Telescopic boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
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7.06 LUBRICATION CHART AND FILLING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
7.07 SCHMIERSTOFFTABELLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

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CONTENTS
8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
8.01 REPEAT CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
8.04 INSPECTION OF CRANE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES . . . . . . . . . . . . 514
9.02 GUIDELINES TO PREVENT FIRES IN THE ENGINE AREA AND IMPORTANT SERVICE WORK
TO BE PERFORMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
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1.00 DESCRIPTION OF THE CRANE 021672>00
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021672>00
Chapter 1
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Description of the Crane

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1.01 TERMINOLOGY 023448>00
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186000
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Abbreviation of boom systems
T = Telescopic boom
TK = Telescopic boom with folding jib 0∞ / 20∞ / 40∞
Boom combination:
T: = T 9.2 m to 30 m
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TK: = T 24.8 m + K 8.6 m
T 29.0 m + K 8.6 m
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T 30. 0 m +K 8.6 m
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T 24. 8 m + K 15.0 m
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T 29. 0 m + K 15.0 m
T 30. 0 m + K 15.0 m
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186001
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1 Crane chassis
1.1 2>alxe chassis

1.2 Tires, axles 1 and 2 with single wheels
1.3 Diesel engine with power shift / reversing gear
1.4 Driverπs cab
1.5 Sliding arms with outrigger cylinders
1.6 Support pads
2 Crane superstructure
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I Winch I Hoist gear for T, TK > operation
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2.1 Control valve blocks
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2.2 Crane operatorπs cab
2.3 Counterweight
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2.4 Telescopic boom control > luffing cylinder

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186002
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3 Telescopic boom T
3.1 Pivot section
3.2 Telescopic section 1
4 Telescopic boom with folding jib TK
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4.1 Folding jib 8.6 m ca. 465 kg
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4.2 Dual folding jib 8.6 m and 15.0 m ca. 680 kg
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1.02 PRODUCT DESCRIPTION 025385>00
The crane chassis
Frame : Liebherr designed and manufactured, weight optimized and torsion resistant
construction made of high >tensile structural steel.
Outriggers: Four point support system, hydraulically extendible in horizontal and vertical direction.
Engine: 6>cylinder Diesel, Made by Mercedes>Benz OM 906 LA, water cooled

Output : 205 KW at 2300 RPM
according to ECE 24.03 and 1999/96 EG (EURO III)
max. torque: 1100 Nm at 1200 > 1500 RPM
Fuel tank capacity: 300 l
Transmission : Powershift transmission

ZF>gear type 6 WG 210 with torque converter and Lock>up coupling, distributor gear
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with addition of front axle drive, 6 forward gears and 2 reverse gears.
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Axles: The axles are welded, made of high >tensile structural steel and require low
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maintenance.
Front axle :Planetary axle with differential lock, steerable
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Rear axle: Planetary axle with differential lock, steerable
Suspension : All axles are guided via lengthwise and crosswise controls. The axles are hydro >
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pneumatically suspended through maintenance free hydraulic cylinders, can be

adjusted in height and can be hydraulically locked.
Tires: 4way, 14.000 R 25, all wheels with single tires, with on road and off road profile.
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Steering : Mechanical steering of front axle, hydraulically supported, reserve steering pump,
steering of rear axle can be hydraulically added. Hydrostatic steering of both axles from
the crane operatorπs cab.
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The steering conforms to EC regulations 70/311 EWG.
Brakes: Service brake: All wheel Servo air booster brake, both axles are equipped with drum
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brakes, 2 circuit brake system.

Manual brake: Effective via spring accumulators onto the drum brakes on both axles.
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The brakes are self>adjusting expanding wedge brakes.

A one chamber air dry is installed in the air pressure system. The brake system
conforms to 71/320/EWG.
Driverπs cab: 2 person driverπs cab in corrosion protected all>steel version with comfort equipment,
front resilient mounted suspension, hydraulically muffled on the rear, all round safety
glass windows, driverπs seat pneumatically suspended and adjustable, with additional
back support. Steering wheel height and incline adjustable. Standardized control and
indicator instruments.
Electr. system: 24 V DC, 2 batteries, lighting .
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1.02 PRODUCT DESCRIPTION 025385>00
The crane superstructure
Frame: Liebherr>made torsion resistant, welded construction of high tensile structural steel. All
load carrying parts are insensitive to temperature fluctuations. Roller slewing ring between
crane superstructure and crane chassis, for continuous 360∞ rotation .
Hydraulic system: An axial piston pump and a two way gear pump, driven by the diesel engine in the chassis,
open hydraulic circuits with hydraulic "LOAD SENSING" regulation. 4 working
movements can be carried out at the same time, i. e. up / down, slewing, luffing, telescoping.
Crane control: Comfort armrest control with 2 self centering, 4way joysticks, integrated in the crane
operatorπs seat, stepless regulation of all crane movements.
Hoist gear: Axial piston fixed displacement motor, hoist drum with integrated planetary gear and
spring loaded disk brake. Drive in open hydraulic circuit.
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Luffing gear: 1 differential cylinder with pilot controlled brake valve.
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Slewing gear: Hydro motor, planetary gear with spring loaded slewing brake. Rotational speed with
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stepless regulation, drive in open hydraulic circuit.
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Crane cab: Fully galvanized, corrosion resistant, all>steel construction with all around safety glass
windows. Crane operatorπs seat with various adjustments, equipped with back support and
head rest. Standardized control and indicator instruments, ergonomically located. All travel
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movements can be carried out from the crane operatorπs cab.
Safety devices: LICCON safe load indicator, hoist limit, safety valves to protect hydraulic system against
pipe and hose ruptures.
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Telescopic boom: The telescopic boom is a dent safe and torsion resistant construction design made of high
tensile steel and consists of one pivot section and 3 telescopic sections. All telescopic sections
are full hydraulically telescopable, even under partial load.
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Boom length: 9.2 m to 30 m.

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Additional equipment
Folding jib : Single folding jib 8.6 m long, can be installed under an angle of (m) 0∞, 20∞ or 40∞ to the
telescopic boom.
Dual folding jib 8.6 m and 15.0 m long, can be installed under an angle of (m) 0∞, 20∞ or
40∞ to the telescopic boom.
Tires: 4 tires, tire size: 16.00 R 25.
Split crane
operatorπs cab: To obtain a lower height when passing under overpasses or tunnels, the upper section of the
crane cab can be removed easily via its quick locks.
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1.03 TECHNICAL DATA 025386>00
Dimensions
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186202
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Dimensions (mm)
Tires A A 1) B B 2) C D q ˚
14.00 R 25 3550 3450 3050 2950 2094 400 18∞ 19∞
16.00 R 25 3600 3500 3100 3000 2054 450 20∞ 21∞
1) 100 mm lowered
2) lowered, without upper section of the cab
Tires
Tire pressure for Tire pressure for crane

Weight of Tire pressure for
driving with the operation
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Tire size wheel driving on public
attachment in place ªfreestanding on
[approx. kg] roads [bar]
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[bar] tires´ [bar]
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according to load
carrying chart
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14.00 > 25 260 10 10
ªfreestanding on
tires´
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according to load
carrying chart
16.00 > 25 * 320 9 10
ªfreestanding on
tires´
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* Optional
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Emissions values on cab

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Noise level while parked LpAeq [db(A)]

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Noise level at nominal engine speed

left ear right ear
Driverπs cab, driverπs side 73 72
Driverπs cab, passenger side 73
Crane operatorπs cab 78
Maximum supporting load
Maximum supporting load [t] front rear
per support 23 30
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Lifting heights
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186203
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Weight
Axle loads, crane in travel direction
Axle 1 2 Total weight 4)
t 12 12 24
4) with 2.5 ton ballast and dual folding jib
Load tackle
Load carrying Weight

Pulleys Reevings
capacity [t] [kg]
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35.0 5 10 240
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22.4 3 7 150
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10.0 1 ER 3 130
3.3 > 1 65
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Speeds
Travel speeds
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Gear 1 2 3 4 5 6 R1 R2 R3 1 2 3 4 5 6 R1 R2 R3
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On road 9,5 14,5 23 36 56 75 9,5 14,5 23 10,5 16 25,5 39 61 80 10,5 16 25,5
Uphill driving
> 60 % 60 %
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14.00 R 25 16.00 R 25
Crane speeds
Drives stepless Cable a / Cable length
Hoist gear 0 > 120 m/min for single reeving 13 mm / 150 m
Slewing gear 0 > 2.4 RPM
Luffing gear approx. 33 s to 81 ∞ Boom position
Telescoping approx. 60 s for boom length 9.2 m > 30 m
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2.00 SAFETY 021673>00
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021673>00
Chapter 2
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Safety
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2.01 ROAD TRAFFIC REGULATIONS 021178>04
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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.
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The steering system, the service brake, parking brake and retarder will then no
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longer conform to regulations!
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The life of the brakes, axles, wheel hubs, suspension cylinders and bearings will be
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reduced.
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A hook block may only be carried on the front if:

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> it is reeved not more than 4 times,

> it has been marked by the manufacturer on the data tag with the letter ∫E∫ for ∫entschßrft (chamfered)∫
and
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> the cable was attached to the front towing eyes or if the hook is held with an auxiliary cable and attached to
the towing coupling .
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DANGER: When moving the crane on public highway, then the field of vision of the driver may
not be obstructed by the hook block.
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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
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Travel with the crane according to the national road traffic regulations.
Carrying passengers in the crane cab is not permitted.
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2.02 INSTRUCTIONS ON RUNNING>IN 021617>03
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2.02 INSTRUCTIONS ON RUNNING>IN 021617>03
Instructions on run>in
CAUTION: The crane is not yet running>in
For this reason, the following instructions must be followed:
1. The oil pressure and temperature gauges must be monitored constantly while driving!
> If either gauge shows an excessive reading, stop operation immediately.
2. 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).
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> Check coolant and oil levels in the engine.
> Check oil level in powershift gearbox or automatic transmission.
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> Check engine, transmission and axle mountings for secure seating and for leaks (visual check).
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> Check drive shafts for secure connection.
> Check all other chassis components for secure mounting.
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> Check air pressure and conditions of the tyres (visual check).
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Breaking in the brake pads

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In order to obtain optimum braking acting, new brake pads must be activated or broken in. Breake in the new
pads by applying the brakes in intervals in low to medium speed range, do not brake forcefully! The breaking in
route > preferably at least 500 km (310 miles) depends on the vehicle. In this phase, the maximum brake drum
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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.
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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
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high speed.
DANGER: If this point is not strictly observed, you could cause a serious accident!
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2.03 OPERATIONAL PLANNING 021674>00
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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
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> Electrical overhead wires (complete with voltage data)
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> Space requirements at the operating sites
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> Movement restrictions due to surrounding structures
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> Weight and dimensions of load(s) to be lifted
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> Required lifting height and radius
> Load>bearing capacity of soil or surface to be operated upon

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The crane operator can then use this information to decide on the correct crane operating equipment:
> Hook blocks / load blocks

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> Auxiliary telescopic boom

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> Lifting / slinging tackle

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> 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!
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2.04 SAFETY>TECHNICAL NOTES 021675>06
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1. 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 the following important safety notes.
Many problems and damages with mobile cranes are caused by 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,
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> loose cable formations
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Overloading
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Driving too fast with a load, or setting up and loading on an uneven surface.
Improperly slinging a load.
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Operating in unsuitable conditions, especially pulling at an angle or fixed loads coming loose.
Wind on suspended load.
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Improperly driving on public roads without a load, for example, engine or transmission overloaded.
Collision with bridges, ceilings, high>voltage wires.
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Insufficient support; support base beneath the outriggers not sufficient in capacity.
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Improper assembly / disassembly of telescopic booms.

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20% of all accidents involving cranes are due to improper maintenance:

> Lack of oil, grease or antifreeze
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> Accumulation of too much dirt

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> 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.
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180000
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2. 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.
3. Slopes and trenches
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The crane must not be set up too close to slopes or trenches and depending on the type of soil, a safe distance
C
must always be kept from them.
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Note: Safe distance is measured from the foot of the trench and is:
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> soft or backfilled soil = 2 ¥ depth of trench (A2 = 2 ¥ T)
> hard or grown soil = 1 ¥ depth of trench (A1 = 1 ¥ T)
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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 collapse.
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4. 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 fitted 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
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[daN / cm2]
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Type of Soil
[kg/cm2]
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A) lled soil, not artificially compacted 0>1
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B) Natural soil, apparently undisturbed
1. sludge, peat, marshy earth 0

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2. noncohesive, sufficiently firm soil:

fine to medium sand 1,5
course sand to gravel 2,0
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3. cohesive soils:
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loamy 0
soft 0,4
stiff 1,0
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semi solid 2,0

hard 4,0
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4. rock with a minimum of fissures, in healthy, unweathered

condition and favorably situated:
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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.
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180001
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5. Supporting the crane
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 force between the sliding arms is guaranteed.
The outriggers may only be used when the sliding arms are extended to these positions!
DANGER: Intermediate adjustments between the prescribed support widths may not be made
as the transmission of 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
they could cause a serious accident, causing the crane to topple over.
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Always extend all 4 sliding arms and support jacks, including those on the side opposite the load. If only the
C
sliding arms and support jacks on the load side are extended, the results could be dangerous as:
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DANGER: 1. The load hanging on the hook tensions the hoist cable, the telescopic boom, the
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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
-S
released 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
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necessary to slew the load to the opposite side.

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Therefore the crane may topple over.
3. When turning from longitudinal direction, the crane can tip over due to the
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momentum of the boom or counterweight.

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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.
43
Checking safety measures
Crane supported
> Has the operating site been selected so that the crane may operate within the smallest possible boom
radius?
> Is the load>bearing capacity of the ground sufficient?
> Is there a sufficiently safe distance from slopes and trenches?
> Has it been established that the crane is not in the vicinity of electrical overhead wires?
> Are there any obstacles in the area that will hinder necessary crane movements?
> Is axle suspension blocked?
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> Are all 4 sliding arms and support jacks extended to the support base as given in the load>capacity tables?
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> Are the sliding arms secured with pins?
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> Are the support pads secured?
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> Is the crane horizontally aligned?
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> Have the axles been relieved of loads, i.e., is there no longer contact between the ground and the tires?
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6. 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 deducted from the
load capacity.
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
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Actual useful load of the crane =29.590 kg
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In this case, the load to be lifted may not exceed 29,590 kg.
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Ballast
The required ballast is dependent on the load to be lifted and necessary boom radius for operating with that
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load. Data in the corresponding load capacity table is decisive in selecting ballast.
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DANGER: If ballast is not mounted according to the load capacity table, there is danger of the
crane toppling over.
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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.
45
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.
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6. An excessive load is attached to the hook during dismantling work, which then hangs freely on the
crane when it is detached.
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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
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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.
-S
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.
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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
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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
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Rated Voltage
[m] [ft]
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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!
46
7. 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.
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If necessary, we recommend to connect a power isolating transformer.
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CAUTION: To check the protective measures and to decide if the crane can be supplied with
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power from the general power supply distribution network, a competent trained
electrician must be called in with the appropriate test instruments according to
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VDE (Association of German Electrotecnical Engineers).
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8. Working near transmitters

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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
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objects, for example:

> Effect on human organs due to temperature increase
> Danger of burns or inflammation due to temperature increase
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> Spark or electric arc formation

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In any case, before working with the crane near transmitters, contact your LIEBHERR representative .
In addition, consult a high frequency specialist.
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189640
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The high frequency (HF>) rays from a transmitter require an increased working protection and
special UVV>guidelines (Accident Control Regulations) 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
E
(master) any time such a contact has occurred, so that the cables can be checked and inspected.
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6. An insulator (1) must always be between the load hook of the crane and the tackle. This insulator (1) may
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not be removed. This is strictly prohibited. ER
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.
-S
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!
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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).
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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.
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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.
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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.
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180003
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9. Hand signals for guides
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.
DANGER: A suspended load is always a risk
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.
CAUTION: 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.
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When operating in foreign countries, always observe NATIONAL TRAFFIC REGULATIONS.
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Explanation of hand signals
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1 = Raise boom
-S
2 = Lower boom
3 = Lift load slowly
4 = Lower load slowly
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5 = Raise boom slowly

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6 = Lower boom slowly

7 = Raise boom and hold load
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8 = Lower boom and hold load

9 = Extend boom
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10 = Retract boom
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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!
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10. 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.
DANGER: Before beginning any work, the crane operator must receive information on the
expected wind speeds from the responsible meteorological authorities.
If impermissible wind speed are forecast, hoisting a load is prohibited.
If this is not observed there is a danger of accidents!
Wind Force Wind Speed

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

Telephone lines begin to whistle,
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umbrellas are difficult to use

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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
53
3.00 OPERATION OF THE CHASSIS 021676>00
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021676>00
Chapter 3
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Operation of the Chassis

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3.01 CONTROLS AND INSTRUMENTS > VEHICLE 025384>00
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188972
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Pos.:
1 Foot pedal > Service brake

2 Foot pedal > Engine regulation
3 Button > pneumatic incline and height adjustment of steering wheel
4 Steering column switch > Turn signal indicator lights
(left) > Windshield wiper operation
> Windshield wiper > intermittent operation
> Windshield washer system
> Change headlight from dim to high beam
> Horn
> Headlight flasher
5 Steering column switch > Engine brake

(right) > Tempomat
> Temposet
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6 Tachograph > Speedometer with trip odometer and clock
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7 Warning light > Warning signal > speed (set at the factory)
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8 Warning light > lights up if recorder has a problem (pens donπt register or diagram
disk is not inserted)
9 Container > Windshield washer fluid
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10 Fuse box
11 * Radio
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12 * Two way radio

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13 * CD Player
14 Diagnostic plug > The diagnostic plug for the engine and for the transmission is
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installed under the center console.

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* Optional
57
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193021
58
Pos.:
15 * Digital clock > Timer > added heater

16 Button > electric mirror adjustment
17 Hour meter
18 * Plug / two way radio 12 V
19 Plug 24 V DC
20 Cigarette lighter
21 Change over switch > Chassis operation / superstructure operation
22 Keyed switch > Ignition, starter
23 Lever > Change seat surface incline
24 Button > Lower back support in lower area of back rest
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25 Button > Lower back support in upper area of back rest
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26 Lever > Change of back rest angle
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27 Manual lever > Release for horizontal seat adjustment
28 Manual lever > Parking brake
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29 Battery master switch
30 Indicator unit
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31 Keyboard
> If function is selected and carried out, the function control on the corresponding button lights
up.
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> If function is selected but not carried out, the function control on the corresponding button
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blinks.
> If a function is not permissible, an acoustical signal (beep) can be heard when the button is
pressed.
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Note: For safety technical reasons, all functions of the rear axle steering and axle
suspension or blocking system can be operated only via a "2>Hand>Button" .
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32 * EMERGENCY OFF button > engine shut off

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* Optional
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185775
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KEYBOARD
Pos.:
50 Travel direction switch > Reverse "R"
51 Travel direction switch > Neutral "N"
52 Travel direction switch > Forward "D"
53 not used
54 Button > Travel program 1 or 2
FP1: Automatic operation O Function control does not light up
FP2: manual control O Function control lights up
55 Button > Gear higher, upper gear limit higher (FP1)
56 not used
57 Button > 1. Gear forward / reverse
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58 Button > Gear lower , upper gear limit lower (FP1)
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59 Indicator > For example operational error (function code)
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60 Button > Information key (Diagnosis) O System error on indicator unit
61 not used
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62 2>Hand>Button > Vehicle incline position, raise left front
63 2>Hand>Button > Vehicle incline position, raise right front
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64 Indicator > for example operational error, heater stage, brightness stage
65 Button > Brightness adjustment, indicator and keyboard unit
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66 Button > Start the test program, together with button 60+65+93
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67 Button > Rear axle steering, left (wheel deflection > right )
68 Button > Rear axle steering, right (wheel deflection > left
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69 2>Hand>Button > Vehicle incline position, lower left front

70 2>Hand>Button > Vehicle incline position, lower right front
71 not used
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72 not used
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73 not used
74 not used
75 not used
76 not used
77 2>Hand>Button > Vehicle incline position, raise left rear
78 2>Hand>Button > Vehicle incline position, raise right rear
79 2>Hand>Button > Leveling
80 2>Hand>Button > Axles blocked O Function control lights up
81 not used
82 not used
83 not used
84 not used
* Optional
61
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185775
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KEYBOARD
Pos.:
85 2>Hand>Button > Vehicle incline position, lower left rear
86 2>Hand>Button > Vehicle incline position, lower right rear
87 2>Hand>Button > Rear axle release
88 2>Hand>Button > Cut in > front axle
89 2>Hand>Button > Cut in > traverse differential lock
90 not used
91 not used
92 not used
93 Button > Confirmation for 2>Hand control
94 * Button > Auxiliary heater
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95 Button > Cab heater warmer
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96 Button > Cab heater colder
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97 Button > Fan speed (blower) higher
98 Button > Fan speed(blower) lower
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99 * Button > Seat heater, driverπs seat
100 Button > Headlight
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101 * Button > Fog light (only if head light or parking light is turned on)
102 * Button > Air conditioner
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103 Button > Air circulation

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104 Button > Fresh air

105 Button > Air supply > floor
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106 Button > Air supply > front windshield

107 * Button > Seat heater, passenger seat
108 Button > Parking light
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109 Button > Rear fog light (only if head light or parking light is turned on)
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110 Button > Heater for outside mirror

111 * Button > Nozzle heater
112 not used
113 not used
114 not used
115 Button > Beacon
116 Button > Emergency blinker
60+65+66+93 button combinations > Start the test program

Prerequisites: Ignition ON, engine OFF, operating mode chassis,
gear in neutral (see diagnostics hand book )
* Optional
63
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193022
64
INDICATOR UNIT
Pos.:
130 not used
131 not used
132 Warning light > Coolant level > engine too low
133 Indicator light > Air filter contaminated
134 Indicator light > Preglow Diesel engine
135 Warning light > Steering circuit I (steering pump)
136 Warning light > Steering circuit II (auxiliary pump)
137 Warning light > lights up when exceeding factory adjusted highest speed (blinks if
there is a problem with the speed signal of the tachograph recorder)
138 Indicator light > Converter coupling open
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139 Indicator light > Transmission off, communication problem between travel switch N
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transmission
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140 not used
141 not used
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142 not used
143 not used
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144 not used

145 Indicator light > Hi beam
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146 Indicator light > Low beam

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147 Indicator light > Rear fog light

148 Indicator light > Beacon, left front
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149 * Indicator light > Beacon, right front

150 Indicator light > Engine brake (s) active
151 Indicator light > Parking brake applied
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152 * Indicator light > Delay brake (Eddy current brake) active
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153 Warning light > Problem in brake system

154 Warning light > Brake pad wear indicator
155 not used
156 not used
156 not used
157 Indicator light > ABV, Automatic blocking prevention > trailer
158 Indicator light > ABV, Automatic blocking prevention
Indicator light lights up = Problem
Indicator light blinks = Communication problem with vehicle
electronic
159 not used
* Optional
65
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193022
66
INDICATOR UNIT
Pos.:
160 Indicator > Travel direction vehicle, left / right
161 Indicator > Travel direction, trailer left / right
162 Warning light > Emergency blinker
163 Indicator light > Beacon, left rear
164 Indicator light > Beacon, right rear
165 not used
165 not used
167 not used
168 not used
169 not used
170 Warning light > lights up = Engine problem
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blinks = Communication problem between vehicle electronics N
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engine problem
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171 Indicator > Engine RPM / engine error code if "i >key" (60) is actuated
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172 Warning light > Gear error
173 Indicator > Gear / Gear error code if "i >key" (60) is actuated
174 Warning light > General error in vehicle electronics
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175 Indicator > Error code LEC (LEC = LICCON > ERROR > CODE) if "i >key" (60) is
actuated
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176 Bar graph > Transmission oil temperature [degrees], 30 to 120∞C

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177 Warning light > Increased gear oil temperature

178 Bar graph > Fuel reserves [%], 0 to 100 % (approx.310 liter)
179 Warning light > Fuel reserves < 10% (approx.30 liter)
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180 Bar graph > Coolant temperature (T) Diesel engine [degrees], 30 to 120 ∞C
181 Warning light > Diesel engine overheated T f 120 ∞C
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182 Bar graph > Engine oil pressure [bar], 0 to 10 bar

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183 Warning light > Oil pressure too low

184 Bar graph > Battery voltage [V], 21 to 30 V
185 Warning light > Battery (charge indicator)
186 Bar graph > Air pressure reserves in brake circuit I [bar], 0 to 10 bar
187 Warning light > Air pressure reserves in brake circuit I < 5.5 bar
188 Bar graph > Air pressure reserves in brake circuit II [bar], 0 bis 10 bar
189 Warning light > Air pressure reserves in brake circuit II < 5.5 bar
190 Bar graph > Air pressure reserves in brake circuit III [bar],0 bis 10 bar
191 Warning light > Air pressure reserves in brake circuit III< 5.5 bar
192 Bar graph > Current brake pressure if brake, circuit I [bar] is actuated, 0 to 10 bar
193 Warning light > Blinking: Brake pressure sensor in circuit I is defective
194 Bar graph > Current brake pressure if brake, circuit II [bar] is actuated, 0 to 10
bar
195 Warning light > Blinking: Brake pressure sensor in circuit II is defective
* Optional
67
3.02 BEFORE VEHICLE STARTUP 024231>00
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1. Pre>checks before start up

Before starting the vehicle, the following pre>checks must be carried out:
Check the engine, gearboxes, axles and hydraulic system for leaks.
Note : For a more complete description of the below listed pre>check procedures, refer to
Chapter 7.04, ™MAINTENANCE GUIDELINES > CRANE CHASSIS™.
1.1 Check oil levels and filters

> Oil level on engine.
> Oil level on automatic transmission.
> Oil level on hydraulic tank for steering, outriggers, axle suspension and crane hydraulic.
> Filter on hydraulic tank.
1.2 Check fuel level
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Check the fuel level on the fuel gauge in the driverπs cab.
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Note: Do not wait until the tank is empty before refueling, or the fuel system must be bled.
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1.3 Check the coolant level
The coolant reservoir must be filled to the rim.
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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!
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1.4 Check the tires (including spare tire *)

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> Condition of tires

> Depth of tread
> Tire pressure
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D A NG E R : If there is any tire damage, the depth of the tire tread is insufficient and the
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tire pressure in the tires differs, then there is an increased risk of accidents!
1.5 Check the counterweight mount
DANGER: If the centering stubs on the additional ballast plates are damaged or if you
find distortions on the seat area, then the tight seating of the additional
ballast plates is no longer assured. As a result, the additional ballast plates
may fall off.
If the additional ballast plates are damaged, they must be replaced.

If base is bent, the seating area must be aligned or replaced.
*Optional
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2. 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 forward position™.
> The slewing brake must be applied.
> The auxiliary drive must be engaged.
> The rotary switch (2) must be in ∫chassis∫ position .
> The telescopic boom must be placed down in travel direction to the front and must be attached to the
front tow coupling with the lift cable.
> The windows and doors in the crane operatorπs cab must be closed.
> The step on the crane operatorπs cab must be pushed in and secured.
> The four sliding arms in the hydraulic outriggers must be individually secured with pins (4) to prevent
unintentional extension and movement.
> The four support pads must be pushed in, and must be secured in end position with pins (3) to prevent
unintentional extension and movement.
> Two wedges / wheel chocks must be carried along.
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> The two control boxes for the outrigger support (5) must be locked.
> Secure engine compartment doors (9) and check all locks (7, 6) on all covers and doors on the chassis
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and on the crane superstructure to assure that they are locked securely.
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> Check all pins and spring retainers to see if they are properly seated:
on the outrigger pad receptacle (3)
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locking pins on the sliding arms (4)
pins on the tow coupling to attach the hoist cable (1)
locking pins for added ballast (1,1 t) *
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on the spare tire *

> Check the counterweight receptacle
Make sure that there are no foreign particles are under the counterweight on the vehicle frame.
> Check all locking pins used in crane operation, and make sure that all of them are there and they are
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complete, secure them for transport.

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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
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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
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increased risk of accidents!

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Note: When driving on public roads, to stay within the maximum axle pressure of 12 tons,
transport the counterweight, the hook block and the double folding fly jib as
described in chapter 3.04 ∫DRIVING ON PUBLIC ROADS∫.
A hook block may only be transported on the front, if:

> it is, at a maximum, quadruple reeved,
> if it is attached and tightened to the front tow coupling with the eyehook which has been installed for
this purpose.
*Optional
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3. Driverπs cab
Adjust the driverπs seat

The pneumatically > mechanically suspended driverπs seat can be adjusted to fit any body size:
> Adjustment of seat surface angle (23)

> Lower back support adjustment (24)
> Upper back support adjustment (25)
> Adjustment of back rest angle (26)
> Horizontal seat adjustment (27)
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
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driver, while he is seated in the driverπs seat, to assure an unobstructed view to the front, side and rear.
The mirror adjustment can be made electrically via the switch (16).
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Adjust the steering wheel
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Press the button (3) to adjust the incline as well as the height of the steering wheel to suit the driver.
The steering wheel is adjusted pneumatically.
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DANGER: NEVER adjust the steering wheel, the driverπs seat and / or the mirrors while
driving!
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4. Check the hazard warning flashers / emergency blinkers, blower, windshield wipers and horn
Turn on the battery master switch (29) to carry out these checks.
Before starting the engine, check the following:
a) Before the ignition is turned on,

> Emergency blinker system
Key (116) with function check
> Beacon
> Parking light
> Added heater *
b) After the ignition is turned on,
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(turn the ignition key one notch to position ∫1∫ )
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> Check the blower > heater, ventilation (air conditioner *)
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> Check the switch for the windshield wiper and washer system (1)
> Check the reservoir for the windshield washer system(9)
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> Check the horn (1)
D A N G E R : If any of the other above mentioned functions are defective, DO NOT start to
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travel. Make sure that these functions are repaired by trained personnel before
operating the vehicle, otherwise there will be an increased risk of accidents!
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5. Check fuses
> Open the cover on the center console (10) and fold it upward.
> Remove the cover on the fuse box.
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> Check the fuses, replace any defective fuses.
C A U T I O N :NEVER repair or short circuit a fuse! NEVER use a different size or stronger
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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
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fire.
* Optional
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6. 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)
> Rotating beacon (5)
> Brake lights (6)
> Back up lights (7)
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> Rear fog lights (8)
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> Boom head light (9)
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> License plate illumination (10)
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> Side running lights (11)
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> Position lights (12)
> Tail lights (13)

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> Fog lights (14) *

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DANGER: Missing or defective lights increase the risk of accidents.

Any defective lights must be repaired by qualified mechanics or changed
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before starting the vehicle.

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* Optional
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7. Two part crane operatorπs cab *

To reduce the height of the crane for travel under underpasses or tunnels, the upper section of the crane
operatorπs cab can be removed.
The lift off device consists of the support (2) with cable winch (4) and the carrier arm (3) as well as the 4>
part hook chain (5).
7.1 Remove the upper section of the cab
Note: Before removing the upper section of the cab (6), the necessary ballast condition must be
established. Ballasting is no longer possible when the upper section of the cab has been
removed!
> Release the retaining belt (16) on the transport retainer.

> Remove the support!(2) from the transport retainer (13) and insert it in the receptacle (1).
> Remove the carrier arm (3) from the transport retainer (13) and insert it all the way into the
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support!(2).
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Note: The stub on the stop of the carrier arm (3) must be in the guide on the counterstop of the
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support (1). ER
> Place the cable of the cable winch over the pulley on the carrier arm (3).
> Install all 4 shackles (10) on the rigging points (I, II, III and IV).
> Attach the hook chain (5) on the cable.
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> Attach the four strands (A, B, C and D) of the hook chain onto the 4 shackles!(10).
Note: Pay attention to the chain length of the individual strands, the upper section of the
cable must hang vertically on the cable.
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Chain length: A 660 mm

B 715 mm
C 840 mm
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D 800 mm
> Open and remove the cover of the control box (12) on the back side of the crane operator's cab.
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> Open the hose clamp on the heater hose and loosen the heater hose.
> Loosen the antenna cable on the plug connection.
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> Loosen both supply lines for the windshield washer system on the hose couplings.
> Disconnect the electrical plug connections.
Disconnect the plug connection >X 133.
Disconnect the plug connection >X 131.
Install the dummy plug on plug >X 131.
Note: If the dummy plug is not added, then the parking brake cannot be released.
> Open the door (9) .

> Losen the counter nuts (15) on the retaining screws (14) for the cab doors.
> Screw in both retaining screws (14) to the stop.
> Lift the cab doors (9) and tilt them out slightly.
> Lower the cab doors (9) a little and place them down.
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(Continuation 7.1 Remove the upper section of the cab)
> Release all 6 turnbuckles (8) on the cab.
Note: To release the turnbuckles on the right hand outside wall on the crane
operator's'cab, the telescopic boom must be luffed up slighly.
CAUTION: If not all 6 turnbuckles are released, the cab will be damaged when it is lifted
off.
> Slightly lift the upper section of the crane cab (6) with the cable winch.
CAUTION: When lifting the upper section of the cab, pay attention to the electrical
connections and hoses!
> Raise the upper section of the cab (6) all the way and place it down.
> Remove the support and the carrier arm and secure in the transport retainer with the retaining belt.
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> Add the cover of the control box (12) and close it.
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7.2 Install the upper section of the cab
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> Install the support (2) and the carrier arm (3).
> Attach the four strands of the hook chain into the shackle (10) on the rigging points (I, II, III and IV).
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Note: Pay attention to the chain length (A, B, C and D) of the individual strands.
> Attach the hook chain onto the cable.

> Open and remove the cover of the control box (12) .
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> Lift the upper section of the cab (6) with the cable winch and place it on the lower section of the cab.
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C A U T I O N :When placing the upper section of the cab, pay attention to the electrical
connections and hoses!
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> Close all 6 turnbuckles.

> Insert the door (9).
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> Turn out both stop screws (14) on top of the cab door and secure with counter nuts (15).
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Note: Turn out both stop screws (14) untilthe cab door can no longer be tilted out.
> Plug in the heater hose and secure with hose clamp.
> Assemble the antenna cable on the plug connection.
> Close both supply lines for the windshield washer system on the hose couplings.
> Close the electrical plug connections .
Unplug the dummy plug from plug >X 131.
Close the plug connection >X 133 .
Close the plug connection >X 131 .
> Add and close the cover on the control box (12).
> Disengage the hook chain!(5) on the cable and disconnect it from the four shackles.
> Remove the shackles on the rigging points.
> Remove the cable from the carrier arm (3) and roll it up on the cable winch (4) .
> Pull the carrier arm (3) from the support (2) and bring it into the transport retainer (13) .
> Pull the support (2) from the receptacle (1) and bring it into the transport retainer (13).
> Pull the carrier arm and support with the belt (16) into the transport retainer.
*Optional
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3.03 AXLE SUSPENSION / AXLE LOCKING SYSTEM 023370>01
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1. Description
All axles are guided via length and transverse guides. The axles are hydro > pneumatically suspended
via maintenance free hydraulic cylinders, are adjustable in height and can be locked hydraulically.
Axle suspension blocked

Is used to drive with a load (slewing platform to the rear and pinned) on level ground. All axles are bloc>
ked.
Axles suspended
Is used to drive on a road. All axles are suspended (suspension ±100 mm). To improve the fording abili>
ty, the complete chassis can be raised by 100 mm . To reduce the craneπs clearing height, the complete
chassis can be lowered by 100 mm. To drive on a slope, the complete chassis can be tilted to the side by
2 x 7.6∞ . The side stability of the vehicle is assured for driving in curves.
In addition, each wheel can be raised or lowered independently of the other wheels.
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2. Controls and instruments
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> If function is selected and carried out, the function control on the corresponding button lights up.
> If function is selected but not carried out, the function control on the corresponding button blinks.
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> If a function is not permissible, an acoustical signal (beep) can be heard when the button is pressed.
Note: For safety technical reasons, all functions of the rear axle steering and axle suspen>
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sion or blocking system can be operated only via a "2>Hand>Button" . This means
the confirmation key (93) must always be pushed together with the function keys.
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Pos.:
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80 2>Hand>Switch > Axle suspension blocked / suspended

(Function check lights up if axle suspension is blocked)
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79 2>Hand>Button > Automatic leveling regulation

If this button / key is actuated (function check lights up), then the
crane aligns automatically via the hydro cylinder to the correct
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height for on road travel.

(Function check on button blinks when the level is reached. .)
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62 2>Hand>Button > Vehicle incline position, up left front (fill)

63 2>Hand>Button > Vehicle incline position, up right front (fill)
69 2>Hand>Button > Vehicle incline position, down left front (empty)
70 2>Hand>Button > Vehicle incline position, down right front (empty)
77 2>Hand>Button > Vehicle incline position, up left rear (fill)
78 2>Hand>Button > Vehicle incline position, up right rear (fill)
85 2>Hand>Button > Vehicle incline position, down left rear (empty)
86 2>Hand>Button > Vehicle incline position, down right rear (empty)
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2.1 Axles ∫SUSPENDED ∫

For transfer travel on roads, highways and off road, the button (80) must be turned off (function check
does not light up). In this position, all axles are suspended.
The level of the crane can be regulated in this position automatically or manually.
2.1.1 Automatic leveling

Leveling is carried out by pressing the button (79)+(93) until the function check on button (79) blinks.
During the automatic leveling regulation, the function key on button (79) lights up.
Note: The individual function controls for manual leveling (62, 63, 69, 70, 77, 78, 85, 86) blink
when the corresponding hydraulic cylinder has reached the level for on road travel.
The crane is set to leveling position (travel height for on road travel) automatically via the leveling
switch, which is located on the suspension cylinders.
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2.1.2 Manual leveling
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By pressing the 2>Hand>Button (62, 63, 69, 70, 77, 78, 85, 86) + confirmation (93) , the level can be set
as follows by filling or emptying the hydro>pneumatic system:
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Pos.:
62 2>Hand>Button > Vehicle incline position, up left front (fill)
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63 2>Hand>Button > Vehicle incline position, up right front (fill)

69 2>Hand>Button > Vehicle incline position, down left front (empty)
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70 2>Hand>Button > Vehicle incline position, down right front(empty)

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77 2>Hand>Button > Vehicle incline position, up left rear (fill)

78 2>Hand>Button > Vehicle incline position, up right rear (fill)
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85 2>Hand>Button > Vehicle incline position, down left rear (empty)

86 2>Hand>Button > Vehicle incline position, down right rear (empty)
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Raise vehicle: 2>Hand>Button (62, 69, 77, 85) + confirmation (93)

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Lower vehicle: 2>Hand>Button (63, 70, 78, 86) + confirmation (93)
CAUTION : When driving on an uneven roadway ( for example off road ) , the vehicle
may never be raised completely or lowered completely! Some suspension
must be assured .
The boom must be placed in vehicle lengthwise direction, to the front, in the
boom receptacle and must be secured properly for transport.
DANGE R: Before actuating the axle suspension or blocking system, be sure that there
are no persons within the danger range of the crane.
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2.2 Axle suspension ∫LOCKED∫

By pushing the 2>Hand>Buttons (80) + confirmation (93), the hydro>pneumatic suspension of all axles
is blocked. The function check on button (80) lights up.
The axles must be locked for :
2.2.1 Supporting the crane

Before supporting the crane, the axle suspension must be ∫LOCKED ∫ by pressing the 2>Hand>Buttons
(80) + (93) .
When the support cylinders are extended, 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 flexation of the
vehicle frame during crane operation.
When lowering the supported crane onto the wheels, the outrigger cylinders must be retracted until the
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wheels have ground contact again. Switch the 2>Hand>Button (80) + (93) to ∫SUSPENDED∫ .
Function check on the button (80) turns off.
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CAUTION : DO NOT actuate the button (80) until the wheels touch the ground again.
If this point is not observed, the axle suspension will be damaged due to the
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sudden release of the axle blocking system .
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2.2.2 Working range ∫Freestanding on tires∫ and ∫Driving the crane with a load∫
This switch position is needed for working with load capacity chart ∫Freestanding on tires∫ and ∫Dri>
ving the crane with a load∫ on level, solid ground with sufficient load carrying capacity. See chapter
4.11, CRANE OPERATION "FREESTANDING".
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CAUTION : Driving the crane with a load is only permissible to the ∫REAR∫ , on level
ground of sufficient load carrying capacity!
The route may not change by more than ±0.15 m over a length of 10 m .
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The slewing platform must be locked to the chassis via the manual
lever (212) .
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2.2.3 Axle oscillation, 1st axle *

The axle oscillation is used to drive the crane on job and constructions sites.
Note: The cut in of the axles oscillation for the 1st axle * is only possible from the
crane operatorπs cab.
See chapter 4.10, DRIVING FROM THE CRANE OPERATORπS CAB .
CAUTION : Axle oscillation of the 1st axle is not possible if the crane is in lowered
position.
*Optional
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3.04 DRIVING ON PUBLIC ROADS 025383>00
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1. Travel condition of crane for on road travel
Travel condition of the

Fig. 1 Fig. 2
crane
Tires: 14.00 R 25 / 16.00 R 25 * 14.00 R 25 / 16.00 R 25 *
Telescopic boom: in vehicle lengthwise direction, in vehicle lengthwise direction,

placed to the front and tightened placed to the front and tightened
Counterweight:
on crane superstructure: 2.3 t 2.3 t +1.1 t=3.4 t
on vehicle: none 2.1 t
Hook block: 1>pulley, rigged as described in 3>pulley, rigged as described in

chapter 3.02, General transport chapter 3.02, General transport
condition condition
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Dual folding jib: * folded in 1) folded in
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tow coupling: * mounted mounted
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Spare tire: * none none
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Axle loads front: 12.0 t 14.0 t
rear: 11.8 t 13.3 t
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1.1 Axle load 12 t per axle (fig. 1)

To stay within an axle load of 12 tons per axle, the travel condition as shown in the illustration
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according to StVZO must be established.

In countries other than Germany, follow NATIONAL AND REGIONAL REGULATIONS.
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Required adjustment of axle suspension system: "SUSPENDED"

Button (80) turned off.
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Push button (79) for leveling + button (93) for confirmation, until the function check on the button
blinks.
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1.2 Travel condition of crane for on road travel in countries with higher permissible axle load as
well as driving on job and constructions sites, axles loads > 12 t per axle (fig. 2)
Required adjustment of axle suspension system: "SUSPENDED"

Button (80) turned off.
Push button (79) for leveling + button (93) for confirmation, until the function check on the button
blinks.
* Optional
1) For single folding jib
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2. Travel operation
2.1 Apply the parking brake

When the brake is applied, the manual brake lever (28) points to the rear, indicator light (151) lights up.
Note: To apply the parking brake, pull the manual brake lever (28) straight out and then
move it to the rear.
2.2 Change over to travel operation

Prerequisite:
Crane is on level ground.
Switch (80) is turned off, axle suspension is active.
> Turn off engine and ignition (22) .

> Turn switch (21) to "vehicle symbol".
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Note: Before actuating the switch (21) the gear must be in neutral position "N".
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Before changing over, the parking brake in the cab and in the crane operatorπs cab
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must be closed. ER
CAUTION: DO NOT change over unless the engine is at a standstill and the ignition is
turned off.
If the change over switch (21) is actuated when the ignition is turned on, then
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the engine cannot be started afterwards.

If the change over switch (21) is actuated when the engine is running, the
engine and the ignition turns off automatically.
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2.3 Turn on the ignition > check the instruments

Turn on the battery master switch.
> Insert the key into the ignition (22) and turn it clockwise to "Stage 1".
Note: All indicator lights, bar graphs and 7 segment indicators on the indicator unit and
keyboard will light up for approx. 2 seconds.
The following indicator lights, gauges and bar graphs light up:
> Indicator light for battery voltage (185)

> Indicator light for torque converter coupling is open (138)
> Engine RPM gauge (171)

> Transmission gauge (172)
> Gear oil temperature (176)

> Fuel reserves (178)
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> Coolant temperature (180)
> Battery voltage (184)
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> Brake circuit I (186)
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> Brake circuit II (188)
> Brake circuit III (190)
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> current brake pressure circuit I (192)
> current brake pressure circuit II (194)
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Note: The indicator lights (187, 189, 191) for the individual brake circuits are on if the
pressure in the brake system has dropped below approximately 5 bar.
Fuel or coolant must be added before starting the engine, if the indicator light (179) or
the warning light (181) lights up.
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If the brake pressure sensor in circuit I or II is defective, the corresponding indicator

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light (193 or 195) lights up.

If the oil temperature in the transmission is too high, the warning light (177) lights up.
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2.4 Travel direction switch

The engine can only be started in "N" position.
> Push the "N" neutral position button (51), the function check lights up.
See paragraph 2.11, Engine > transmission management.
Note: Before shifting from neutral position "N" into another travel range, the operating
brake must be applied.
CAUTION: When the vehicle is at a standstill, the engine must be running at low idle
speed before switching from "N" into another gear.
Do not give gas during or shortly before switching from "N" into another
gear.
2.5 Start the engine

Prerequisites:
Change over switch in position "chassis"
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Gear in neutral position
Parking brake applied
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Ignition is turned on
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Indicator light > battery voltage (185) lights up ER
> Turn ignition key to position "2".
Note: The pedal for engine regulation (gas pedal) does not have to be pushed.
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If necessary, discontinue the starting procedure after max. 20 seconds and wait for 1
minute before repeating the procedure.
Per starting procedure, do not crank the starter more than 3 x 20 seconds, with a
one minute break in between.
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When starting the engine if it is warm, do not press on the gas pedal to reduce
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exhaust emissions.
CAUTION: Do not increase engine speed if no oil pressure is shown. If the oil pressure is
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not shown after approx. 10 seconds, turn the engine off and find the cause.
Do not apply a full engine load until it is at operation temperature.
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2.6 The engine is running > check the instruments

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> Check the bar graph which indicates the oil pressure (182) and check the warning light (183)
immediately after starting the engine.
CAUTION: If no oil pressure is shown or if the warning light (183) does not turn off, turn
the engine off immediately to prevent engine damage.
> Battery charge indicator light (185)

> Steering circuit I (135)
> Steering circuit II (136)
Note: The indicator light for steering circuits II (136) does not turn off until the crane
drives at approx. 10 km/hr.
> Brake circuits I (186 and 187), II (188 and 189), III (190 and 191)
Note: The indicator lights for the brake circuits turn off if a pressure of approx. 5.5 bar
has built up in the brake system .
The shut off pressure is at approx. 8.5 bar.
Only when the air pressure has reached approx. 5.5 bar in brake circuit III can be
parking brake be released. Then indicator light (151) turns off.
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2.7 Adjust axle suspension

The button (80) must be turned off, function check does not light up. In this position, all axles are
suspended.
Note: For description of the "AXLE SUSPENSION / AXLE LOCKING SYSTEM", see
chapter 3.03.
2.7.1 Automatic leveling
Note: The automatic and the manual leveling regulation must be carried out on level and
solid ground!
> Push the button (79) for automatic leveling +confirmation (93) until the function check blinks. The
correct level (travel height) is now set.
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2.7.2 Manual leveling
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CAUTION: Manual leveling on public roads is only permitted to conform the crane for
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special circumstances, for example lowering it for passing under bridges, to
reduce the height of the crane .
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2.8 Travel readiness > engine is running at low idle RPM

After turning the ignition on, the gear is automatically in travel program 1, Automatic operation.
See paragraph 2.11, Engine > transmission management.
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2.9 Release the parking brake

> Pull the manual lever (28) all the way out in lengthwise direction of the lever, and push it forward,
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indicator light (151) turns off.
Note: The manual lever points forward when the brake is released.
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CAUTION: As long as the required brake release pressure (approx. 5.5 bar) is not
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available in brake circuit III > warning light (191) lights up > the parking
brake is not released, even when the manual lever has been moved forward.
Return the manual lever to the rear again, fill the brake circuit III until the
warning light (191) turns off. The air pressure reserves in brake circuit III
can be read on the bar graph (190) in bar .
2.10 Service / Operating brake

> Increase the engine RPM by pressing the gas pedal (2) down , the crane will begin to move.
> Test the service brake with the brake pedal (1)
CAUTION: Check the brakes immediately after the crane starts to move.
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2.11 Engine > transmission management

With switch (54), two different travel programs (FP), "FP 1" and "FP 2", can be preselected.
In FP 1, the engine runs with torque regulation (automatic operation), in FP 2, the engine runs with
RPM regulation (manual shifting). Travel program 1 is automatically active, if "ignition ON".
2.11.1 Travel program 1 (Automatic operation )

In FP 1, the engine is running with torque regulation. The high and back shift points vary depending on
gas pedal position,
> is turned on with "ignition ON".
Note: Before shifting from neutral position "N" into a travel range, the operating brake
must be applied.
Forward "D"
> When the button "D" (52) is pressed, the gear goes into travel range 1 > 6 "forward". The transmission
normally starts in 1st gear.
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> By pushing the button (58) again, the range is reduced downward by one gear (upper gear limit lower)
1 > 6 Æ 1 > 5 Æ 1 > 4 etc.
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> By pushing the button (55) again, the range is increased upward by one gear (upper gear limit higher)
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1 > 4 Æ 1 > 5 Æ 1 > 6 etc.
> By pressing the button "D" (52) again, the gear jumps into range 1 > 6, independent of the range it was
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in previously.
Note: The converter coupling closes all gears dependent of speed.

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Reverse "R"
> When button "R" (50) is actuated, the gear moves into travel range 1 > 2 "reverse". The vehicle starts
out in 1st gear and shifts up automatically until the 2nd gear.
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> By pushing the button (58) or (55) again, the range can be limited or increased (same function as
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"forward").
> By pushing the button (50) again, the gear jumps into range 1 > 2.
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Note: The converter coupling does not close in reverse travel.
Indicator
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The indicator contains the following information:

> (171) Engine RPM in min >1
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Engine problem, if "i>key" (60) is actuated O see error code

> (173) Selected travel range with actually placed gear and travel direction indicator
Gear error, if "i>key" (60) is actuated O see error code
O automatic shifting 1st to 6th gear "forward" (D)

and actually placed gear (4th gear)
O automatic shifting 1st to 6th gear "neutral position" (N)
O automatic shifting 1st to 2nd gear "reverse" (R)

and actually placed gear (2nd gear)
Note: In case function is selected but not carried out by transmission or engine, the travel
direction indicator blinks.
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2.11.2 Travel program 2 (manual shifting )

In FP 2, RPM regulation is used (powershift program)
> Select travel program 2 via button (54) , the function check lights up.
Note: Before shifting from neutral position "N" into a travel range, the operating brake must
be applied.
Forward "D"
> When the button "D" (52) is pressed, the 1st gear ∫forward∫ is engaged.
> By pressing the button (55), the gear can be increased gear by gear to the 6th gear, independent of
engine RPM and speed.
> By pressing the button (58),the gears can be returned gear by gear , whereby the desired gear is
accepted, but the control into the next lower gear is only carried out when the connection speed no
longer exceeds a certain value.
Note: The converter coupling closes all gears dependent of speed.
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Reverse "R"
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> When button "R" (50) is actuated, the gear moves into travel range "reverse".
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> By pressing button (55),the gear can be shifted up from 1st gear to 2nd gear, independent of the engine
RPM and speed.
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> By pushing the button (58), the range can be decreased the same way as in ∫forward∫ travel.
Note: The converter coupling does not close in reverse travel.

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Indicator
The indicator contains the following information:
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> (171) Engine RPM in min >1

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Engine problem, if "i>key" (60) is actuated O see error code

> (173) Selected travel range with actually placed gear and travel direction indicator
Gear error, if "i>key" (60) is actuated O see error code
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O manual shifting "forward" (D) selected (6th gear) and actually

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placed gear (4th gear)

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O manual shifting "Neutral position" (N)
O manual shifting "reverse" (R) selected (2nd gear) and actually placed
gear (1st gear)
Note: In case function is selected but not carried out by transmission or engine, the travel
direction indicator blinks.
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2.11.3 Emergency travel program
If the vehicle electronic system recognizes
> a longer period of downtime of the keyboard (approx. 3 seconds)

> Communication error travel switch N transmission
(all travel switch keys blink on the keyboard,error code is shown)
then it automatically shifts to emergency travel program.
The transmission is then in automatic operation:

V: forward 1st to 4th gear
N: Neutral
R: Reverse 1st gear
The travel switch (3) for the emergency travel program is in the center console. The cover of the center
console (4) must be opened and raised for access.
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If a travel range is not accepted, either via the keyboard nor in the automatic emergency travel
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program, then there still is the possibility to ∫clamp off∫ the transmission from the bus system .
> Pull the plug X615 and X625 from E/A module 1 (1) and 2 (2).
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> Select the travel range with the emergency travel switch (3).
Note: The two plugs may only be unplugged if they are "not energized".
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The change over switch must be switched before to operating mode "chassis" to
disengage the crane hydraulic pump .
CAUTION: > No engine start monitoring

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(It is possible to select the travel range even without applying the service
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brake)
> no engine stop possible from the support control units
> no superstructure operation possible.
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DANGER: This measure may only be used in emergency situations. The error must be
fixed immediately by expert personnel.
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2.12 Engine regulation

Steering column lever (5) functions
1 Increase low idle RPM

Accelerate vehicle
Store speed
2 Decrease low idle RPM
Decelerate vehicle
Store speed
3 Turn off increase of low idle speed
Turn off tempomat
Turn off temposet
4 Turn on temposet
2.12.1 Low idle RPM
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After starting the engine, the low idle speed is automatically regulated depending on the coolant
temperature. If necessary, the low idle RPM can also be increased with the steering column lever (5),
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when the vehicle is at a standstill.
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> Steering column lever in position
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1 hold = increase low idle RPM
tap = increase low idle RPM by approx. 20 min >1
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2 hold = decrease low idle RPM

tap = decrease low idle RPM by approx. 20 min >1
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After releasing the lever, the engine runs at that obtained speed.
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3 tap = Turn off increase of low idle RPM.

The low idle RPM increase is automatically turned off after travel starts (at approx.
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20 km/hr.).
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2.12.2 Tempomat
With the tempomat, every speed above 45 km/ht. can be stored (affixed). The vehicle drives at the stored
speed.
Note: Use the tempomat only if traffic conditions permit an even speed. On uphill and
downhill slopes, the speed may not be able to be retained.
If the tempomat is turned on, remove your foot from the engine regulation (gas pedal).
The tempomat is turned on with the steering column lever (5) .

> Accelerate the vehicle with the engine regulation / throttle control (above 45 km/hr. )
1 hold = increase. Release the lever and the obtained speed is stored.
tap = store current speed or increase stored speed by 0.5 km/hr. increments.
2 hold = decrease. Release the lever and the obtained speed is stored.
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tap = store current speed or decrease stored speed by 0.5 km/hr. increments.
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After releasing the lever, the vehicle drives at the stored speed.
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The stored speed is shown momentarily on indicator (173).
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3 tap = Turn off tempomat .
The set speed is deleted.
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DANGER: Do not turn on tempomat on smooth road surfaces. DANGER OF

SKIDDING!
The tempomat is automatically turned off, i. e. the set speed is deleted.

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> If the operating brake is applied.

> At a speed below 45 km/hr.
> If temposet is turned on.
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Note: If the vehicle is accelerated with engine regulation if the tempomat is turned on, the
stored speed is reset after release of the engine regulation / throttle control.
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The stored speed is deleted if the ignition key is returned to "0" position.
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2.12.3 Temposet
With the temposet, the travel speed from 15 km/hr. on can be limited.
Turn on:
> Accelerate the vehicle to the desired speed.
> Push the button (4). The speed limitation becomes effective.
The stored speed is shown momentarily on indicator (173).
Turn off:
> Steering column lever in position 3. The adjusted highest speed (speed limitation) is automatically
deleted.
The adjusted speed is automatically deleted if the ignition key is turned back to "0" position, or if the
tempomat is turned on.
Note: > If the highest set speed is to be exceeded (for example when passing another vehicle) :
Press down the engine regulation quickly all the way,past the full gas position (kick
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down). After acceleration, release the engine regulation and actuate it again. The
preset speed is effective again.
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> If the preset highest speed is to be increased: push the button (4), hold it and accelerate
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the vehicle. When the desired speed is reached, release the button (4) .
> If the preset highest speed is to be decreased: release the engine regulation (if
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necessary, apply the brake to slow down the vehicle), push the button (4) when the
desired speed is reached.
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2.12.4 Engine brake

With the right, three stage steering column lever (5), two engine brake stages can be selected.
The engine brake is only effective at an engine RPM of more than 900 /min and can be utilized until
approx. 2500/min.
The effectiveness of the engine brake is dependent on the engine RPM (high engine RPM = high engine
brake performance).
Stage 1 Constant restrictor > Diesel engine

Stage 2 Exhaust flap+Constant restrictor > Diesel engine

0 Turned off
1 Engine brake stage 1
2 Engine brake stage 2
Note: If the engine brake is active, the indicator light (150) is on.
If the engine regulation is actuated when the engine brake is active, the engine
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brake is deactivated. If the engine regulation is no longer actuated, the engine
brake becomes active again.
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DANGER: When going downhill, only the engine brake may be used.
If the braking action is not sufficient, the vehicle must be slowed down with
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the operating brake.
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Going downhill
To save the operating bake, the vehicle should be slowed down by using the engine brake.
Note: A simple rule:

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Drive downhill with the same gear as you used to drive uphill.
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2.13 Stopping in traffic

> Slow down the crane until it is at a standstill with the operating brake (1).
> The travel range can remain.
> Secure the vehicle to prevent it from rolling off by applying the operating or hand brake.
2.14 Interrupting travel with the engine running

> Slow down the crane until it is at a standstill with the operating brake (1) .
> Before leaving the operatorπs seat, switch the travel direction switch to neutral position ∫N∫ .
> Apply the parking brake (28), the indicator light (151) must light up.
2.15 To end travel

> Slow down the crane until it is at a standstill .
> Switch the travel direction switch to neutral position ∫N∫.
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> Apply the parking brake (28).
> Turn the engine off with the keyed switch (22).
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Note: After running the engine at full engine speed or if the coolant temperature is
increased (above 95∞C), let the engine run for about 1 > 2 minutes at low idle without
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a load.
> Turn off the ignition with the keyed switch (22) .
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> If necessary, turn off special functions, such as headlight, beacon, emergency blinker, auxiliary
heater*)
Note: If the auxiliary heater * runs after, the indicator light in the indicator unit does
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NOT turn off. The keyboard remains turned on, even if the ignition key is turned
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off. After the after run has been completed, the indicator light and the keyboard will
turn off automatically .
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> Turn the ignition key in counterclockwise direction to ∫0∫ position and pull it off.
> Turn off the battery master switch and pull the cam.
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CAUTION: The battery master switch may not be turned off as long as the engine is
running, otherwise the engine stops without control!
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> Close off the driverπs cab.

> Secure the crane with wheel chocks / wedges to prevent if from rolling off.
2.16 EMERGENCY OFF button *

In case of danger, the engine can be turned off by pressing the EMERGENCY OFF button. This locks
knob of the button .
To restart the engine:

> Turn the ignition key all the way to the left.
> Unlock the kob of the EMERGENCY OFF button with the key.
> Start the engine.
CAUTION: The EMERGENCY OFF button may only be used in dangerous situations.
It is strictly prohibited to use the EMERGENCY OFF button for operational
shut down.
*Optional
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3. Important indictor instruments during travel
3.1 Steering circuit II (136)

At a travel speed of approx. 10 km/hr., the warning light (136) must turn off for the hydraulic steering
circuit II.
CAUTION: If the warning light does not turn off, then the steering circuit II is not
functioning, the crane must be brought to a standstill, and the problem must
be fixed.
3.2 Engine oil pressure (warning light 183, bar graph 182)
Indication of engine oil pressure on bar graph from 0 to 10 bar.
CAUTION: After reaching the operating temperature, the engine oil pressure may not
drop below
> 2.5 bar at nominal RPM
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> 0.5 bar at low idle RPM.
If these values are lower, turn the engine off and and find the problem. This
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can cause engine damage.
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3.3 Coolant temperature (warning light 181, bar graph 180)
Indication of coolant temperature on bar graph from 0 to 130 ∞C.
If the temperature increases during travel to a level above f 120 ∞C, the red warning light (181) lights
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up. Try to reduce the load and increase the RPM to lower the temperature to a permissible range
between 85 ∞C to 90 ∞C.
CAUTION: If the coolant temperature does not drop to a permissible range, the crane
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must be brought to a standstill immediately and the engine must be turned

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off. Increased engine temperature can cause engine damage.

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3.4 Gear oil temperature (warning light 177, bar graph 176)
Indication of gear oil pressure on bar graph from 30 to 120 ∞C.
In normal travel operation, the gear oil temperature must be within the permissible range (below
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120!∞C), otherwise the warning light (177) lights up.

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CAUTION: If the indicator moves into the red range in the bar graph, the crane must be
brought to a standstill. Shift the automatic transmission to neutral position
"N" and let the engine run at approx. 1500 min>1. The oil temperature must
drop within a short time into the permissible temperature range.
If the oil temperature does not drop into a permissible temperature range,
then the crane must be brought to a standstill immediately and the engine
must be turned off. Increased temperature can cause transmission damage.
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3.5 Fuel gauge (indicator light 179, bar graph 178)

Indication of fuel quantity on bar graph in percentages (%), 0 to 100%.
If the fuel reserves is less than (e) 10% (approx. 30 liter), the yellow indicator light (179) lights up .
Note: Do not run the crane until the fuel is completely empty, otherwise the fuel system must
be bled.
3.6 Emergency fan drive, fig. 1

If the coolant temperature indicator (180) moved into the "red range", then it is possible that the fan
control is defective. To be able to drive for short distances, for example into the shop or service station,
the fan drive can be added via emergency control. In this case, the ball cock (1) must be closed all the
way.
C A U T I O N :The emergency fan control may only be used for short distances. After
completion of the emergency operation, the ball cock (1) must be opened again
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all the way.
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4. Off road driving

For travel off road, on unsurfaced paths and in wintry conditions, added controls are available.
The maximum off road driving ability is obtained by adding the front axle drive. In addition, transverse
differential locks can be applied.
Note : The addition of the front axle can be done separately.

The transverse differential locks require the length differential locks.
For safety reasons, the cut in or cut off of the front axle or the differential locks can
only be made via the "2>Hand>button" . This means that the confirmation key (93)
must always pushed together with the function keys.
CAUTION: To prevent damage on the drive axles, the following must be prevented and
observed:
Turn the differential locks on and off only when the vehicle is at a standstill!
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The greatest danger of damaging the drive components occurs when the
differential locks are turned on while the wheels are still turning.
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Drive carefully (not jerky, do not run at full throttle).
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Do not drive in curves.
Use the differential locks only to drive on difficult terrain, such as sand,
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mud, slush, loose or soft underground, etc.
Turn the differential locks on just shortly before the obstacle, and turn them
off IMMEDIATELY after passing.
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Never drive a long stretch or on normal, hard road surface with locked
differentials. When driving on hard, solid ground with added front axle drive
or transverse differential lock, significant damage can occur on the drive
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axles as well as on the complete drive train!

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4.1 Addition of the front axle

To prevent the drive wheels from slipping, the front axle can be added via button (88+93).
> Bring the crane to a standstill .

> Push the button (51) for neutral position "N".
> Turn on the length differential with button (88+93), the function check in button (88) lights up.
> Set the desired travel range.
Note: If the front axle cannot be added in neutral position, the function check on button
(88) blinks. The travel range must be shifted to ∫forward∫ (50) or ∫reverse∫ (51)
position while applying the operating brake at the same time. By pressing the
buttons (88+93) again, add the front axle drive.
CAUTION: With engaged gear, the front axle drive may only be engaged or disengaged
at low idle RPM and when the vehicle is at a standstill, otherwise it cause
significant damage to the axle as well as the complete drive train .
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4.2 Transverse differential locks
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If the addition of the front axle drive is not sufficient to prevent the wheels from slipping, press
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buttons!(89+93) to add the transverse differential locks for the driven axles.
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Note : Prerequisite for adding the transverse differential locks is the added front axle
drive. If the transverse differential locks are added without the front axle drive, the
function check in the button blinks.
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The transverse differential locks always become effective on the two driven axles.
> Bring the crane to a standstill.

> Push the button (51) for "neutral position" (N).
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> Turn on transverse differential with button (89+93), the function check on the button (89) lights up.
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> Set the desired travel range.
Note : If the transverse differential locks cannot be added in neutral position, the function
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check on button (89) blinks. The travel range must be shifted to ∫forward∫ (50) or
∫reverse∫ (51) position while applying the operating brake at the same time. By
pressing the buttons (89+93) again, add the transverse differential locks.
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CAUTION: With engaged gear, the transverse differential locks may only be engaged or
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disengaged at low idle RPM and when the vehicle is at a standstill, otherwise
it cause significant damage to the transverse differential.
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5. Hydraulic rear axle steering

The rear axle steering makes it possible to turn the wheels of the 1st and 2nd axle into the same
direction for offset movement of the crane (for the so > called dog or crab walk) and tight turning radii.
CAUTION: The rear axle steering may not be used on public roads.
For offset movement of the crane (dog or crab walk), all wheels must be turned into the same travel
direction (steered).
For tight turning radii, all wheels on the front axle must be turned in travel direction and the wheels of
the rear axle must be turned in the opposite direction.
Note: The turn>in angle of the rear axle should be about the same as that of the front axle.
This prevents unnecessary chafing of the tires.
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5.1 To put the hydraulic rear axle steering in operation
> Bring the vehicle to a standstill on level ground, move the wheels of the front axle to ∫straight travel
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position™,and apply the parking brake.
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> Push the button (51) for "neutral position" (N).
> With buttons for rear axle release (87)+confirmation (93), open (unlock) the steering lock of the rear
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axle, the function check on button (87) lights up.
Note: The release is possible in neutral position in 1st and 2nd forward and reverse gear.
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> Move the rear axle steering button (67 or 68) slightly to the left and right.
Note: If the function check blinks on one button, then the rear axle release is in an
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intermediate position
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In this case, actuate the rear axle release again.
> With the steering button (67 and 68), the rear axle can now be moved to the left or right, as desired,
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independent of the front axle.

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5.2 To take the hydraulic rear axle steering out of operation

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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 the rear axle to straight travel position.
> Apply the parking brake.
> Via buttons (87+93) apply the steering lock for the rear axle. The function check on the button (87)
turns off.
> Move the steering button (67 or 68) to check if the rear axle steering is locked. This means, the wheels
may no longer steer to the right or left.
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3.05 THE CRANE AT THE JOB SITE 024741>00
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3.05 THE CRANE AT THE JOBSITE 024741>00
1. Site selection
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.
D A N G E R : The safety guidelines in chapter 2.04 must be strictly observed and adhered to,
as they may prevent personal injury and death of yourself and others and
possible damage to the crane and equipment!
2. Changing from driving to crane operation
Prerequisites:
> The crane must be parked on even ground.
> The manual brake lever (28) in the driverπs cab an din the crane operatorπs cab (258) is applied.
> The gear selector switch in the driverπs cab and in the crane operatorπs cab is in neutral position ∫N∫.
> The engine is running.
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> The button (80) is turned off (in position Axles suspended).
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2.1 Lock the axle suspension
> Align the crane via the manual leveling control (button 62, 63, 69, 70, 77, 78, 85, 86) as level as
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possible.
> Turn on the button (80) to ™block the axle suspension™+press the confirmation key (93) .
The function check in the button (80) lights up.
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> Turn the engine off .

> Turn the ignition off.
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2.2 Change over to superstructure operation

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> Change the changeover switch (21) to position "superstructure" .

The axle suspension is automatically locked.
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Note: The condition "axle suspension locked " remains active also for the change over
from superstructure to chassis operation. By pressing the button (80) +(93), the
system can be changed over again to "axles suspended" .
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If the switch (21) is actuated, the gear selector switch in the cab (51) as well as the
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travel direction switch in the crane operatorπs cab must also be shifted to neutral po>
sition ∫N∫ .
CAUTION : The switch (21) may only be actuated when the engine is at a standstill and
only if the ignition is turned off.
If the change over switch (21) is actuated when the ignition is turned on, the
engine cannot be started from the superstructure afterward.
If the change over switch (21) is moved when the engine is running, the
engine and the ignition turn off automatically.
2.2.1 Crane hydraulic

The crane hydraulic is only added if the air pressure reserve in circuit I, II and III is more than f6,5 bar
(bar graph) and the engine is off.
If the crane hydraulic is not added when the engine is running, increase the air pressure in circuit I, II,
and III to at least 6.5 bar .
Turn the engine off and start it from the crane operatorπs cab again O the crane hydraulic is
automatically added.
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3. Support the crane from the chassis

On both sides of the vehicle is a support control unit (control box) with keys to control the support
system.
Note: The sliding arms on the left side of the vehicle can only be actuated by the control
box on that side.
The sliding arms on the right side of the vehicle can only be actuated by the control
box on that side.
CAUTION : The crane operator must assure that the appropriate support width
according to the load capacity chart has been entered in the LICCON safe
load indicator system .
The vertical support cylinders must be supported properly and may not be
extended to the lower stop. The crane operator must take a measurement to
assure that the extended cylinder stroke is less than the maximum cylinder
stroke.
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3.1 Control elements > support control unit left / right
Pos.: Support control unit, Support control unit, Pos.:

left right
350 Outrigger support cylinder , right Outrigger support cylinder, right 380
front up front up
351 Outrigger support cylinder, right Outrigger support cylinder, right 381
front down front down
rear up rear up
rear down rear down
354 Sliding arm, left front out Sliding arm, right front out 384
355 Sliding arm, left front in Sliding arm, right front in 385
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356 Sliding arm, left rear out Sliding arm, right rear out 386
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357 Sliding arm, left rear in Sliding arm, right rear in 387
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358 Outrigger support cylinder left Outrigger support cylinder, left 388
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front up front up
359 Outrigger support cylinder, left Outrigger support cylinder left 389
front down front down
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360 Outrigger support cylinder, left re> Outrigger support cylinder, left re> 390
ar up ar up
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361 Outrigger support cylinder, left re> Outrigger support cylinder, left re> 391
ar down ar down
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362 not used not used 392

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366 Incline indicator > sight gauge Incline indicator > sight gauge 366
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369 Release support control unit Release support control unit 369
371 Automatic leveling UP Automatic leveling UP 371
372 Automatic leveling DOWN Automatic leveling DOWN 372
373 Engine OFF Engine OFF 373
374 Engine ON Engine ON 374
375 RPM lower RPM lower 375
376 RPM higher RPM higher 376
Note: Before the outrigger support cylinders or sliding arms can be retracted, the release
support control unit (369) must be actuated. The button lights up when the support
control unit is actuated. The release turns off if no other button is actuated within 60
seconds or if the button (369) is pressed again. When the support control unit is
deactivated, the buttons blink.
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3.2 Bring outrigger pads from transport position (A) into operating position (B)
> Remove the circlip ( 5 ) on the pin (3) .
> Pull the pin (3) from the bore hole (2) .
> Pull the outrigger pad by the handle outward until pin (4) stops on the ball head of the outrigger
cylinder.
> Insert the pin (3) into the bore hole (1) and secure with circlip (5) .
3.3 Support pads

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 technical guidelines and observe the permissible ground
bearing load (chapter 2.04 SAFETY TECHNICAL GUIDELINES ) .
Outrigger support pad area = 2500 cm2
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D A N G E R : Use only suitable material for making the foundation.
The foundation must be placed in the center beneath the outrigger pads.
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If this point is not observed, there is a serious risk of accidents.
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3.4 Extend the sliding arms
Note: The sliding arms on the left side of the vehicle can only be actuated by the control box on
that side.
The sliding arms on the right side of the vehicle can only be actuated by the control box
on that side.
> Remove the mechanical retainer, pin (B), on the four sliding arms.
> Open the control box for the left or right outrigger support control unit.
DANGER: The operator must monitor the extension or retraction of the sliding arms.
When the sliding arms are extended or retracted, it must be assured that
there are no persons or objects within the danger zone.
> Extend the sliding arms to the support base given in the load capacity chart.
Note: wide support base: 6.27m x 6,0m
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reduced support base: 6.27m x 4,3m
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> Secure all 4 sliding arms with one pin (B) each.
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DANGER: The sliding arms must be pinned to secure them in place to prevent the
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support bases from moving later on, this could cause a serious a c c i d e n t !
The pins (B) must be inserted all the way and secured, otherwise there is a
danger of tipping over.
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3.5 Extend / retract the outrigger cylinders

> From the two side outrigger support control units, extend the support cylinders.
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> Raise the crane until the wheels are no longer in contact with the ground.
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CAUTION : If this point is not observed, the axles may be damaged , because the axles
might damaged during crane operation.
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The vertical support cylinders may not be extended all the way to the "stop".
DANGER: When extending or retracing the support cylinders, is must be assured that
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3.6 Align the crane horizontally

> Align the crane horizontally by extending or retracting the individual outrigger cylinders. This is
achieved when the air bubbles in the two sight gauges are in the innermost ring.
Note: 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.
3.6.1 Check the supports
Note: It must be checked again that the extension conditions and all safety
regulations and guidelines have been observed, otherwise there is a danger of
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causing a serious accident!
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DANGER: All 4 sliding arms on the support system must be extended, even those on the
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opposite side of the load. ER
If the sliding arms only on the side of the load are extended, it could have
dangerous consequences.
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1. Due to the load hanging on the hook, the hoist cable and the telescopic
boom (when using the auxiliary boom, this also applied to it and the guy
ropes) are tensioned and contorted.
If the load were to drop from the tackle ropes or the tackle or hoist cable
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were to breaks, it would cause a sudden relief . The boom would quickly
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flex backward, which could cause the crane to topple over.
2. It could also be possible that it might be necessary to swing the load to

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the opposite side, contrary to previous assumption. This could cause the
crane to topple over.
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3. When the crane is turned from vehicle lengthwise direction, the crane
could topple over due to the boom or counterweight momentum.
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3.7 To start the crane

See chapter 4.03, STARTING THE CRANE.
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3.8 Retract the outrigger cylinders

> Open the control box on the left or right hand side of the vehicle.
> Start the engine.
> Retract all outrigger cylinders evenly by pressing the buttons and lower the crane until the wheels are
in contact with the ground.
> Retract all four outrigger cylinders all the way .
DANGER: When retracting or extending the outrigger cylinders, it must be assured that
3.9 Bring the support plates from operating position (B) to transport position (A)
> Remove the circlip (5) from the pin (3) .
> Pull the pin (3) from the bore hole (1) .
> Insert the support plate by the handle all the way to the stop on the ball head of the support cylinder.
> Insert the pin (3) into the bore hole (2) and secure with circlips (5) .
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3.10 Retract the sliding arms ER
Note: The sliding arms on the left side of the vehicle can only be actuated by the control
box on that side.
The sliding arms on the right side of the vehicle can only be actuated by the control
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box on that side.
> Loosen and remove the mechanical retainer (pin) on the four sliding arms .
> Retract the sliding arms individually and secure them with the four pins.
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DANGER: The operator may actuate only the sliding arms he can see directly.
When extending or retracting the sliding arms, it must be assured that there
are no persons or objects within the danger zone.
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> If necessary, reduce the engine RPM to low idle speed.

> Turn the engine off.
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4. Supporting the crane from the crane operatorπs cab

The control of the support system from the crane operatorπs cab is carried out via a process visualization
on the LICCON monitor.
DANGER: All regulations, guidelines and danger notes already given for the support
procedure from the crane chassis also apply.
General prerequisites:
> The crane is positioned on level ground of sufficient load carrying capacity.
> The parking brake in the driverπs cab and in the crane operatorπs cab is applied.
> The support pads are in operating position and secured.
> The retaining pins on the four sliding arms have been pulled.
> The battery master switch on the crane chassis is turned on.
> The change over switch in the driverπs cab is switched to ∫superstructure∫ position .
> The axle suspension is locked.
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4.1 Control elements
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The control of the functions is carried out via a process visualization on the LICCON monitor. When the
key combination "SHIFT +P3" is pressed , the control base for the support from the superstructure
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appears.
When the sliding arms and the support system is controlled from the LICCON monitor, the following
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functional and safety technical peculiarities must be observed:

> Only one sliding arm can be extended or retracted at the same time.
> Any support or support combination can be moved at the same time.
> It is possible to move either a sliding arm or a support combination.
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The following elements are important for the support procedure from the crane operatorπs cab:
2) Crane type / model
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4) Monitoring and control field

4.1 Crane symbol
4.2 Dimension of maximum support in the given unit (either m / ft.)
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4.3 Function selectors to control the support cylinders

4.4 Function selectors to control the sliding arms
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6) Function keyboard at start of program (monitoring / control)

F3 Extend preselected support cylinders
F4 Retract preselected support cylinders
F5 Extend selected sliding arm
F6 Retract selected sliding arm
F7 Set sliding arm selector to next
F8 Return to crane operating view
F3 + SHIFT all 4 support cylinders are extended at the same time
F4 + SHIFT all 4 support cylinders are retracted at the same time
8) numeric keyboard on LICCON monitor

1 to 4 select or unselect the corresponding support (toggle function)
CAUTION : For safety reasons, functions behind "F3" to "F6" are only active as long as
the corresponding key is held down. A rhythmic sound is emitted as along as
the function is on. Functions "F3" and "F4" (retract / extend support
cylinders) is only applicable if at least one support cylinder has been
selected. If no support cylinder is selected, the horn sounds to report an
error.
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4.2 Extend the sliding arms
Note: Only ONE sliding arm can be extended at the same time.
> With the sliding arm selector "F7", select the desired sliding arm, the selector (double arrow) appears
on the selected sliding arm.
> With function key "F5", extend the preselected sliding arm.
DANGER: The operator must visually monitor the extension / retraction of the sliding
arms.
If he cannot see the extension / retraction of the outriggers with the
corresponding support cylinder or the sliding arm, then he must use another
person to aid him .
When extending / retracting the sliding arms, it must be assured that there
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All 4 sliding arms of the support system must be extended, even those on the
opposite side of the load.
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If the crane is not horizontally aligned, there is an increased danger of
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4.3 Extend the support cylinders
Note: Any of the outrigger cylinders can be moved at the same time.
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> With the numeric keyboard (1 to 4) on the LICCON monitor, select or unselect the corresponding
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support or support combination. Selector(s) appear or disappear on the selected support or support
combination.
> Extend the preselected support or support combination with function key "F3" .
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or
> All 4 support cylidners are extended at the same time with function keys "F3 + SHIFT" .
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4.4 Retract the outrigger cylinders
Note: Any of the outrigger cylinders can be moved at the same time.
> With the numeric keyboard (1 to 4) on the LICCON monitor, select or unselect the corresponding
support or support combination.
> Retract the preselected support or support combination with function key "F4".
or
> All 4 support cylinders are retracted at the same time with function keys "F4 + SHIFT" .
4.5 Retract the sliding arms
Note: Only ONE sliding arm can be retracted at the same time.
> With the sliding arm selector "F7", select the desired sliding arm, the selector (double arrow) appears
on the selected sliding arm.
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> With function key "F6", retract the preselected sliding arm.
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DANGER: The operator must visually monitor the extension / retraction of the sliding
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arms.
If he cannot see the extension / retraction of the outriggers with the
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corresponding support cylinder or the sliding arm, then he must use another
person to aid him .
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When extending / retracting the sliding arms, it must be assured that there
All 4 sliding arms of the support system must be extended, even those on the
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opposite side of the load.

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If the crane is not horizontally aligned, there is an increased danger of

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5. Changing from crane to driving operation
Prerequisites:
In the crane operatorπs cab

> The parking brake is applied.
> The travel direction switch is in neutral position "N".
> The ignition is turned off.
> The ignition key has been pulled.
In the driverπs cab

> The engine has been turned off .
> The ignition is turned off.
> The gear selector switch is in neutral position "N".
> The axle suspension is blocked, the button (80) is turned on.
> The change over switch (21) is switched to "Crane symbol" .
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On the crane
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> The battery master switch is turned on.
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> The crane is supported and horizontally aligned (wheels are no longer in contact with the ground)
> The crane superstructure is mechanically locked to the chassis.
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> All telescopic sections are retracted.
> The telescopic boom is placed to the front in the boom receptacle.
> The hook block is attached, as described in chapter 3.04 .
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> The added ballast has been distributed, as described in chapter 3.04.
Note: For transport on public roads, the added ballast and the hook block must be
transported as described in chapter 3.04 DRIVING ON PUBLIC ROADS.
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5.1 Change over from superstructure to chassis operation

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> Switch the change over switch (21) to "Chassis" position.
Note: The condition "Axle suspension blocked" also remains active when changing
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over from superstructure to chassis operation.

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CAUT ION: If the change over switch (21) is actuated when the engine is running, the
engine and the ignition will turn off automatically.
> Start the engine.
5.2 Retract the support cylinders and the sliding arms

as described in this chapter.
5.3 Activate the axle suspension

> Press button (80) + (93) to activate the axle suspension.
C A U T IO N : Do not turn the button (80) off until the wheels are again in contact with the
ground.
If this is not observed, the axle suspensions can be damaged due to the
sudden release of the axle blocking system.
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6. Check the following items before leaving the job site
In the crane operatorπs cab :

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

> Is the rear axle steering locked in ∫straight forward position™?
> Is the button for the axle suspension ∫blocked∫ turned off?
On the crane:
> Are the outrigger cylinders fully retracted ?
> Are the outrigger pads fully in transport position and secured?
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> Are the sliding arms fully retracted and secured with pins?
> Are the pins secured?
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> Are the pins in their retainers and secured so they cannot fall out?
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> Are the engine and the transmission covered?
> Are the covers on the slewing platform closed?
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> Are the wheel chocks in their retainers and secured so they cannot fall out ?
> Is the telescopic boom fully retracted, locked down and positioned in the boom retainer ?
> Are the control boxes on both sides of the vehicle closed and locked ? ?
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> Is the spare tire secured properly? *

> Is the hoist cable (with hook block) fastened on the pin of the towing coupling and secured, so that it
cannot fall out?
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DANGER: All locks, spring retainers and pins must be attached and secured in such a
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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.
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Note: After an extended period on a job site, before driving off, make sure to complete all
checks described in chapter 3.02, BEFORE VEHICLE STARTUP .
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4.00 OPERATION OF THE SUPERSTRUCTURE 021677>00
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021677>00
Chapter 4
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Operation of the Superstructure

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4.01 CONTROLS AND INSTRUMENTS 024237>00
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Pos.:
200 Foot pedal > Engine regulation

201 Foot pedal > Service brake
202 Foot pedal > Slewing brake
203 Foot button > Bypass of seat contact switch (control release)
204 Foot button > Horn
205 to 209 Reserved
210 Switch > Dome light
211 Container > Windshield cleaner fluid
212 Manual lever > mechanical crane superstructure lock
213 Arm rest > right
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214 to 215 Reserved
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216 Electr. socket > 24 V DC
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217 Retaining lever > Arm rest height adjustment, right
221 Arm rest > left
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222 Retaining lever > Arm rest height adjustment, left
223 to 225 Reserved
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226 Knob > Fan (3>stage)

227 Regulator > Temperature for cab heater
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228 Change over switch > Air circulation / air ventilation, air quantity
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229* Regulator > Temperature / air conditioning system

230 Manual lever > Adjustment for back rest incline
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231 Bar > Lock for horizontal seat adjustment

232 Button > Back rest support in the upper area of the back rest
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233 Button > Back rest support in the lower area of the back rest
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234 Manual lever > Adjustment of seat surface incline , seat height adjustment
235 Seat contact switch
236 * EMERGENCY OFF button > Engine shut off
237 to 249 Reserved
* Optional
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Pos.:
250 Manual control lever> Slewing gear and telescoping gear

251 Reserved
252* Button > Tilt cab
253 Switch > Brake > slewing gear
254 Button > Luff up at overload (bypass of safe load system)
255 Change over button > Steering right / left, in relation to the vehicle axis ™in the rear™
256 Manual control lever > Hoist gear and luffing gear
257 Button > Rapid gear for hoist gear, luffing gear and telescoping gear
258 Reserved
259 Change over switch > Blinker: left / right, in relation to the superstructure
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260 Change over button > Steering: left / right, in relation to the vehicle axle ™in direction of the
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boom"
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261 Change over switch > Travel direction forward / reverse, in relation to the superstructure
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262 to 279 Reserved
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* Optional
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Pos.:
280 Hour meter

281* Indicator light > Air conditioning system
282 Switch > Instrument illumination
283 Reserved
284* Switch > Hydraulic oil preheat
285* Switch > Seat heater
286* Switch > Beacon
287* Switch > Height adjustment of working floodlight on boom head / boom pivot sec>
tion
288* Switch > Working floodlight , on boom head or boom pivot section
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289* Switch > Working floodlight , on cab roof
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290 Switch > Working floodlight for hoist winch and mirror heater *
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291 Switch > Working floodlight on left hand side of cab, slewing platform *
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292* Switch > Air conditioner
293* Indicator light > Auxiliary heater turned on
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294* Switch > Auxiliary heater

295 to 301 Reserved
302 Switch > Release of brake
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303 Button > Windshield washer system, front window

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304 Switch > Windshield wiper, front window

305 Button > Windshield washer system, roof window
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306 Switch > Windshield wiper, roof window

307 * Switch > Ballasting
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308 Switch > Light :

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Position I Parking light

Position II Parking light + head light
309 * Digital clock with the following indicators:

> time of day and day of the week,
> problems in auxiliary heater,
> air temperature,
> preselection of auxiliary heater operation with 3 preselection times,
which can be preprogrammed up to 7 days in advance.
310 to 319 Reserved
* Optional
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Pos.:
320 Ignition starter switch (keyed switch)

330 Control and indicator unit of ∫LICCON∫ safe load system
(refer to more chapter 4.02 ™CONTROL AND INDICATOR UNIT FOR LICCON OVERLOAD
SAFETY DEVICE")
A Alpha>numeric keyboard
P Program keys to start various LICCON programs
C Input key ∫ENTER∫ to confirm changes
D Keyed button
E Special function keys
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F Function keys
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G Monitor ER
H "SHIFT" key
I LED indicator
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4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE 024473>00
1. General
2. Control elements of the LICCON
3. LICCON programs for crane operation (overview)
4. Booting the LICCON system after turning it on
5. The ∫SET UP∫ program > the equipment configuration view
6. The ∫OPERATION∫ program > crane operation view
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7. The "Support" program
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1. General
The LICCON safe load indicator system is processed on the central microprocessor unit 0 in the basic
component group 0.
The LICCON works by comparing the actual load and the maximum permissible load according to the
load capacity chart and the reeving.
Actual load
The actual load is determined by registering changing values:
The load stress on the crane is combined of load momentum and boom momentum. It affects a force in
the boom luffing cylinder, which is measured by pressure sensors.
The boom momentum is calculated from the angle sensor information (boom angle) and the length sen>
sor information (boom length) and the crane data (boom weights) for the adjusted operating mode.
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The radius is calculated with the aid of the angle sensor information (boom angle), the length sensor
information (boom length) and the geometry data for the adjusted operating mode. A boom flexation
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due to its own weight and the weight of the load are taken into account.
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The actual load is calculated from the total load, the boom momentum and the radius
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Maximum load according to load capacity chart and reeving
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The crane data, such as load charts, boom weights and geometry data are stored in the central memory
bank of the LICCON .
The ∫maximum load according to load capacity chart and reeving∫ is constantly being determined from
load capacity charts for the adjusted equipment configuration, for the adjusted reeving and the calcula>
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ted radius.
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Comparison
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The actual load and the "maximum load according to load capacity chart and reeving " are compared.
As soon as the values get close to the preset limit, a prewarning is given. When this limit is reached or
exceeded, the overload warning is triggered and all load moment increasing crane movements are tur>
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ned off.
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2. The control elements of the LICCON

The LICCON control and indicator elements are located in the crane operatorπs cab, in direct view of the opera>
tor.
The MONITOR consists of three components:
> Display
> Controller
> Keyboard
A Alpha numerical keyboard
P Program keys to start the various LICCON programs

P0: SET UP
P1: OPERATION
P2: CRANE DELIVERY (corrective coefficients)
P3: Program support
P4: not used
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P5: not used
P6: not used
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P7: not used
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P8: LICCON TEST SYSTEM * ER
C Input key ∫ENTER∫ to confirm changes
D Keyed switch
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> Position to the right (touching) LML inactive

> Center position (self retaining) LML active

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The brightness level of the monitor can be changed with these keys.
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Brightness control for screen

Hold E3 down and then push E1 to change the brightness level (2 stages)
Hold E3 down and then push E2 for finer brightness level change (4 stages)
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Additional functions of the special function keys depend on the programs and are explained in detail in the
description of the various LICCON programs.
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F Function keys
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The function keys should always be viewed together with the function key symbol bar shown above on the
screen.
G Screen
The screen can show views in various programs. The illustration on the left, for example, shows the set up
view of screen .
H SHIFT key
Key assignment on 2nd level , "Supervisory function"
I LED Indicator
I1 LED red Monitor error
I2 LED yellow Supply voltage for monitor available "Power On"
Note: The functions of the various monitor control elements depends on the program, i. e. it can be
different, depending on which LICCON program is currently running. For that reason, de>
tails are given in the descriptions of the various LICCON PROGRAMS.
* Optional
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3. LICCON programs for crane operation
3.1 The ∫SET UP∫ program

shown on the screen in the ∫equipment configuration view∫
Description, see paragraph 5.
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3.2 The ∫OPERATION∫ program

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shown on the screen in the ∫crane operation view∫

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Description, see paragraph 6.

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3.3 The ∫Support∫ program

Description, see section 7 and chapter 3.05, THE CRANE AT THE JOB SITE:
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4. Booting the LICCON system after turning it on (= Boot >up phase)
After the LICCON system is turned on, it runs through a self test.
It first checks the connections from the central processing units (CPUs) to the monitor. If no error is found
during this check, then the monitor displays :
O DATA LINE CHECK PASSED >> O.K. !! (fig. 1)

SYSTEM CHECK......
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If the test found no problems with the connections, then a system test is carried out on all central micro proces>
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sing units (CPUs). The step>by>step self test procedure can be monitored on the 7>segment CPU indicators.
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These indicators are described in more detail in chapter "Localizing and fixing system errors".
If no error was found during this test, then the monitor displays:
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O DATA LINE CHECK PASSED > > O.K. !! (fig. 2)
SYSTEM CHECK...... PASSED > > O.K. !!
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After that, all 4 LICCON monitors display the general initialization view
LIEBHERR>WERK EHINGEN (fig. 3)
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Booting the LICCON system (continuation)
When the starting procedure is completed successfully,the EQUIPMENT CONFIGURATION VIEW will appe>
ar on the monitor .
Normally, the EQUIPMENT CONFIGURATION VIEW is shown, which was used before the system had been
turned off, with the last selected hoist cable reeving.
Note: After a "cold boot" (for example in case of a loss of data in the memory ) the indicator of the hoist ca>
ble reeving is on "0".
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5. The ∫SET UP∫ program > the equipment configuration view
The ∫SET UP∫ program permits the crane operator to set the LICCON on the monitor with the aid of the equip>
ment configuration view and the control elements of the LICCON to the current operating mode, the current
equipment configuration view of the crane and the reeving number of the hoist cable .
In addition, after corresponding operating mode preselection, all load capacity charts stored in the system can
be viewed with the ∫SET UP™ program.
After turning the system on and confirming the operating mode preselection group, the ∫SET UP∫ program
appears automatically and shows the equipment configuration view.
Normally the exact same equipment configuration view will appear, which was last used, and the reeving
which was used then will appear.
If the LICCON is turned on for the first time, or if there was a memory loss (cold boot), then the equipment
configuration view for the 1st valid equipment configuration for the 1st valid operating mode will appear.
CAUTION: When rebooting the system (cold boot), the setting for the hoist cable reeving is set
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to ∫0∫!
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The operating mode and the equipment configuration can be set two ways:
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1. Set up with function keys: (see also paragraph 5.3)
F2 Set the operating mode "Main boom" (if available)
F3 Set the operating mode "Auxiliary equipment" (if available)
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F4 Set the equipment configuration "Slewing platform counterweight"(if available)

F5 Set the equipment configuration "Support base"
F6 Set the equipment configuration "Slewing range of crane superstructure"
Push the "ENTER" key.
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2. With a short code:

Enter the 3>digit short code with the numeric keys of the alpha numeric key board (A) on the monitor ,
Push the "ENTER" key.
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Then the data in the selected load capacity chart can be viewed.
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F7 Set the "Hoist cable reeving"

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F8 end the ∫SET UP∫ program and to take over the selected parameters into the ™OPERATION∫ program by
using the "O.K." key.
Note: If the equipment configuration has been confirmed with "O.K." at least once, then the ∫SET
UP∫ program can be ended by pushing one of the program keys (P1 > P8) . The LICCON
throws out the adjustments made in the ∫SET UP∫ program and continues to use the old ope>
rating condition, which has been confirmed last with "O.K.™
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The screen in the ∫SET UP™ program (equipment configuration view) is divided into three sections:
5.1 General information line
5.2 Indicator range for the values of the load capacity chart
5.3 Function key bar
5.4 Other control elements
Note: The illustrations in this chapter are used only as an example.

The numeric values in the various symbols and charts will not necessarily match your crane
configuration.
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5.1 General information line

This line, from left to right, are the following symbols and data:
1) Symbol ∫Telescopic boom length∫ (looks the same for all operating modes)
2) Abbreviation for programed length units (LE) and weight units (GE). Length units include meters [m]
and feet [ft]. Weight units are shown either in tons [t] or pounds [lbs].
3) Next to the word ∫CODE∫ , inside pointed brackets, it a 3>digit short code. Every short code describes an
crane equipment configuration. The valid equipment configuration and the corresponding short code for
the crane are taken from the craneπs load capacity book.
4) an 8>digit operating mode dependent organization number ( (B xxx yyyy for the set load capacity chart.
The first letter designates the calculation base for the load capacity charts (as used in the country of ope>
ration) for example ∫B∫ = DIN, BS 75% )., then the 3>digit number combination (xxx) describes the cra>
ne type (for example ∫104∫ = LTM 1030/2 ) . The 4>digit number block (yyyy) defines the correspon>
ding operating mode.
5) A period ∫.∫ separates the organization number from the page number of the currently shown section of
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the load capacity chart, behind it, in parenthesis ( ) is the total number of pages for this load capacity
chart (see also description of function key ∫F∫).
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5.2 Indicator range for load chart values

This section is divided into the following areas:
1) Telescopic boom lengths in length unit meters ([m] or foot [ft]) in max. 7 columns per page. They form
the horizontal axle of the load capacity value field.
2) The operating mode dependent symbol ∫radius∫ in length unit meters ([m] or foot [ft]) in max. 19 lines of
radii values. They form the vertical axle of the load capacity value field.
3) Load capacity value field
In the columns below the telescopic boom lengths and the lines to the right of the radii values are the load
capacity values, which depend on boom length and radius.
4) Line * n * = Hoist cable reeving
The numbers in this line show, how often the hoist cable must be reeved between boom head and hook
block in order to lift the maximum load according to the corresponding load capacity chart column.
If a load capacity value in the column exceeds the load which can be lifted with the maximum reeving,
then an exclamation mark (∫!∫) is next to the reeving number to signify that special equipment is requi>
red to lift this load.
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5) Line for special indicators
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If a load chart consists of more than 7 columns, then it cannot be shown completely on the screen due to
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its size. In this case, arrows in the first field (<<) or in the 7th field (>>) in this line show that other
columns are to the left or right, they can be viewed by moving the arrow key ∫<∫ or ∫>∫ .
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As supporting information, the presently selected column number and the number of columns in this
chart are given (for example 4 (10) = 4th of 10 columns ).
6) Range ∫extension condition of telescopic sections in percentages [%]∫
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In the first column is the symbol ∫boom length∫ [%]. next to it are 3 lines for extension condition of teles>
copic sections. In this case, the number in the symbol column shows the corresponding telescopic sec>
tions (the highest number is for the outermost telescopic section) and the value in the ∫boom length co>
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lumn™ shows the extension condition in percentages, which must be retained for the corresponding boom
length.
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5.3 The function key bar

The function key bar contains 8 function key symbols, which correspond to the function keys below, which me>
ans they either designate a function, which can be triggered with the function key (F1 to F8) or they change
their view or their contents and designate a change of operating mode or equipment configuration.
F1 Vertical paging
Due to the size of the screen, no more than 9 lines of the load capacity chart can be shown at the same ti>
me. If a chart consists of more than 9 lines, then they are shown on several pages. By pushing the but>
ton, the next page of the load capacity chart is shown, and the number of the current page is increased
by 1 in the ∫General information line∫. When the last page is reached and the F1 key is pushed, page 1
will reappear.
F2 To set the operating mode (main boom)

The various main boom operating modes of the crane can be entered here. The types are described in
the symbol with abbreviations for length data, for example "30 m T" =telescopic boom with a
maximum length of 30 m.
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F3 To set the operating mode (auxiliary equipment condition)
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Here, the crane operator can select various auxiliary equipment types and type them in. The types are
described in the symbol with abbreviations for length and angle data (for example: ∫K 20∞ 8.6 m∫ =
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folding jib 8.6 m long, installed at an angle of 20∞ to the telescopic boom). .
Note: If function keys F2 and / or F3 are pushed, all operating mode and equipment
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configuration dependent data is deleted from the screen and the short code in the ∫General
information line ∫ is set to ∫CODE >? ? ? <∫.
Operating mode depending data are:
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> Telescopic boom length symbol for the general information line
> Length units and weight units
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> Organization number of load capacity chart

> Radius symbol
> Telescopic boom lengths
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> Telescopic boom length symbol in the range ™extension condition of telescopic sections in
percentages (%)
> Percentage of extension condition of telescopic sections with status indicator
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Equipment configuration dependent data are:

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> Numbering of current page number and total page numbers of load capacity chart
> Radius values in length units
> Load capacity values in weight units
F4 To set the equipment configuration ™Counterweight™

Use this key to set the current counterweight on the craneπs slewing platform in the LICCON. By
pushing the key, the next symbol with text will appear in the counterweight symbol.
F5 To set the equipment configuration "Supporting base".
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F6 To set the equipment configuration ™Slewing range of crane superstructure™

> 360∞ for unlimited slewing,
> 0∞ for working range to the rear (pinned)
> !0∞ for working range to the rear
This means that for the same equipment configuration there is also a 360∞ load capacity
chart.
If the slewing platform in not pinned, the LICCON shifts automatically to the "weaker" lo>
ad capacity chart for the "360∞ working range" . The indicated short code differs then from
the short code for the "360∞ working range", as well as from the short code for the "!0∞ wor>
king range".
If the working range 0∞ is shown, then no corresponding 360∞ load chart is available. If
the slewing platform lock is not applied, then the crane CANNOT be operated any longer.
Note: If function keys F4, F5 or F6 are used, all operating mode dependent data (if it was not
shown before and the chosen operating mode exists) and all equipment configuration de>
pendent data is deleted from the screen (if it was shown before). The short code in the ∫Ge>
neral information line ∫ is set to ∫CODE >? ? ? <∫
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F7 "Hoist cable reeving "
Use the F7 key to set the reeving number of the hoist cable, which is reeved on the pulley head (telesco>
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pic boom or folding jib), which has been selected via the load capacity chart.
The number of hoist cable reevings shown in the symbol is increased by 1 every time the button is
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pressed, until a maximum value, which is preset for the corresponding operating mode; then the counter
starts again with the minimum value. When changing the operating mode, if the set value is within
this range (minimum value e actual value e maximum value), then it remains valid. Otherwise, it is
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set to the minimum value for the new operating mode.
Note: After rebooting ∫cold start∫ (for example after a loss of data in the memory), the indicator
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for the hoist cable reeving is at ∫0∫..

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F8 "O.K." Confirmation of set equipment configuration

The crane operator confirms the chosen equipment configuration and the chosen reeving (which
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matches the actual equipment configuration of the crane) with ∫O.K.∫ and transfers the parameters to
the ∫OPERATION∫ program.
The following must be noted:
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> The equipment configuration input must be completely finished, which means a valid short code
must be shown and load capacity values are shown in the chart fields.
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Otherwise, "ERROR 50" will be shown.

> If required, the external condition for this equipment configuration must be fulfilled, (for example
superstructure lock).
> The crane may not be utilized by more than 20% in the previous configuration, or the load hanging
on the hook may not be heavier than 0.5 tons.
Otherwise, the program can only be switched to the ∫OPERATION™ program via the program key
P1 . In this case, the new equipment configuration settings are not taken over.
> If the crane is equipped with a sliding arm monitor, then the sliding arms must be extended to the
given support base for the selected load capacity chart.
Otherwise, "ERROR 155" will be shown .
Note: The crane operator must assure before changing into the operating view, that the selected
equipment condition ( short code ) and hoist cable reeving (s) have been accepted.
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The remaining control elements on the indicator and control unit of the LICCON in the ∫SET UP∫ program ha>
ve the following functions:
A Alpha numeric key board

With the keys 1 to 9 on the alpha numeric keyboard, the short code field of the General information line
can be directly accessed and the short code can be entered.
Note : Use of the alpha numeric keys deletes all operating mode and equipment configuration de>
pendent data from the screen.
The keys ∫p∫ and ∫.∫ have no function in the ∫SET UP∫ program.
P Program keys
Use the program keys to select the various programs. Setting made in the equipment configuration pro>
gram are thrown out and the equipment configuration and reeving is used, which was last confirmed by
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the "O.K." key .
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The currently running program cannot be called up again via its program key.
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C Input key ∫ENTER∫
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∫ENTER∫ is the input confirmation for entering the short code as well as changing the operating mode
or the equipment configuration via the function keys.
∫ENTER∫ after short code input searches the short code in all stored load capacity charts. If the
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appropriate load capacity chart has been programmed, then it will be shown in full (including new
lettering for symbols in the function key bar), otherwise, an error message in the form of question marks
∫???∫ will appear in the 2nd part of the organization number and the horn will sound.
∫ENTER∫ after changing the operating mode via the function keys searches this operating mode, if
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successful sets the 1st equipment configuration and shows the corresponding load capacity chart and its
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short code. In case of error, the short code indicator remains on CODE >???<. The organization number
is shown as ∫axxx????∫ and the horn will sound.
∫ENTER∫ after changing the equipment configuration shows this load capacity chart, if it is available,
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with short code, on the screen. In case of error, the short code indicator remains on CODE >???< and
the horn will sound.
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D Keyed switch
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has no function in the ∫SET UP∫ program.
E Horizontal paging E1 and E2 (< and >)

The keys E1 and E2 (< and >) are only functioning if it is noted in the ∫line for special indicators∫ (see
[paragraph 4.2) .
If the load chart consists of more than 7 columns, then columns 1 to 7 are always shown during the in>
itial equipment configuration view.
The double arrow on the right edge of the line shows that there are more columns. If the cursor is moved
to the marked edge, then the next three columns are shown.
The cursor will be centered automatically.
H SHIFT key
has no function in the ∫SET UP∫ program.
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6.The ∫OPERATION∫ program > crane operation view
The LICCON ∫OPERATION∫ program supports the crane operator by constantly displaying data relevant for
the crane operation on the monitor (crane operation view). In addition, the crane operator is alerted to upco>
ming overload conditions. In case of overload and many error conditions, which could lead to dangerous condi>
tions, the dangerous crane movements are shut off.
The monitor is divided into 6 sections in the crane operation view :

6.1 Information about crane geometry and load
6.2 Alarm functions
6.3 Special functions
6.4 Monitored additional functions
6.5 Winch indication > winch 1
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6.6 Function key symbol bar
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6.7 Other control elements ER
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Note: The illustrations in this chapter are only examples.

The values in the individual symbols may not match in all cases.
In addition. the illustrations show the maximum possible placement if symbols on the ope>
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rating view on the monitor .

In normal crane operation, the LICCON screen would not show identical views.
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6.1 Information about crane geometry and load
1) The reeving number of the hoist cable is given as ∫n = <number>∫, which is reeved via the pulley he>
ad which was chosen via the load capacity chart (previously set in the equipment configuration view).
2) Symbol "maximum load carrying capacity " in weight units of tons [t] or pounds [lbs] .
3) Maximum load carrying capacity according to load capacity chart and reeving:
The "maximum load carrying capacity according to load capacity and reeving" is shown in the indicated
weight unit of either tons [t] or pounds [lbs] .
The "maximum load carrying capacity according to load capacity chart and reeving " is dependent on
the chosen operating mode and the chosen equipment configuration (Æ load chart), on the radius and
the reeving of the hoist cable.
"? ? ? ?" is shown if no load capacity chart value is available, for example because the crane is not in a
range for a load capacity chart or one or more sensors are missing or are defective, so that the radius
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cannot be calculated.
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4) Symbol "Momentary load " with weight unit of tons [t] or pounds [lbs] .
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5) Momentary load (Actual load indication)
=Load (in weight units of tons [t] or pounds [lbs]), which is suspended at the moment on the crane hook.
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Indicated is the calculated total load, including the weight of the load carrying, take up and / or tackle.
When actuating the ∫tare∫ function, (see description F7 in chapter 6.6) the indication can be changed
over to net load indication. In the symbol appears also the word ∫net∫, the weight unit is then directly
next to the load symbol.
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"? ? ? ?" is shown if one or more sensors are missing or are defective, so that the momentary load cannot
be calculated.
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6) 8digit organization number (denotes the type of the set load capacity chart and the operating mode, see
chapter 5)
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7) Short code (CODE >number<) of the set equipment configuration, see chapter 5.
8) Dynamic utilization bar indication

=(momentary load) /(maximum load according to load capacity chart and reeving in percentages (%))
In operating modes without derrick ballast, this bar is the only measurement for crane utilization .
9) Utilization scale , which is marked at important points with percentage values (static view) .
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10) "Radius " symbol with length units in meters [m] or feet [ft]
11) Radius in meters [m] or feet [ft]

= horizontal distance from the center of gravity of a load (on the load hook, chosen by the operating mo>
de , for example T,K) from the axle of rotation of the crane superstructure, measured on the ground. The
flexation of the boom due to its own weight and the suspended load is taken into consideration.
"?!?!?!?" is shown if geometry data or sensor values are missing, so that the radius cannot be calculated.
12) Main boom angle to the horizontal in degrees [∞]
"?!?!? ?" is shown if geometry data or sensor values are missing, so that the main boom angle cannot be
calculated.
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13) "Main boom length " symbol in length units in meters [m] or feet [ft]
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14) Length of main boom in meters [m] or feet [ft] ER
15) Extension of various telescopic sections in percentages (%)
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16) Symbol "Pulley head height" in length units in meters [m] or feet [ft]
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17) Pulley head height in meters [m] or feet [ft]

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= vertical distance from ground level to selected pulley head axle, for which the indicated maximum lo>
ad capacity is valid.
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"?!?!?!?" is shown if geometry data or sensor values are missing, so that the pulley head height cannot be
calculated .
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6.2 Alarm functions
The crane movements are monitored in their limit ranges. As soon as the limit is reached, the crane
operator is alerted by the following blinking symbols on the monitor:
1) Boom limit
The luffing range of the boom is limited upward as well as downward. If , when luffing the boom, an end
position for the selected load capacity chart is reached, then this symbol will appear.
Two upward directed arrows show that the movement was shut off because the upper limit had been
reached, it is still possible to luff down.
Two downward directed arrows show that the movement was shut off because the lower limit had been
reached, it is still possible to luff up.
2) Upper hoist limit on the telescopic boom

appears if the hook block runs against the upper hoist limit switch on the telescopic boom .
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Then the crane movements ∫spool up hoist winch 1 ∫, and ∫luff down boom ∫ are shut off .
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3) Upper hoist limit on the folding jib
appears if the hook block runs against the upper hoist limit switch on the folding jib .
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Then the crane movement ∫luff down boom ∫ is shut off .
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4) Prewarning symbol
From the "current load " and the "maximum load carrying capacity according to load capacity chart and
reeving" the current load capacity chart utilization can be calculated.
The prewarning symbol appears if the current load capacity chart utilization has exceeded the
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preprogrammed limit (such as 90 %).

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5) STOP symbol
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appears if the "current load " exceeds the "maximum load carrying capacity according to load capacity
chart and reeving" (100%).
All crane movements, which would increase load momentum are turned off .
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6) ∫Horn∫ acoustical signal

Any errors found on the central processing unit in the electronics basic components group,
> operational errors, which cause the movement to shut off , and
> application errors with error number
for example sensor errors, which occur due an insufficient sensor signals or defective sensor, in addition to
the optical indication, are also reported through an acoustical signal ∫HORN∫ by the monitor. ∫HORN∫ is
a 0.5 second long sound, which is being repeated in second intervals.
Operational errors are :

> Overload
> Boom outside the angle range of the load capacity chart
> Boom outside the radius range of the load capacity chart
> Extension condition of the telescopic sections does not correspond to the load capacity chart.
Monitored sensors are :

> Hoist limit switch
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> Length sensor
> Pressure sensor
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> Angle sensor
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> Wind sensor
> Battery voltage
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∫Short horn "
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Error messages, which have no error number and which do not lead to an immediate shut down of crane mo>
vements by the LICCON overload safety device are also reported, in addition to the optical indication, with
an acoustical signal ∫SHORT HORN∫ . ∫SHORT HORN∫ is a 0.1 second long sound, which is repeated in 2
second intervals.
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Monitored errors are:

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> Maximum permissible wind speed has been exceeded (only at activated wind sensor)
> Crane utilization value for ∫CAUTION∫ (90%) has been reached.
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Priority and "Horn off∫

The alarm ∫HORN∫ has a higher priority than the alarm ∫SHORT HORN∫, which means ∫HORN∫ superse>
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des ∫SHORT HORN∫.

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∫HORN∫ as well as ∫SHORT HORN∫ can be shut off via function key F8, however, they are activated again
as soon as a new error occurs.
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6.3 Special functions
1 The "Installation operation" symbol

blinks, if the crane control is turned to ∫installation∫™ position via the installation keyed switch. Then
the operation view is locked, which means no other program can be turned on via the program keys (P).
2 Symbol "Rapid gear"

Rapid gear for crane movement
Hoist gear 1 > up / down
Boom > luff up
Telescope out
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6.4 Monitored additional functions

Via the function key F3, additional symbols with additional information for crane operation can be displayed, if
necessary. These symbols have a fixed place on the monitor.
The following symbols can be shown:
2 Wind speed
3 Slewing platform lock
4 Battery voltage
If function key F3 is turned off, and an error occurs in one or more of these functions, then the symbol is shown
on the monitor.
6.4.1 Additional function (Wind speed∫ *
The wind speeds are shown in the unit of measure used in the load capacity chart, either meters [m/s] or feet
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[ft/s] .
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2.1 Symbol "Wind speed" in measuring units of meters [m/s] or feet [ft/s]
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2.2 Current wind speed ER
2.3 Maximum permissible wind velocity with symbol text "max:"
The value depends on operating mode and equipment configuration.
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If the current wind velocity value exceeds the indicated maximum value, the value starts to blink and the
acoustical alarm ∫SHORT HORN∫ can be heard.
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CAUTION : The crane movements are not shut off .

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6.4.2 Additional function (Slewing platform lock∫

Shows condition of lock between crane superstructure and crane chassis
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Unlocked / locked
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6.4.3 Additional function (Battery voltage∫
4.1 Symbol battery voltage
4.2 Current value of the battery voltage in the unit of volts [V].
The numbers in the symbol will blink if the operating voltage is <18 V or > 36V.
The indication is accurate to ±1/10 V.
* Optional
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6.4.4 Additional function (Leveling∫ *

This symbol shows the incline of the crane superstructure to the horizontal in lengthwise and crosswise direc>
tion. The indication is shown graphically as well as numerically.
1.1 the graphic view looks like a sight gauge, a point ( small square ) represents the air bubble. The center
of the point shows the exact incline value.
1.2 In the numerical section of the symbol appear 3 numeric values, which have the following designation:
This value shows the graphic view, the sight gauge distance of 2 lines (lengthwise and crosswise). It is
shown in the unit of degrees [∞] and can only take on the values ∫0.2∫ or ∫1∫ . The change occurs auto>
matically. If the crane incline is in crosswise <1.1 [∞] and in length wise direction <0.9 [∞], then the
gauge moves in the 0.2 degree range. If at least one value exceeds the above limit, then it changes into
the 1 degree range.
1.3 Incline of crane superstructure in degrees [∞] in crosswise direction .

The dual arrow shows the direction of the slope :
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Dual arrow to the left = The crane superstructure slopes to the left
Dual arrow to the right = The crane superstructure slopes to the right
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1.4 Incline of crane superstructure in degrees [∞] in lengthwise direction .
The arrow shows the direction of the slope :
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Arrow pointing upward = The crane superstructure slopes to the rear
Arrow pointing downward = The crane superstructure slopes to the front
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* Optional
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6.5 Winch indication

The monitor shows the function on winch 1 .
1) If the winch is operated with the reeving set in the equipment configuration view , then the indicated value
is the completed hook path from a predetermined zero point is shown in the indicated length units of meters
([m] or feet [ft])
The numbers in front of the period are shown with maximum 3 large figures.
The numbers after the period are shown in small figures.
(See also chapter 6.6 , description of function keys F1 and F2).
The prerequisite for the correct indication is the accuracy of the entered value and the actual number of ca>
ble skeins between boom head and hook block.
If the set reeving does not match the reeving of the corresponding winch, (for example: winch on mast stub,
but load capacity chart was set for main boom) , then the correct hook path can be calculated from the indi>
cated hook path as follows:
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indicated hook path ¥ set reeving
correct hook path =
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The hook path calculation only works correctly if the load is freely suspended and if you donπt luff down du>
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ring the hoisting procedure. Flexation and cable stretch are not taken into account.
The length indication (hook path indication) is only correct and the layer jump is only then correctly taken
into account if the winch has been calibrated and since that time, there was no power supply interruption to
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the CPUs (™Cold start"). The calibration of the hook path indication is done by spooling the cable up / out
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until the calibrating switch is triggered.

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2) The arrows on the length value show the direction of the hook movement in relation to the zero point:
Arrow pointing upward = Hook has moved from the zero point upward,
Arrow pointing downward = Hook has moved from the zero point downward.
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3) Length unit for hook path indication : [m] or [ft]
4) Winch status indication

The following winch status symbol are available (all blinking) :
4.1 spool out

4.2 spool up
4.3 spooled out Æ spool out is locked
4.4 If no winch status symbol appears, then the activated winch is at a stand still and is neither
spooled out nor up.
5) Winch symbol (with cable end for winch status symbol)
6) Winch number
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6.6 Function key symbol bar

The function key symbol bar contains up to 8 function key symbols, which correspond to the functions keys F1
to F8 underneath , i.e. they designate either a function, which can be triggered with the corresponding key and
/or, when the key is pushed, changes its depiction and thereby its meaning.
F1 no function
F2 Zero point for hook path indication, winch (1)

Via the key F2 appears the symbol (set winch indication to zero∫, by pushing the key, the hook path in>
dication is set in the above winch symbol to ∫000,00∫ and the path measurement starts at this point .
F3 Turn monitoring symbols on or off

With the function key F3 (™Caution™ symbol in the function key frame) the crane operator is able to turn
all monitored additional functions for his crane off or on . The function key symbol changes accordingly:
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thick frame = added function symbols turned off
thin frame = added function symbols turned on
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The monitoring mode for the added functions (wind speed, battery voltage) is always turned on; only
the symbols can be turned off. If the monitored limits are being exceeded, then a warning is given with
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the horn and the corresponding symbol is shown, even if the monitoring symbols had been turned off.
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F4 Change monitoring side

This function key is only active and is only shown in the function key symbol (arrows in the function key
frame) via the keys on the monitor, if the triggered function has any meaning (see also paragraph 6.4
∫Monitored additional functions ∫).
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F5 No function in the ∫OPERATION∫ program .

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F6 No function in the ∫OPERATION∫ program
F7 Tare
The load hook symbol and the number ∫0∫ in the FUNCTION KEY symbol frame describe the function.
When actuating the F7 key, the actual load indicator (6.1 Pos. 2) is set to ∫zero∫. At the same time, the
word ∫net∫ appear in the symbol of the actual load indicator. This function makes it possible, for
example, to eliminate the weights of hoist cable, carrier unit and tackle and shows only the weight of
the load to be lifted (net load). This tare function is eliminated again by 3 actions:
1. repeated actuation of the F7 key,
2. Telescoping the boom by more than 3 length units (dm or 1/10 ft ),
2. Luffing by more than ± 4 ∞
The words ™net™ disappear again from the actual load indicator system (6.1 Pos. 2) and the gross load
values are shown.
F8 Horn OFF
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The crossed out horn symbol in the function key frame via the F8 key describes the function.
The acoustical warning signals "HORN" and "SHORT HORN" can be turned off by pressing the F8
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key. A new error will turn the acoustical warning on again.
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Error (8)
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Vi a the F8 key, an error code appears in the symbol element ∫Horn™if a system error, operational error
or application error occurs. If more error appear at the same time, the F8 key can be pressed to show
all errors occurring at this time. If an error is fixed, the error code disappears in the symbol element.
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for example E1187074 O System error (engine, gear , LWE error LEC)
B2011203 O Operational error
E120 O Application error
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Special function key F8 (7)

For crane delivery, a special program is available in the LICCON system.
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To prevent errors, access is only permitted for trained LIEBHERR personnel. After completion of cra>
ne delivery, access to this program is locked. The delivery program condition can be seen in the function
key symbol Horn OFF in the crane operation view.
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Note: An additional mark (claw) in the symbol shows that the crane delivery program is not
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yet locked.
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The remaining control elements in the indicator and control unit of the LICCON in the ∫OPERATION∫ pro>
gram have the following functions:
A Alpha numeric key board

The 0 to 9 keys in the ∫OPERATION∫ program have no function.
Alpha numerical keyboard "P" and "." .
The test view function can be turned on / off with the ™P™ key, which means all existing symbols appear
on the screen with erroneous indicator values. The monitored additional functions, however, must be
opened to the desired page, if they are to appear in the test view. The test page can be held in place by
pushing the "." key, otherwise the normal operating view will appear after 10 seconds or after pushing
the ™P™ key.
P Program keys
Use the program keys to choose among the various program. However, you must note the program spe>
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cific peculiarities (for example, from ∫SET UP∫ always switch to ∫OPERATION∫ by pressing 1¥ O.K.
). The currently running program cannot be called up again via its program key
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The programs can only be called up via their program key, if the keyed switch ™Installation" on the
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instrument panel is not in ∫Installation™ position.
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C ENTER > This key has no function in the ∫OPERATION™ program
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D Keyed switch
This key has no function in the ∫OPERATION™ program
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These keys have no function in the ∫OPERATION™ program .

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H The "SHIFT" key has no function in the ∫OPERATION™ program .

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7. The ∫Support∫ program
7.1 Control basis for support system

The support system is controlled from the superstructure. The control of the various functions occurs
via a process visualization on the LICCON monitor.
7.2 Support control
2. Crane type
4. Monitoring and control symbol
4.1 Crane symbol
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4.2 Dimension of maximum support in given unit
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4.3 Function selectors with support numbers to control the support system
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4.4 Function selectors to control the sliding arms
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6. Function keyboard at the start of the program
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F3 Move the preselected support downward
F4 Move the preselected support upward

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F5 Extend the selected sliding arm
F6 Retract the selected sliding arm

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F7 Set the sliding arm selector to next

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F8 Return to crane operating view

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F3 + SHIFT all 4 support cylinders are extended at the same time
F4 + SHIFT all 4 support cylinders are retracted at the same time
Note: Functions F3 and F4 (extend / retract outrigger supports) can only be actuated if
at least one support has been selected. If no support has been selected, the horn
will sound to report an error.
or
Function "F3 + SHIFT" to extend all 4 outrigger cylinders is actuated or
function "F4 + SHIFT" to retract all four outriggers cylinders is actuated.
C A U T I ON : For safety reasons, the functions behind F3 to F6 are only active as long
as the corresponding key is held down. As an acoustical signal, a rhyth>
mic sound can be heard for the duration of the function.
8. Numeric keyboard
Select or unselect the corresponding support 1 to 4.
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4.03 STARTING THE CRANE 024233>00
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1. 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 SUPERSTRUC>
TURE.
Check oil level and filter

> Check the oil level on the engine (fig. 1)
> Check the oil level on the hydraulic tank for the crane hydraulic (fig. 2)
CAUTION : Check the oil level with the telescopic boom placed down, the sliding arms
and the support cylinder fully retracted and the vehicle in level position.
> Check the filter on the hydraulic tank (fig. 3)
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Check the fuel level
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During travel, the tank contents is shown permanently, in percentages (%) in the form of a number in
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the crane operating view, automatically or manually actuated.
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IMPORTANT: Do not run the engine until the fuel tank is empty, otherwise the fuel sy>
stem must be bled.
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Check the coolant level (fig. 4)

The coolant level reservoir must be filled to the rim on the filler neck.
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DANGER: NEVER check the coolant level if the temperature is higher than 50∞C and if
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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!
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Central lubrication system (fig. 5)

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Make sure that the grease containers is always filled with grease, as specified to the lubrication chart.
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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 switches are free of snow and ice,
> There are no loose parts and objects on the crane superstructure, telescopic boom and 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 seve>
re injuries due to falling objects, which might strike persons or objects and
equipment on the ground.
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2. The crane operatorπs cab
2.1 To tilt the crane operatorπs cab *

The crane operatorπs cab can be tilted upward hydraulically by approx. 20∞ to provide the crane operator
with more visibility and an increased field of vision .
DANGER: The cab must be returned to horizontal position at the completion of work,
otherwise the operator cannot leave the cab safely .
To tilt the crane operatorπs cab ∫upward"

> Push the button (252) ∫on the bottom∫ until the desired optimum field of vision is obtained.
Note: When the crane operatorπs cab is tilted, the cab door moves back quickly due to it
own weight. For that reason, hold the door by the handle and open it slowly.
Return the crane operatorπs cab to horizontal position

> Push the button (252) ∫on the top∫ until the horizontal position is reached.
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2.2 Crane operatorπs seat
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Seat adjustment
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The pneumatically suspended crane operatorπs seat can be adjusted for any body size.
> Adjustment of seat surface incline (234)
> Adjustment of back rest incline (230)
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> Release for horizontal seat adjustment (231)

> Adjustment of pneumatic back rest support in the upper area of the backrest (232)
> Adjustment of pneumatic back rest support in the lower area of the backrest (233)
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Seat heater *
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> The seat can be heated by turning on the switch (285) .

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2.3 Heater / ventilation

The crane operatorπs cab can be heated or ventilated as ambient temperatures require.
The controls for the heater or ventilation are located below the crane operatorπ seat.
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Refer to chapter 6.01 HEATER for a detailed description.

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Heating the cab

> Switch the change over switch (228) to air circulation.
> Turn on the blower with knob (226) .
> Regulate the temperature with knob (227) .
Ventilating the cab

> Switch the change over switch (228) to fresh air operation.
> Turn on the blower with knob (226) .
* Optional
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2.4 Air conditioning system *

Refer to the more detailed air conditioner manufacturerπs operating manual .
2.5 Windshield wiper / windshield washer system
Windshield wiper
The windshield wipers on the front window as well as on the overhead roof window can be operated with
the 2 stage switch:
(1st stage > Intermittent operation, 2nd stage > wipe operation).
Actuate the windshield wiper on the front window with switch (304) or on the roof window with switch
(306).
Windshield wiper /washer system

The windshield wipers on the front window as well as on the roof window can be supported by a winds>
hield washer system . Add commercially available antifreeze fluid suitable for windshield washer sy>
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stems to the reservoir before the start of the cold season.
Actuate the windshield wiper / washer system for front window with button (303) or for the roof wind>
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ow with button (305) .
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2.6 Front window
The front window may be opened from the inside by simply pushing on it. A pair of nitrogen cylinders
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helps to raise the window.

If you want to open the window only partially, you can retain it in 5 different angle positions on the per>
forated strap.
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C A U T I O N :Be careful when closing the window, that you donπt pinch or crush your hands.
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2.7 Horn
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Before you start working, make sure to check the horn for proper function by pressing down the foot
button (204) .
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D A N G E R: The horn should be used ONLY in dangerous situations to warn others, to pre>
serve its warning effectiveness.
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2.8 Lighting
The beacon can be turned on via switch (286) . *
The movable floodlight on the boom head (or on the boom pivot section) can be turned on via switch
(288) and controlled with button (287) . *
The working floodlights on the roof of the cab can be turned on via switch (289). *
The winch illumination and the outside mirror heater * can be turned on via switch (290) .
The working floodlights on the left hand side of the crane operatorπs cab or the slewing platform * can be
turned on via switch (291)*.
* Optional
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3. Change over to superstructure operation

> Switch the change over switch (21) to "superstructure" position.
The axle suspension is automatically blocked.
The "Bus connection " from superstructure to chassis will be established.
Note: The condition "axle suspension blocked" remains active even when the system is
changed over from superstructure to chassis operation. By pressing the button (80)
the system is changed over to "axles suspended" .
If the switch (21) is actuated, the gear selector switch in the driverπs cab (51) as well
as the travel direction switch in the crane operatorπs cab (261) must be in neutral po>
sition ∫N∫ .
If the air pressure reserve is less than 6.5 bar, when the system is changed over from
chassis to superstructure operation, the pump for the crane hydraulic is not enga>
ged when the engine is started later from the superstructure.
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CAUTION : The switch (21) may only be actuated when the engine is at a standstill and
the ignition is turned off.
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If the change over switch (21) is actuated when the ignition is turned on,
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then the engine cannot be started from the superstructure.
If the change over switch (21) is moved when the engine is running, then the
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engine and the ignition will turn off automatically.
DANGER: For safety reasons, do not enter the driverπs cab during crane operation!
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Danger of injury due to the turning steering wheel.

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4. Starting procedure > engine

The procedure is monitored mainly via a process visualization on the LICCON monitor. In the crane
operating view, the symbols for the engine monitoring are shown in the area of the monitoring symbols .
This is done automatically when :

> the travel direction keys are actuated
> the steering is actuated
or if the key combination "SHIFT" + "F4" are pressed, on the LICCON monitor.
The monitoring symbols are differentiated in the following groups:

permanent indicators
> Speed with travel direction indicator (6)
> Tank contents (7)
Warning and indicator devices (appear only if necessary)
> Engine problem ™oil pressure" (1)
> Engine problem ™engine overheat" (2)
> Gear problem (3)
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> Parking brake (5)
> Air pressure reserves (4)
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4.1 Crane hydraulic / Air pressure reserves
The crane hydraulic is only added if the air pressure supply in circuit I, II and III is more than >6.5 bar
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and the engine is off.

If the air pressure reserves is less than < 6.5 bar, the symbol element "air pressure reserves" (4)
appears on the LICCON screen.
If the crane hydraulic is not added when the engine is running, increase the air pressure in circuit I, II,
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and III to at least 6.5 bar (symbol element "air pressure reserves" blinks).
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Turn the engine off and start it again (the symbol element "air pressure reserves" turns off). O the
pump for the crane hydraulic is automatically engaged.
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4.2 Turn on the engine ignition

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> Insert the ignition key into the ignition (320) and turn it one notch to "1" .
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4.3 Start the engine
Note: The engine can only be started if both travel direction switches (superstructure
and chassis) are in neutral position, and the change over switch is actuated
when the ignition is turned off.
> Continue to turn the ignition key (320) in clockwise direction to position "2" , start the engine.
Note: If the engine does not start after 20 seconds, repeat the procedure again after
waiting for one minute. The starter should only be cranked three times for 20
seconds per starting procedure, with a 1 minute break in between. When star>
ting a warm engine, do not press down the pedal for the engine regulation to re>
duce exhaust emission during the starting procedure.
IMPORTANT: After booting up the LICCON system, check if the symbol ™engine pro>
blem oil pressure" lights up in the operating view. In this case, turn the
engine off immediately, because t insufficient oil pressure can damage
the engine.
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4.4 The engine runs

As soon as a stable voltage is available, the electric crane control and the LICCON system turn on auto>
matically. The microprocessor system runs through a self test.
After a few seconds, the equipment configuration view will appear on the monitor .
> Enter the actual equipment configuration into the LICCON system.
> Check the equipment configuration .
> Push the "F8" function key to confirm the new parameters and take them over into the "OPERA>
TION" program.
> Check if the correct short code and the correct reeving is entered in the operating view.
For a more detailed description of the LICCON safe load indicator system, see chapter 4.02, CONTROL
AND INDICATOR UNIT OF THE LICCON SAFE LOAD INDICATOR SYSTEM.
4.4.1 Check the instruments

The following monitoring symbols may not appear in the operating view when the engine is running :
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> Engine problem "oil pressure" (1)
> Engine problem "overheating" (2)
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> Gear problem (3)
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The symbol element appears with a blinking number, if the operating voltage is less than < 18 Volt or
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more than > 36 Volt .
Note: If a problem occurs, these symbols will appear automatically in the crane operating
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view (in the area of the monitoring symbols) .
Watch the following additional symbols when the engine is running:

> Tank contents (7)
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CAUTION : If the symbol ™engine problem engine oil pressure™ does not turn off after
approx. 10 seconds, or a if it comes on during crane operation, turn the engi>
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ne off immediately and find the problem!

If this is not observed, then the engine can be damaged do prevent engine da>
mage due to insufficient oil pressure.
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If the symbol ™Engine problem overheating™ appears during operation, then

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turn the engine off immediately. Increased coolant temperature can cause
engine damage.
Do not put a full load on the engine until it is at operating temperature.
Do not turn the battery master switch off as long as the engine is running ,
this would bring the engine to a standstill without control.
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4.5 Turn the engine off

> Turn the engine off by turning the ignition key (320) counterclockwise, to the stop.
> Turn off the ignition key.
Note: After operating the engine at full power or in case of increased coolant temperature
(above 95∞ C), let the engine run without a load for 1 > 2 minutes at low idle speed to
cool down.
CAUTION : The engine must must turned off immediately , in case of :

> the oil pressure drops or fluctuates strongly,
> the output and speed changes without changing the engine regulation le>
ver,
> smoky exhaust fumes,
> increasing coolant and oil temperature,
> sudden abnormal noise in the engine or turbocharger .
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4.5.1 EMERGENCY OFF button *
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In case of danger, the engine can be turned off by pressing the EMERGENCY OFF button in the crane
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operator's cab (236) or in the driver's cab. The knob of the button will lock down .
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This occurs due to an interruption of the operating voltage (Kl. 15) for the vehicle engine regulation
(FMR).
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To restart the engine:

> Turn the ignition key all the way to the left .
> Unlock the knob of the EMERGENCY OFF button with the key.
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> Start the engine.

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CAUTION : The EMERGENCY OFF button may on ly be used in danger situations. The
EMERGENCY OFF button may not be used for operational engine shut off!
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4.04 SAFETY DEVICES 024234>00
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1. Check the safety devices

The crane operator MUST CHECK EVERY TIME before he operates the crane, that all safety devices
function properly.
D A N G E R : DO NOT OPERATE THE CRANE WITH DEFECTIVE WARNING DEVICES ,

this can lead to serious accidents, causing injury or death.
2. Leveling instruments in the control box for the outrigger support system
In order to assure the safety while working with the crane, the crane must be horizontally aligned.
Note: The maximum permissible deviation from the horizontal line is ± 0.5% (± 0.3∞ ).
D A N G E R : If the crane is not aligned horizontally, there is an increased risk of accidents.
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3. Hydraulic safety valves
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Pressure relief valves against broken pipes and hoses.
Shut off valves in luffing, telescopic and outrigger cylinders.
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4. EMERGENCY OFF button *

In case of danger, the engine can be turned off by pressing the EMERGENCY OFF button (32 or 236).
The knob of the button will lock down .
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CAUTION : The EMERGENCY OFF button may only be used in danger situations. The
EMERGENCY OFF button may not be used for operational engine shut off!
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5. LICCON (LIEBHERR COMPUTED CONTROLLING)
Safe load indicator

The electronic safe load indicator turns all load moment increasing crane movement off as soon as the
permissible 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 free 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.
D A N G E R : The load moment limiter is a safety device, it may not be used as an operational
shut off control when extending the boom or luffing it with a suspended load .
Before operating the crane, the load moment limiter must be adjusted to the ac>
tual 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 gre>
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at danger that the crane overturns and is damaged beyond repair, despite a
functioning safe load indicator system.
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The safe load indicator system cannot monitor and control all possible opera>
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ting conditions, this is still primarily the responsibility of the operator .
The safe load indicator registers, but does not monitor > for example if incline is
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too large.
The safe load indicator registers, but does not shut off > for example if wind velo>
city is too high.
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5.1 Control release

When working while seated, the control release for the crane operation is enabled by the depressed seat
contact switch (235).
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If the crane operator works standing up, he must press down the foot button (203). If he works in seated
position, the foot button is bypassed by the seat contact switch .
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Note : This safety control is installed in order to prevent any unintentional crane movement
which may be accidentally caused if the manual control levers are touched when
entering or exiting the cab.
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5.2 Button ∫Luffing up at overload∫ (254)

In overload, the ∫luffing up" crane movement is also turned off, even though it is a load reducing crane
movement with a freely suspended load.
If the button "luffing at overload" is held down and the manual control lever is moved in ∫luffing up∫
direction, then this crane movement can be carried out.
D A N G E R : IT IS NOT PERMITTED to lift a load with the hoist gear by ∫luffing the boom ™,
when it has already triggered the load moment limiter and therefore shut off the
crane movement.
This could lead to overload and cause the crane to topple over.
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5.3 Bypass key (D )

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

1. the LICCON safe load indicator or
2. the shut off for the 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.
5.3.1 Bypassing the LICCON safe load indicator
DANGER: The LICCON safe load indicator system is not effective as long as the keyed
button is operated.
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5.3.2 Bypass of the ∫upper™ hoist limit switch
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DANGER: The hoist limit > hoist ∫top∫ is bypassed as long as the keyed button is
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operated.
The hoist limit switch may only be bypassed during crane operation, if
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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.
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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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5.4 Hoist limit switch > Hoist top

The hoist limit switch is installed to prevent a collision of the hook block on the boom head.
It must be checked for proper function before every crane operation by running the hook block against
the weight .
The crane movements ∫up∫, ∫luff down∫ and ∫telescope out∫ must be turned off.
DANGER: The hoist limit switch may only be bypassed during crane operation, if anot>
her 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 autho>

rized personnel only!
The limit switches may not be used as operational shut off functions. If this
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is not assured, then components of the crane can be damaged in case of a
malfunction or the crane can topple over.
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5.5 Limit switch winch spooled in / out
A cam limit switch is installed in the hoist winch and turns off the ™ down / lower ™ crane movement , if
there are at least 3 safety loops remaining on the drum.
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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 cable still remains in front of the winch and is not spooled up over the
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winch, because if the end of the cable is then pulled over the winch by anot>
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her 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.
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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.
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If this point is not observed, the cable mount can be torn out, causing the
load to fall.
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5.6 Pressure switch > hoist gear 1

The pressure switch is installed to prevent the actuation of the crane movement ∫hoist gear down™ if a
control valve is defective. This prevents the load from falling down if the control valve is defective.
DANGER: The pressure switch may not be bypassed manually.
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5.7 Indication of direction of rotation of w inch and hook path 1) (fig. 1)

Via this symbol on the ∫LICCON∫ crane operating view, the direction of rotation of the winch and
the hook path is shown, if the winch spools in or out, even even if the actual movement of the hook
block is hard to detect due to multiple reeving or due to slow speed.
C A U T I O N :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.
Loose cable can damage the winch cable.
5.9 Wind velocity warning device *, 1), (fig. 3)

The wind sensor symbol appears on the crane operation view of the LICCON. It shows the momentary /
current wind speed.
As soon as the max. permissible wind speed is exceeded, an acoustical signal ªSHORT HORN´ sounds
and the wind velocity warning light blinks , but the crane movement is NOT shut off.
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DANGER: If the permissible wind speed is exceeded, shut down is NOT carried out au>
tomatically. This is only a warning system!
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YOU YOURSELF MUST cease crane operation and lower the boom.
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If you do not adhere to this rule, the risk of causing a serious accident is si>
gnificantly increased.
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CAUTION: When operating the crane with the folding jib, the removable wind sensor
must always be installed and properly connected and fully functional, other>
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wise the ∫LICCON∫ safe load indicator will indicate a malfunction.

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1) Refer to chapter 4.02 for more details about the LICCON system
* Optional
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4.05 CRANE OPERATION 024238>00
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1. 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 engine is running,
> the crane hydraulic is turned on (air pressure supply in circuit I, II and III is above 5.5 bar)
> 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,
> the LICCON safe load indicator system is set to reflect the current equipment configuration.
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 wor>
king range of the crane and that the danger zone is free of any personnel.
Before initiating a crane movement, sound the horn as a warning signal .
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2. Tilt the crane operatorπs indicator system *
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The crane operatorπs cab can be ™tilted upward™ by approximately 20∞.
This increases the crane operatorπs visibility onto the job site.
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(see also chapter 4.03, STARTING THE CRANE)
D A N G E R: After completion of crane operation, the cab must be set again into
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horizontal position, otherwise the operator cannot exit safely.

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3. LICCON Safe load indicator system

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(See also chapter 4.02 , CONTROL AND INDICATOR UNIT OF THE LICCON SAFE LOAD INDICA>
TOR SYSTEM )
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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.
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If no error has been found, the first view will appear on the monitor (equipment configuration > prese>
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lection view).
Note: In case of a "cold start" (reboot), the 1st valid equipment configuration with the 1st
valid operating mode will appear. The hoist cable reeving is set to "0" .
*Optional
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4. Control of crane movements
LOAD SENSING System

Due to the hydraulic LOAD SENSING system, up to four working movements can be carried out at the
same time, i.e. up / down, slewing, luffing, telescoping.
If several working movements are carried out at the same time, the quicker working movement is
regulated back in favor of the slower working movement, i.e. that movement, which has been actuated
with the manual control lever deflected the farthest, is automatically reduced.
Release of crane control

The crane control is released when the seat contact switch (235) 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 (250, 256), the crane control is shut
off by the seat contact switch (235) 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
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bypassed via button (203) .
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4.1 Control of crane movement > ∫luffing∫ the telescopic boom
Move the manual control lever (256) to the left = to luff up the boom
Move the manual control lever (256) 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
and the engine regulation .
An additional increase of the luffing up speed can be made by adding the rapid gear .
> Turn the rapid gear on by pressing the button (257) once, on the monitor appears the symbol ™rapid ge>
ar™.
Note: The rapid gear remains operational until the button (257) is pushed again and the
symbol ™rapid gear™ turns off in the operating view.
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4.2 Crane movement "up /down"
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Deflect the manual control lever (256) to the front = hoist down
Deflect the manual control lever (256) to the rear = hoist up
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The speed of the crane movement is controlled by the deflection of the manual control lever and via the
engine regulation .
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An additional increase of the up / down movement can be made by adding the rapid gear .
> Turn the rapid gear on by pressing the button (257) once, on the monitor appears the symbol ™rapid ge>
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ar™ in the operating view.

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Note: The rapid gear remains operational until the button (257) is pushed again and the
symbol ™rapid gear™ turns off in the operating view.
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On the LICCON crane operating view, the direction of rotation of the winch is
shown on the screen, even if it is not always possible to detect any movement of the
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hook block, due to the number of rope runs and slow speed.
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CAUTION: When spooling the hoist cable out, keep watching the winch to make sure
that there is no excess loose cable on the winch. Keep an eye on the winch!
Loose cable can damage the winch cable.
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4.3 "Slewing" crane movement

Before initiating the ∫slewing∫ crane movement, the crane superstructure lock must be released. The
symbol in the crane operating view changes to "released".
Deflect the manual control lever (250) to the right = to turn to the right
Deflect the manual control lever (250) to the left = to turn to the left
The speed of the crane movement is controlled via the deflection of the manual control lever and the en>
gine regulation.
DANGER: Before initiating the ∫slewing∫ crane movement , the crane operator must as>
sure 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 .
> The slewing movement can be slowed down via the foot pedal (202) .
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> If the switch (253) is actuated, the mechanical disk brake is applied immediately.
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CAUTION : The switch (253) may only be actuated when the slewing gear is at a stand>
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still. If this is not assured, then it can overload the slewing gear and therefo>
re the crane.
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In general, the following rule applies:
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Longer boom
} slower speed
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More load
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DANGER: When slewing with a load, initiate the slewing movement and /or braking
movement very carefully and very gently.
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Jerky, irregular movements and braking the slewing movement too sudden>
ly can cause the load to swing.
A swinging load can cause the boom to break off and could cause the crane
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to topple over.
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4.4 ™Telescoping™ crane movements
Deflect the manual control lever (250) to the front =to telescope out
Deflect the manual control lever (250) to the rear = to telescope in
The telescoping sections must be extended to the necessary extension condition according to the load ca>
pacity chart by moving the manual control lever (250) .
Every extension condition has a 2>digit Code No. assigned to it.
This Code No. can be taken from the current load capacity chart and must be entered via the keyboard
on the LICCON control unit. The current extension condition of the various telescopic sections is
shown in percentages [%] .
(see chapter 4.02, CONTROL AND INDICATOR UNIT OF THE LICCON SAFE LOAD INDICATOR
SYSTEM)
The speed of the crane movement is controlled via the deflection of the manual control lever and the en>
gine regulation .
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The crane movement "telescoping out " can be accelerated by adding the rapid gear.
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> Turn the rapid gear on by pushing the button (257) on the manual control lever once .
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In the operating view appears the symbol element "rapid gear."
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Note: The rapid gear remains active until the button (257) is pushed again. The symbol
element "rapid gear " turns off in the operating view.
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CAUTION : The telescopic boom should normally be extended to the required length wit>
hout a load. The load should be attached afterward.
However, it is possible to telescope the boom under partial load.
This partial load depends on the lubrication of the bearing shoes as well as
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the existing guy lengths of the telescopic sections.

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The maximum permissible partial load is limited by the pressure adjustment

on the pressure relief valve of the telescoping cylinder.
However, in no case may the partial load shown by the LICCON be excee>
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ded!
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4.06 CABLE REEVING 023387>01
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1. Reeving the hook block
Prerequisite:
> The crane is properly supported and horizontally aligned.
> An assistant is present to guide the hoist cable.
1.1 Installation procedure

> Loosen the spring retainers / circlips and remove the cable retainers (1) on the pulley head.
> Place the required hook block under the pulley head of the telescopic boom .
> On the hook block, remove the spring retainers and pull the cable retaining bars (2) .
> Start the engine.
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.
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DANGER: This work should be completed while standing on a secure base.
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If it is unavoidable that the cable must be hand>guided on the telescopic
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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
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function is not operated properly and the person guiding the cable slips on
the telescoping boom.
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> 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 (2 ) and secure them with spring retainers.
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1.1.1 Insert the hoist cable on the cable lock

> Pin the cable lock (3) , depending on the reeving on the pulley head or on the hook block and secure
with spring retainer (4) (fig. A).
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Note: The pin (5) 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 (5) or the
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spring retainer (4).

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> On the cable lock (3), push in the retainer pin (9), move the lever (6) ∫downward∫ and hold it in this
position (fig. B).
Note: This causes the locking lever (8) to swing downward.
> Insert the end of the cable with the cable fitting (7) into the cable lock (3) and strongly pull the cable
∫downward∫ (Fig. B).
CAUTION: The cable fitting (7) must touch the taper in the cable lock (3) , the lever (6)
must be locked with the lock pin (9) . The safety mechanism (6, 8 and 9) on
the cable lock must be freely movable.
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1.1.2 Install the hoist limit switch weight

> Open the hoist limit switch weight (B), open the chain lock (13) .
> Using a 13 mm wide open end wrench , loosen the hex head nut (12) and turn it ∫up∫ by hand .
> Release the hoist limit switch weight (B) .
CAUTION: The hoist limit switch weight (B) consists of two interconnected parts, the
weight (11) and the carrier (10) .
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 section (10) behind the cable, underneath the weight (11) .
Note: With multiple reeving, the hoist limit switch weight (B) must always be routed
around the ∫fixed cable∫, meaning around the cable, whose end makes up the cable
fixed point..
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> Push the weight (11) over the carrying section (10) .
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> Hang the hoist limit switch weight (B) again into the chain lock (13).
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> Turn the lock nut (12) down and manually tighten it with a SW 13 open end wrench.
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DANGER: The chain lock (13) 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 (13) must always be attached in such a way that the lock nut
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(12) is on ∫top∫, meaning on the chain (14) and the chain lock is closed by
turning the lock nut (12) ∫downward∫ .
This procedure assures that the lock nut (12) does not loosen up by itself,
causing the chain lock to open.
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1.1.3 Visual inspection

Is the chain lock (13) fully closed?
Is the hoist limit switch weight (B) attached to the ∫fixed or stationary cable∫?
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> Enter the number of reeves into the ∫LICCON∫ safe load moment indicator or recheck it.
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DANGER: The crane operator must make sure that the reeving process has been done
properly and that the safe load indicator has been set correctly.
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Incorrect reeving or entering an incorrect number of reeves can lead to

serious accidents.
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2. Unreeving the hook block
2.1 Installation procedure

> Lower the hook block to the ground and make sure it is positioned safely.
2.1.1 Release the hoist cable

> On the cable lock (3), push in the retaining pin (9) , swing the lever (6) ∫down∫ and hold it in this
position.
Note : This causes the locking lever (8) to swing downward and releases the cable fitting
(7) .
> Push the cable ∫upward∫ and release the fitting (7) .
> Slowly rewind the hoist cable .
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DANGER: The area around the hook block must be free and clear of any personnel .
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During the rewinding procedure, the cable can lash out like a whip .
Have another person observe the rewinding procedure to make sure that the
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cable does not rewind loosely .
> Mount the hoist cable with the cable lock to the pulley heard or rewind the cable fully onto the winch.
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CAUTION : Rewind the hoist cable up to the point where there are at least 2 m of
remaining cable .
Do not pull the cable end under the winch!
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3. Reeving plans
The various reeving plans are listed as follows.
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3.1 1 > sheave hook block

3.2 3 > sheave hook block
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3.3 5 > sheave hook block *

3.4 Added installation for 35 t load capacity *
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* Optional
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3.1 Reaving plans: 1 > sheave hook block
Fixed point on the side of the pulley head or hook block T
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3.2 Reeving plans: 3 > sheave hook block
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3.3 Reeving plans: 5 > sheave hook block
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3.4 Added installation for 35 t load capacity*

Reeving plan : 11 fold
Fixed point on the side of the hook block
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5 > sheave hook block *
Reeving plan : 12 fold

Fixed point on the side of the pulley head
7 > sheave hook block *
For the 11 fold or 12 fold reeving, an additional pulley (1) must be installed on the telescopic boom (pivot
section).
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Installation of additional pulley
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> Remove the spring retainer (3) from the pin (2) on the added pulley.
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> Pull the pin (2) .
> Insert the added pulley into the suspension (4) on the pivot section.
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> Install the pin (2) .
> Secure the pin (2) with spring retainer (3) .
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Reeve the hoist cable

> Reeve the hoist cable as noted on the reeving plans (11 fold or 12 fold).
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* Optional
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4.07 COUNTERWEIGHT 025390>00
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1. Counterweight combinations
The counterweight or added ballast plates are marked with their own weight.
DANGER: The mounted counterweight must correspond to the data given in the load
capacity chart.
If this is not followed, it could cause a serious accident!
The following combinations are possible:
Total counterweight Combination Individual weight
2.3 t Counterweight (3) 2.3 t

Added ballast (1) 1.1 t
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Note: The added ballast plate 1 (1) is locked with two pins (6).
The pins (6) must be secured in their retaining sleeves.
The added ballast plate 2 (2) is held in place by the two ballasting cylinders (5).
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DANGER: The 2.3 ton counterweight (3) must be attached with 4 screws M 24 ¥ 200 (4)
on the slewing platform frame.
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Tightening torque: MA = 500Nm

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2. Installation / removal
Prerequisite:
> The crane is supported according to the load capacity chart and horizontally aligned.
> The transport vehicle with the added ballast plates is positioned in close proximity to the supported
crane.
> The hook block is reeved properly, according to the reeving plan.
CA U T I O N : The ballasting cylinders 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.
If the boom is positioned in a steep position for which no load capacities are
entered in the load capacity chart, there is great danger of tipping the crane
to the rear, to the counterweight side,when the crane is being turned.
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This danger is especially acute if:
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> the support base is reduced or
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> if the crane is supported, but the sliding arms have been retracted.
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2.1 Check the added ballast plates
Check the plates for damage before stacking the counterweight plates, and make sure there are no
foreign particles underneath the plates. Make sure when placing the added ballast plate (2) onto the
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vehicle frame and when adding the added ballast plate (1), that no foreign particles or objects get
between the plates.
DANGER: If there is any damage, the added ballast plates must be replaced.
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If the locking stubs are broken off, then the plates might not sit tightly.
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As a result, they might fall off.

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2.2 Stack the added ballast plates individually on the vehicle

> Start the engine.
> Adjust the LICCON safe load indicator according to the load capacity chart to 2.3 t counterweight.
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> Unlock the slewing platform with the mechanical lock (manual lever 212).
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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 adjusted according the valid load capacity chart .
> Attach the added ballast to the lifting cables and place them with the crane into the receptacle on the
vehicle frame.
Note: The added ballast plate (2) must always be placed first onto the vehicle frame, as
carrier plate for the added ballast plate (1).
CAUTION: The ballasting cylinders (5) must be fully retracted during this slewing
procedure, otherwise they could collide with the counterweight plates,
which are stacked on the vehicle!
D A N G E R : The slewing range must be free and clear of personnel and objects.
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2.3 Taking on the added ballast

> Start the engine.
> Set the LML according to the load capacity chart and the counterweight.
> Unlock the slewing platform (212).
DANGER: Before lifting the boom from its transport position, support the crane
according to the load capacity chart and set the LICCON safe load indicator
system according to the valid load capacity chart.
If this is not assured, the crane may topple over and cause a serious accident.
> Turn the crane superstructure until the ballasting cylinders are over the openings on the added ballast
plate (1) (pointer on the slewing platform).
CAUTION: The ballasting cylinders must be fully retracted during this slewing
movement, otherwise they could collide with the added counterweight plates
on the vehicle!
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DANGER: The slewing range must be free and clear of personnel and objects.
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2.3.1 Taking on the added ballast (3.2 t) (total weight of the counterweight 5.5 t)
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> Push the button (307) ∫on the bottom∫ until the ballasting cylinders (5) are all the way extended.
> Turn the crane superstructure (telescopic boom in travel direction to the rear).
> Lock the crane superstructure (212) .
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CAUTION: The superstructure must be locked to the chassis, so that the ballasting
cylinders are centered in the receptacles of the added ballast plate (2).
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> Push the button (307) ∫on the top∫ until the ballasting cylinders (5) are all the way retracted. The
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added ballast is raised until it touches the counterweight.

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Note: Secure the added ballast 1 with two pins, see paragraph 2.4
> Set the LICCON safe load indicator system according to the load capacity chart and the installed
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counterweight.
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2.3.2 Take on the added ballast (1.1 t) (Total weight of counterweight 3.4 t)
> Turn the crane superstructure until the ballasting cylinders are over the receptacles of the added
ballast plate 1 (1) (pointer on the slewing platform).
> Push the button (307) ∫on the bottom∫ until the ballasting cylinders (5) are all the way extended .
> Lock the crane superstructure (212).
cylinders are centered in the receptacles of the added ballast plate (2).
> Push the button (307) ∫on the top∫ until the ballasting cylinders (5) are all the way retracted. The
added ballast is raised until it touches the counterweight.
> Lock the added ballast plate (1) with 2 pins (6), see paragraph 2.4.
> Extend the ballasting cylinders all the way.
The added ballast plate (2) is placed on the receptacle on the vehicle frame.
> Unlock the crane superstructure.
> Turn the crane superstructure until the ballasting cylinders can be extended from the receptacle of tee
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added ballast plate (2) (pointer on the slewing platform) ).
> Retract the ballasting cylinders all the way via button (307).
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2.4 Secure the added ballast 1
> With the added ballast plate (1) raised all the way, insert both pins (6).
> Secure the pins by turning them into the recesses intended for this purpose) to prevent them from
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loosening up inadvertently.
Note: In addition, secure the two pins with the retaining sleeve on the mounting plate.
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2.5 Remove the added ballast
DANGER: Before placing the added ballast on the vehicle frame, make sure that there
are no foreign objects under the added ballast .
If that is not the case, then the tight seating of the added ballast plates is no
longer assured.
Before initiating the slewing movement and before lowering the added
ballast, the crane operator must make sure that there are no obstacles with
in the working range and that the danger range is free and clear of
personnel.
2.5.1 Remove the added ballast (1.1 t + 2.1 t)

> Turn the crane superstructure (telescopic boom in travel direction to the rear) until the added ballast
is over the receptacle on the vehicle.
> Lock the crane superstructure to the crane chassis (212).
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> Unpin the pin on the added ballast plate (1).
> Slowly lower the added ballast by pressing the button (307).
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CAUTION: The superstructure must be locked to the chassis, so that the added ballast
plate (2) can be placed on the centerings installed for this purpose and
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affixed in place.
> Push the button (307) ∫on the bottom∫ until the added ballast has been placed on the ballast receptacle.
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> Unlock the crane superstructure (212).

> Turn the crane superstructure until the ballasting cylinders can be extended from the intake
receptacles of the added ballast plates (pointer on the slewing platform).
> Push the button (307) ∫on top∫ until the ballasting cylinders are fully retracted.
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2.5.2 Remove the added ballast (1.1 t)

> Turn the crane superstructure until the ballasting cylinders can be extended into the intake
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receptacles on the added ballast plate (2) on the ballast receptacle (pointer on the slewing platform).
> Push the button (307) ∫on the bottom∫ until the ballasting cylinders are fully extended.
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> Lock the crane superstructure to the crane chassis (212).

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cylinders can be centered in the receptacles of the added ballast (2).
> Retract the ballasting cylinders all the way.

The added ballast (2) is raised to the stop on the added ballast plate (1).
> Remove the retaining sleeves on both pins.
> Remove both pins (6) from the added ballast plate (1).
> Push the button (307) ∫on the bottom∫ until the added ballast has been placed on the ballast receptacle.
> Unlock the crane superstructure (212).
> Turn the crane superstructure until the ballasting cylinders can be extended from the intake
receptacle of the added ballast plates (pointer on the slewing platform).
> Push the button (307) ∫on top∫ until the ballasting cylinders are fully retracted.
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2.6 Lift the added ballast from the vehicle frame

Requirements:
> The crane is supported and horizontally aligned, according to the load capacity chart.
> a transport vehicle to take on the counterweight plates has been positioned in close proximity to the
supported crane.
> Set the LICCON safe load indicator system according to the load capacity chart .
> Release the mechanical crane superstructure lock (212).
DANGER: The boom lengths and working radii noted on the load capacity charts may
not be exceeded.
If this point is not observed, it could cause a serious ACCIDENT due to the
crane toppling over.
Before initiating a slewing movement and before lowering the

counterweight, the crane operator must make sure that there are no
obstacles within the slewing range, and that the danger range is free and
clear and that there are no persons within this area.
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> Attach the added ballast plates individually to the lifting cables and place them with the crane onto
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the vehicle.
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3. Travel operation with added ballast

The axle loads are increased if the counterweight plates have been placed on the vehicle frame. For that
reason, travel on public roads and highways is NOT permitted, or only in countries with higher
permissible axle loads. When driving on public roads (only in countries with higher permissible axle
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loads), then the added ballast must be distributed as described in chapter 3.04, DRIVING ON PUBLIC
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ROADS.
C A U T I O N :Before driving on public roads and highways, make sure to secure the added
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ballast plates on the vehicle by placing the telescopic boom into the boom
receptacle.
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DANGER: Before starting to drive, visually check the added ballast plates for damage.
Damaged added ballast plates must be replaced.
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If there are any distortions on the receptacle, then it must be fixed and
realigned.
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1. 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∫,
to 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 lo>
ad capacity chart is not permitted.
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This also applies if there is no load on the hook.
Doing so increases the risk of accidents!
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> Always maintain the number of reevings corresponding to the maximum load capacity as specified in
the load capacity chart.
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DANGER: If this rule is not observed, the cable could snap and cause a serious acci>
dent and injury or death!
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> Always initiate any crane movement and braking movement very slowly and carefully, to prevent the
load,which is suspended from the hook, from swinging.
> As soon as the lowest cable layer of a winch drum is reached, another person must make sure that the>
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re are always at least three coils remaining on the winch drum.

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D A N G E R : If this rule is not observed, it could cause a serious accident and injury or death.
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> It is not permitted to use larger hook blocks than the size specified to hoist the maximum load as sta>
ted on the load capacity chart.
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Note: If this rule is not observed, the hook cannot be lowered to the ground because the
hoist cable is too short.
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2. Inspection
Before beginning any crane operation, the crane operator must carry out a thorough inspection to ensu>
re 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.
> 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!
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3. Visual inspection for damage
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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.
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DANGER: The crane operator must immediately stop crane operation if any mal>
functions are found or should occur, which could endanger the operational
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safety of the crane operation, particularly the following:
> if there is any damage to the load carrying parts of the crane structu>
re, such as boom, outriggers, etc.
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> any time the load slips due to hoist brake failure,
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> any time there is a functional problem in the crane control,

> any time any of the indicator and/or warning lights are not functio>
ning properly,
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> 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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4. Setting the safety devices

> Start the crane engine, as described in chapter 4.03, STARTING THE CRANE.
DANGER: For safety reasons, do not remain or step into the driverπs cab (crane chassis)
during crane operation.
You could be injured by the running steering wheel .
4.1 Enter operating mode and equipment configuration into the ∫LICCON∫ safe load indicator sy>
stem
See also chapter 4.02 ™LICCON SAFE LOAD INDICATOR SYSTEM ™.
The operating mode and the equipment configuration must be reentered before starting to work or after
an equipment change according to the load capacity chart into the LICCON safe load indicator system.
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 can be heard after the ENTER key has been pressed, then this change was not ac>
cepted. In this case, it must be checked which of the entered functions is not correct.
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DANGER: The proper function of the LICCON safe load indicator system and safe cra>
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ne operation is only assured, if the data given in the load capacity chart has
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been entered correctly and matches the actual equipment configuration.
The crane operator is obligated to recheck the correct adjustment of the safe
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load indicator system before starting to work with the crane (even if he only
leaves the cab for a short time) .
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4.2 Wind velocity warning device *

The wind velocity warning device is integrated into the LICCON safe load indicator.
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> Turn the CRANE OPERATING VIEW on via program key ™P1™.
> Press function key ™F3™ to show the wind sensor symbol .
The wind speed will appear on the screen, it is depicted in meters [m/s] or foot [ft/s], depending on the
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unit of measurement used in the load capacity chart.

The maximum permissible wind velocity (same unit of measurement) shown below depends on the ope>
rating mode, the equipment configuration and the boom length.
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If the current value exceeds the maximum value, an acoustical signal ªSHORT HORN´ will sound and
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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 veloci>
ty 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 sen>
sor must always be installed and properly connected and fully functional, ot>
herwise the ∫LICCON ™ safe load indicator will indicate a malfunction.
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5. Working near overhead electrical wires

If there are any overhead electrical wires close to the job site, they must be disconnected by trained elec>
tricians. 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 bet>
ween the crane / boom and any wires:
Minimum Minimum
Rated Voltage
distance in meters distance in feet
up to 1kV 1 3
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if rated voltage is 5 16
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unknown
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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
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touch the crane,

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> Move the crane from the danger zone.
DANGER: If this is not observed, serious injury or damage can occur.

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* Optional
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6. 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.
6.1 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.
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At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear if the
crane is loaded with more than 50% of its maximum permissible load
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carrying capacity at the corresponding reach.
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It is strictly prohibited to lift a load by luffing the boom, after the LICCON
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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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6.2 Pulling a load at an angle is prohibited!

The crane is designed to lift loads vertically.
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Pulling at an angle causes horizontal stress in addition to the vertical stress, which the crane has been
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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
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the permitted stress level for the height of the boom head pulley.
DANGER: DO NOT pull a load at an angle! This is strictly Prohibited

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Pulling a load at an angle can damage the crane and cause it to topple over.
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6.3 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.
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7. 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 swin>
ging.
DANGER: A swinging load can damage the crane or cause it to topple over.
It could cause a serious accident!
7.1 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.
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7.2 Moving persons
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This crane is NOT designed to move any personnel.
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It is prohibited to move or let anybody ride along on the load being lifted.
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DANGER: Moving or letting any persons ride along on the load or load tackle is strictly
PROHIBITED.
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It could cause a serious accident.

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7.3 Danger of being crushed

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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.
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DANGER: When lowering the load, no personnel or objects may be below or underne>
ath the load!
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It could cause a serious accident.

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4.09 DRIVING WITH THE ATTACHMENT IN PLACE 025391>00
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1. General Guidelines
The crane can be driven with a raised boom and with the attachment in place if it is positioned on level
ground and the axle suspension system is locked.
DANGER: When driving with the attachment in place, it is imperative to adhere to the
values and notes given on the following charts.
If this is not observed, there is a great danger of accidents as the crane might
turn over.
2. The following measures must be performed before driving

When planning to drive the crane from one area of the jobsite to another (after crane operation, before
supporting the crane), the following measures must be carried out.
2.1 Check the road bed

Before supporting the crane and driving, you must check the roadbed and driving surface to see if it is
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level or if there are any dips or uneven areas.
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DANGER: The driving surface may not slope by more than 3∞, even within the
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permissible tolerance range of +/> 0.10 m over 10 m length !
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2.2 Before supporting the crane
Make sure to level the vehicle via the automatic leveling system (79) + (93) in horizontal direction.
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Then you must lock the axle suspension by pressing the buttons (80) + (93). These selections are
prerequisites for driving the crane with the attachment in place.
Then complete the supporting procedure as described in chapter 3.05, THE CRANE AT THE JOBSITE.
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2.3 After crane operation

> Telescope the telescopic boom in all the way.
> Turn the crane superstructure to the position given in the charts, either to the front or rear.
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> Swing the locking lever!(212) down to lock the crane superstructure to the crane chassis.
> Set the telescopic boom or the folding jib* and the telescopic boom to the angle given on the
corresponding load capacity charts.
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DANGER: Before turning the crane superstructure, make sure the crane is properly
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supported according to the load capacity chart and horizontally aligned and
give a warning sound by actuating the horn.
The sliding arms must be pinned.
After turning, the crane superstructure must be locked with the vehicle in
lengthwise direction.
2.4 Lower the crane onto the blocked axles

Carefully lower the crane onto the blocked axles by retracting the outrigger cylinders.
DANGER: While lowering the crane, you must continuously check the horizontal
position of the crane .
CAUTION: All wheels must touch the ground evenly, otherwise the axle suspension will
be damaged!
The driving surface must be level and horizontal and it must be able to carry
the axle load.
* Optional
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3. Prerequisites for driving with the attachment in place

> The crane superstructure must must be positioned in lengthwise direction of the vehicle, either to the
front or to the rear and it must be mechanically locked to the crane chassis.
DANGER: Before turning the crane superstructure, the crane must be properly
supported.
> The hydro > pneumatic suspension of axles must be locked.

> The outrigger cylinders must be extended to approx. 10 >15 cm above the ground, so that the crane can
catch itself, if the ground should give.
> All tires must be properly inflated to the correct tire pressure.
> You may only drive with utmost care, the least possible increase in speed and only with careful
braking action.
> The ground must be level, horizontal and able to carry the axle load (see charts).
> There may be no persons or any obstacles within the travel range.
> During travel, another person must observe the luffed up boom as well as the outriggers to prevent any
collision.
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> It is only permitted to drive without a load on the hook.
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CAUTION: These prerequisites must be observed and assured when driving with the
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attachment in place, otherwise there is a great danger of causing a serious
accident, as the crane might turn over.
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4. Charts for driving with the attachment in place
Chart 1: without folding jib Telescopic boom telescoped in all the way, T > 9.2 m (0 / 0 / 0)
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Chart 2.1: with folding jib 0∞ Telescopic boom telescoped in all the way, T > 9.2 m (0 / 0 / 0)
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DANGER: The driving surface must be checked to see if it is level or if there are any
dips or uneven areas in the road.
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The driving surface may not slope by more than 3∞, even within the
permissible tolerance range of +/> 0.10 m over 10 m length!
Driving with raised boom is only permitted on level route with sufficient
load carrying capacity, without a suspended load. The counterweights listed
in charts 1, 2.1 and 2.2 must be installed and distributed as shown .
The crane may only be driven WITH LOCKED AXLE SUSPENSION. If axles
are suspended, the crane may turn over!
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Chart 1
Driving with the attachment in place
Main boom T > 9,2 m (0 / 0 / 0 )
Maximum
Counterweight Minimum
Telescopic angle axle load
Boom to the on crane supporting
to horizontal Axle
superstructure width B
1 2
front 5,5 t 0∞ > 83∞ 2,3 m 10 t 22 t
0∞ > 8∞ 2,3 m 10 t 17 t
4,4 t 0∞ > 84∞ 2,3 m 10 t 21 t
0∞ > 28∞ 2,3 m 10 t 15 t
3,4 t 0∞ > 84∞ 2,3 m 11 t 19 t
0∞ > 11∞ 2,3 m 11 t 13 t
2,3 t 0∞ > 84∞ 2,3 m 11 t 18 t
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0∞ > 29∞ 2,3 m 11 t 12 t
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rear 5,5 t 0∞ > 84∞ 2,3 m 19 t 14 t
15∞ > 30∞ 2,3 m 13 t 13 t
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4,4 t 0∞ > 84∞ 2,3 m 17 t 14 t
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16∞ > 46∞ 2,3 m 13 t 13 t
3,4 t 0∞ > 84∞ 2,3 m 17 t 14 t
37∞ > 45∞ 2,3 m 12 t 13 t
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2,3 t 0∞ > 84∞ 2,3 m 15 t 14 t

38∞ > 58∞ 2,3 m 13 t 12 t
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In the chart, a pulley block weigh t of 240 kg on the boom head has been taken into consideration.
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Note: Slight increase of axle load if folding jib is folded on the side of the telescopic boom *.
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Chart 2.1
Telescopic boom telescoped in all the way T>9,2 m (0 / 0 / 0 ) TK 0∞

with folding jib *
Intermediate angle 0∞
Maximum
Boom to the Jib on crane supporting
to horizontal Axle
1 2
front K > 8,6 5,5 t 1∞ > 83∞ 2,3 m 11 t 23 t
1∞ > 15∞ 2,3 m 11 t 15 t
4,4 t 1∞ > 84∞ 2,3 m 12 t 21 t
1∞ > 28∞ 2,3 m 12 t 14 t
3,4 t 1∞ > 84∞ 2,3 m 12 t 20 t
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1∞ > 17∞ 2,3 m 12 t 13 t
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2,3 t 1∞ > 84∞ 2,3 m 13 t 18 t
23∞ > 41∞ 2,3 m 12 t 12 t
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front K > 15,0 5,5 t 1∞ > 84∞ 2,3 m 13 t 23 t
1∞ > 11∞ 2,3 m 13 t 14 t
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4,4 t 1∞ > 84∞ 2,3 m 13 t 21 t
1∞ > 24∞ 2,3 m 13 t 13 t
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3,4 t 1∞ > 84∞ 2,3 m 14 t 20 t

29∞ > 30∞ 2,3 m 12 t 12 t
2,3 t 1∞ > 84∞ 2,3 m 14 t 18 t
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35∞ > 46∞ 2,3 m 13 t 12 t

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rear K > 8,6 5,5 t 1∞ > 84∞ 2,3 m 19 t 15 t

41∞ > 43∞ 2,3 m 13 t 13 t
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4,4 t 1∞ > 84∞ 2,3 m 18 t 15 t

41∞ > 53∞ 2,3 m 13 t 13 t
3,4 t 1∞ > 84∞ 2,3 m 17 t 15 t
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51∞ > 53∞ 2,3 m 12 t 12 t

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2,3 t 1∞ > 84∞ 2,3 m 16 t 15 t

51∞ > 62∞ 2,3 m 12 t 13 t
rear K > 15,0 5,5 t 1∞ > 84∞ 2,3 m 19 t 17 t
49∞ 2,3 m 13 t 13 t
4,4 t 1∞ > 84∞ 2,3 m 18 t 17 t
49∞ > 57∞ 2,3 m 13 t 13 t
3,4 t 1∞ > 84∞ 2,3 m 17 t 17 t
57∞ 2,3 m 12 t 12 t
2,3 t 1∞ > 84∞ 2,3 m 16 t 17 t
57∞ > 64∞ 2,3 m 12 t 12 t
In the chart a pulley block weight of 130 kg or 70 kg on the boom head has been taken into account.
* Optional
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Chart 2.2

with folding jib *

Maximum
to horizontal Axle
1 2
front K > 8,6 5,5 t 10∞ > 84∞ 2,3 m 11 t 22 t
10∞ > 17∞ 2,3 m 11 t 15 t
4,4 t 10∞ > 84∞ 2,3 m 12 t 21 t
10∞ > 30∞ 2,3 m 12 t 14 t
3,4 t 10∞ > 84∞ 2,3 m 12 t 19 t
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10∞ > 19∞ 2,3 m 12 t 13 t
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2,3 t 10∞ > 84∞ 2,3 m 13 t 18 t
25∞ > 43∞ 2,3 m 12 t 12 t
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front K > 15,0 5,5 t 13∞ > 84∞ 2,3 m 12 t 22 t
13∞ 2,3 m 12 t 14 t
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4,4 t 13∞ > 84∞ 2,3 m 13 t 21 t
13∞ > 27∞ 2,3 m 13 t 13 t
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3,4 t 13∞ > 84∞ 2,3 m 13 t 19 t

32∞ > 33∞ 2,3 m 12 t 12 t
2,3 t 13∞ > 84∞ 2,3 m 14 t 18 t
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38∞ > 49∞ 2,3 m 12 t 12 t

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rear K > 8,6 5,5 t 10∞ > 84∞ 2,3 m 18 t 15 t

43∞ > 45∞ 2,3 m 13 t 13 t
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4,4 t 10∞ > 84∞ 2,3 m 17 t 15 t

43∞ > 55∞ 2,3 m 13 t 13 t
3,4 t 10∞ > 84∞ 2,3 m 16 t 15 t
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53∞ > 55∞ 2,3 m 12 t 12 t

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2,3 t 10∞ > 84∞ 2,3 m 15 t 15 t

53∞ > 64∞ 2,3 m 12 t 12 t
rear K > 15,0 5,5 t 13∞ > 84∞ 2,3 m 18 t 16 t
52∞ 2,3 m 13 t 13 t
4,4 t 13∞ > 84∞ 2,3 m 17 t 16 t
52∞ > 60∞ 2,3 m 13 t 13 t
3,4 t 13∞ > 84∞ 2,3 m 16 t 16 t
60∞ 2,3 m 12 t 12 t
2,3 t 13∞ > 84∞ 2,3 m 15 t 16 t
60∞ > 67∞ 2,3 m 12 t 12 t
* Optional
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Chart 2.3

with folding jib *

Maximum
to horizontal Axle
1 2
front K > 8,6 5,5 t 20∞ > 84∞ 2,3 m 11 t 22 t
20∞ > 35∞ 2,3 m 11 t 16 t
4,4 t 20∞ > 84∞ 2,3 m 12 t 20 t
20∞ > 30∞ 2,3 m 12 t 14 t
3,4 t 20∞ > 84∞ 2,3 m 12 t 19 t
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20∞ > 36∞ 2,3 m 12 t 13 t
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2,3 t 20∞ > 84∞ 2,3 m 13 t 17 t
25∞ > 44∞ 2,3 m 12 t 12 t
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front K > 15,0 5,5 t 26∞ > 84∞ 2,3 m 12 t 22 t
26∞ > 33∞ 2,3 m 12 t 15 t
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4,4 t 26∞ > 84∞ 2,3 m 12 t 20 t
26∞ > 28∞ 2,3 m 12 t 13 t
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3,4 t 26∞ > 84∞ 2,3 m 13 t 19 t

33∞ > 34∞ 2,3 m 12 t 12 t
2,3 t 26∞ > 84∞ 2,3 m 13 t 17 t
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40∞ > 51∞ 2,3 m 12 t 12 t

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rear K > 8,6 5,5 t 20∞ > 84∞ 2,3 m 18 t 15 t

44∞ > 46∞ 2,3 m 13 t 13 t
BH
4,4 t 20∞ > 84∞ 2,3 m 17 t 15 t

44∞ > 56∞ 2,3 m 13 t 13 t
3,4 t 20∞ > 84∞ 2,3 m 16 t 15 t
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54∞ > 56∞ 2,3 m 12 t 12 t

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2,3 t 20∞ > 84∞ 2,3 m 15 t 15 t

55∞ > 65∞ 2,3 m 12 t 12 t
rear K > 15,0 5,5 t 26∞ > 84∞ 2,3 m 18 t 16 t
54∞ 2,3 m 13 t 13 t
4,4 t 26∞ > 84∞ 2,3 m 17 t 16 t
54∞ > 62∞ 2,3 m 13 t 13 t
3,4 t 26∞ > 84∞ 2,3 m 16 t 16 t
62∞ 2,3 m 12 t 12 t
2,3 t 26∞ > 84∞ 2,3 m 15 t 16 t
62∞ > 70∞ 2,3 m 12 t 12 t
* Optional
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4.10 DRIVING FROM THE CRANE OPERATORπS CAB 023483>01
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1. Change over to ∫superstructure operation ∫

> Apply the parking brake (28) in the driverπs cab, turn the engine off by turning the keyed switch (22)
to the ™left™ and turn the ignition off.
> Turn the switch (21) to the ∫crane superstructure∫ position, the axle suspension is automatically bloc>
ked.
Note: If the switch (21) is actuated, the gear selector switch in the driverπs cab as well as
the travel direction switch in the crane operatorπs cab must be in neutral ∫N∫ posi>
tion .
The condition "axle suspension locked" remains active when changing from su>
perstructure to chassis operation. By pressing the button (80)+confirmation (93) ,
the system can be returned to "axles suspended" .
CAUTION : The switch (21) may only be turned when the engine is at a standstill and the
ignition has been turned off.
If the change over switch (21) is actuated when the ignition is turned on, then
the engine cannot be started afterward.
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If the change over switch (21) is actuated when the engine is running, the en>
gine and the ignition turn off automatically.
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The "Bus connection" from superstructure to chassis are established.
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DANGER: For safety reasons, DO NOT enter the driverπs cab during crane operation!
A serious injury could occur due to the turning steering wheel.
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2. Travel operation
The crane can be driven from the crane operatorπs cab .
The crane is steered via the rocker switches (255) and (260).
The travel operation is monitored mainly via a process visualization on the LICCON monitor.
In the crane operating view, the symbols for travel monitoring are shown in the area of the monitoring
symbols. This is done automatically if:
> the travel direction button (261) is actuated
> the steering (260) and (255) is actuated
or upon request via the key combination "SHIFT" + "F4" on the LICCON monitor.
All measures and controls described in chapters
3.02 ∫BEFORE VEHICLE START UP ™,

3.05 ∫CRANE AT THE JOBSITE ∫ and
4.03 ∫STARTING THE CRANE ∫
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must be strictly observed.
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2.1 Engine starting procedure
see chapter 4.03, STARTING THE CRANE ; paragraph 4.2 to 4.4
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2.2 Ready to drive
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In crane operation, the engine runs at working RPM regulation. A nominal RPM is entered via the engi>
ne regulation, which the engine tries to keep via a torque control.
Note: The converter coupling does not close when driving from the superstructure.
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The control of the transmission is handled by the travel direction switch (261).
> Forward "V" (Switch position to the front )

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> Neutral "N" (center switch position)

> Reverse "R" (Switch position to the rear )
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When the travel direction switch is moved in "V" (forward) direction, the gear shifts into travel range
"Forward" (1st gear).
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When the travel direction switch is moved in "R" (reverse) direction, the same occurs, except in travel
range "reverse".
Note: Before switching the travel range, apply the service brake (201) .
> Apply the service brake (201) .

> On the travel direction switch (261), select the desired travel direction ("V" or "R" / forward or rever>
se).
In the travel direction indication in the operating view, the selected travel range appears, in relation
to the chassis.
Note: If the function is selected but not carried out by the transmission or the engine, the
travel direction indicator will blink.
In travel operation, the speed is permanently displayed in the operating view (in km/h), in form of num>
bers.
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2.2.1 Travel direction, steering and blinker

If the superstructure is turned in travel direction to the "rear" (>±90∞), the switch function of blinker,
steering (front axle / rear axle) and travel direction (forward / reverse) will change. These functions al>
ways orient themselves to the crane operatorπs direction of view .
> The change over switch "travel direction forward / reverse" (261) always remains in relation to the su>
perstructure.
CAUTION: Be careful in the border range ± 90∞ !

The travel direction indication in the crane operating view is always in
relation to the crane chassis. If the superstructure is in the ∫border ran>
ge" (± 90∞ ), the selected travel direction of the chassis can always be re>
ad with the travel direction indicator.
> The change over switch "Blinker" always related to the superstructure.
> The steering button (255) always relates to the vehicle axle "in back".
> The steering button (260) always relates to the vehicle axle "in boom direction".
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Note: If the crane is driven and the superstructure is turned in travel direction "to the re>
ar" (>± 90∞) at the same time, the switch functions for steering and travel direction
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will only change when the travel direction switch is actuated again via the neutral
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position.
The switch function of the blinker changes automatically if the crane eis turned into
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the slewing range "to the rear" .
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2.3 Release the parking brake

> Release the parking brake with switch (302).
Note: Without releasing the parking brake via switch (302), it is not possible to automati>
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cally release the parking brake by actuating the travel direction switch.
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> Release the parking brake by actuating the travel direction switch (261) in travel direction forward or
reverse .
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The symbol element "parking brake" (5) turns off in the operating view.
Note: The parking brake is not released as long as the required brake release pressure of
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approx. 5.2 bar is not available in brake circuit √ , even if the parking brake is
switched to release and a gear is applied.
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CAUT ION : Apply the brakes immediately after starting to drive to test them.
2.4 During travel, observe the following important symbols:

> Oil pressure (1)
> Coolant temperature (2)
> general gear problems (3)
CAUTION : If the symbol elements "oil pressure", "coolant temperature" or "general ge>
ar problems" appear during travel, then bring the crane to a standstill imme>
diately and turn the engine off.
If this is not done, the engine or gears can be damaged severely.
> Tank contents in % (7)

Do not use all the fuel in the fuel tank, otherwise the fuel system must be bled.
The symbol element appears with blinking numbers, if the battery voltage is less than 18 volts or more
than 36 volts.
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2.5 Off road driving

For off road driving, on unpaved surfaces and during winter conditions, additional gears can be added.
The maximum off road driving ability is obtained by adding the front axle drive. In additional the
transverse differential locks can be applied.
Note: The front axle can be added separately.

The transverse differential locks require the addition of the front axle drive.
CAUTION : To prevent damage to the drive axles, the following must be observed:
Turn differential locks only on or off if the vehicle is at a standstill!
The greatest danger for drive system damage is when the differential locks
are turned on if the drive wheels are turning.
Drive carefully (do not start out suddenly, do not use full power)
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Do not drive in curves.
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Use the differential locks only when driving on difficult terrain, such as
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sand, mud, slush, loose or slippery ground, etc.
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Turn the differential locks only on shortly before the obstacle, and turn them
off immediately after passing.
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Never drive with the locked differentials over a longer distance or on nor>
mal, hard surfaces.
Driving with the front axle drive or the transverse differential locks on solid
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ground can cause significant damage to the drive axles as well as the com>
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plete drive train!

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2.5.1 Adding the front axle

To prevent the wheels from slipping, the front axle drive can be added via the "F5" key .
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> Bring the crane to a standstill. .

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> Move the travel direction switch (261) to neutral position "N".
> Add the font axle with the "F5" key.
The symbol element ™front axle added™ appears as a message in the operating view .
> With the travel range switch (261), select the desired travel range while applying the service / opera>
ting brake at the same time.
Note: When the front axle cannot be added in neutral position, the symbol element "front
axle added" will appear blinking in the operating view. The travel range switch
must be switched to ∫forward∫ or ∫reverse™ and the service brake must be applied at
the same time. Press the "F5" key again to add the front axle .
CAUTION: If the gear is selected, the front axle may only be added or turned off at low
idle speed and when the vehicle is at a standstill, otherwise the axle or the
complete drive train may be damaged.
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2.5.2 Transverse differential locks

If the front axle drive is not sufficient to prevent the wheels from spinning, then the transverse differen>
tial locks for the driven axles can be added via the "F6" key.
Note: Prerequisite for adding the transverse differential locks is the added front axle dri>
ve. If the transverse differential locks are added without the front axle, the symbol
"transverse differential lock" will blink in the operating view, and an acoustical si>
gnal can be heard (beep). By adding the front axle, the front axle as well as the diffe>
rential locks will become active.
The transverse differential locks always become active on the two driven axles.
> Bring the crane to a standstill.

> Move the travel direction switch (261) to neutral position ∫N∫ .
> Turn on the transverse differential with the "F6" key.
The symbol element ™transverse differential lock™ appears as a message in the operating view.
> With the travel range switch (261), select the desired travel range while applying the service / opera>
ting brake at the same time.
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Note : When the transverse differential locks cannot be added in neutral position, the sym>
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bol element "transverse differential locks" will appear blinking in the operating
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view. The travel range switch must be switched to ∫forward∫ or ∫reverse™ and the
service brake must be applied at the same time.Press the "F6" key again to add the
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transverse differential locks.
CAUTION: If the gear is selected, the transverse differential locks may only be added or
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turned off at low idle speed and when the vehicle is at a standstill, otherwise
the transverse differential may be damaged.
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2.6 Axle oscillation, 1. Axle *
Note: The axle oscillation is used to drive the crane on construction and job sites, it
is only possible from the crane operatorπs cab.
Prerequisite:
> The corresponding load capacity 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 ON LEVEL".
CAUT ION : The oscillation of the 1st axle is only possible if the boom is positioned to the
rear and the crane superstructure is mechanically locked to the crane chas>
sis.
The axle oscillation is not possible if the crane is lowered all the way (sus>
pension cylinder mechanically on lock).
> Enter the corresponding CODE>No. or via the function keys in the "Set up" program of the LICCON
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safe load indicator system.
> Enter and confirm the entry by pressing the "ENTER" key and "O.K.".
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In condition axle suspension "LOCKED", the 1st axle is automatically switched to "oscillation", which
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is indicated by the symbol (1). The 2nd axle remains locked.
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As long as the crane is operating with the load capacity chart in the safe working range, the 1st axle re>
mains on oscillation.
If the crane leaves the safe range or another load capacity chart is set, then the LICCON safe load indi>
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cator system automatically switches back to axle suspension "LOCKED", which is indicated by symbol
(2).
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* Optional
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2.7 Hydraulic rear axle steering

The rear axle steering makes it possible to move in the wheels of the 1st and 2nd axle in the same direc>
tion to offset the crane and for maneuvering in tight turning radii.
CAUTION: The rear axle steering may NOT be used while driving on public roads.
To offset the crane (dog walk) , all wheels must be turned into the same direction.
For tight turning radii, the wheels of the front axle must be turned in travel direction and the wheels for
the rear axle must be against the travel direction.
Note: The angle of the rear axle should be about the same as the angle for the front axles
to prevent the tires from ∫chaffing∫ or rubbing against each other.
2.7.1 Using the hydraulic rear axle steering

> Bring the vehicle to a standstill on level ground, and move the wheels of the front axle to ∫straight for>
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ward travel™.
> Switch the travel direction switch (261) to neutral position "N", the parking brake is applied automa>
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tically.
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> Turn the crane superstructure in ∫vehicle lengthwise direction∫ to the front or to the rear and lock it
to the chassis.
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> Turn the rear axle lock off via the "F3" key.
In the operating view appears the symbol for "rear axle release".
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Note: The axle can only be released in "neutral position", in travel range "forward" as well as
in "reverse".
> Move the steering column switch (255) slightly to the left and right.
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Note: If the symbol for "rear axle released" blinks in the operating view ( rear axle cannot be
steered), then the rear axle release is in an intermediate position. In this case, press the
"F3" key again.
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Then move the steering column switch (255) slightly to the left and right.
> Now the rear axle can be moved to the left or right, as desired, independent of the front axle, via the
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steering column switch (255).

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Note: If the engine is turned off in locked condition, the rear axle remains locked, even when
the engine is restarted.
2.7.2 To take the hydraulic 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 tra>
vel.
> Switch the travel direction switch (261) to neutral position "N". The parking brake is applied automa>
tically.
> With the "F3" key, apply the steering lock of the rear axle.
The symbol for the rear axle release turns off in the operating view.
> Move the steering column switch (255) for the rear axle steering slightly to the left and right and make
sure that the rear axle steering is locked, while watching the wheels of the rear axle, these wheels
may no longer steer to the right or left.
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2.8 To end travel

> Bring the crane to a stop by applying the service brake (201) .
> Move the travel direction switch (261) to neutral position "N" , the parking brake is applied automati>
cally.
The symbol for the parking brake appears in the operating view.
> Lock the release for the parking brake also via switch (302) .
2.9 Turn the engine off

> Turn the crane engine off by turning the ignition key (320) to the left, to position "1".
Note: After operating the engine at full power or in case of increased coolant temperature
(above 95∞ C) , let the engine run for 1 to 2 minutes at low idle speed.
CAUTION : The engine must be turned off immediately in case of:

> dropping or significantly fluctuating engine oil pressure
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> decreasing engine power and engine speed , even though the position
of the gas pedal has not changed
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> increasing exhaust fumes
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> increasing coolant and oil temperature
> sudden abnormal noise coming from the engine
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2.10 Turn the engine ignition off

> Turn the ignition off by turning the ignition key (320) counterclockwise to ∫0∫ position and then pull
it off.
> Lock the crane operatorπs cab.
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> Secure the crane with wedges to prevent it from rolling.

> Turn the main battery switch off and pull the cam.
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2.11 Additional devices for travel operation

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> Windshield wiper for front window, switch (304).

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> Windshield washer system for front window, button (303).

> Windshield wiper for overhead roof window , switch (306).
> Windshield washer system for overhead roof window, button (305).
> Parking and low beam light, 2 stage switch (307).
> Emergency blinker system, "F4" key on the LICCON monitor.
The symbol for the "emergency blinker" appears in the operating view.
> Working floodlights, switch (288, 289, 290, 291) *.
> Interior light for crane operatorπs cab.
> Travel direction indicator, switch (259).
The symbol for "travel direction indicator" appears in the operating view.
> Horn (warning signal), foot button (204).
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4.11 CRANE OPERATION ∫FREE STANDING∫ 023484>01
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1. Crane operation "freestanding on tires"

he 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 pro>
grammed .
The instructions of the appropriate load capacity chart MUST be followed!
Non > adherence can cause serious accidents!
1.1 Crane operation "free standing on tires", working range to the rear
> All tires must be inflated to the correct tire pressure, as noted in the load capacity chart for crane ope>
ration ∫free standing on tires" .
> The boom may be moved, even without a load, only in ranges where load capacity values are available
for ∫free standing, on tires∫, otherwise there is a danger that the crane will tip over.
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> The ground must be able to securely support the maximum operating weigh t of the crane and the
weight of the suspended load.
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> The ground must be level and without any slopes .
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> The axle suspension must be "blocked on level", button (80) must be turned on.
> The crane superstructure must be in lengthwise vehicle direction ∫to the rear∫ and mechanically loc>
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ked to the chassis, lever (212) must be moved downward.
> For safety reason, always try to work with the crane supported, even in cases, when you could work
∫freestanding on tires".
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> For safety reason, the crane must be supported and horizontally aligned before turning the crane su>
perstructure into the working position ∫to the rear∫ and before lifting the telescopic boom from the
boom retainer .
To do so, extend and pin the sliding arms at least to the support basis of 6.27m ¥ 4.3m.
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The telescopic boom must be fully retracted.

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The LICCON safe load indicator must be set to the corresponding operating mode.
Proceed the same way to return the crane superstructure from working position "free standing on ti>
res, working range to the rear" into the travel condition.
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> The 4 sliding arms must remain pinned for the extension, and the support cylinders with installed sup>
port pads (in working position) must be raised to just above ground level.
The crane will then be able to catch itself on the supports should the ground give.
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> The telescopic boom may be telescoped out only to a maximum length of 14,4 m .
> The suspended load must be carried as close as possible to the ground and it must be secured to prevent
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it from swinging.
*Optional
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1.2 Driving the crane with an attached load

The crane can be moved with an attached load ∫to the rear∫ , if the load capacity charts ∫freestan>
ding on tires, working range to the rear™ are available. In addition, all notes in paragraph 1.1 must
be strictly observed.
In addition, the following applies:

> The crane superstructure must be positioned in vehicle lengthwise direction and to the rear and locked
to the chassis.
> The attached load must be carried as close as possible to the ground and must be secured to prevent it
from swinging.
> Driving in 360∞ working range is not permitted!
> The crane may only be moved with utmost care and in step by step speed.
> Avoid jerky travel movements, which means the least possible increase in speed and careful braking ac>
tion.
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1.3 There is a danger of tipping over or a danger of overload, if :
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> the crane superstructure is not positioned in vehicle lengthwise direction to the rear.
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> if the boom is telescoped out to a length of more than 14.4 m and the crane superstructure is moved from
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vehicle lengthwise direction.
> the axle suspension is not blocked.
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> the ground is not able to securely carry the maximum operating weight and the weight of the suspended
load.
> the ground is not level and /or without slopes.
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> you drive too quickly with a load or if you start out or slow down jerkily or brake .
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> the outrigger cylinders with outrigger plates (in working position) are not lowered close to ground level.
> the load values or working radii noted in the load capacity charts are exceeded or fallen below.
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> the crane is not kept within sufficient distance to excavations, cellars, slopes, embankments, etc.
> the load starts to swing due to improper crane control.
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> the load is pulled diagonally.

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> the tire pressure does not match the value given in the load capacity chart.
> the data in the LICCON safe load indicator system does not match the equipment configuration.
> the hydraulic system for the axles suspension system is not fully functioning.
* Optional
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5.00 EQUIPMENT 021678>00
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021678>00
Chapter 5
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Equipment
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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
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and unpinning the lattice sections. This is strictly prohibited!
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Transport of lattice sections
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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
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accident, because the inner lattice sections may fall out.

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Checking the safety measures

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> Is axle suspension / axle floating locked?

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> 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
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capacity table?
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> 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?
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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.
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Checking the cables
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Before assembly and at regular intervals, the cables must be subjected to expert inspection in order to recognize
possible damage and signs of wear.
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DANGER: The cables must be taken off the crane immediately if any of the following defects
are found:
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> broken strand

> broken wires
> groups of broken wires
> cable diameter 10% or more narrower than the nominal value
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> cable deformation

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New cables must be of the same design, strength rating and diameter as the old ones.
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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
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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.
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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.
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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.
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Raising / Lowering ER
Before raising or lowering a boom combination, the following requirements must be fulfilled:
Requirements:
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> 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.
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> All limit switches are correctly mounted and properly functioning.
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> 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.
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> 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
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speed gauge, etc.) are free of snow and ice.

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DANGER: Incorrectly mounted or nonfunctioning limit switches as well as falling parts (pins,
spring keepers, ice, etc.) are dangerous and can cause serious injury.
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5.02 FOLDING JIB > TK 023372>00
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5.02 FOLDING JIB > TK 023372>00
1. Folding jib variations
This crane can be equipped with different folding jibs, as desired:
Fig. 1 SINGLE / ONE PART FOLDING JIB 8.6 m long

consisting of :
1 Pivot section 8.6 m ca. 465 kg
Note: In this variation, the end section (2) remains pinned to the telescopic boom pivot sec>
tion.
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Fig. 2 DOUBLE > TWO PART FOLDING JIB 15.0 m long
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consisting of:
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1 Pivot section 8.6 m ca. 465 kg
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2 End section 6.0 m ca. 215 kg
complete ca. 680 kg
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The folding jib variations (fig. 1 to 2) can be installed and operated as straight extensions (0∞) or at an angle of
20∞ or 40∞ to the telescopic boom.
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For on road travel, the double / two part folding jib > end section folded in > is folded onto the telescopic boom pi>
vot section and mechanically secured.
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5.02 FOLDING JIB > TK 023372>00
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5.02 FOLDING JIB > TK 023372>00
1.1 Component overview of folding jib
Pos.:
1 Pivot section > Folding jib
2 End section > Folding jib
3 Pin with spring retainer > To secure end section (2) on folding jib receptacle (5)
4 Pin retainer > For pin (3)
5 Folding jib receptacle > Also transport retainer for folding jib
6 Spring retainer > To secure the pin
7 Pin > Lock for folding jib receptacle (5) in corresponding end posi>
tion (in or out)
8 Pin with retaining clip > Pin (top and bottom) to swing and attach the end section (2)
on the pivot section (1)
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9 Lock > Retainer, end section (2) on pivot section (1)
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10 Rope > To release the lock (9)
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11 Pin with retaining clip > Swing and mounting pin to swing and attach the folding jib
on the telescopic boom head
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12 Locking pin > Swing pin (pivot point) and lock between folding jib and te>
lescopic boom pivot section
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13 Lever > To unlock between folding jib and telescopic boom pivot sec>
tion
14 Hand pump > To actuate the installation aid (16)
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15 Knob > To open and close the valve on the hand pump (14)
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16 Installation aid > To install the upper pin on the telescopic boom head
17 Pin > Pivot point of installation aid
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18 Installation rod > To release the locking pins (12) on the pivot point between
folding jib and telescopic boom pivot section
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19 End pulley > On the pivot section of the folding jib

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20 End pulley > On the end section of the folding jib

21 Cable guide pulley > Can be turned upward
22 Set screw > Distance adjustment / end section to receptacle
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5.02 FOLDING JIB > TK 023372>00
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5.02 FOLDING JIB > TK 023372>00
1.2 Description
The folding jib is 2part and can be operated in working lengths of 8.6 m and 15 m . It can be installed
either as a straight extension (0∞) or at an angle of 20∞ or 40∞ to the telescopic boom .
When driving on a rod, the folding jib must be folded onto the telescopic boom and mechanically secured.
1.3 Installation
DANGER: For installation work above a height of 2 meter,either a safety belt must be
used, which must be attached on the crane framework, or a safe installation
scaffolding / working platform must be used. All installation procedures
must be performed from a stable position. DO NOT improvise! There is a
great danger of falling and causing a serious accident .
Prerequisites:
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> The crane is properly supported and horizontally aligned .
> The counterweight is installed on the slewing platform, according to load capacity chart .
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> The telescopic boom is fully retracted .
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> The folding jib is mounted for transport to the telescopic boom pivot section .
> The telescopic boom is positioned to the rear or to the side, luffed down to 0∞ position.
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Note: Angle indicator 0∞, refer to the control and indicator unit of the ∫LICCON∫ safe lo>
ad indicator.
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.
DANGER: The telescopic boom must be in 0∞ position, otherwise there is the danger
that the folding jib swings out by itself when the locks are released !
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1.4 Unreeve the hoist cable on the telescopic boom head

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For folding jib operation , the hoist cable must be unreeved on the boom head.
> To do so, telescope the telescopic boom out to approx. 8.6 m or 15 m, depending on the folding jib
length in use.
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> Place the hook block on the ground.

> Detach the hoist cable from the cable fixed point.
> For safety reasons, remove the hoist limit switch weight and the chain .
> Remove the cable retaining rods on the pulley head and on the back pulley.
> Telescope the telescopic boom in again to the stop.
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2. Installation of the folding jib
2.1 Installation of the 8.6 m long folding jib

The end section (2) of the folding jib, which is not needed, remains pinned on the telescopic boom pivot
section.
D A N G E R: It must be assured that the end section (2) remains pinned and secured on
the telescopic boom pivot section with pins (3) , and that it is locked to the he>
ad (22) and on the receptacle with the set screws.
If this is not observed, then there is a danger of a serious accident, because
the end section will fall down.
> Unpin the folding jib receptacle (5) , remove the spring retainer (6) and pull the pin (7) down to release.
> Swing the folding jib receptacle (5) out until the pin (7) engages.
CAUTION : The pin must be engaged, check visually to make sure.
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Note: When folded in, the folding jib receptacle (5) also serves as the transport retainer
for the complete folding jib on the telescopic boom pivot section.
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> Attach the auxiliary rope on point (Z) .
> Remove both pins (8) on top and on the bottom.
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> Pull the rope (10) to release the lock (9) between end section (2) and pivot section (1) .
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2.1 Installation of the 8.6 m long folding jib (continuation)
> Swing the pivot section (1) around the pivot point (12) until it can be pinned at (O) on top and on the
bottom with pins (11) . Secure the pins (11) with the retaining clip.
CAUTION: To secure the pins (11) use the special retaining clips!
It is not permitted to use other spring retainers or spring pins on these pins.
D A N G E R: All pins must be secured.

Otherwise there is a great danger of causing a serious accident due to falling
crane sections, also the folding jib can fold down during crane operation.
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2.2 Swing the folding jib to the front

> Loosen the lock on the pivot point (12) .
> Insert the installation rod (18) into the eye on the lever and push the lever (13) up and secure it by
notching it to the left into the bracket. This releases the lock between the folding jib and the telesco>
pic boom pivot section .
DANGER : Before releasing the lock, make sure that both pins ( 11) , on the top and bot>
tom are inserted at point (O) and secured !
During the release procedure of the pivot section (1), hold it with the auxilia>
ry rope to prevent it from swinging out by itself .
This could cause a serious accident.
> Swing the pivot section (1) with the auxiliary rope by 180∞ to the front, until it can be pinned at (P)
∫on the bottom∫ .
> Insert the pin (11) and secure with retaining clip .
Note: To be able to pin at point (P) "on top" , the installation aid (16) must be used.
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DANGER: Make sure there are no persons or objects within the swing range or the fol>
ding range on the telescopic boom and the folding jib .
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There is a great DANGER OF ACCIDENTS .
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2.3 Pin the folding jib at point (P) ∫on top∫
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The upper pin can only be inserted with the hydraulic > mechanical installation aid.
> Swing the installation aid (16) to the stop around the pivot point (17) "to the rear" . (Pos. II)
> Close the knob (15) on the hand pump (14) .
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> Extend the hydraulic cylinder of the installation aid by actuating the hand pump (15)until the bore ho>
le on the eye of the folding jib aligns with the eye on the telescopic boom head.
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> Insert pins (11) and secure with retaining clip.
CAUTION: When all pins (11) are pinned and secured at (O, P) , the knob (15) must be
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opened again on the hand pump (14), this causes the hydraulic cylinders of
the installation aid to return to initial position, the pin (17) is relieved.
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2.4 Installation of the 15 m long folding jib

The installation of the 15 m long folding jib must be handled just as the installation of the 8.6 m long
folding jib.
However, the following deviations must be observed:
D A N G E R: Since the end section is folded out at the same time, the following deviations
must be observed:
> The connection between the pivot section (1) and the end section (2)
may not be released. The pins (8) must remain p i n n e d.
> The pin (3) on the connection end section (2) to folding jib receptacle
(5) must be unpinned.
> Do not loosen the lock (9)between end section (2) and pivot section
(1). The folding jib on the telescopic boom head must be pinned and
secured.
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Note : Insert and secure the pins (3) into the pin receptacle (4) for storage.
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2.4.1 Swing the end section (2) to the front
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> Remove the auxiliary rope on point (A) and attach on point (H) on the end section (2) .
> Pull the rope (10) to release the lock (9) between end section (2) and pivot section (1) .
DANGER : During the release procedure, the end section must be held with the auxilia>
R
ry rope to prevent it from swinging out by itself.

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> Swing the end section (1) forward by 180∞ until it can be pinned at (G) .
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> Pin the pin (8) ∫on top and bottom∫ and secure with retaining clips.
> Remove the auxiliary rope .
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DANGER: Make sure there are no persons or objects within the swing range or the fol>
ding range on the telescopic boom and the folding jib .
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There is a great DANGER OF ACCIDENTS .
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3. Hoist cable reeving on the 8.6 m and on the 15 m long folding jib
3.1 Swing the cable guide pulley (21) ∫upward∫

> Fold out the cable guide on the handles from transport position to working position.
Note: The cable guide does not have to be secured in working position.
3.2 Cable guide

> Remove the folding pins on the cable retaining pins (31, 32, 33) and (34, only on the 15 m long folding
jib) , pull out the cable retaining pin.
> Place the hoist cable over the cable guide pulley (21) and over the end pulley (19 or 20) of the 8.6 or
15.0 m long folding jib.
> Repin the cable retaining pin and secure with folding pins.
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CAUTION: On the 15.0 m long folding jib, the cable retaining pin (33) may not be pinned
on the end pulley (19) .
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If this is not observed, the slack hoist cable might scrape on the cable retai>
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ning pin (33) and be damaged. ER
> Reeve the load hook on the hoist cable or the hoist cable into the hook block, attach on the fixed point
and secure.
> Attach the hoist limit switch weight.
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4. Change over the 8.6 m long or the 15 m long folding jib from 0∞ to 20∞ / 40∞
There are three possibilities to change the folding jib to 20∞ or 40∞ .
Prerequisites:
> The folding jib is installed as a straight extension in 0∞> position, as described in paragraph 2.
> The telescopic boom is turned to the rear or to the side.
The angle installation can be carried out as follows:
4.1 Hoist cable as retaining cable (installation rope), Fig. 1
CAUTION : The angle installation with the hoist cable as retaining cable is NOT identical
for working lengths 8.6 m and 15 m .
4.1.1 8.6 m long folding jib

4.1.2 15 .0 m long folding jib
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4.2 The folding jib is laying on the ground or on a support, Fig. 2
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4.3 With the hook block or load hook, Fig. 3
CAUTION : The angle installation with the hook block or the load hook is only possible
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for the 8.6 m long working length .

The 5>pulley hook block* may not be used for the angle adjustment.
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* Optional
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4.1 Angle installation with the hoist cable as retaining cable (installation rope)

> Unreeve the hoist cable on the cable lock.
> Remove the lock on the end section and pin on the installation fixed point (B) of the pivot section.
> Attach the hoist cable in the cable lock .
> Tighten the hoist cable by sensitively deflecting the corresponding manual control lever.
DANGER: Do not telescope the telescopic boom out or luff it down as long as the hoist
cable is pinned and tensioned on the installation fixed point (B) .
If this is not observed, the sections of the folding jib and the hoist cable will
be overloaded and damaged.
> Remove and unpin the spring retainer (37) on the two pins (36) .
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DANGER : The pins (36) may only be unpinned if the folding jib is held by the hoist ca>
ble.
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If this is not done, there is a danger of causing a serious accident, because
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the folding jib can suddenly ∫fold down∫ !
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> Insert the pins (36) into the corresponding bore hole for 20∞ and secure with spring retainers (37) .
Note: At an angle of 40∞, unpin the pins (36) , insert it in the transport retainer and secure
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with spring retainer . The fixed installed pins (38) will then serve as the stop for
40∞.
> Spool out the hoist cable by deflecting the corresponding manual control lever and luff up the telesco>
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pic boom at the same time, until the two pull bracket (39) touch on pins (36) or at 40∞ , on pins (38)
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and the folding jib is held by the pins.
> Remove the hoist cable on the cable lock, remove the lock and install on the end section.
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4.1.2 15 m long folding jib

> Unreeve the hoist cable on the cable lock.
> Insert the hoist cable into the installation bore hole (40) .
> guide the fitting in the installation fixed point (A) .
cable is pinned and tensioned on the installation fixed point (A) .
> Remove and unpin the spring retainer (37) on the two pins (36) .
DANGER : The pins (36) may only be unpinned if the folding jib is held by the hoist ca>
ble.
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40∞.
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> Spool out the hoist cable by deflecting the corresponding manual control lever and luff up the telesco>
pic boom at the same time, until the two pull bracket (39) touch on pins (36) or at 40∞ , on pins (38)
and the folding jib is held by the pins.
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> Guide the hoist cable from the installation fixed point (A), and install on the cable lock on the end sec>
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tion.
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4.2 The folding jib must rest on the ground or on a support

> Luff down the telescopic boom until the folding jib lays on the ground at 15 m or at 8.6 m .
Note: If necessary, support the folding jib underneath .
> Remove the spring retainer (37) on pins (36) and unpin.
DANGER: The pins (36) may only be unpinned if the end section of the folding jib rests
on the ground.
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40∞.
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> Luff up the telescopic boom until the brackets (39) touch on pins (36) or at 40∞ , on pins (38) and the
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folding jib is held by the pins. ER
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4.3 With hook block or load hook
CAUTION : The angle installation with the hook block or the load hook is only possible
for the working length of 8.6 m .
The 5 pulley hook block* may not be used for the angle installation.
> Luff down the telescopic boom all the way, while holding the hook block or the load hook about 1 m
above the ground.
> Remove the hoist limit switch weight with chain.
CAUTION : The host limit switch weight and the chain must be removed to install the one
part folding jib at an angle.
> Bypass the upper hoist shut off on the LICCON control and indicator unit.
> By sensitively deflecting the corresponding manual control lever, carefully run the hook block (1 pul>
ley or 3 pulley) or the load hook against the stop on the end section of the folding jib and lift it over the
hoist gear and hold it.
> Release the upper hoist bypass .
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DANGER: As long as the hook block touches the stop of the folding jib, do not telescope
out the telescopic boom nor luff it down. If this is not observed, the sections
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of the folding jib and the hoist cable can be overloaded and damaged.
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> Remove the spring retainer (37) on the pin (36) and unpin.
D ANGER: The pins (36) may only be unpinned if the pivot section of the folding jib is
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held by the hook block via the hoist cable.

If this is not observed, there is a danger of causing a serious accident, as the
folding jib can suddenly πfold down©!
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> Insert the pins (36) into the corresponding bore holes for 20∞ and secure with spring retainer (37) .
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40∞.
> Luff up the telescopic boom while luffing up the folding jib at the same time by lowering the hook block
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or the load hook until the brackets (39) touch on pins (36) or at 40∞ , on pins (38) and the folding jib is
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held by the pins.

> Lower the hook block until about 1m above the ground .
> Luff down the telescopic boom until the hoist limit switch weight can be installed .
> Install the hoist limit switch weight and chain.
> Attach the hoist limit switch weight on the hoist cable.
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5. Electrical connections
5.1 Electrical connections on the single, one part folding jib > 8.6 m
> Unplug the cable plug (>X 556) for the wind velocity sensor * from socket (>X 500A) .
> Remove the wind velocity sensor * on the telescopic boom head and attach it on the pivot section of the
folding jib .
> Insert the cable plug (>X 556) for the wind velocity sensor * in socket (>X 505A) .
> Unplug the cable plug (>X 451) from socket (>X 411) .
> Insert the cable plug (>X 500) in socket (>X411) on the telescopic boom head.
Note: The connection cable plug (>X 501) to bushing (>X 500B) on the pivot section of the
folding jib must be closed.
CA U T I O N : Only the hoist limit switch for the single one part folding jib is active!
5.2 Electrical connections on the double / two part folding jib > 15 m
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> Unplug the cable plug (>X 556) for the wind velocity sensor * from socket (>X 500A) .
> Remove the wind velocity sensor * on the telescopic boom head and attach it on the end section of the
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folding jib.
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> Insert the cable plug (>X 556) for the wind velocity sensor * in socket (>X 556A) .
> Insert the cable plug (>X 505) into socket (>X 505B) .
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> Insert the cable plug (>X 500) in socket (>X 411) on the telescopic boom head.
CA U T I O N : Only the hoist limit switch for the double, two part folding jib is active!
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Note: All additional electrical hoist limit switches (boom head, single folding jib) connec>
ted to the Bus system (LSB) are also active and can cause the safe load indicator sy>
stem to shut off.
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5.3 Function check

Prerequisites:
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> All electrical connections are established.

> The control levers of the limit switch have been checked for easy movement and are lubricated.
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5.3.1 Wind velocity sensor*

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Check the wind velocity sensor for movement and function.
CA U T I O N : In folding jib operation, the removable wind velocity sensor must always be
installed and connected ( functioning), otherwise the ∫LICCON∫ safe load
indicator system reports a problem. The function must be checked after
every new installation.
5.3.2 Hoist limit switch

Actuate the hoist limit switch manually, the symbol ∫Hoist top∫ on the LICCON monitor must appear.
The hoist winch must turn off in hoist mode.
Note: When replacing or changing a hoist limit switch (HES), the HES must have the cor>
rect Bus address as well as the correct software version, to be recognized again by
the Bus system (LSB) .
HES Boom head Bus address 28

HES Single folding jib Bus address 27
HES Double folding jib Bus address 26
* Optional
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6. Erection
Prerequisites:
> The crane is properly supported and horizontally aligned .
> The counterweight has been installed on the slewing platform, according to the load capacity chart .
> The telescopic boom is telescoped in all the way .
> The folding jib has been assembled according to the load capacity chart and the instructions given in
the operating manual .
> All limit switches have been properly installed and are fully functioning .
> All pin connections are secured.
> The hoist cable has been inserted correctly into the cable pulleys and has been secured with the cable
retainer pins to prevent it from jumping out.
> There are no loose objects and parts on the telescopic boom and the folding jib .
> In winter, the telescopic boom , the folding jib, and all components (limit switch, cable drum, airplane
warning light , wind velocity sensor , etc.) are free of snow and ice .
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DANGER : Improperly installed or non>functioning limit switches as well as falling ob>
jects or parts (such as pins, spring clips, ice, etc.) can cause serious acci>
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dents!
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6.1 Erection procedure
> Set the ∫LICCON∫ safe load indicator according to the required equipment configuration.
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> Luff up the telescopic boom with installed folding jib to the steepest telescopic boom position (fig. 3).
> Telescope the telescopic boom out to the values noted in the load capacity chart.
Note: For adjustment of LICCON safe load indicator system, see chapter 4.02.
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D A N G E R: Telescoping in and out with installed folding jib is only permissible in stee>
pest telescopic boom position.
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The working radii given in the load capacity chart may not be exceeded nor
fallen below, even if there is no load on the hook!
If this rule is not observed, it may cause the crane to tip over !
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The LICCON settings must be checked and compared with the actual equip>
ment configuration.
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7. Changing the 8.6 m or the 15 m long folding jib from 20∞ / 40∞ to 0∞
First, the telescopic boom must be telescoped in all the way.
The change can be made as follows:
7.1 with the hoist cable as retaining cable (installation rope)
CAUTION : The angle installation with the hoist cable as retaining cable for the 8.6 m
working length is NOT identical with that of the 15 m length.

7.2 The folding jib must be placed on the ground or on a support.
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7.3 With hook block or load hook (8.6 m long folding jib)
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CAUTION : The angle installation with the hook bloc or the load hook can only be made
at a working length of 8.6 m.
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The 5>pulley hook block* may not be used for the angle adjustment.
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* *Optional
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7.1 Changing with the hoist cable as retaining cable (installation rope)

> Luff down the telescopic boom until the hook block can be unreeved on the end section of the folding
jib.
> Unreeve the hoist cable on the hook block.
> Remove the hoist limit switch weight.
> Remove the cable lock on the end section and pin it on the installation fixed point (B) .
> Attach the hoist cable on the installation fixed point (B) to the lock.
cable is pinned and tensioned on the installation fixed point (B) .
> Luff down the telescopic boom and s pool up the hoist cable at the same time so that the end section of
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the folding jib always remains at the same height, approx. 1 to 1.5 m above the ground, until the 0∞ po>
sition is reached (stop on the pull brackets).
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CAUTION : As soon as the folding jib has reached the 0∞ stop, stop the ™hoisting™ and
™luffing™ movement immediately.
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> Remove the spring retainer (37) , unpin both pins (36) , insert at 0∞ position and secure with a spring
retainer (37).
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> Remove the hoist cable on the installation fixed point (B) and remove the cable lock.
DANGER : Do not remove the hoist cable if the pins (36) are not inserted and secured.
If this is not observed, there is a danger of causing a serious accident, becau>
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se the folding jib can suddenly ∫fold down∫ !

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> Unpin the cable retaining pins on the cable pulley, spool up the hoist cable.
> Swing the cable guide pulley (21) in transport position "downward".
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Note: The cable guide pulley (21) does not have to be secured in transport position.
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> Luff up the telescopic boom again to the horizontal.

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> Luff down the telescopic boom until the hook block can be unreeved on the end section of the folding
jib.
> Unreeve the hoist cable on the hook block.
> Remove the hoist cable from the cable lock.
> Insert the hoist cable into the installation bore hole (40).
> Guide the fitting into the installation fixed point (A) .
DANGER: Do not telescope the telescopic boom out as long as the hoist cable is inser>
ted and tensioned on the installation fixed point (A) .
> Luff down the telescopic boom and s pool up the hoist cable at the same time so that the end section of
the folding jib always remains at the same height, approx. 1 to 1.5 m above the ground, until the 0∞ po>
sition is reached (stop on the pull brackets).
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> Remove the spring retainer (37) , unpin both pins (36) , insert at 0∞ position and secure with a spring
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retainer (37).
> Remove the hoist cable on the installation fixed point (A) .
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DANGER : Do not remove the hoist cable if the pins (36) are not inserted and secured.
If this is not observed, there is a danger of causing a serious accident, becau>
se the folding jib can suddenly ∫fold down∫ !
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> Unpin the cable retaining pins on the cable pulley, spool up the hoist cable.
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7.2 The folding jib must rest on the ground or on a support
> Luff down the telescopic boom until the hook block can be unreeved from the folding jib.
> Remove the cable lock and the hoist limit switch.
> Luff down the folding jib until the end section of 15 m or at 8.6 m long folding jib lays on the ground.
CAUTION: The support surface must be sold and level so that the folding jib is not pus>
hed into the ground when it is luffed down.
> Continue to luff down the telescopic boom until the 0∞ position (stop on the pull brackets) is reached.
> Insert both pins (36) at 0∞ position and secure with spring retainer (37) .
> Unpin the cable retaining pins on the cable pulleys, spool up the hoist cable.
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7.3 With hook block or load hook
> Luff down the telescopic boom until the hoist limit switch weight on the end section of the folding jib
can be removed, while holding 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 the chain and place it on the ground.
> Bypass the upper hoist limit shut off on the LICCON control and indicator unit.
> By sensitively deflecting the corresponding manual control lever, carefully run the hook block (the lo>
ad hook) to the stop on the pivot section of the folding jib and lift it over the hoist gear .
> At the same time, luff down the telescopic boom until the pivot section of the folding jib has reached
the 0∞ position.
> Remove the spring retainer (37) , unpin both pins (36) , insert them at 0∞ position and secure with
spring retainer (37) .
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DANGER: Do not remove the hoist cable if the pins (36) are not inserted and secured. If
this is not observed, there is a danger of causing a serious accident, as the
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folding jib can suddenly πfold down©!
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> Lower the hook block until about 1 m above the ground.
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> Luff down the telescopic boom until the hoist limit switch weight can be installed.
> Install the hoist limit switch weight and chain.
> Attach the hoist limit switch weight on the hoist cable.
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> Unpin the cable retaining pin on the cable pulleys, spool up the hoist cable.
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5.02 FOLDING JIB > TK 023372>00
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5.02 FOLDING JIB > TK 023372>00
8. Removal of the folding jib
8.1 Change the 15 m long double folding jib into transport position
Prerequisites:
> The counterweight is installed on the slewing platform, according to load capacity chart .
> The telescopic boom is fully telescoped in.
> The telescopic boom is luffed down to the rear or to the side, in 0∞ position.
> The folding jib is in 0∞ position.
> The electrical connections on the pivot section or the end section of the telescopic boom head are un>
plugged.
> The lines are stored properly.
> The cable guide pulley is folded from working position to transport position.
D A N G E R: The crane must be horizontally aligned and the telescopic boom must be in
0∞ position, otherwise there is a danger of causing a serious accident if it
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swings out by itself when the folding jib head and the pivot section are un>
pinned.
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For installation work above a height of 2 meter,either a safety belt must be
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used, which must be attached on the crane framework, or a safe installation
scaffolding / working platform must be used. All installation procedures
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must be performed from a stable position. DO NOT improvise! There is a
great danger of falling and causing a serious accident .
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8.1.1 Swing the end section (2) of the folding jib to the rear
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> Attach the auxiliary rope (H) to the end section (2) of the folding jib .
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> Unpin both pins (8) on connection (G) ∫on top and bottom∫ .
D A N G E R: The two swing pins (8) must remain pinned.

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During unpinning, the end section must be held with the auxiliary rope to
prevent it from swinging out by itself.
This could cause an accident.
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> Swing the end section (2) with the auxiliary rope by 180∞ to the rear to the pivot section (1) until the
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lock (9) engages with an audible ∫click∫ . Check visually!
DANGER : Make sure that there are no persons or objects within the swing range of the
folding jib .
> Remove the auxiliary rope.
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5.02 FOLDING JIB > TK 023372>00
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5.02 FOLDING JIB > TK 023372>00
8.2 Change the 8.6 m long single folding jib into transport position
8.2.1 Swing the 8.6 m single folding jib to the rear
> Attach the auxiliary rope on point (Z) to the pivot section section (2) .
> Unpin the folding jib receptacle (5) and swing it out until the pin engages.
CAUTION : The pin must engage, check visually.
> Remove the retaining clip on the ∫upper ∫ pin (11) at (P) and unpin .
Note: To unpin the ∫upper∫ pin (11) , use an hydraulic installation aid.
> Swing the installation aid to the stop to position II.

> On the hand pump (14), close the valve (15) and actuate the hand pump until the upper pin !(11) can be
unpinned by hand.
> Remove the retaining clip and unpin the upper pin (11) , insert it into the transport retainer and secu>
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re with the retaining clip.
> On the hand pump (14), open the valve (15) .
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CAUTION: If the pin (P) is unpinned, the knob (15) on the hand pump must be opened
again, this causes the hydraulic cylinder to return to the initial position, the
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pin (17) is relieved.
Swing the installation aid again to position I .
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DANGER: During the unpinning procedure, the folding jib must be held with the auxi>
liary rope, to prevent it from swinging out by itself.
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> Swing the folding jib to the rear.

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DANGER: Make sure that there are no persons or objects within the swing range of the
folding jib .
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5.02 FOLDING JIB > TK 023372>00
Swing the 8.6 m long single folding jib to the rear (continuation)
> Swing in the folding jib until the swing pin engages with an audible ∫click∫ , due to the spring force ,
on lock (12) on the telescopic boom pivot section.
> Check visually!
DANGER : The lever (13) must be in the lower position before swinging it in, otherwise
the swing pin does not engage due to the spring force on the lock (12).
This could cause an accident.
> Remove the retaining clip on the pin (11), unpin the pin ∫on top and bottom∫ (11) at point (O) and in>
sert it into the transport retainer and secure it.
> Move the folding jib around the pivot point (12) to the telescopic boom pivot section until the pin (3) for
the transport retainer can be pinned on the connection end section (2) to the folding jib recepta>
cle(5) .
> Secure the pin (3) with spring retainer .
> Release the folding jib receptacle, pull the pin (7) downward.
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> Swing the folding jib receptacle (5) in, engage the pin (7) and secure with the spring retainer .
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> The folding jib is folded onto the telescopic boom pivot section for transport.
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DANGER: All pins must be secured, otherwise there is a danger of causing an accident
due to falling crane section.
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6.00 ADDITIONAL EQUIPMENT 021679>00
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021679>00
Chapter 6
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Additional Equipment
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6.01 HEATER / ENGINE PREHEAT SYSTEM * 023364>01
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1. Heating system > driverπs cab

The control of the engine dependent heater as well as the engine independent additional heater * is car>
ried out via the control elements on the keyboard.
1.1 Control elements of the heating system
"Temperature", buttons (95 and 96)

The temperature can be set to 4 different temperature stages (0="cold" to 3="warm"). When the but>
ton is pressed, the function control in the button lights up and the adjusted temperature stage is shown
on the indicator unit (64) .
> Heater warmer, button (95)
> Heater colder, button (96)
"Blower", buttons (97 and 98)

The fan speed can be set to 4 stages ( 0="off" to 3="highest fan speed") . When the button is pressed,
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the function control in the button lights up and the adjusted fan speed is shown on the indicator unit
(64) .
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> Fan speed higher, button (97)
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> Fan speed lower, button (98) ER
"Air circulation / fresh air ventilation ", button (103 and 104)
If the buttons are turned to air circulation or fresh air ventilation, the function control in the button
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lights up.
Air circulation Fresh air

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Button (103) Button (104)

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on off only air circulation
off on only fresh air

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on on approx. 70% air circulation / 30% fresh air

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off off approx. 30% air circulation / 70% fresh air

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"Floor board/Front windshield ", (buttons 105 and 106)

If the buttons ™floor board™ or ™front windshield™ are turned on, the function control in the button lights
up.
Floor board Front windshield

Button (105) Button (106)
on off only floor board
off on only front windshield
on on approx. 70% floor board / 30% front windshield
off off approx. 30% floor board / 70%front windshield
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1.2 Engine dependent heater

The heat for the driverπs cab is supplied by the engine coolant .
The engine dependent heater can be regulated via the control elements on the keyboard (see paragraph
1.1).
After the ignition is turned on, the heater is set as follows:
> Position ∫temperature™ and ∫blower∫ to ™stage 0™
> Air circulation 30%, fresh air 70%
> Floor board 30%, front windshield 70%
1.3 Engine independent auxiliary heater *

The engine independent heater is used to heat the driverπs cab if the engine is not running and as an au>
xiliary heating system in case ambient temperatures are extremely low and the engine heating system
is not sufficient.
Please refer to the more detailed auxiliary heater operating instructions issued by the heater manufac>
turer.
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DANGER: The heater may not be operated in closed areas, such as garages or works>
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hops, not even with timer operation * or Tele start *.
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If this rule is not followed, there is a danger of poisoning or suffocation!
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The heater must be turned off at gasoline or refueling stations.
If this rule is not followed, there is a danger of causing an EXPLOSION!
The heater must be turned off in areas where combustible vapors or dust
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may form (such as near fuel, coal, wood dust, grain or similar storage areas).
There is a danger of EXPLOSION !
The driverπs cab can be heated via the engine independent auxiliary heater by pressing the control ele>
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ments on the keyboard (see paragraph 1.1)

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Operation:
> Turn on the auxiliary heater by pressing the button (94) .
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Function check in the button (94) lights up.

Indicator light (130) in the indicator unit lights up.
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Note: When the auxiliary heater is turned on, the blower is set automatically to "Stage 1"
to prevent the auxiliary heater from overheating.
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Turn off the auxiliary heater:

> Turn the auxiliary heater off by pressing button (94).
Indicator light in the button (94) turns off.
Indicator light (130) in the indicator unit turns off.
Note: If the auxiliary heater runs after, the indicator light (130) in the indicator unit does
NOT turn off. The keyboard remains on, even if the ignition key is turned off. When
the after run is completed, the indicator light turns off, and the keyboard turns off
automatically.
CAUTION : The main battery switch may only be turned off after the heater has stopped
running!
1.3.1 Digital clock with thermostat *

For a detailed description of the digital clock refer to the manufacturerπs operating manual.
Set the desired turn on time, temperature and operating time for the heater on the digital clock!(15) .
*Optional
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1.3.2 To bleed the system

When draining the engine coolant fluid, the contents of the heating system must also be drained , becau>
se the engine coolant system and heater system are part of the same single circuit. When refilling the
system, it must be bled carefully, the quickest way is to bleed the system with 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 auxiliary heater .
> Start the engine, as described in chapter 3.04, OPERATION.
> Set the temperature for the driverπs cab via button (95) to "Stage 3" .
> Watch the expansion tank if air bubbles rise up.

> If no more air bubbles are visible in the expansion tank, set the button (96) for the temperature in the
driverπs cab to ™stage 0™, which bleeds the heater circuit. If no more air bubbles rise in the expansion
tank, then it is also bled properly.
CAUTION: The valve on the bleeder line must always be closed in operation!
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The main battery switch (25) may only be turned off after the heater has
stopped running!
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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 pro>
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tect the heater control unit. Attach the positive cable to the vehicle ground.
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Note: During the summer month, let the auxiliary heater * run once a month, for at least 15
to 20 minutes.
Maintain the auxiliary heater according to the enclosed manufacturerπs Operation Ma>
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nual.
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1.4 Air conditioning system*

The driver's cab can be air conditioned.
Note: For detailed description of the air conditioner, refer to the manufacturer's operation ma>
nual.
1.4.1 Putting the system into service
Prerequisite:
The battery master switch is turned on.
The engine is running.
> Close the doors an dwindows in the driver's cab.

> Set the temperature to stage 0 (cold) via the button (96) .
Press the button to show the temperature stage on indicator (64) .
> Set the fan speed with button (97) or (98) at least to stage 1.
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The fan speed is shown on indicator (64) by pressing the button.
> Turn the air conditioner on with button (102). The function check on the button lights up.
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> Press the button to increase (97) / decrease (98) the air flow (103) / fresh air supply (104) and fan
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speed, which changes the air conditioning output.
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Note: Air conditioning system * and added heater * can be turned on independent of each ot>
her.
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1.4.2 Maintenance
see manufacturer's operation manual.
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2. Heater / crane operatorπs cab

The crane operatorπs cab can be heated with an engine independent heater * .
2.1 Engine independent auxiliary heater *

Please refer to the more detailed auxiliary heater operating instructions issued by the heater manufac>
turer.
DANGER: The heater may not be operated in closed areas, such as garages or works>
hops, not even with timer operation * or Tele start *.
If this rule is not followed, there is a danger of poisoning or suffocation!
The heater must be turned off at gasoline or refueling stations.

If this rule is not followed, there is a danger of causing an EXPLOSION!
The heater must be turned off in areas where combustible vapors or dust
may form (such as near fuel, coal, wood dust, grain or similar storage areas).
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There is a danger of EXPLOSION !
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2.1.1 Operation
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> Set the blower switch (226) to stage 1.
> Set the temperature regulating valve (227) to "WARM" and turn the auxiliary heater on via switch
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(293) , the indicator light (294) lights up.
Now the coolant fluid can be regulated via the temperature regulating valve (227) and the air flow can
be regulated via the blower switch!(226) .
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2.1.2 Digital clock * with thermostat

For a detailed description of the digital clock refer to the manufacturerπs operating manual.
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Set the desired turn on time, temperature and operating time for the heater on the digital clock!(308) .
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> Preselect the air distribution upward / downward by opening / closing the air vents,
> Set the temperature regulating valve (227) to "WARM" .
> Close both doors and all windows.
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2.1.3 To bleed the system

When refilling the heating system, it must be bled carefully.
> Add coolant via the expansion tank for the heating system, according to the lubrication chart.
> Set the temperature regulating valve (227) to "WARM" .

> Watch the expansion tank of the heating system if air bubbles rise up.
> If no more air bubbles rise in the expansion tank, then it is bled properly.
CAUTION: The main battery switch 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 pro>
tect the heater control units*. Attach the positive cable to the vehicle
ground.
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Note:
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During the summer month, let the auxiliary heater * run once a month, for at least 15 to 20 minutes.
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Maintain the auxiliary heater according to the enclosed manufacturerπs Operation Manual.
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2.2 Air conditioning system * for the crane operatorπs cab

The crane operatorπs cab can be cooled with an air conditioning system.
Refer to the Operating Manual * supplied by the air conditioner manufacturer for a more detailed des>
cription.
Operation
> On the crane chassis, turn on the main battery switch (29) ,
> In the crane cab, turn on the ignition for the crane engine,
> Preselect the air flow to the top or bottom via the air vents ,
> Close both windows and the cab door.
> Set the regulator (228) for fresh air / air circulation to ™air circulation™.
Note: The air intake opening for air circulation must be clear.
> Turn on the air conditioning system via switch (292) , the illuminated indicator light (281) shows that
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the system is operational.
> Preselect the air flow to the top or bottom by opening / closing the air vents.
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> Turn the blower on via rotary switch (226) ,
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> adjust the temperature with regulator (229) . ER
C A U T I O N : The main battery switch may only be turned off after the heater has stopped
running!
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If arc welding must be done on the crane, remove the negative and positive bat>
tery cable from the vehicle and the crane superstructure batteries to protect the
air conditionerπs control units*. Attach the positive cable to the vehicle ground.
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Maintenance of the air conditioning system*

Maintain the system according to the manufacturerπs Operation Manual.
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6.02 EMERGENCY CRANE CONTROL 025389>00
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1. Crane chassis
In case of a failure of the electrical control of the solenoid valves for the hydraulic outrigger support
system and the rear axle steering, they can be manually controlled.
To actuate the individual movements, 2 each solenoid valves for the support system are installed on the
rear two sliding arm boxes and under the driver's cab and an additional solenoid valve for the rear axle
steering is installed on the right rear.
2 solenoid valves (Y23 and Y24) are installed on the left hand side under the vehicle, on the vehicle
frame. These two solenoid valves are installed for the hydraulic supply of the solenoid valves (Y22, Y26,
Y27, Y28, Y29, Y30, Y31, Y32, Y33)
Note: The emergency control of the hydraulic support system can only be actuated from the
opposite side of the vehicle.
C A U T I O N :When extending or retracting the outrigger support system without visual

contact of the corresponding support cylinder or the sliding arm, another
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person must be available to guide the operator.
When extending or retracting the sliding arms, it must be assured that there are
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no persons or objects within the danger zone.
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Prerequisites for the emergency control:
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The engine must be running and the hydraulic system in the crane chassis must be functioning.
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1.1 Emergency control of hydraulic outrigger support system
Note: For every movement, the solenoid valves (Y23 and Y24), as well as the solenoid valves
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(Y26, Y27, Y28, Y29, Y30, Y31, Y32, Y33) assigned for that movement must be
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actuated.
> On the front side (A) of the two solenoid valves (Y23 and Y24), remove the union nut (a) with dust cap
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(b) and actuator pin (c).

> Screw on the emergency control union nut (S) onto the solenoid valves.
The crane hydraulic is thereby switched over to the crane chassis.
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> Carry out the same procedure on the corresponding solenoid valve.
The hydraulic supply is thereby established.
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> After completion of the emergency control, remove the emergency control union nut (S) immediately!
Note: As soon as the pressure exerted by the emergency control union nut on one of the
solenoid valves stops, the movement stops.
> After emergency control, reinstall the union nuts (a) with dust caps (b) and actuator pins (c) in initial
position.
1.2 Emergency control of hydraulic rear axle steering

The emergency control of the rear axle steering (Y22) can be carried out accordingly.
The emergency control of the rear axle steering is used to return the rear wheels into ∫straight forward∫
position, in case the electrical control should fail while the wheels are turned in, preventing them from
being returned to straight forward direction. Letting the crane roll slowly facilitates the return. See also
chapter 3.04, ∫DRIVING ON PUBLIC ROADS∫.
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1.3 Functional diagram hydraulic support / rear axle steering
Function Solenoid valve actuate (A) actuate (B)
Axle suspension / support / winch Y23 added $

Superstructure Y24 added $
Sliding arm, right front Y27 retract extend
Support cylinder, right front Y32 retract extend
Support cylinder,left front Y30 retract extend
Sliding arm, left front Y29 retract extend
Sliding arm, right rear Y26 retract extend
Support cylinder, right rear Y33 retract extend
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Support cylinder, left rear Y31 retract extend
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Sliding arm, left rear Y28 retract extend
Rear axle steering Y22 wheels turned to left wheels turned to right
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2. Crane superstructure
2.1 Emergency control in case of LICCON system failure

If the LICCON system is not opertiona, the crane can still be taken down.
Prerequisite:
The engine is running.
The hydraulic system is fully functioning.
> Open the control box cover on the rear of the crane oeprator's cab.
> Remove the cover.
> Unplug the plug >X21B from >X21.
> Plug in plug >X21B in >XNOT.
> Hold the keyed switch (D) to the "right".

> Take down the crane equipment.
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D A N G E R : In emergency operation, all safety devices are bypassed !
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Bypassing the LICCON system is only permitted in emergency situation and
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only by authorized personnel. ER
Crane operation with bypass is strictly P R O H I B I T E D !
All crane movements must be carried out with utmost care, and another person
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must monitor the movements. This person must be in direct visual contact with
the crane operator!
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2.2 Self locking button (K) to bypass the electric crane control
Note: The button "K" (>S82) is used to bypass the electronic crane control in case of alternator
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failure, it is not part of the emergency control.
If the engine is not running or if the alternator fails, then the electrical crane control can be turned on
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by actuating the bypass button "K" (>S82). In this case, the battery voltage may not drop below 20 Volt.
The bypass button is in the control box of the electric crane control (crane operatorπs cab).
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> Turn the bypass button "K" to position ∫I∫ (down).
Note: When the ignition is turned off, the bypass switch (>S82) returns to the "OFF" position.
C A U T I O N :For crane operation, the bypass button "K" must be turned off.
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7.00 SERVICE AND MAINTENANCE 021680>00
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021680>00
Chapter 7
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Service and Maintenance

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7.01 SERVICING AND MAINTENANCE 021681>05
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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
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available and operational.
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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.
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Also we will train your maintenance personnel in all questions relating to crane servicing and repairs because
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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.
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A further benefit of our After Sales Service are our special Service Advisors who are only a telephone call away
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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∫.
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Our Field 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
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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.
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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, accepts no liability for utilization of

replacement parts not manufactured originally by Liebherr. This applies to the
functioning capability as well as to the actual parts!
391
Cleaning and care of the crane
Care of sound>absorbing mats

Sound>absorbing mats in the engine area or other noise sources are an integrated part of the total design . They
have the task, together with all sound>aborbing material and the constructive design of the machine, to keep
the noise levels for vehicles > as specified by law > as well as noise levels on the work place within the specified
levels. They are an intergral part of the machine design and permission to operate. They may not be removed
and in case of damage, they must always be replaced with Original spare parts.
They are designed to be maintenance free. They are made with dirt, oil and water repelling surfaces, they are
fire retardent and in part, depending on the application, even non>flamable .
Therefore, these parts need no special care. Light deposits of dirt can be overlooked, since the acoustical
properties of the mats are not reduced.
Crude dirt deposits can be removed with suitable tools (soft plastic scrapers). Tools with sharp edges are
unsuitable. Steam cleaners may only be used with utmost case, i.e. with sufficient distance to the sound>
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absorbing mats and low water pressure. Cleaning solutions may not be used for cleaning.
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It is especially dangerous if contaminants contain solutions or foreign matter, such as oils (engine oils, gear oils
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or hydraulic oils) and fuel, since these substances could ignite and / or significantly affect the flame retardent
qualities of the mats.
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For that reason, if any such substances are found on these mats, the mats must be removed and replaced
immediately with Original replacement parts.
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Care of the driver's cab and the crane operator's cab

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The steering wheel, center console, control panel cover, floor covering and dirty upholstery in the driver's and
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crane operator's cab should be cleaned with warm water mixed with dish detergent.
Do not use scouring pads!

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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.
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Maintenance work on the crane chassis is carried out according to the number of operating hours or
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kilometers covered. ER
Maintenance work on the crane superstructure is carried out according to the number of operating hours
only.
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7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS 025010>01
regular maintenance every minimum inspections

1st main>
main>
tenance
250 hrs. 500 hrs. 1 000 hrs. tenance
after
5 000 km 10 000 km 20 000 km annually daily weekly
" Diesel engine
¥
> Check oil level
For all further maintenance

work, observe
manufacturer's instructions
> Check coolant level in
E
¥
equalizing reservoir
C
every
VI
> Change coolant liquid ER 2 years
" Air filter
> Observe monitoring device ¥

-S
> Clean the filter element

(Observe the guidelines if
issued by the engine necessary
R
manufacturer!)
ER
> change the filter element

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

¥
E
oil level
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> 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.
394

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

> Check oil pressure ¥
> Check operating temperature ¥
> check for proper seals ¥
> Check / tighten fastening
screws
¥
E
C
> Oil change 100 hrs. ¥ ¥
VI
> Replace oil filter 100 hrs. ¥ ¥
" Power shift gearbox
ER
-S

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

ER
" Automated transmission

BH
> Oil change 90 000 km ¥

> Replace oil filter 90 000 km ¥
E
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1st main>
main>
tenance
after
" Displacement gear

> check fastenings ¥
> oil change 1 000 km ¥ ¥
" Distribution gearbox
> Oil change 1 000 km ¥ ¥
E
C
> Check for proper seals ¥
VI
> Check / tighten fastening
¥
screws
ER
> Check road/off>road gear ¥
switchover function
-S
> Check all>wheel drive switch>

¥
on function
R
> Check tachometer connection ¥

ER
> Clean ventilation nipple ¥ ¥

" Pump distributor gearbox
BH

> check fastenings ¥
E
> oil change 200 h ¥ ¥

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

drive shafts) and bearing
bracket
every
> Grease 25 000 km
2 years *
> Check flange screws, tighten

100 km 2500 km
if necessary
" Driven axles
E
> Test for proper seals ¥
C
> Oil level check at axle
VI
housing, differential housing ¥
and wheel hubs
ER
> Grease steering knuckle every
25 000 km
bearings 2 years **
-S
> Check mounting tightness ¥

every
R
2 years
ER
> Replace grease filling in

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

¥ ¥
housing
E
" Axle drive DK>7

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every
2 years
" Non>driven axles
> Grease steering knuckle every

25 000 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.
397

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 ¥
E
> Check condition and
¥ ¥
C
mounting
VI
> Drain off water and
¥ ¥
contamination
ER
> Clean pre>filter for fuel
¥ ¥
auxiliary pump
-S
" Tires
> Check lug nut tightness,

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

" Brake system
BH
> Check function of service

¥
brake and parking brake
E
> Check brake lining wear ¥

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> 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
5 000 km ¥
guidelines)
* in hot regions, 2 ¥ per year
398

1st main>
main>
tenance
after
" Compressed air system

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

> Check pressurized air
reservoir automatic water ¥
E
bleeder valve functioning
C
> Replace air dryer granulate
cartridges
¥
VI
> Clean air dryer
¥
ER
pre>filter
" Axle suspension

-S
> Check hydraulic tank oil

¥
pressure
R
> Check hydraulic system seals ¥

ER
> Blocking cylinder function ¥

test
> Replace oil filter 100 h ¥

BH
> Check hydraulic pressure, set

if necessary
¥
E
> Check pressure reservoir

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¥* ¥*
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
399

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

> Check hydraulic tank oil
¥
pressure
> Check sliding arm

¥
movement / oil
E
> Grease fleyer chains ¥
C
> Oil sliding arm keeper pins ¥
VI
> Oil operating level fork heads ER ¥
> Check level, adjust if nec. ¥
> Oil change (oil sample) ¥ ¥
-S
> Replace hydraulic filter 100 hrs. ¥

> Replace bleeder filter on
100 hrs. ¥
hydraulic tank
R
> Check hydraulic system

ER
¥
operating pressure
" Hydraulic accessories,

BH
e.g. ventilator, ballasting

cylinders
E
> Check hydraulic operating ¥

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

> Check indicator light
¥
function
> Check motor brake

¥
activation
> Check retarder activation ¥

" Emergency control
> Check emergency control

¥
function
400
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)
E
> Grease track rollers (with oil
C
¥
lubrication)
VI
> Grease support rollers ¥ ER
> Grease guide rails on sliding
¥
piece
" Track shoes

-S
> Check shoe tension, tighten if

necessary
¥
R
> Inspect for fastening and

¥
ER
damage
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7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE 025011>01
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1st main>
main>
tenance
tenance
after 125 h 250 h 500 h 1 500 h annually daily weekly
" 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
E
" Air filter
C
> check dust indicator ¥
VI
> clean resp. change
according to manufacturers
ER
maintenance instructions
" Slewing ring
-S
every 3
> lubricate
months *
> inspect and check bolts for
R
200 hrs. ¥ ¥
tightness
ER
> check tilt play ¥ ¥

" Rope winches
BH
> inspect for leaks ¥

E
> check fastening bolts for

200 hrs. ¥ ¥
tightness
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3 000 every
> oil change
hrs. 4 years
" Propeller shafts
> check flange bolts ¥
> lubricate ¥ ¥
* if the crane is not moved
403

1st main>
main>
tenance
tenance
" Tension rods

> check condition ¥
" Overtopping guard struts
> lubricate pivots ¥ ¥
" Fall back cylinders
> inspect for leaks ¥*
> check preload pressure
¥ ¥
(nitrogen gas)
E
> check oil quantity ¥ ¥
C
" A bracket mounting
> lubricate ¥
VI
" Counterweight
ER
or
> check tightening torque of
1 000 km 10 000 ¥
fastening bolts
km
-S
" Ballasting system

R
" Rope drum contact rollers

ER
> grease guides ¥ ¥

" Rope pulleys
BH
> inspect and lubricate ¥ ¥

" Ropes
E
> inspect, grease if necessary ¥ ¥

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" Hook blocks

> lubricate ¥ ¥
* visual check before starting up the crane
404

1st main>
main>
tenance
tenance
" 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 ¥
E
C
VI
" Load moment limiter
ER
" Electrical system
> check cable connections and
¥*
-S
battery acid level

" Fuel system
R
> check for leaks ¥

> check condition and
ER
¥ ¥
mounting
> drain off water and
¥ ¥
BH
contamination
" Slewing gear transmission
E

LI
> check fastening bolts for

200 hrs. ¥ ¥
tightness
4 000 every
> change oil
hrs. 4 years
" Locking of the slewing
brake
> lubricate ¥ ¥
* in hot regions, 2 ¥ per year
405

1st main>
main>
tenance
tenance
" Pump distributor gearbox

> oil change 400 hrs. ¥ ¥
" Hydraulic system
> check for leaks ¥
> replace control and feed
circuit pressure filter ¥
200 hrs.
element
E
> replace returnline filter
C
element (cranes with open 200 hrs. ¥
VI
hydraulik circuit only) ER
> replace bleeder filter on
200 hrs. ¥
hydraulic tank
> check hydraulic oil
400 hrs. ¥ ¥
-S
(oil sample test)

" Hydraulic cylinders
R

" Hydraulic pressure
ER
reservoirs (nitrogen gas)

> check preload pressure ¥* ¥*
BH
" Compressed air system

E
> Check operating pressure ¥

LI
> Check shutdown pressure ¥

> Check automatic water
¥
bleeder valve functioning
> Replace air dryer granulate
¥
cartridges
> Clean air dryer
¥
pre>filter
" Emergency control
> check emergency control
¥
function
* refer to chapter 7.05, MAINTENANCE INSTRUCTIONS CRANE SUPERSTRUCTURE
406

1st main>
main>
tenance
tenance
" 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
E
" Pneumatic boom locking
C
> clear the air filter for
VI
¥ ¥
compressed air
> check boom locking holes ¥ ¥
ER
> lubricate boom locking bolts ¥ ¥
" Telescopic boom system
-S
TELEMATIC
> check telescopic boom for
¥
distortion, cracks and leaks
R
> check telescopic cylinder for

¥ ¥
ER
proper condition
> check push out tong for
¥ ¥
proper condition
BH
> check locking pins and

locking bores for proper ¥ ¥
E
condition
> check inner and outer glide
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surfaces for proper condition

¥ ¥
> lubricate glide surfaces ¥*
* and as necessary
407
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE 024235>02
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1. Maintenance and repairs in the engine area

When performing maintenance and repairs in the engine area, observe the following:
CAUTION : When working on the fuel system (for example when changing the filters),
the two shut off valves (in travel direction on the left, behind the 1st axle)
must be closed to shut off the supply and return fuel lines to prevent the fuel
tanks from running dry.
All maintenance tasks on the engine, fuel, oil and air filters must be
completed as noted in the separately issued ªMercedes Benz´ industrial
engine manual.
Never step on the fuel lines.

When changing the filter, spread out a layer of absorbent material before loosing the filter to absorb any
fuel which might drain out.
Dispose of the absorbent material properly.
DANGER: YOU MUST make sure that no Diesel fuel is spilled in the engine area and it
E
remains free of Diesel fuel, otherwise there is a risk of causing a
C
Fire!
VI
When you change the filters and bleed the system, you must assure utmost
ER
cleanliness. Any fuel spills must be dried up.
-S
1.1 Check the engine coolant (fig.1)
DANGER: Check the engine coolant only when the engine is cold! The radiator cap
R
must be cool enough to touch. Avoid contact with components containing

ER
coolant, since it could cause SEVERE SKIN BURNS !
Refill the coolant reservoir only via the filling nozzle !

BH
> Turn the radiator cap on the filling nozzle of the radiator tank / reservoir to the left by one notch to
E
release the pressure.

> Remove the radiator cap.
LI
> If necessary, add coolant according to the lubrication chart until it runs over.
> Reinstall the radiator cap and tighten.
IMPORTANT : If any coolant has been lost, the coolant must be replaced in the same ratio
according the the LUBRICATION CHART.
Mixture ratio: 50 Vol % Corrosion and antifreeze fluid

50 Vol % Fresh water
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1.2 Check oil level and filters on the engine (fig. 2)

The oil must be between the minimum and maximum ( MIN and MAX) mark on the dipstick.
CAUTION: For all maintenance work, make sure you assure utmost cleanliness, so no
dirt or contaminants enter the internal engine areas.
> To check the oil level in the engine, the crane must be in horizontal position.
> Turn the engine off and wait 2 to 3 minutes until the oil has drained into the oil pan.
> Insert the dipstick, wipe it off, reinsert it and pull it out again.
> After checking the oil level, make sure to push the dipstick in firmly.
> If necessary, add engine oil according to the lubrication chart.
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.
E
1.2.1 To change the oil :
C
Refer to the separately issued !Mercedes Benz industrial engine manual.
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1.3 Air filter

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 (133) on the instrument panel in the
driverπs cab will light up. In that case, clean or replace the filter elements.
CAUTION : The engine must be turned off when cleaning, maintaining or repairing
items. Do not start the engine when the filter element is removed!
1.3.1 Change the main filter element

To remove the main filter element:
> Pull out both hooks on the bottom of the filter housing, remove the bottom of the housing (fig. 1).
> Pull the main filter element by turning it slightly (fig. 2).
To clean the main filter element (fig. 3):

> To clean the filter, attach a 90∞ elbow tube to the air gun. The tube must be long enough to reach the
bottom of the cartridge.
E
> Using dry pressurized air (max. 5 bar), move the tube up and down in the cartridge and blow air from
the inside to the outside until all dust has been eliminated.
C
VI
Note: The main filter element may be cleaned up to 5x . However, it must be replaced at
least once every two years.
ER
IMPORTANT : Do not wash or brush out the main filter element .
When blowing out the dust, make sure no dust gets on the inside of the main
-S
filter element.
To install the main filter element:

R
ER
Note: Before reinstallation, check the cleaned main filter element, to make sure the paper
pleats and the rubber seals are not damaged (use a light source to shine though the
paper, see fig. 4).
BH
CAUTION : DO NOT use a damage main filter element. In case of doubt, replace the
main filter element .
E
> Carefully slide the main filter element into the upper part of the filter housing.
LI
When the bottom of the housing is closed, the main filter element is automatically pushed into the
correct position .
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1.4 Check the oil level and filter in the powershift reversing gear (Fig. 3)
See also separate operating manual of the gear manufacturer.
1.4.1 Check the oil level
C A U T I O N : When checking the oil, make sure to observe all safety regulations per ß 6 of the
accident prevention regulations for drive gears / transmissions in Germany, and
all other applicable regulations in other countries. The vehicle must be secured
with wedges / wheel chocks to prevent it from rolling off.
Prerequisites:
> The vehicle is parked on level, horizontal ground.
> The gear is in neutral position.
> The engine is running at approx. 1000 RPM.
> The gear oil is at operating temperature (70 to 80 ∞C)
E
Procedure to check the oil level:
C
> Release the dipstick by turning it in counterclockwise direction, clean it off ,
VI
> Reinsert the dipstick and remove it again (at least 2x).
ER
The oil level is valid for 70 > 80 ∞C .
C A U T I O N :If the oil level has dropped below the "HOT" range in operating temperature (70
-S
to 80 ∞C), then oil must be added until the oil level is again between the range
marks.
If no oil is added, there is a danger of causing serious damage to the gears .
R
> Reinsert the dipstick and turn it in clockwise direction to tighten.

ER
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1.4.2 To change the oil
Prerequisites:
> The vehicle is parked on level ground.
> The engine is turned off.
> The gear oil is at operating temperature (70 to 80 ∞C).
Oil change procedure:

> With the machine at operating temperature, open the oil drain plug with seal ring and drain the old oil
into a suitable container.
Note: The oil can only be drained from the gear and the upper section of the transducer.
> Clean the oil drain plug with magnetic insert and the seal ring surface on the housing, reinstall with
new O>ring.
E
> Add oil according to the lubrication chart on the dipstick until it reaches at least to the ª MIN COLD´
mark.
C
VI
C A U T I O N :Make sure that oil and filter are absolutely clean, observe utmost cleanliness!
In any case, the marks on the dipstick are the deciding measure!
ER
> Start the engine and let it run at low idle RPM.
> Shift through all travel switch positions.
-S
> Check the oil level again at operating temperature (70 to 80 ∞C), add oil, as needed.
C A U T I O N :Always observe utmost cleanliness, to prevent any dirt infiltration, so that the
internal area of the gear is not contaminated .
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ER
1.4.3 Filter change

BH
When changing the filters in the main oil supply, it must be assured that no dirt or contaminated oil
enters the circuit. In addition, cover and / or protect the parking brake to prevent it from being splashed
with oil. Do not use force when inserting the filter.
E
Note: Change the fine filter (pressure filter) every time you change the oil.
LI
Handle the filter carefully when installing, transporting or storing it!
C A U T I O N :DO NOT install damaged filters!
Install the filter as follows:

> Lightly lubricate the seal with oil .
> Screw in the filter until it contacts the sealing surface, then tighten it by hand by turning it another
˝ to Ω turn.
> Add oil.
> Start the engine.
> Check the oil with the engine running (approx. 1000 RPM) and with the transmission at operating
temperature.
> The oil level is correct at 70 to 80∞C .
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2. Check the oil level in the hydraulic tank (Fig. 6)

for Steering system, support and suspension hydraulic, crane hydraulic
With the crane in horizontal position, the oil level must be in the center of the sight gauge.
If no il is visible in the sight gauge, oil as specified on the lubrication chart must be added until the oil
level is again in the center of the sight gauge.
CAUTION : When checking the oil level :

> The luffing cylinder, the telescoping cylinder, the outrigger cylinders as
well as the sliding arms must be retraced and the vehicle must be lowered to
the lowest axle suspension level.
> If you would check the oil in extended condition and with the vehicle at a
high axle suspension level, you would run the risk of adding too much oil
and overfilling the system.
When the cylinders are retracted, the oil is discharged through the bleeder
valve.
Do not retract the cylinders too quickly, this can cause damage to the oil
E
tank.
C
D A N G E R: If the oil level has dropped below the minimum mark, oil must be added
VI
according to the lubrication chart.
If the oil level is too low, the hydraulic pump can be damaged, which
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increases the risk of causing an accident, due to a decrease in steering
ability.
In addition, the outrigger cylinders cannot be fully extended and the vehicle
-S
cannot be leveled.
To add oil
> Add oil according to the lubrication chart, until it is visible in the center of the sight gauge ( Fig. 6).
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CAUTION : Use a fine mesh strainer when adding the oil.

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2.1 Air intake and bleeder filter (Fig. 5)

> Open the turn cap and check the filter visually for contamination.
If the filter is very dirty, it must be replaced.
> Close the cap again.
Return filter (7) on hydraulic tank

The return filter is equipped with a maintenance indicator *.
If the red bar is visible when the oil is at operating temperature (check weekly), then change the filter
insert.
Filter change
> Loosen both filter covers and catch any oil in a container.
> Remove both filter covers.
E
> Remove both filter inserts and dispose of them properly.
> Flush out both filter housings.
C
> Clean the sealing surfaces on the covers and the filter housing.
VI
> Insert new filter inserts in the housing.
> Lightly oil the rubber seal rings in the covers.
ER
> Set both covers again onto the housing and tighten.
> Start the engine and check for leaks.
> Then recheck the oil level, add more oil if necessary.
-S
3. Air dryer, pressurized air and brake system(Fig. 4)

R
The air dryer for the pressurized air and brake system are maintenance free.
ER
The cartridge should be replaced once a year.

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4. Check the oil level in the planetary gears of the wheel hubs (Fig. 8)
Check the oil level

> Align the crane, with blocked axle suspension, via the outriggers until it is in horizontal position and
raise it until the 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.
C A U T I O N :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. .
4.1 Check the oil level in axles (axle casing)
E
Check the oil level
> With the crane in horizontal position.
C
> The oil level in axle casing for the driven axles must be to the lower edge of the corresponding
VI
inspection port. If necessary, add oil according to the lubrication chart.
ER
5. Hydraulic hoses
-S
The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in
safe working condition.
R
Changing hoses
ER
The hoses and lines must be replaced periodically.
On the basis of our experiences with mobile cranes, we recommend the maximum usage:
BH
> in severe operation

at high operating temperatures and frequent movements approximately 3 years
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> in normal operation approximately 6years

> in assembly operation with rare high output frequency approximately 12 years
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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!
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6. 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: :
> The axles must be suspended, the button (80) is turned off.
> Push the button (69, 70, 85, 86)+confirmation button (93) until the oil has drained from the
diaphragm reservoirs .
E
> Check the pretension pressure with a testing and inflation device and correct the pressure, if
necessary.
C
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DANGER : To fill the reservoirs, DO NOT use a i r or o x y g e n. This can cause an
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EXPLOSION !
The pressure in the nitrogen cylinder may not exceed the maximum
-S
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.
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After the test :

ER
> Press button (79) "LEVEL" , until the function indicator in the button blinks
The vehicle is automatically raised via the axle suspension cylinders to the required height for on road
travel.
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7. Tires / wheels
DANGER : The risk of having an accodent are greatly increased if you drive a vehicle
with damaged tires, insufficient tire tread and different air pressure in the
tires!
7.1 Check
> Check condition of tires (including spare *), check for damage.
> The depth of the tire tread (including spare*) may not fall below the minimum value, according to law.
> Tire pressures (including spare*) must match the pressure given for the type of tire : see chapter 1.3,
TECHNICAL DATA .
Note: The tire pressure must be checked when the tires are cold.
7.2 To inflate tires
E
Before inflation of tires, make sure that the tire is seated properly on the rim and that the lock ring is
seated properly.
C
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CAUTION : The highest permissible air pressure may not be exceeded!
ER
DANGER : When adding air to the tires on the vehicle, make sure that nobody is within
the danger zone to prevent injury due to flying parts.
-S
7.3 Tire change

> Loosen the wheel lugs on the defective wheel and support the crane properly.
R
For support procedure, refer to chapter 3.05, THE CRANE AT THE JOBSITE.
ER
> Lift the spare tire with the crane, place it next to the defective wheel and secure it to prevent if from
rolling off or toppling over.
BH
Note: Do not lay wheels down on the ground, they are very heavy and are hard to lift up
again.
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> Remove the wheel lugs and replace the defective wheel with the spare .
> Reinstall the wheel lugs and tighten them crosswise. See also chapter 9.02, paragraph 7.
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C A U T I O N : Do not overtighten the wheel lugs !

The max. permissible tightening torque is 600 Nm.
Check the wheel lugs after the first 50 and 100 kilometers to ensure they are
seated tightly.
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8. Tilt the cab

The driver's cab can be tilted forward with the own crane by approx. 40∞ to facilitate installation and
removal tasks.
However, before the driver's cab may be tilted,

> the 2 stabilizers and bumpers (1) on the rear of the cab must be unbolted,
> and any cable mountings or mounts for hose (2) must be released on the underside of the cab.
DANGE R: The cab can be tilted to no more than 40∞ before it hits the bumper.
When tilted, the driver's cab must be secured by propery supports to prevent
it from falling down.
There is an increased risk of ACCIDENTS!
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9. 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.
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If any damaged rim components are found, they must be replaced immediately with new components.
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If chipped paint or minor rust is found, the rust layer should be removed and the area should be repaired
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with commercially available paint. You must make sure that the surface is smooth, especially on the
tire seating surface.
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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
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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
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changes in the material, which can lead to sudden fractures.

ER
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10. Wheel alignment

The wheel alignment must be checked in regular intervals.
If this is not done, the tires will wear prematurely.
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Recheck the wheels if the tires had been subjected to greater than normal stress, for example, if they hit
the curb.
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Note: The wheel alignment can only be checked by qualified and especially trained
personnel.
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11. 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
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the alternator.
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The electrolyte level in the batteries must be checked once a month, in the summer and in warm
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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
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of the plates. Add distilled water, if necessary.
C AU T I O N : Do not use a metal funnel to add distilled water.

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If distilled water has been added, wait 1/2 hour and then check the specific gravity of the battery acid.
For this test, the acid temperature should be as close as possible to +20∞C ( 68∞ F) .
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ER
Specific gravity
Condition of battery charge
[kg/dm3]
1.28 well charged
BH
1.20 half charged, recharge

1.12 dead, recharge immediately
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The battery must be especially well charged before and during the cold season, since the electrical
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power consumption increases as the battery performance decreases.
C AU T I O N : If the batteries must be recharged, use DC current only, the current may
never be higher than 1/10th of the battery capacity.
E x a m p l e: 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.
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7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE 023365>01
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1. Central lubrication system

The crane superstructure is equipped with a central lubrication system. It is sufficiently sealed to
permit the use of car washes or steam cleaners .
All grease fittings on the slewing ring, the bearing of the pivot section, the luffing cylinders and the
hoist winches are supplied with the correct amount of grease automatically, depending on operating
hours.
The lubrication time is 1 minute, in 3 hour intervals.
CAUTION: If the crane has not been moved for longer than 3 months, use an external
lubrication pump every 3 months and lubricate on the grease fitting (3) until
grease emerges on all lube points.
Then repeat the corresponding crane movement several times and repeat
the lubrication procedure .
1.1 Components of the system , fig. A
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Pos. Description
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1 Grease container
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2 Grease fitting > To fill the central lubrication pump
3 Grease fitting > To fill the lube lines
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4 Pump outlet
5 Pressure relief valve
6 Pump element
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7 Button
8 Control
9 Illuminated diode (yellow)
10 Switch > rest period (hrs.)
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11 Switch > lubrication time (minutes)

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12 Distributor combination progressive 3/4

13 Distributor combination progressive 3/5
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1.2 To set the lubrication time and rest period

> Turn the ignition for the crane engine on, when the ignition is turned on, the yellow diode (9) lights up
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for approx. 2 seconds and shows functional readiness of the control (8) .
The yellow diode (9) on the engine cover blinks during the lubrication procedure, in 0.5 second intervals.
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The lubrication time and rest period is set at the factory. The times can be changed, if necessary, via the
switches (10 and 11).
1.3 Function check

> With the ignition turned on, trigger 2 to 3 additional lubrication impulses to determine if grease
emerges on all lube points.
> If the system is blocked, but the electric pump is functioning properly, grease emerges via the pressure
relief valve (5) . It is used to secure and monitor the system .
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1.4 Access to the automatic lubrication (intermediate lubrication ).

> With the ignition turned on , actuate the red button (7) on the pump motor cover .
This allows for additional lubrications, for example to lubricate the crane again after washing it or to
fill grease lines again with grease after a repair.
1.5 Fill the grease container (1)

> Use a commercially available grease pump to fill the system via a grease fitting (2) on the central
lubrication pump.
CAUTION: Make sure that the grease container (1) is always filled with grease, as
specified on the lubrication chart.
When filling the grease container, observe utmost cleanliness!
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1.6 To bleed the system
If the grease container (1) has run dry, then it might be necessary to bleed the system.
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> Fill the grease container.
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> Unscrew the main line from the pump outlet (4) .
> Trigger the additional lubrication impulse until grease free of air bubbles emerges on the pump outlet
-S
(4) .
> Reconnect the main line.
> Trigger additional lubrication procedure .
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1.7 Fill the lubrication lines

BH
> With an external lubrication pump, fill the lubrication lines via the grease fitting (3) or,
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> with the ignition turned on, press the red button (7) on the pump motor cover.
CAUTION: Refill the lubrication lines after every repair of lubricated components.
If this is not observed, the unit can run dry.
When filling the lubrication lines, observe utmost cleanliness!
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1.8 Troubleshooting the central lubrication system
Problem Cause Remedy
Pump does not work integrated, electronic control Replace lower part of the motor
defective housing
electr. lines interrupted replace electr. line
Pump defective replace pump
Pump works, but does not Air cushion in supply piston Bleed pump
supply grease fallen below min. fill level Fill grease container
Pump element defective Replace pump element
No grease collar on all lube Pump does not work see "Pump does not work"
points Rest period too high or lube time too Reduce rest period or increase lube
short time
System blocked see "Grease emerges on pressure relief
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valve"
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No grease collar on several lube Supply lines to distributors burst or Change lines
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points leak
Screw fitting leaks Tighten screw fittings or change them
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No grease collar on one lube Corresponding lube line burst or Change lines
points leaks
Screw fitting leaks Tighten or change screw fittings
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Pump speed drops High system pressure Check system / bearing points
low ambient temperature no damage
(lubricate once or twice in between)
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Grease emerges on pressure System pressure too high Check system

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relief valve Progressive distributor blocked Replace distributor

System blocked Fix plugged / stuck bearing point
Replace pressure relief valve
BH
Valve spring defective

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2. Check the maximum tilt play on the slewing ring

Ball bearing type slewing ring connections (KUD = Kugeldrehverbingungen) have bearing plays,
which ensure good running properties and functional safety. The operational readiness of the large anti>
friction bearings is only limited by the maximum degree of wear of the running system. The wear limit
can be determined by measuring the tilt play of the installed bearing.
The tilt play should be checked every 1200 operating hours or at least 1x annually.
Danger limit 2.6 mm (Replace slewing ring)

The danger limit is the absolute wear limit or the maximum permissible tilt play, where the operating
safety is not yet reduced. If the tilt play has reached the danger limit or has exceeded it, then the
slewing ring must be replaced.
Danger zone: 2.5 mm + 0.1 mm (Tolerance)
DANGER: If the maximum permissible play is being exceeded by more than 15%, there
is an increased danger of causing a serious ACCIDENT!
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The slewing ring must be replaced!
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2.1 Test procedure
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To obtain the least possible influence on the test values by distortions of the connecting design (chassis /
superstructure frame), the test should be made at close as possible to the test axis "Y" (center > bearing
running surface).
-S
If this is not possible, for example due to design reasons, then there might be a slight deviation of the
test results.
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Example of test deviation

ER
Distance of test axis "Y" to "X": for example +40 mm

Slewing ring diameter : 1304 mm (LTM 1030/2)
Tilt play: 1.6 mm
BH
Test deviation approx. 0.05 mm
a) Support the crane properly to wide support base and align it horizontally.
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b) Telescope the boom out to approx. 1/2 to 3/4 of the total boom length.
c) Luff the boom up all the way and turn the slewing platform to test point 1 .
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d) Attach the test gauge and set the pointer to "zero" .

e) Luff down the boom to the LML shut off limit.
f) Read the tilt play on the test gauge.
g) Repeat this test procedure (c to f) on test points 2, 3 and 4 .
Note: Measure only in lengthwise direction (symmetrical axis) of the slewing platform. The
test gauge should have an accuracy of at least 1/10 mm .
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3. Counterweight
After the first 1000 km, check the mounting screws, which were used to screw the counterweight onto
the slewing platform, to assure they are still seated tightly.
In addition, check them every 10 000 km or every 400 operating hours.
DANGER: If this is not observed, the tight seating of the slewing platform ballast is no
longer assured.
Due to oscillating movements during travel, the screws can be subjected to

fatigue., which can cause them to break.
This may cause the slewing platform ballast to fall down.
4. Slewing gear
Check the oil level on the sight gauge, with the slewing gear at a standstill.
CAUTION: Any loss of oil indicates a problem, which must be remedied immediately.
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5. Hoist gear
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Check for leaks (visually). ER
CAUTION: Any loss of oil indicates a problem, which must be remedied immediately.
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6. Hydraulics
6.1 Hydraulic hoses

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The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in
ER
safe working condition.

BH
6.2 Changing hoses

The hoses and lines must be replaced periodically.
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Due to our experiences with mobile cranes, we recommend the maximum usage:
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> 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.
440
6.3 Diaphragm reservoirs in the hydraulic system

The following diaphragm reservoirs are installed in the hydraulic system:
> Control pressure on control bar 10 bar
> Control pressure on basic block 8 bar
> Control pressure / hoist gear down 9 bar
> Control pressure / slewing gear (2 accumulators) each 9 bar
> Ballasting (2 reservoirs) each 40 bar
It is important that the pretension pressure given in the hydraulic schematic and on the accumulators is
available. It 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 pretension pressures must be
checked and corrected, if necessary.
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6.3.1 Prerequisite:
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> The crane hydraulic (or engine) is turned off, which relieves the fluid side of the diaphragm reservoir .
ER
Check the pretension pressure with a testing and inflation device and correct the pressure, if necessary.
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DANGER: To fill the reservoirs, DO NOT use a i r or oxygen. This can cause an
EXPLOSION!
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The pressure in the nitrogen cylinder may not exceed the maximum
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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.
BH
Note: In addition, you must observe any applicable national or local regulations !
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7. Telescopic boom
The internal sliding surfaces of the telescopic sections are lubricated via grease fittings in the bearing
pads .
These grease fittings are accessible from the outside via inspection ports on both sides of the telescopic
sections, if the telescopic sections are extended to 66.6% or 90%.
For the internal and external sliding surfaces, you must use a special grease, as specified on the
lubrication chart.
7.1 Telescoping cables

The telescopic sections II and III are pushed out synchronously with the telescopic cylinder by a cable
mechanism when the telescopic section I is being extended.
The telescopic sections II are extended via one 6 way flat cables (telescoping cables).
The telescopic section III is extended via two 2 way flat cables (telescoping cables).
The telescopic sections II and III are retracted by 3 return cables.
Via several inspection ports each on both sides of telescopic sections, it is possible to monitor the
telescopic and return cables without having to disassemble the boom.
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AC AU T I O N : If a new cable is installed, then it must be the same make and strength and
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the same diameter as the original cable.
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The telescoping cables ( flat cables) must always be replaced as a set.
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7.2 Maintenance
The telescopic boom should be removed after 20 000 operating hours or once every 10 years, to properly
inspect the bearings, telescoping and return cables, cable pulleys and the telescoping cylinders.
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The telescoping cables are pretensioned by the return cables.

ER
In case this pretension has disappeared due to stretching of the cables, then the return cables must be
retensioned.
BH
7.3 To retighten the return cables

Extend telescopic sections II and III by about 1 m and tighten the return cables on both sides evenly
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with the adjustment nuts (1) , until the return cables are tightened.
Visually check the cables via the side openings in the telescopic sections.
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The return cables should not slack more than 10 cm over the total length.
CAUTION: 1. When tightening the nuts (1) ,make sure not to twist the return cable.
2. After every retightening, the sliding synchronization of the telescopic
sections II and III must be checked.
7.4 To check the synchronization

Carefully telescope the telescopic sections I, II and III in. The stop of telescopic section II must touch
telescopic section first .
If this is not the case, the stop of telescopic section II must be reinforced by inserting a plate or by
reducing the stop of telescopic section III.
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7.5 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 16000 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.
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3. Sleeve
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If there is any damage, corrosion or deformation on the sleeve.
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4. Settling of cone (2) in sleeve (1)
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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:

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> dynamic changes of casting volume during cool down period

ER
> roughness of casting surface in the cable fitting

> stress which occurs during cable pull
BH
The settling of the cone can be determined by:

> measuring the settling
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Number of cable strands in Max. permissible cone settling (L max.) when cable
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casting must be discarded
2 3 mm
6>7 5 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.
445
7.06 LUBRICATION CHART AND FILLING CAPACITIES 023491>00
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7.06 LUBRICATION CHART AND FILLING CAPACITIES 023491>00
ca. Liter
Diesel engine OM 906 LA

Engine oil 33.0
Coolant 38.0
Fuel tank
Diesel fuel 310.0
Powershift transmission
ATF 27.0
1. Axle
Gear oil Axle drive 13.0
per wheel side 1.2
2. Axle
Gear oil Axle drive 13.0
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per wheel side 1.2
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Hydraulic tank *
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ATF 418.0
+ Hydraulic lines 100.0
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+ Radiator capacity 5.2
Total: 523.0
Slewing gear
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Gear oil 3.0
Hoist gear
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Gear oil 1.0

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Central lubrication system

Grease 2 kg
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IMPORTANT : The given quantities are only orientation values.

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The markings on dipsticks, control ports and sight gauges are indicative of the
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filling level .
* When checking the oil, all hydraulic cylinders must be retracted. The upper mark on the sight gauge may
not be exceeded.
IMPORTANT : Synthetic oils may not be mixed with mineral oils!
Explanation to the lubrication chart

1 Engine oil
2 Gear oil
3 ATF
4 Grease
5 automatic grease supply via the central lubrication system
447
7.07 SCHMIERSTOFFTABELLE 013098>10
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 $ 40 ∞C Æ + 30 ∞C
1 Dieselmotor SAE 10W>40 SAE 10W>40
diesel engine API CG>4 API CG>4
moteur Diesel ACEA E3>96, E4>96 ACEA E3>96, E4>96
LWE>Identnr.: 861005408 LWE>Identnr.: 861005408
unter $ 20 ∞C mit unter $ 20 ∞C mit
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Vorwßrmung Vorwßrmung
below $ 20 ∞C with below $ 20 ∞C with
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preheating preheating
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en>dessous de $ 20 ∞C avec en>dessous de $ 20 ∞C avec
pr±chauffage pr±chauffage
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2 Antriebsachse mit Differentialen, SAE 90 SAE 75W>90
Planetengetrieben und angebautem API GL 5 API GL 5
Verteilergetriebe ZF TE>ML 05 ZF TE>ML 05
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driving axle with differential, planetary LWE>Identnr.: 861901008 LWE>Identnr.: 861904014

gears and flanged transfer case
essieu moteur ° diff±rentiel, r±ducteurs
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plan±taires et bo¿te transfert

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ZF Achsantieb DK>7
axle drive ZF DK>7
entra¿nement des essieux ZF DK>7
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Fahrzeug Verteilergetriebe
transfer box
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bo¿te de transfert
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KESSLER (VG 1800 / 2400)

STEYR PUCH
(VG 1200 / 1600 / 2000 / 3800)
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
448


mode grue
3 ZF Lastschaltgetriebe SAE 10W>40 ATF II D
ZF power shift gears API CG>4 ALLISON C4
ZF bo¿tes de vitesse et d'inversion ACEA E2>96, E3>96, E4>96
(WG 120 / 150 / 180 / 181 / 200 / 201) ZF TE>ML 03 ZF TE>ML 03
ALLISON Versatzgetriebe (drop box)
ALLISON drop box unter $ 20 ∞C warmfahren unter $ 20 ∞C warmfahren
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ALLISON decaleur de bo¿te de transfert gemß˚ Betriebsanleitung gemß˚ Betriebsanleitung
below $ 20 ∞C warm up in below $ 20 ∞C warm up in
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CLARK Lastschaltgetriebe accordance with operating accordance with operating
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CLARK power shift gears instructions instructions
CLARK bo¿tes de vitesse et d'inversion en>dessous de $ 20 ∞C mise en>dessous de $ 20 ∞C mise
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en temp±rature en temp±rature
conform±ment aux conform±ment aux
instructions du manuel instructions du manuel
d'utilisation d'utilisation
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4 Automatikgetriebe ATF II D ATF II D

automatic transmissions ALLISON C4 ALLISON C4
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bo¿tes de vitesses automatiques ZF TE>ML 03 ZF TE>ML 03

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ALLISON
(CLBT 740 / 750 / 754 / 755) unter $ 20 ∞C warmfahren unter $ 20 ∞C warmfahren
(HT 755 / HD 4560) gemß˚ Betriebsanleitung gemß˚ Betriebsanleitung
BH
below $ 20 ∞C warm up in below $ 20 ∞C warm up in

ZF Wendegetriebe accordance with operating accordance with operating
ZF reversing transmission instructions instructions
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ZF bo¿tes d'inversion en>dessous de $ 20 ∞C mise en>dessous de $ 20 ∞C mise

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(WG 210 / 251 / 260 / 310) en temp±rature en temp±rature

conform±ment aux conform±ment aux
instructions du manuel instructions du manuel
d'utilisation d'utilisation
5 Automatisiertes Schaltgetriebe CASTROL Syntrans CASTROL Syntrans

automatic transmission LWE>Identnr.: 861903608 LWE>Identnr.: 861903608
bo¿te automatis±e
ZF>AS Tronic unter $ 35 ∞C Getriebe gemß˚
Betriebsanleitung
vorwßrmen
below $ 35 ∞C preheat gears
in accordance with operating
instructions
en>dessous de $ 35 ∞C
pr±chauffer la bo¿te de
vitesses conform±ment aux
instructions du manuel
d'utilisation
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mode grue
6 ZF Schaltgetriebe SAE 30 oder Getriebe‘l SAE 75W80/90
ECO>Split ZF TE>ML 02 ZF TE>ML 02
7 Seilwinde ISO VSG 220 ISO VSG 220

winch PGLP 220, DIN 51 502 PGLP 220, DIN 51 502
treuil LWE>Identnr.: 861901208 LWE>Identnr.: 861901208
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Drehwerksgetriebe nicht mischbar mit nicht mischbar mit
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slewing gears Mineral‘len! Mineral‘len!
m±canismes d'orientation do not mix with mineral oils! do not mix with mineral oils!
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non miscible avec des huiles non miscible avec des huiles
TA>Abspannwinde mit Klinkensperre min±rales! min±rales!
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TA>pawl guy rope winch
TA>treuil de haubanage ° cliquet
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8 Kranhydraulik ATF II D AVILUB Artic 32

fÂr Kranfahrgestell und Kranoberwagen LWE>Identnr.: 861900608 LWE>Identnr.: 890034814
crane hydraulics
for crane carrier and crane superstructure
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hydrauliques
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pour ch£ssis porteur et partie tournante
9 Bremsanlage, wenn hydraulisch betßtigt DOT 4 DOT 4

brake system if hydraulically actuated SAE J 1703e SAE J 1703e
BH
syst∞me de frein, si il est command± LWE>Identnr.: 861000108 LWE>Identnr.: 861000108

hydrauliquement
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Kupplungsbetßtigung
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clutch actuation
commande du dispositif d'accouplement
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mode grue
10 Allgemeine Gleit> und Wßlzlagerungen Sondervorschrift: Sondervorschrift:
wßlzgelagerte Gelenke LIEBHERR LIEBHERR
general plain and roller bearings Spezialfett 9610 PLUS Spezialfett 9610 PLUS
joints on rolling bearings LWE>Identnr.: 861301308 LWE>Identnr.: 861301308
paliers lisses et ° rouleaux courants
articulations ° palier special prescription: special prescription:
LIEBHERR LIEBHERR
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Zentralschmieranlage Kranoberwagen special grease 9610 PLUS special grease 9610 PLUS
centralized lubricating system crane
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superstrcture prescription sp±ciale: prescription sp±ciale:
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graissage central partie tournante LIEBHERR LIEBHERR
graisse sp±ciale 9610 PLUS graisse sp±ciale 9610 PLUS
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Auslegerverriegelung
boom locking
verrouillage de la fl∞che
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Drehkranz>Wßlzlagerungerungen
slewing ring rolling bearings
paliers couronnes d'orientation
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Gelenkwellen, wenn nicht wartungsfrei

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cardan shafts if not maintenance>free

arbres articul±s, si ils ne sont pas exempts
d'entretien
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11 Kunststoff>Gleitlagerungen der Sondervorschrift: Sondervorschrift:

Teleskopausleger LIEBHERR LIEBHERR
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synthetic sliding bearings of the telescopic Spezialfett 9613 Spezialfett 1026 LS

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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
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12 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:
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LIEBHERR special LIEBHERR special
grease!1336 with LM carrier grease!1336 with LM carrier
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(spray grease) (spray grease)
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prescription sp±ciale: prescription sp±ciale:
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LIEBHERR graisse LIEBHERR graisse
sp±ciale!1336 ° v±hicule LM sp±ciale!1336 ° v±hicule LM
(graisse ° pulv±riser) (graisse ° pulv±riser)
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13 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)
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Laufende Seile
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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)
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lubrifiant adh±sif lubrifiant adh±sif

OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
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(r±sistant ° l'eau) (r±sistant ° l'eau)

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14 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
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15 KÂhlerfÂllung fÂr Dieselmotoren und KÂhlerschutzmittel KÂhlerschutzmittel
Heizanlagen LIEBHERR>Norm LIEBHERR>Norm
radiator filling for Diesel engines and 50 % Korrosions> / 50 % Korrosions> /
heatings Frostschutzmittel Frostschutzmittel
remplissage de radiateur pour moteurs LWE>Identnr.: 861600508 LWE>Identnr.: 861600508
Diesel et chauffages 50 % Wasser 50 % Wasser
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radiator protective agent radiator protective agent
LIEBHERR standard LIEBHERR standard
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50 % corrosion preventatives / 50 % corrosion preventatives /
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antifreeze fluids antifreeze fluids
50 % water 50 % water
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agent de protection de agent de protection de
radiateur radiateur
norme LIEBHERR norme LIEBHERR
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50 % produit antigel / 50 % produit antigel /

anticorrosion anticorrosion
50 % eau 50 % eau
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16 Fahrgetriebe fÂr Raupenkran siehe Typenschild siehe Typenschild

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travel gear transmission for crawler crane see gear rating plate see gear rating plate
r±ducteur de translation pour grues sur voir la plaque signal±tique voir la plaque signal±tique
chenilles
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17 Bergewinde siehe Typenschild siehe Typenschild

recovery winch see gear rating plate see gear rating plate
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treuil de remorquage voir la plaque signal±tique voir la plaque signal±tique

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8.00 CRANE INSPECTIONS 022101>00
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022101>00
Chapter 8
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Crane inspections
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8.01 REPEAT CRANE INSPECTIONS 021686>08
General
This crane has been inspected before delivery at the factory, according to the valid ISO, FEM and DIN
standards or BGV D6 (BGG 905).
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, BGV D6.
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
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part , the operator must have the crane inspected by an experienced technician
before putting the crane back in service.
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In addition, national and regional regulations apply. ER
Experienced technicians are persons who, due to their vocational background and experience, have sufficient
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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).
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Expert engineers are engineers experienced in the design, construction and maintenance of lifting devices, such
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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.
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A repeat crane inspection is generally a visual inspection, where the experienced technician / expert engineer
inspects the condition of the crane and components. .
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This inspection should prevent accidents through timely recognition of defects.

Any defects found by an experienced technician / expert engineer must be documents, remedied and
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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 !
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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.
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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.
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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
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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.
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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.
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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
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that they are complete!

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Vehicle fame
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185046
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Sliding arms
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185047
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Folding arm
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185060
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Slewing platform frame
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185048
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Slewing platform frame
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185049
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Telescopic boom
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185050
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Lattice jib
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185051
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NA / WA> bracket
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Installation unit with lattice jib
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Pulley head
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Guy rods
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Lattice boom
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Folding jib
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185057
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Folding jib
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TA> guying
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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 inspection of cranes, the outside and the inside of the
rims must 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, regardless 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.
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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:
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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.
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2.1.5 Evaluation of foreign particles found in oil
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Maximum permissible foreign particle parts are 0.15% of the total oil quantity, by weight.
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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
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contamination. Replace any damaged parts and fill the gear with new oil.
CAUTION: These repairs may only be made by expertly trained personnel.

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2.1.6 Visual inspection

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

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2.1.7 Check brakes in gears

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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
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due to increased oil contamination, check the brakes at the same time.
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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.
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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!
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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
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2. Insufficient maintenance: oil has not been changed at the proper intervals
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3. Erroneous operation : extreme acceleration or deceleration of the load
Load fell into the cables
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4. Maintenance errors: Use of wrong oil

Wrong quantity
Contamination during oil change
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5. Installation errors during repair or maintenance

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6. Leakages which were not taken care of

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7. Improperly adjusted safety devices
8. Hidden accident damage

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9. Extreme ambient conditions: Low or high temperatures

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aggressive atmosphere
Dust and dirt
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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 BGV
D8).
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.
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From the determination of the actual operating conditions, choose one of the following load collectives
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and enter them in the crane inspection book for the corresponding inspection interval.
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Note: For mobile cranes in assembly operation, we normally use the load collective L1
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(Q1), with the load collective factor km = 0.125.
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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 aaaaaaaa

Load %
aaaaaaaa
aaaaaaaa
Q1 thereof, which run only with largest load aaaaaaaa
aaaaaaaa
aaaaaaaa
100
L1 at high utilization in (dead load + 1/1 load aaaaaaaa
aaaaaaaa
exceptional cases , but capacity) aaaaaaa
are subjected to 40 % of running time aaaaaaa
aaaaaaa aaaaaaaaaa
aaaaaaaaaa
aaaaaaa aaaaaaaaaa
aaaaaaa aaaaaaaaaa
constant, but only light with dead load + 1/3 aaaaaaa
50
aaaaaaa aaaaaaaaaa
aaaaaaaaaa
40 %
aaaaaaa aaaaaaaaaa aaaaaaaaaa
duty load capacity) aaaaaaaaaa
aaaaaaaaaa
aaaaaa aaaaaaaaaa
aaaaaaaaaa
50 % of running time aaaaaa aaaaaaaaaa
10 %
aaaaaa
aaaaaa aaaaaaaaaa
with only dead load aaaaaa aaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
0
aaaaaa aaaaaaa aaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaaaaaa
50
aaaaaaa aaaaaaaa
100
aaaaaaaa
aaaaaaa aaaaaaaa
Running time %
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Medium Drive gear or parts 1/6of running time with km = 0,25 aaaaaaaa
Load %
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aaaaaaaa
aaaaaaaa
Q2 thereof, which often largest load aaaaaaaa
aaaaaaaa
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L2 run at high utilization, (dead load + 1/1 load aaaaaaaa
100
aaaaaaaa
aaaaaaaa aaaaaaaaaa
aaaaaaaaaa
but are subjected to capacity) aaaaaaaaaa
aaaaaaaaaa
aaaaaaa aaaaaaaaaa
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aaaaaaa aaaaaaaaaa
73aaaaaaaaaa
%
light duty 1/6 of running time aaaaaaa
aaaaaaa
aaaaaaaaaa
aaaaaaaaaa
aaaaaaaaaa
aaaaaaa
aaaaaaa aaaaaaaaaa
aaaaaaaaaa
with dead load + 2/3 50
aaaaaaa 47 %
aaaaaaaaaa aaaaaaaaaa
aaaaaaa aaaaaaaaaa aaaaaaaaaa
load capacity aaaaaaaaaa
aaaaaaaaaa
aaaaaaaaaa
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aaaaaa 20 %
aaaaaaaaaa
1/6 of running time aaaaaa aaaaaaaaaa
aaaaaa
aaaaaa
with dead load + 1/3 aaaaaa aaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
0
load capacity aaaaaa
aaaaaaa aaaaaaaa
50
aaaaaaa
aaaaaaa aaaaaaaa
100
aaaaaaaa
50 % of running time
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aaaaaaa aaaaaaaa
only with dead load aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
Running time %
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Heavy Drive gear or parts 50 % of running time km = 0,5 Load %
aaaaaaaa
aaaaaaaa
Q3 thereof, which often with largest load aaaaaaaa
aaaaaaaa
aaaaaaaa
aaaaaaaa
100
L3 run at high utilization, (dead load + 1/1 load aaaaaaaa
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aaaaaaaa
but are subjected to capacity) aaaaaaa
aaaaaaa
aaaaaaa aaaaaaaaaa
constant medium duty 50 % of running time aaaaaaa aaaaaaaaaa
aaaaaaa
aaaaaaa aaaaaaaaaa
aaaaaaaaaa
only with dead load
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50
aaaaaaa aaaaaaaaaa
aaaaaaa aaaaaaaaaa
40 %
aaaaaaaaaa
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aaaaaa
aaaaaa
aaaaaa
aaaaaa
aaaaaa
0 aaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
aaaaaaa
50 aaaaaaaa
100
aaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
Running time %
Very heavy Drive gear or parts 90 % of running time km = 1 Load %
aaaaaaaa
aaaaaaaa
aaaaaaaa
Q4 thereof, which with largest load aaaaaaaa
aaaaaaaa
aaaaaaaa
100
aaaaaaaa aaaaaaaaaa
aaaaaaaaaa
L4 regularly run at high (dead load + 1/1 load aaaaaaaa aaaaaaaaaa
aaaaaaaaaa
aaaaaaaaaa
utilization, and are capacity) 80 %
aaaaaaaaaa
aaaaaaa aaaaaaaaaa
subjected to constant 10 %of running time aaaaaaa
aaaaaaa
aaaaaaa
heavy duty only with dead load aaaaaaa
50
aaaaaaa
aaaaaaa
aaaaaaa
aaaaaa
aaaaaa
aaaaaa
aaaaaa
aaaaaa aaaaaaa
aaaaaaa aaaaaaaa
aaaaaa
0
aaaaaa aaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
aaaaaaa
50
aaaaaaa aaaaaaaa
100
aaaaaaaa
aaaaaaa aaaaaaaa
aaaaaaaa
Running time %
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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.
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2.2.2.2.3 Hour meter for both travel and crane operation
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The winch operation portion of the total operating hours of the superstructure must be guessed.
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Note: For mobile cranes in assembly operation, normally, 60% of the total operating
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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.
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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 .
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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
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operator.
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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 BGV D8), 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
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Di (see example).
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If the remaining theoretical service life is insufficient for the next operating period, then the winch
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must be reconditioned or overhauled. ER
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.
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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
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manufacturer or by a person authorized by the manufacturer and the overhaul must be documented in
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the inspection booklet.
After the general reconditioning or overhaul, the manufacturer or the person authorized by the
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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.
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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.
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The superstructure hour meter read 800 hrs. Winch operation was about 20 % of that, which means
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T1!= 160 hrs.
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At the 1st inspection, the used part S of the theoretical service life is therefore as follows:
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0.125
S1 = &&&&& ¥ 160 hrs = 160 hrs.
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0.125
remaining theoretical service life:

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D1 = 3200 hrs > 160 hrs. = 3040 hrs.

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The above values are entered in the chart in the crane inspection booklet, see paragraph 2.2.4)
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2nd Inspection (2nd year )

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The crane has been utilized for unloading ships in the harbor:
Load collective: L3, which means km2 = 0.5
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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.
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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
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D3 = 1120 hrs. > 600 hrs. = 520 hrs.
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The above values are entered in the chart in the crane inspection booklet as shown in chart 1.
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2.2.4. Addendum
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Chart 1 shows an example.

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Document the remaining theoretical service life on chart 2.

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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
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Theoretical service life D: 3200 hrs. Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
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Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining
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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
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inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
-S
0 10.06.90 > > > 0 0 3200
R
160
1 05.06.91 L1 0,125 > 800 800 > (20 % of 800) 160 3040 MÂller
ER
480
2 20.05.92 L3 0,5 > 2000 1200 > (40 % of 1200) 1920 1120 Huber
H
300
3 18.05.93 L2 0,25 > 3000 1000 > (30 % of 1000) 600 520 Maier
EB
LI
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
E
Theoretical service life D: ................... Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
C
Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining Name of Signa> Remarks
VI
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
ER
inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
-S
R
ER
H
EB
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CAUTION: Perform general overhaul at least once every 10 years.

General overhaul last performed on : .........................
E
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ER
-S
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180068
484
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 .
E
Note: The initial measurements ∫y∫ or ∫y1∫ and ∫y2∫ are noted on the load hook. Measure
C
from point to point, as shown.
VI
ER
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.
-S
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 .
R
ER
refer to chapter
4. Check the cable push out mechanism in the telescopic boom.

BH
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
E
LI
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.
485
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.
E
The deviation may not be more than 10% of the load capacity in these two extreme positions.
C
9.2 The given radius must be measured again for the longest boom for the smallest radius and at a boom
VI
angle of 45∞ .
The deviation may not be more than 10% of the measured radius.
ER
-S
10. Check the slewing ring connection

10.1 For tilt play measurement, see chapter 7.05
R
ER
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.
BH
11.1 The mounting screws of the rotary connections are pretensioned at the factory, and normally should not
loosen up during normal operation.
E
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.
LI
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.
486
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 .
E
C
VI
ER
-S
R
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E BH
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Addendum
To aid the inspector, attached find a check list for repeat inspections of LIEBHERR mobile and crawler cranes.
487
Inspection guidelines for repeat inspection of LIEBHERR mobile and crawler cranes according to
ß26(1) or (2) UV ™Cranes™ (BGV D6)
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
E
Crane control book
C
Load chart manual
VI
Work planer
2. Inspection group:Decals / signs
ER
Data tag
-S
Load capacity data

Decal for operating instructions
R
Warning and safety decals

ER
Other safety signs

3. Inspection group:Travel gear 1)
BH

Frame 2)
E
Supports 2)
LI
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
488
Company: . . . . . . . . . . . . . . . . . . . . . . . Inspector: . . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . .
Crane manufacturer:LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
4. Inspection group: Chassis 1)

Covers
Steps
E
Counterweight retainers 2)
C
Tackle devices
VI
Ladders
Retainer for hook block 2)
ER
Boom receptacle 2)
5. Inspection group: Chassis > Driverπs cab 1)
-S

Doors
R
Window / windshields
ER
Windshield wiper
Mirror
BH
Seat
Heater
E
Ventilation
LI
Noise protection
Recorder
First aid kit
Spare bulbs
Warning triangle
Warning vest

489
6. Inspection group: Chassis > Drive 1)

Engine
Exhaust system
Fuel tank
E
Filter
C
Muffler
VI
Engine suspension
ER
Oil levels
Fuel lines
-S
7. Inspection group: Chassis > Hydraulic system 1)

Oil tank
R
Filter
ER
Pumps
Motors
BH
Valves
Lines
E
Hoses
LI
Cylinder
Pressure relief valves
8. Inspection group: Chassis > Air pressure system 1)
Compressor
Filter
Air tank
Valves
Lines
Hoses
Cylinder

490
9. Inspection group: Chassis > Electrical system 1)

Motors
Generators / Alternators
E
Battery
C
Schalter
VI
Lines
Fuses
ER
Resistors
Lighting
-S
Brake lights
Blinkers
R
Tail lights
ER
Floodlights
Signal devices
BH
Indicator lights
Battery switch
E
Limit switch:
LI
Gear, steering, drive

Support force indicator 2)

491
10. Inspection group: Chassis > Control systems 1)

Engine regulation
Gears
E
Couplings / clutches
C
Gear shifts
VI
Brakes
Steering
ER
Indicators
Engine stop line
-S
Control of outrigger supports 2)

Axle suspension
R
Crane leveling control

ER
Rear axle steering

11. Inspection group: Superstructure
BH

Frame
E
Covers
LI
Steps
Mounting
Counterweight
Relapse retainer
Slewing ring: tilt play
Slewing ring: mounting screws
Slewing ring: gear
Slewing gear: Mounting screws
Slewing gear: Gear

492
12. Inspection group: Superstructure > Crane operatorπs cab

Doors
Windows / windshields
E
Windshield wiper
C
Mirror
VI
Seat
Heater
ER
Ventilation
Shock absorber
-S
Control lever for working functions

Gear controls
R
Retention: Scrapes / chafings/ kinks

ER
13. Inspection group: Superstructure > Retention and protective devices

BH
Handles and ladders / steps to the cab and to drive gears
Covers
E
Coverings
LI
Flaps
14. Inspection group: Superstructure > Drive system
Engine
Exhaust system
Fuel tank
Filter
Muffler
Engine suspension
Fuel lines

493
15. Inspection group: Superstructure > Hydraulic system

Oil tank
Filter
E
Pumps
C
Motors
VI
Valves
Lines
ER
Hoses
Cylinder
-S
Pressure relief valves

Brake lowering valves
R
Brake control: Hoist gear

ER
Brake control: Slewing gear

16. Inspection group: Superstructure > Electrical System
BH

Motors
E
Generators / Alternators
LI
Batteries
Switches
Lines
Fuses
Resistors
Lighting

494
Crane manufacturer: LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
17. Inspection group: Superstructure > Control systems

Engine regulation
Gear
E
Elastic couplings
C
Controls
VI
Engine stop line
Indicators
ER
18. Inspection group: Superstructure > Cable drive systems
-S
Winch I 3)
Winch II 3)
R
Winch III 3)
ER
Winch IV 3)
Cable pulleys
BH
Cable end mounting

Cable for winch I
E
Cable for winch II

LI
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

495
Crane manufacturer: LIEBHERR . . . . Crane type: . . . . . . . . . . . . . . . . . . . . . . . S/N:
20. Inspection group: Superstructure > Safety and Control devices

Hoist limit switch I
Hoist limit switch II
E
Lowering limit switch I
C
Lowering limit switch II
VI
Boom limit switch I
Boom limit switch II
ER
Luffing jib: boom limit switch I
Luffing jib: boom limit switch II
-S
Load moment limiter

Angle indicator: Boom
R
Angle indicator: Luffing jib

ER
Angle indicator: Slewing gear

Safety devices: Steuerung
BH
Working range limitation

Pressure sensor
E
Speed sensor
LI
Wind velocity sensor

Sliding arm monitor
Support force monitor
Incline monitor
Length indicator:
radius, boom length
Emergency off
Engine stop

496
20. Inspection group: Boom

Welding construction
Cable pulleys
E
Luffing cylinder
C
Telescoping cylinder
VI
Push out cables
Return pull cables
ER
Boom bearing / mounting
Boom pinning
-S
Guy rods
Relapse cylinder
R
ER

BH

E
LI
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∫ (BGV D29)).
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.
497
8.04 INSPECTION OF CRANE CABLES 024478>00
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 1030/2 13 Even lay 126 3 6
E
C
Non torsion free cables
VI
ER
Telescoping cable I

-S

[mm]
R
LTM 1030/2 16 Cross lay 208 9 18

ER
Telescoping cable II

BH

[mm]
E
LTM 1030/2 14 Cross lay 208 9 18

LI
Back pull cable I

[mm]
LTM 1030/2 13 Cross lay 208 9 18
Back pull cable II

[mm]
LTM 1030/2 12 Cross lay 152 6 13
498
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
E
> Total placement time
C
VI
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
ER
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.
-S
Any changes in cable behavior must be especially well monitored.

R
DANGER: As soon as the cable strands hit together above the hook block, there is a danger of
ER
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.
BH
Note: Refer to the paragraph describing ™Extension torsion in torsion free hoist cables and its
E
elimination™
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499
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180069
500
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)
E
> Reduction of cable diameter as compared to the nominal diameter by more than 15% or
C
> by 10% with simultaneous occurrence of corrosion and / or abrasion (fig. 4)
VI
> Slackening of cable structure (fig. 4)
ER
> Constriction (fig. 5)
-S
> Kinks and compressions (fig. 6+8)
> Pulls or remaining distortions (fig. 7)

R
ER
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.
BH
CAUTION: If there are doubts if the crane cable is still operational safe, then put it down or
consult an expert for an opinion.
E
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501
E
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180070
502
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.
E
The best procedure is to spool up the cable from a raised reel to the drum ( fig. 2).
C
Winding the cable in the same bending direction prevents additional cable tension and assures that the cable
VI
lays better on the drum. ER
CAUTION: Make sure that the cable is not pulled over the ground to prevent it from getting
dirty.
-S
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.
R
ER
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.
BH
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
E
the bending radius of pulley and drum.

LI
503
E
C
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ER
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504
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
E
reason, for longer lasting crane work, it is recommended to match the cable length to the task.
C
If certain section of the cable are more used than others then the cable should be turned over after a certain
VI
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
ER
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
-S
by shorting the drum end by a length which corresponds to 1/3 of the drum circumference.
R
Extension torsion in torsion free hoist cables and its elimination

ER
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.
BH
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.
E
Measures to take care of an elongation cable twist are noted below.

LI
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!
505
E
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183627
506
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.
E
In that case,the fixed point of the cable is easily accessible on the hook block and it can
easily be released.
C
VI
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.
ER
Note: It is important that the correct reference point is taken and that the crane operator holds
the cable in front of him .
-S
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.
R
The rule is that for torsion compensation, the end of the cable must be turned against the direction of
ER
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
BH
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
E
would destroy the cable structure permanently.

LI
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.
507
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM 025045>00
E
C
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-S
R
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190108
508
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.
Note: On membrane cylinders, the lower breather bore (4) must be clear (plug removed).
The breather bores (1, 2 and 3) must be closed with plugs.
E
CAUTION: The lower breather bore (4) must be clear.
If this is not observed, the membrane skin can twist, the accumulator is not
C
fully released, the brake gets hot.
VI
1.3 Air tank is not damaged, no external corrosion can be seen.
ER
The tank is marked properly.
CAUTION: No welding nor heat applications may ever be done on the tank walls .
-S
1.4 Condensation is drained from the air tank.
1.5 Dust guards are not damaged.

R
ER
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.
BH
1.8 Brakes are adjusted properly (ventilation, brake cylinder stroke, pad thickness, linkage plate).
E
LI
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.
509
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/s
! 2.
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]
E
20 6.5
C
30 12.5
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40 19.8
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50 29.0
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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:
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F1¥i1+F2¥i2 ... Fn ¥ in
z = &&&&&&&&&&&&&&&&&&&&& ¥ 100 [%]
ER
Gz
Gz = Permissible total weight of the vehicle [N]

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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]
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Fn = Brake power of last axle, which has been measured at pn pressure [N]
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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
510
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, Bremskerl 6275 and Beral 1549 brake pads may be used.
DANGER: Always replace the pads on both wheels of each axle.
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3.3 The brake drums should also be turned.
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Note: When turning the brake drums, do not exceed the permissible turning measurement
of 0.75 % of the nominal diameter!
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Example: Nominal diameter: 500.00 mm
Permissible turning measurement: 3.75 mm
-S
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.
R
Otherwise there is a danger of causing a serious accident!

ER
3.4 To correct the brake pad wear or to center the brake, it is equipped with an automatic adjustment devi>
BH
ce, which is maintenance free.
DANGER: In case of damage to any parts, replace the automatic adjustment device
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completely, using repair kit ∫adjustment device∫.

If this is not done, there is a danger of causing a serious accident!
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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.
511
9.00 GENERAL NOTES 022102>00
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022102>00
Chapter 9
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General Notes
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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
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its safety function:
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1. Overload safety devices (overload motion cut devices) mut not be used in normal operations for switching off
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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.
ER
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.
-S
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
R
such duties, the overload safety device (safe load limiter) must not be used as a means of measuring the
ER
force.
BH
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
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conformity with the Accident Prevention Regulations for Telescopic Boom Cranes.
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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.
514
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
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> excessive braking forces
> loads dropping into the rope
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> pulling at an angle
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> moving the crane to an area of ground with a greater slope
> ground which gives way
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> wind load
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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.
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On no account may the overload safety device be switched off or overridden in order to lift a load which
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exceeds the maximum permissible load lifting capacity of the crane.

BH
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
E
(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
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concerned. Unauthorized interference in the mechanism of the overload safety device will invalidate the
warranty provisions.
515
9.02 GUIDELINES TO PREVENT FIRES IN THE ENGINE AREA
AND IMPORTANT SERVICE WORK TO BE PERFORMED 022103>04
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.
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1.4 Check if electrical lines are still routed and mounted properly, with sufficient distance to exhaust pipes,
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and assure that they are not damaged and still properly insulated.
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1.5 To reduce noise emission, insulating baffle mats have been installed in the engine and gear
compartments on some crane models. They are fire retardent and, depending on the job location, even
inflamable.
-S
It must be checked if the baffle mats are in any way contaminated with solutions, covered with oil and
fuel or are damaged. In any of these cases, they must be removed immediately and replaced with
original replacement parts.
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ER
When cleaning the engine or gear area, note the instructions for maintenance of these mats, see
chapter!7.01.
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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
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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.
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VI
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3. Important service tasks
-S
3.1 To prevent dry runs, the gear shafts must be lubricated regularly and properly with specified
LIEBHERR grease.
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3.2 The gear shaft screws must be checked regularly to assure they are seated tightly.
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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
BH
and remedy the problem.

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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.
517
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:
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For disposal, undiluted antifreeze fluids / corrosion protective oils must be handled as special hazardous
material.
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When disposing of used coolant fluids (mixture of antifreeze / corrosion protective oils and water,
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observe all state and local regulations applicable to the disposal of these items.
ER
-S
7. Rotating wheels
7.1 Tires used on crane vehicles are exposed to different loads and stresses, depending on the location of the
R
wheels on the crane, such as:

ER
> non > propelled steering and fixed axles.

> propelled steering and fixed axles and
> various wheel positions exposed to more or less load.
BH
Depending on the type of the tire tread, tires often wear differently.
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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.
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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!
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LIEBHERR

TELESCOPIC BOOM MOBILE CRANE

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

Telefon (07391) 5 02>0, Telefax (07391) 5 02>33 99

www.lwe.liebherr.de, E>mail: info@lwe.liebherr.com

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.02 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.03 TECHNICAL DATA ..................................................................... 22

2.01 ROAD TRAFFIC REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.02 INSTRUCTIONS ON RUNNING>IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.03 OPERATIONAL PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8. Working near transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.01 CONTROLS AND INSTRUMENTS > VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.02 BEFORE VEHICLE STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.03 AXLE SUSPENSION / AXLE LOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3.05 THE CRANE AT THE JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4. Supporting the crane from the crane operatorπs cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

5. Changing from crane to driving operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

4.01 CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4.03 STARTING THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

4.05 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

3. LICCON Safe load indicator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

4. Control of crane movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

4.06 CABLE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

4.07 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

4.08 WORKING WITH A LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

4.10 DRIVING FROM THE CRANE OPERATORπS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

4.11 CRANE OPERATION ∫FREE STANDING∫ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

5.01 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

5.02 FOLDING JIB > TK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

7.01 SERVICING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 402

7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

4. Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

7.06 LUBRICATION CHART AND FILLING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

7.07 SCHMIERSTOFFTABELLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

8.01 REPEAT CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456

8.04 INSPECTION OF CRANE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498

8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

Description of the Crane

Abbreviation of boom systems

TK = Telescopic boom with folding jib 0∞ / 20∞ / 40∞

1.1 2>alxe chassis

2.4 Telescopic boom control > luffing cylinder

3.1 Pivot section

3.2 Telescopic section 1

3.3 Telescopic section 2

3.4 Telescopic section 3

4 Telescopic boom with folding jib TK