AC220-5 AC250-5-82640-Part1 539999 2 en

Operating instructions Superstructure
AC 220-5 / AC 250-5
This document is a translation of the original operating instructions which are sent with this
specific machine and are designated as belonging to this machine. It is not intended as a basis
for further translations.
Please use only the original operating instructions as a reference. They are labelled accordingly.
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Disclaimer
Disclaimer
The only warranty applicable to our products is the corresponding

standard written warranty. Tadano shall neither explicitly nor implicitly
provide any warranty beyond this. The named products and services may
be trademarks, service marks or trade names of Tadano Ltd. and/or its
subsidiaries in the USA or other countries. All rights reserved.
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Disclaimer
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Table of contents
Table of contents
1 Safety Instructions ....................................................................... 25

1.1 General ...........................................................................................25
1.2 Warning Information ....................................................................... 25
1.2.1 General ...........................................................................................25
1.2.2 Structure ......................................................................................... 26
1.2.3 Types ..............................................................................................27
1.2.4 Warning symbols ............................................................................ 27
1.3 Intended Use .................................................................................. 30
1.4 Working Conditions and Computed Design of the Crane ...............33
1.4.1 General ...........................................................................................33
1.4.2 Classification of the Crane ..............................................................33
1.4.3 Classification of the power units ..................................................... 34
1.4.4 Load and Utilisation of the Crane ................................................... 34
1.4.5 Required Ambient Conditions .........................................................34
1.4.6 Service Life .....................................................................................36
1.4.7 Scrapping / Disposal .......................................................................37
1.4.8 Standards and Calculation Regulations ......................................... 37
1.4.9 Dangers to Air Traffic ......................................................................37
1.5 Organisational Measures ................................................................37
1.6 Personnel Requirements ................................................................ 38
1.7 Particular Hazards .......................................................................... 39
1.7.1 High voltage ....................................................................................39
1.7.2 High-frequency radiation ................................................................ 41
1.7.3 Lightning ......................................................................................... 41
1.7.4 Gas, dust, steam, smoke ................................................................42
1.7.5 Crushing / collision ......................................................................... 43
1.7.6 Becoming entangled / dragged in ...................................................43
1.7.7 Crushing / shearing ........................................................................ 43
1.7.8 Risks due to slipping, tripping, falling ............................................. 44
1.8 Protection from physical effects ......................................................44
1.9 Combination of Hazards with Combined Operation of Two or
More Cranes ...................................................................................45
1.9.1 Operating Areas of Several Cranes Overlap .................................. 45
1.9.2 Several Cranes Raising a Load Together ...................................... 45
1.10 Driving Operation ............................................................................46
1.10.1 Before Driving .................................................................................46
1.10.2 During Travel .................................................................................. 47
1.11 Crane Operation ............................................................................. 48
1.11.1 Before Crane Operation ................................................................. 48
1.11.2 During Operation of the Crane ....................................................... 51
1.11.3 Disruption of Crane Operation - Parking and Leaving (Partially)
Erected Mobile Cranes Unsupervised ............................................ 54
1.11.3.1 Problems and Risks ........................................................................54
1.11.3.2 General Instructions ....................................................................... 55
1.11.3.3 Specific Instructions for Mobile Hydraulic Cranes with Tele-
scopic Boom ................................................................................... 57
1.11.3.4 Specific Instructions for Crawler-mounted Cranes with Equip-
ment ................................................................................................57
1.11.4 Following Crane Operation .............................................................57
1.12 Power supply failure ....................................................................... 58
1.12.1 General ...........................................................................................58
1.12.2 Winches and cylinders ....................................................................58
1.12.3 Driving the crane in the configured configuration ........................... 58
1.13 Assembling and dismantling crane components ............................ 59
1.14 Hand signals ...................................................................................61
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2 Structure of the Mobile Crane ..................................................... 69

2.1 Specifications ................................................................................. 69
2.2 Main Elements ................................................................................70
2.3 Getting onto and off the Crane ....................................................... 72
2.3.1 General ...........................................................................................72
2.3.2 Overview of the ladders ..................................................................73
2.3.3 Before getting on /off ladders ......................................................... 74
2.3.4 Getting on and down from the crane using folding ladders ............ 75
2.3.4.1 General ...........................................................................................75
2.3.4.2 Placing the Folding Ladders in the Operating Position ...................76
2.3.4.3 Using the Folding Ladder ............................................................... 78
2.3.4.4 Placing the Folding Ladders in the Transport Position ................... 78
2.3.5 Getting onto and down from the Crane Using Mobile Multi-pur-
pose Ladders ..................................................................................79
2.3.5.1 General ...........................................................................................79
2.3.5.2 Placing the Multi-purpose Ladder in Position and Setting it up ...... 81
2.3.5.3 Using the Multi-purpose Ladder ..................................................... 82
2.3.6 Surfaces Permitted for Walking and Standing on the Crane
Chassis ...........................................................................................82
2.3.7 Attachment Eyelets for Personal Protective Equipment ................. 84
2.4 Headlights .......................................................................................85
2.5 Emergency Exit .............................................................................. 86
3 Crane operator's cab ....................................................................87

3.1 Overview of the crane operator's cab ............................................. 87
3.1.1 Total overview ................................................................................ 87
3.1.2 Elements at the front of the cab ......................................................89
3.1.3 Control panel, front ......................................................................... 89
3.1.3.1 Operating elements in the instrument panel, front ..........................90
3.1.3.1.1 Ignition Switch ................................................................................ 90
3.1.3.2 Instrument panel, side .................................................................... 91
3.1.3.3 Connections under side instrument panel ...................................... 93
3.1.4 Roof console ...................................................................................94
3.1.4.1 Overview of the operating elements ............................................... 94
3.1.4.2 Operating elements - instrument panel in roof console .................. 95
3.1.5 Control console, right ......................................................................96
3.1.5.1 Operating elements ........................................................................ 96
3.1.5.2 Control lever, right .......................................................................... 97
3.1.5.3 Instrument panel arrangement, right-hand control console ............ 98
3.1.6 Operating elements on the cab door .............................................. 98
3.1.7 Operating elements in the footwell ................................................. 99
3.1.8 Control console, left ........................................................................99
3.1.8.1 Operating elements ........................................................................ 99
3.1.8.2 Control lever, left .......................................................................... 100
3.1.8.3 Instrument panel arrangement, left-hand control console ............ 101
3.1.9 Crane operator's seat ................................................................... 101
3.1.9.1 General Instructions ..................................................................... 101
3.1.9.2 Setting the crane operator's seat ..................................................103
3.1.10 Setting the arm consoles .............................................................. 105
3.2 Locking/unlocking the cab door from the outside ......................... 105
3.2.1 Locking/unlocking using the vehicle key .......................................105
3.2.2 Locking/unlocking with remote control operation (optional) ..........106
3.2.2.1 Overview/structure of the key remote control (optional) ............... 107
3.3 Unlocking/opening the cab door from the inside .......................... 108
3.4 Opening the cab door ................................................................... 108
3.5 Entry / exit .....................................................................................109
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3.5.1 General .........................................................................................109

3.5.2 Procedure ..................................................................................... 110
3.5.3 Retracting/extending the platform on the cab ...............................111
3.6 Closing the cab door .....................................................................112
3.7 Exiting the cab in an emergency .................................................. 113
3.8 Tilting the crane operator’s cab (optional) .................................... 113
3.9 Opening / Closing Windows ......................................................... 114
3.9.1 Rear Window ................................................................................ 114
3.9.2 Side window (in cab door) ............................................................ 114
3.9.3 Front Window ............................................................................... 115
3.9.3.1 Structure / function of the front window ........................................ 115
3.9.3.2 Opening / Closing front window ....................................................115
3.10 Sunshade ..................................................................................... 117
3.11 Interior Lighting .............................................................................120
3.12 Racks ............................................................................................121
4 motor ........................................................................................... 123

4.1 General .........................................................................................123
4.2 Damage-prevention measures ..................................................... 123
4.3 Control and display elements ....................................................... 123
4.3.1 Additional display ..........................................................................123
4.3.1.1 General .........................................................................................123
4.3.1.2 Structure of the additional display ................................................ 124
4.3.1.3 Operating screen .......................................................................... 124
4.3.1.4 "Engine/hydraulics data" screen ...................................................126
4.3.1.5 Info screen "Diesel particulate filter" (DPF; EM5 engines only) ....126
4.3.2 Engine Display in the Crane Control Screen ................................ 127
4.3.2.1 "Engine display" screen ................................................................127
4.3.2.1.1 Calling up the "Engine display" screen .........................................127
4.3.2.1.2 Display of engine data .................................................................. 128
4.3.2.1.3 Display indicator lights ..................................................................128
4.3.2.2 "Automotive driving" screen / setting the engine speed manual-
ly ................................................................................................... 129
4.3.2.2.1 Switching on/off "Automotive driving" ........................................... 129
4.3.2.2.2 Manually Setting the Engine Speed ............................................. 130
4.4 Starting the Engine ....................................................................... 131
4.4.1 Checks before Starting the Engine ...............................................131
4.4.2 Starting Procedure ........................................................................132
4.4.2.1 Safety Regulations during the Starting Procedure ....................... 132
4.4.2.2 Starting the Engine (Starting Operation) ...................................... 133
4.4.2.3 Starting the Engine (with the Ignition Already Switched on) .........135
4.4.2.4 Starting at Low Temperatures ...................................................... 136
4.4.3 Jump Starting with External Batteries ...........................................136
4.4.4 Battery Charging Device (Optional) ..............................................136
4.4.5 After starting the engine ............................................................... 137
4.4.5.1 General .........................................................................................137
4.4.5.2 Engine oil pressure .......................................................................138
4.4.5.3 Engine fault ...................................................................................138
4.4.5.4 Air filter state .................................................................................139
4.4.5.5 Hydraulic oil temperature ..............................................................139
4.4.5.6 Filling level hydraulic oil ................................................................139
4.4.5.7 Hydraulic filter state ...................................................................... 140
4.4.5.8 Coolant temperature .....................................................................141
4.4.5.9 Engine oil filling level .................................................................... 141
4.4.5.10 Filling level of the fuel tank ........................................................... 142
4.4.5.11 Filling level of the AdBlue / DEF tank ........................................... 142
4.5 Engine during Operation ...............................................................143
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4.5.1 Setting the Required Engine Speed ............................................. 143

4.5.2 Checking the operation functions while the crane is in opera-
tion ................................................................................................144
4.5.2.1 General .........................................................................................144
4.5.2.2 Operating restrictions and indicator lights for exhaust gas after-
treatment system .......................................................................... 144
4.5.2.2.1 ... Engine complies with exhaust emission standard EM5 ............145
4.5.2.2.2 ... Engine complies with exhaust emission standard EM4/
Tier4 ............................................................................................. 148
4.6 Switch off the engine .................................................................... 150
4.6.1 Switching the Engine off under Normal Conditions (with the Ig-
nition Switched on) ....................................................................... 150
4.6.2 Switching the Engine off under Normal Conditions (End of Op-
eration) ......................................................................................... 150
4.6.3 Switching off the Engine in an Emergency ................................... 151
4.6.3.1 Standard design ........................................................................... 151
4.6.3.2 Quick stop equipment with air shut-off valves (optional) .............. 152
4.7 Hydraulic System ..........................................................................152
4.7.1 General .........................................................................................152
4.7.2 Warming up the Hydraulic System ............................................... 154
4.7.3 Hydraulic system in operation ...................................................... 155
5 Supporting the Crane on Outriggers from the Crane Opera-

tor’s Cab (Optional) .................................................................... 157
5.1 General Instructions and Warnings .............................................. 157
5.2 Control elements .......................................................................... 158
5.3 Procedure for supporting on outriggers ........................................ 158
6 Slewing the Superstructure .......................................................161

6.1 General .........................................................................................161
6.1.1 General Instructions on Risks .......................................................161
6.1.2 System Description .......................................................................163
6.1.3 Operating Modes of the Slewing Circuit ....................................... 164
6.1.3.1 Closed Circuit ............................................................................... 164
6.1.3.2 Open Circuit ..................................................................................165
6.1.4 Slewing Angle / Slewing Direction ................................................ 166
6.2 Initiating a Slewing Movement ......................................................167
6.3 Selecting the slewing speed ......................................................... 171
6.4 Braking the Slewing Movement .................................................... 172
6.5 Preparation for Dolly (Optional) .................................................... 173
6.6 Superstructure locking device (optional) ...................................... 174
6.7 Monitoring the Right-hand Side of the Superstructure ................. 174
6.7.1 Monitoring Using A Mirror (Optional) ............................................ 174
6.7.2 Monitoring Using the Camera (Optional) ...................................... 175
7 Counterweight ............................................................................ 177

7.1 General .........................................................................................177
7.2 Counterweight Combinations ....................................................... 178
7.2.1 General .........................................................................................178
7.2.2 Counterweight Combination 0 t (0 kip) ......................................... 178
7.2.3 Counterweight Combination 5.1 t (11.2 kip) ................................. 178
7.2.4 Counterweight Combination 13.1 t (28.9 kip) ............................... 178
7.2.7 Counterweight Combination 29,9 t (65.9 kip) ............................... 180
7.2.10 Counterweight Combination 46 t (101.4 kip) ................................ 181
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7.2.11 Counterweight Combination 51.6 t (113.8 kip) ............................. 182

7.2.12 Counterweight Combination 70,2 t (154.8 kip) ............................. 182
7.3 Fitting the Counterweight ..............................................................183
7.3.1 General .........................................................................................183
7.3.2 Anti-fall Protection Using a Safety Mast (Optional) ...................... 184
7.3.2.1 General .........................................................................................184
7.3.2.2 Using anti-fall protection ............................................................... 186
7.3.3 Setting Down the Counterweight Combination on the Crane
Chassis .........................................................................................193
7.3.4 Fitting the Counterweight Combination to the Superstructure
Frame ........................................................................................... 204
7.3.4.1 General .........................................................................................204
7.3.4.2 Automatic Fitting ...........................................................................205
7.3.4.3 Required tasks in addition to automatic ........................................210
7.3.4.4 Manual Fitting ............................................................................... 211
7.4 Removing the counterweight ........................................................ 215
7.5 Behaviour in Case of a Fault / Bridging Control ........................... 215
7.6 Dimensions ...................................................................................218
7.6.1 Slewing Radius and Width ............................................................218
7.6.2 Transport Dimensions and Weights of the Counterweight Ele-
ments ............................................................................................219
8 Safety Equipment ....................................................................... 221

8.1 IC-1 Crane Control ....................................................................... 221
8.1.1 General specifications on the IC-1 crane control system ............. 221
8.1.2 Overload Cut-off Using the Load Limit Device (LLD) ................... 222
8.1.2.1 Normal Operation ......................................................................... 222
8.1.2.1.1 Function ........................................................................................222
8.1.2.1.2 Displays, Warnings and Interventions of the Control System .......225
8.1.2.1.2.1 "EN 13000" Version ......................................................................225
8.1.2.1.2.2 "Non-EN 13000" Design ............................................................... 228
8.1.2.2 Bridging the Load Limit Device .....................................................231
8.1.2.2.1 Bridging with the key-operated "Setup" pushbutton ..................... 231
8.1.2.2.1.1 Displays, warnings and interventions of the control system
("Set-up" key-operated pushbutton actuated) .............................. 232
8.1.2.2.2 Bridging shutdown of the "Luff up" movement ..............................233
8.1.2.2.2.1 Function ........................................................................................233
8.1.2.2.2.2 Displays, Warnings and Interventions of the Control System .......235
8.1.2.2.3 Bridging the Shut-down of All Movements ....................................236
8.1.2.2.3.1 "EN 13000" Version ......................................................................236
8.1.2.2.3.2 "Non-EN 13000" Design ............................................................... 239
8.1.3 Operating elements and display elements ................................... 240
8.1.3.1 Operating Panel of Crane Control (Structure) .............................. 241
8.1.4 Operating Crane Control (IC-1) .................................................... 242
8.1.5 System start / switching the system off ........................................ 243
8.1.6 Central Screens ............................................................................246
8.1.6.1 "Crane operation" screen ............................................................. 246
8.1.6.1.1 Display of current configuration information ................................. 247
8.1.6.1.2 Load utilisation display ................................................................. 249
8.1.6.1.3 Function-dependent screens (Here: Quick menu) ........................250
8.1.6.1.4 Base line .......................................................................................251
8.1.6.1.5 Display of status information on the crane condition .................... 252
8.1.6.1.6 Display of load and radius ............................................................ 258
8.1.6.2 "Main menu"screen .......................................................................259
8.1.7 Submenus .................................................................................... 262
8.1.7.1 General .........................................................................................262
8.1.7.2 Submenus - basic structure ..........................................................263
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8.1.7.3 Calling up the "System setup (user)" screen ................................ 264

8.1.7.4 "Colour profile settings" screen .................................................... 265
8.1.7.5 "Setup IC-1 Remote" screen ("Setup Teleservice"; optional) ....... 266
8.1.7.6 "System setup (extended)" screen ............................................... 268
8.1.7.7 Calling up the "Crane operation" screen ...................................... 271
8.1.7.8 "Selecting the operating mode" screen ........................................ 271
8.1.7.8.1 General .........................................................................................271
8.1.7.8.2 Individual parameters of the "Selecting the operating mode"
screen ...........................................................................................272
8.1.7.8.3 Important specifications on the "Operating mode selection"
screen ...........................................................................................274
8.1.7.8.4 "Table view" screen ...................................................................... 277
8.1.7.8.4.1 General instructions on this screen .............................................. 277
8.1.7.8.4.2 "Search configuration for load case" screen .................................280
8.1.7.8.4.3 "Length code LC" screen ..............................................................283
8.1.7.9 Simulation screen "Capacities dependent on slewing angles"
(optional) .......................................................................................283
8.1.7.9.1 Structure of the simulation screen "Capacities dependent on
slewing angles" .............................................................................284
8.1.7.9.1.1 Input Area ..................................................................................... 284
8.1.7.9.1.2 Result Display Area ...................................................................... 289
8.1.7.9.1.3 Base line .......................................................................................292
8.1.7.9.2 Carrying out the simulation calculation .........................................292
8.1.7.10 "Operating range limit" screen (optional) ...................................... 295
8.1.7.10.1 General instructions on this screen .............................................. 295
8.1.7.10.2 Structure of the "Operating range limit" screen ............................ 296
8.1.7.10.3 Procedure for Defining, Activating and Deactivating Operating
Range Limits .................................................................................298
8.1.7.10.4 Slewing angle limit ........................................................................300
8.1.7.10.5 Radius limit ................................................................................... 301
8.1.7.10.6 Limits by a virtual wall ...................................................................302
8.1.7.10.7 Height limit ....................................................................................304
8.1.7.11 "Joystick Modes" screen ...............................................................304
8.1.7.11.1 General .........................................................................................304
8.1.7.11.2 Structure of the "Joystick modes" / "Control lever assignment"
screens ......................................................................................... 305
8.1.7.11.3 Display / Change to the Control Lever Assignment ......................308
8.1.7.11.4 Control Lever Assignments (6 Modes) ......................................... 309
8.1.7.12 "Parameter settings" screen ......................................................... 310
8.1.7.12.1 Change profile .............................................................................. 311
8.1.7.13 "Datalogger" screen (optional) ......................................................312
8.1.7.13.1 Call-up and Display ...................................................................... 312
8.1.7.13.2 Event table ....................................................................................312
8.1.7.13.3 Copy and download datalogger file (optional) .............................. 315
8.1.7.14 "Operating hour meter" screen ..................................................... 316
8.1.7.15 Activating / deactivating the "Emergency hydraulic lowering" /
"Emergency operation" functions (options) .................................. 317
8.1.7.16 "Function display" screen ............................................................. 318
8.1.7.17 "I/O view" screen .......................................................................... 319
8.1.7.18 "CAN View" Screen ...................................................................... 320
8.1.7.19 "Load Sensing View" screen ........................................................ 321
8.1.7.20 "Joystick diagnostics" screen ....................................................... 324
8.1.7.21 "Fault messages" screen ..............................................................324
8.1.7.22 "Telescoping display" screen ........................................................325
8.1.7.23 "Counterweight display" screen ....................................................325
8.1.7.24 "Outrigger support area" screen ................................................... 326
8.1.7.25 "Engine display" screen ................................................................327
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8.1.7.26 Operating screen "Capacities dependent on slewing angles" /

capacity radar (optional) ............................................................... 327
8.1.7.27 "IC-1 Remote" screen ("Teleservice"; optional) ............................ 329
8.1.8 Load Monitoring Device ................................................................332
8.1.9 Tilt display .....................................................................................333
8.1.10 Support Force Display (Optional) ................................................. 333
8.1.11 Outrigger support area display (depending on crane design) ...... 335
8.1.12 Automatic Counterweight Recording (Optional) ........................... 337
8.1.13 Lifting loads with capacity values from the capacity table ............ 339
8.1.13.1 Specifications in the capacity tables .............................................339
8.1.14 Raising loads with "Capacities dependent on slewing angles"
(optional) .......................................................................................343
8.1.15 IC-1 Remote ("Teleservice"; optional) .......................................... 345
8.1.16 Hook Height - Moving Repeatedly to a Saved Height .................. 346
8.1.17 Procedure in the Event of Faults .................................................. 347
8.1.17.1 Fault-free Operation ..................................................................... 347
8.1.17.2 Error messages are displayed on a visual display computer ....... 347
8.1.17.3 What to do for safety-relevant faults whose cause cannot be di-
rectly remedied ............................................................................. 349
8.1.17.4 Failure of the Screen – Display Screen Is Black .......................... 349
8.1.17.5 Connection Problems – Crane Control's Control Panel to Crane
Control .......................................................................................... 350
8.1.17.6 Total Failure of Crane Control ...................................................... 350
8.2 Care, maintenance, repairs and disposal ..................................... 351
8.3 Release switch system for crane movements .............................. 352
8.3.1 General .........................................................................................352
8.3.2 Assignment of the Release Buttons ............................................. 352
8.3.3 Activating the Release Buttons .....................................................353
8.4 Speed ........................................................................................... 354
8.4.1 Fine tuning of the movement speed ............................................. 354
8.4.2 High speed ................................................................................... 355
8.5 Limit switches ............................................................................... 357
8.5.1 Hoist Limit Switches ..................................................................... 357
8.5.1.1 Function ........................................................................................357
8.5.1.2 Bridging the Hoist Limit Switches ................................................. 358
8.5.1.3 "EN 13000" Version ......................................................................359
8.5.1.4 "Non-EN 13000" Design ............................................................... 359
8.5.2 Lower Limit Switches ....................................................................360
8.5.2.1 Function ........................................................................................360
8.5.2.2 Malfunction ................................................................................... 360
8.5.2.3 Bridging the Lower Limit Switches ................................................360
8.6 Electric Safety Chain .................................................................... 361
8.6.1 Wind speed indicator (anemometer) and hazard light (option-
al) ..................................................................................................361
8.6.1.1 Operation with the wind speed indicator and hazard light (op-
tional) on the adjustable bracket ...................................................362
8.6.2 Connecting the Distribution Box on the Main Boom Head ........... 365
8.6.3 Using the hoist limit switch ........................................................... 366
8.6.3.1 Operating principle ....................................................................... 366
8.6.3.2 Where are hoist limit switches located ......................................... 367
8.6.3.3 Hoist Limit Switches ..................................................................... 367
8.6.3.3.1 Structure of the hoist limit switch .................................................. 367
8.6.3.3.2 Placing the hoist limit switch in the functional state ......................368
8.6.3.3.3 Bridging the hoist limit switch (putting it out of operation) ............ 369
8.6.3.4 Shift weight of the hoist limit switch .............................................. 370
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9 Working Instructions ..................................................................373

9.1 Operation Planning / Monitoring Safety Measures ....................... 373
9.1.1 General Information on Operational Planning / Monitoring Safe-
ty Measures .................................................................................. 373
9.1.2 Crane Capacity and Capacity Tables ........................................... 376
9.1.3 Ambient Conditions ...................................................................... 377
9.1.4 State of the Crane during Crane Operation ..................................378
9.1.5 Crane Operation ........................................................................... 379
9.1.6 Picking up Loads from a Great Height or Winding onto the Top
Rope Layers of the Winches ........................................................ 382
9.2 Wind on the Crane and on the Load .............................................383
9.2.1 Planning / carrying out a crane operation (with regard to wind) ... 383
9.2.2 Terms / Definitions ........................................................................385
9.2.3 Wind Effects on the Crane and the Load ......................................385
9.2.4 Determining the Permitted Wind Speed for Crane Operation ...... 387
9.2.4.1 General .........................................................................................387
9.2.4.2 Wind Specifications in the Capacity Tables ..................................388
9.2.4.3 Simplified Procedure for Determining the Permitted Wind
Speed for Crane Operation .......................................................... 390
9.2.4.3.1 Calculation of the Permitted Wind Speed .....................................396
9.2.4.3.2 Wind Speed Reduction Diagram .................................................. 399
9.2.4.3.3 Table with Typical Body Shapes and Corresponding Wind Re-
sistance Coefficients .....................................................................402
9.2.4.4 Determining the wind speed anticipated from the weather fore-
cast at the highest point of the boom ............................................403
9.2.4.4.1 General / Procedure ..................................................................... 403
9.2.4.4.2 "Beaufort Scale" ........................................................................... 404
9.2.4.4.3 Wind Gusts ................................................................................... 405
9.2.4.4.4 Term "Surface Roughness" .......................................................... 406
9.2.4.4.5 Determining the Anticipated Wind Speed in Relation to Height
above Ground Level ..................................................................... 407
9.2.4.4.5.1 Table "Wind Speed in Relation to Height above Ground Level"
in m/s ............................................................................................ 407
9.2.4.4.5.2 Table "Wind Speed in Relation to Height above Ground Level"
in mph ...........................................................................................409
9.2.4.4.5.3 Example ........................................................................................410
9.2.4.4.6 Dynamic Pressure in Relation to Height above Ground Level ..... 411
9.2.4.4.6.1 Table "Dynamic Pressure in Relation to Height above Ground
Level" in m/s ................................................................................. 411
9.2.4.4.6.2 Table "Dynamic Pressure in Relation to Height above Ground
Level" in mph ................................................................................ 412
9.2.5 Permitted Maximum Wind Speed Values ..................................... 413
9.2.6 Measuring the Wind Speed .......................................................... 415
9.3 Cameras on the crane (option) .....................................................417
9.3.1 Camera system by the Motec company (optional) ....................... 417
9.3.1.1 Components of the camera system ..............................................417
9.3.1.2 Monitor, camera monitoring (optional) ..........................................418
9.3.1.2.1 General .........................................................................................418
9.3.1.2.2 Operating elements and display elements ................................... 419
9.3.1.3 Hook camera ................................................................................ 421
9.3.1.3.1 General .........................................................................................421
9.3.1.3.2 Important Information / Warning Information ................................ 421
9.3.1.3.3 Operation of the hook camera ...................................................... 422
9.3.1.3.4 Assembling/dismantling of the hook camera at the main boom
head ..............................................................................................423
9.3.1.3.5 Operating panel - load hook camera ............................................ 424
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9.3.2 Camera system by the Motec company (optional) ....................... 426

9.3.2.1 General Information / Important Instructions / Warning Informa-
tion ................................................................................................426
9.3.2.2 Operating elements and display elements ................................... 427
9.3.2.2.1 Monitor ..........................................................................................427
9.3.2.2.2 Zooming in and out with the Load Hook Camera ......................... 427
9.3.2.3 Operation of the hook camera ...................................................... 427
9.3.3 Hanging light on the main boom head. .........................................428
9.4 Conversion of units .......................................................................430
10 Telescoping .................................................................................433
10.1 General .........................................................................................433
10.2 Assembly, Function of the Main Boom ......................................... 434
10.2.1 Components of the Main Boom .................................................... 434
10.2.2 Extension States of the Main Boom ............................................. 435
10.2.3 Telescoping System's Mode of Operation .................................... 435
10.2.4 Locking and Pinning Unit (LPU) ................................................... 436
10.2.4.1 Function of the LPU ......................................................................436
10.2.4.2 Supply of the LPU with Hydraulic Oil ............................................438
10.2.4.2.1 Automatic supply .......................................................................... 438
10.2.4.2.2 Hydraulic accumulator pressure display .......................................439
10.2.4.2.3 Manual loading of the hydraulic accumulator ............................... 441
10.2.4.2.4 Exit screen ....................................................................................441
10.2.5 Correlation of the Components .....................................................442
10.3 Operating Elements / Auxiliary Equipment ................................... 445
10.3.1 Control Levers in the Crane Operator's Cab ................................ 445
10.3.2 Input and Monitoring Screens on Crane Control .......................... 446
10.4 Telescoping the Main Boom ......................................................... 446
10.4.1 General .........................................................................................446
10.4.2 Automatic telescoping .................................................................. 447
10.4.2.1 General .........................................................................................447
10.4.2.2 Input and Monitoring Screens at Crane Control (Automatic Tel-
escoping) ...................................................................................... 450
10.4.2.2.1 "Telescoping display" screen ........................................................450
10.4.2.2.1.1 Calling up the "Tele Display" Screen ............................................ 450
10.4.2.2.1.2 Structure of the "Tele Display" Screen ......................................... 451
10.4.2.2.2 "Length code (LC) selection in accordance with main boom
length" screen ...............................................................................454
10.4.2.2.2.1 Calling up the "Length code (LC) selection in accordance with
main boom length" screen ............................................................ 454
10.4.2.2.2.2 Structure of the "Length code (LC) selection in accordance with
main boom length" screen ............................................................ 455
10.4.2.2.3 "Length code (LC) selection in accordance with capacities (pin-
ned-unpinned)" screen ................................................................. 458
10.4.2.2.3.1 Calling up the "Length code (LC) selection in accordance with
capacities (pinned-unpinned)" screen .......................................... 458
10.4.2.2.3.2 Structure of the "Length code (LC) selection in accordance with
capacities (pinned-unpinned)" screen .......................................... 459
10.4.2.3 Procedure for Automatic Telescoping .......................................... 460
10.4.3 Manual telescoping .......................................................................464
10.4.3.1 General .........................................................................................464
10.4.3.2 Basic procedure for carrying out the functions lock / unlock or
pin / unpin ..................................................................................... 465
10.4.3.2.1 Variant 1: Semi-automatic (with preselection) .............................. 465
10.4.3.2.2 Variant 2: Manually (without preselection) ....................................465
10.4.3.2.3 Note on the described example ....................................................466
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10.4.3.3 Input and Monitoring Screens at Crane Control (Manual Tele-

scoping) ........................................................................................ 466
10.4.3.3.1 "Manual telescoping" screen ........................................................ 466
10.4.3.3.1.1 Purpose of the "Manual telescoping" screen ................................466
10.4.3.3.1.2 Calling up the "Manual telescoping" screen. ................................ 467
10.4.3.3.1.3 Exiting the "Manual telescoping" screen ...................................... 468
10.4.3.3.1.4 Structure of the "Manual telescoping" screen ...............................469
10.4.3.3.1.5 "Visual depiction of the LPU states" screen ................................. 474
10.4.3.3.1.6 "Teach telescope" screen .............................................................474
10.4.3.3.1.7 "Length code (LC) selection - teaching" screen ........................... 476
10.4.3.4 Procedure for manual telescoping with mechanical faults, semi-
automatic ...................................................................................... 479
10.4.3.5 Teaching the Extension State of the Telescopic Sections ............490
10.4.3.5.1 General Instructions on Risks .......................................................490
10.4.3.5.2 Procedure for teaching ................................................................. 491
10.4.3.5.3 Entering the length code directly during teaching .........................492
10.4.3.6 Procedure for manual telescoping in the case of electrical
faults ............................................................................................. 493
10.4.3.7 Locking and Pinning Positions of the Telescopic Drive ................ 495
10.4.3.7.1 LPU Position of the Main Boom of the AC 250-5 ......................... 496
10.5 Capacities in the Unpinned State ................................................. 499
10.5.1 General .........................................................................................499
10.5.2 Display of the "Unpinned capacities" table in crane control's op-
erating unit ....................................................................................501
10.5.3 Example: Permitted capacity / display in the "Crane operation"
screen ...........................................................................................502
10.5.3.1 Example: Capacity comparison AC 250-5 ....................................502
10.5.4 Lifting loads in unpinned intermediate positions ...........................506
10.5.5 Telescoping with a suspended load ............................................. 507
10.6 Put the main boom into transport condition .................................. 507
11 Luffing ......................................................................................... 511

11.1 Luffing Operation .......................................................................... 511
11.1.1 General Safety Instructions .......................................................... 511
11.1.2 Procedure for Luffing .................................................................... 512
11.2 Regulating the Luffing Speed ....................................................... 514
11.2.1 High speed mode "Raise main boom" .......................................... 514
11.2.2 Fine tuning "Lowering main boom" ...............................................514
11.3 Setting down the Main Boom in the Support Device for the
Boom ............................................................................................ 515
11.4 Dolly Preparation / Preparation for Dismantling the Main Boom
(Options) .......................................................................................515
12 Hoist 1 ..........................................................................................517
12.1 Hoist operation ............................................................................. 517
12.1.1 General Safety Instructions .......................................................... 517
12.1.2 Procedure for reeling the hoist rope in and out ............................ 517
12.2 Regulating the hoist speed ........................................................... 519
12.2.1 High speed ................................................................................... 519
12.2.2 Fine tuning ....................................................................................519
12.3 Camera monitoring of the hoist (optional) .................................... 520
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13 Hoist 2 (optional) ........................................................................ 521

13.1 Transport Dimensions and Weights ............................................. 521
13.2 Fitting and Removing Hoist 2 ....................................................... 521
13.2.1 General .........................................................................................521
13.2.2 When Fitting and Removing Hoist 2 with the Auxiliary Crane ...... 522
13.2.2.1 Before Fitting ................................................................................ 522
13.2.2.2 Fitting ............................................................................................524
13.2.2.3 Connecting ................................................................................... 526
13.2.2.4 Dismantling ...................................................................................530
13.2.3 When Fitting and Removing Hoist 2 with the Forklift Truck ..........531
13.2.4 Fitting and removing hoist 2 with your own crane (optional) ........ 532
13.2.4.1 General .........................................................................................532
13.2.4.2 Before Installation .........................................................................532
13.2.4.3 Fitting ............................................................................................535
13.2.4.3.1 Fitting the assembly unit on the draw bars of the counter-
weight ........................................................................................... 535
13.2.4.3.2 Fitting hoist 2 on the superstructure frame ................................... 538
13.2.4.3.3 Removing the configuration frame ................................................542
13.2.4.4 Dismantling ...................................................................................543
13.3 Hoist operation ............................................................................. 543
13.4 Regulating the hoist speed ........................................................... 544
13.5 Camera surveillance of the hoist (optional) .................................. 544
14 Heating and Ventilation ..............................................................547

14.1 Cab heater arrangement, engine-independent (optional auxili-
ary heating) ...................................................................................547
14.1.1 General .........................................................................................547
14.1.2 Operating / Safety Instructions ..................................................... 547
14.1.3 Heating system operating elements ............................................. 550
14.1.3.1 Control Elements in the Crane Operator's Cab ............................ 550
14.1.3.2 Overview of the display and the buttons .......................................551
14.1.3.3 Display ..........................................................................................551
14.1.3.4 Activating the display ....................................................................552
14.1.3.5 Function control button, LED ring and BACK key .........................552
14.1.4 Switching the heating on .............................................................. 553
14.1.4.1 General .........................................................................................553
14.1.4.2 Immediate heating without settings .............................................. 553
14.1.4.3 Heating with settings .................................................................... 553
14.1.4.4 Changing the operating duration during heating operation .......... 554
14.1.4.5 Switching off the heating system .................................................. 555
14.1.5 Preselection times ........................................................................ 556
14.1.5.1 Selecting timer slot ....................................................................... 556
14.1.5.2 Programming the timer ................................................................. 557
14.1.5.3 Deactivating the timer ...................................................................558
14.1.6 Basic settings ............................................................................... 559
14.1.6.1 First Operation ..............................................................................559
14.1.6.2 Set the time .................................................................................. 560
14.1.6.3 Setting the day of the week .......................................................... 561
14.1.6.4 Setting temperature format ...........................................................561
14.1.6.5 Resetting user settings ................................................................. 562
14.1.7 Fault finding and troubleshooting ................................................. 563
14.1.7.1 Error display operating panel ........................................................563
14.1.7.2 Possible faults in operating panel .................................................563
14.1.7.3 Possible faults in the heater assembly ......................................... 564
14.1.7.4 Read out faults ............................................................................. 565
14.1.7.5 Reading/deleting fault code (workshop menu) ............................. 565
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14.1.7.6 Overview of heater assembly fault code .......................................566

14.1.7.7 Diagnostics interface .................................................................... 570
14.2 Air conditioning (optional) ............................................................. 571
14.2.1 Operating the air conditioning .......................................................571
14.2.2 Notes on operating the air conditioning equipment ...................... 572
14.2.3 Switching on the Air-Conditioning (Damage Prevention) ............. 572
14.3 Auxiliary AC System (Optional) .................................................... 572
14.3.1 Operating additional air conditioning ............................................ 572
14.4 Petrol gas heating (optional) .........................................................574
14.4.1 Safety instructions (petrol gas heating) ........................................ 574
14.4.2 Operating element ........................................................................ 576
14.4.2.1 Operating element with combination rotary switch ....................... 576
14.4.2.2 Operating element with sliding switch .......................................... 577
14.4.3 Switching on the heating setting ...................................................578
14.4.3.1 Operating element with combination rotary switch ....................... 578
14.4.4 Switching on the ventilation setting .............................................. 579
14.4.4.1 Control element with combination rotary switch ........................... 579
14.4.5 Switching off the petrol gas heating ..............................................581
15 Reevings ......................................................................................583
15.1 General information/instructions on risks ..................................... 583
15.2 Load-handling Equipment .............................................................586
15.2.1 General .........................................................................................586
15.2.2 Hoist Ropes .................................................................................. 587
15.2.2.1 General .........................................................................................587
15.2.2.2 Rope End Connections .................................................................588
15.2.2.3 Reeving / unreeving the hoist rope ...............................................593
15.2.3 Hook blocks .................................................................................. 603
15.2.3.1 Definition .......................................................................................603
15.2.3.2 Markings ....................................................................................... 605
15.2.3.3 Operation ......................................................................................606
15.2.3.4 Vario Hook Block .......................................................................... 608
15.2.3.4.1 Components ................................................................................. 608
15.2.3.4.2 Placing the Vario hook block in the operating state (assembly) ... 609
15.2.3.4.3 Placing the Vario hook block in the transport condition (disman-
tling) ..............................................................................................612
15.2.3.5 Transport dimensions of the hook blocks ..................................... 616
15.3 Reeving the hoist rope on the main boom head with 4 head
sheaves ........................................................................................ 619
15.3.1 General .........................................................................................619
15.3.2 Reeving 8-, 7-fold ......................................................................... 619
15.3.3 Reeving 7-, 6-, 5-, 4-, 3-fold ..........................................................620
15.3.4 Reeving 3-, 2-, 1-fold .................................................................... 621
15.4 Reeving the hoist rope on the main boom head with 4 head
sheaves and additional head sheave (HD attachment, option-
al) ..................................................................................................622
15.4.1 General .........................................................................................622
15.4.2 Reeving 10-, 9-fold ....................................................................... 622
15.5 Reeving the Hoist Rope on the Main Boom Head with Two
Auxiliary Sheaves (HD Attachment, Optional) ..............................623
15.5.1 Fitting and Removing the HD Attachment .................................... 623
15.5.2 Reeving 14-, 12-fold ..................................................................... 629
15.6 Reeving the Hoist Rope on Additional Equipment ........................632
15.7 Reconfiguration of rope shackle for hoist 2 .................................. 632
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16 Central lubricating system (optional) ....................................... 635

16.1 Structure and lubrication chart ......................................................635
16.2 Settings Ex Works ........................................................................ 637
16.2.1 General .........................................................................................637
16.2.2 Set time values ............................................................................. 637
16.3 Activating the additional lubrication impulse .................................638
16.4 Manual Lubrication in the Case of an Emergency ........................639
16.5 Malfunction ................................................................................... 639
17 Head Sheave (Optional) ............................................................. 641

17.2 General .........................................................................................642
17.3 Fitting (assembly position) ............................................................643
17.4 Preparing the head sheave for operation ..................................... 648
17.4.1 Folding the head sheave down in the operating position ............. 648
17.4.2 Reeving the head sheave .............................................................650
17.4.3 Connecting the head sheave electrically (closing the safety
chain) ............................................................................................655
17.4.3.1 Distribution box "X0550" on the main boom head ........................ 655
17.4.3.2 Distribution box "X0560.1" on the head sheave ........................... 655
17.5 Operation ......................................................................................656
17.6 Fold backwards into transport position ......................................... 658
17.7 Dismantling ...................................................................................661
18 Assembly Jib (Optional) ............................................................ 663

18.2 General .........................................................................................664
18.3 Fitting and Removal ......................................................................665
18.4 Preparing assembly jib for operation ............................................ 668
18.4.1 Lowering the assembly jib into the operating position .................. 668
18.4.2 Reeving the assembly jib ..............................................................671
18.4.3 Connecting the assembly jib electrically (closing the safety
chain) ............................................................................................677
18.4.3.1 Distribution box "X0550" on the main boom head ........................ 677
18.4.3.2 Distribution box on the assembly jib ............................................. 678
18.5 Operation ......................................................................................679
18.6 Fold backwards into transport position ......................................... 680
18.7 Folding back the assembly jib ...................................................... 684
19 Main Boom Extension (Optional) .............................................. 685

19.1 General / Versions of the Main Boom Extension ..........................685
19.2 Important Notes ............................................................................ 687
19.3 Construction of the Main Boom Extension ................................... 698
19.3.1 Main Components of the Main Boom Extension .......................... 698
19.3.2 Combination of the Main Components ......................................... 699
19.3.3 Equipment on the basic machine (MBE with fixed operating an-
gles) ..............................................................................................700
19.3.4 Equipment on the basic unit (MBE with hydraulically smooth
operating angle adjustment) ......................................................... 700
19.4 Operation of the Crane with Main Boom Extension ......................710
19.4.1 Procedure for crane operation ......................................................710
19.4.2 Procedure for deconfiguring the main boom extension ................ 712
19.4.3 Setting the operating mode at crane control in the "Operating
mode selection" screen ................................................................ 714
19.4.4 Raising loads with the main boom extension folded in the
transport position .......................................................................... 715
19.5 Main Boom Extension Fitted to the Main Boom ........................... 715
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19.5.1 General .........................................................................................715

19.5.2 Transport Instructions for the MBE in the Transport Position .......716
19.5.3 General instructions and instructions on risks for folding over
the equipment ...............................................................................719
19.5.4 Folding over the 11,4 m MBE (37.4 ft) ..........................................721
19.5.4.1 MBE (11,4 m (37.4 ft)) Fitted in the Transport Position ................ 722
19.5.4.1.1 Folding over the MBE 11.4 m (37.4 ft) from the Transport into
the Operating Position .................................................................. 722
19.5.4.1.1.1 Procedure ..................................................................................... 722
19.5.4.1.1.2 Carrying out preparations on the main boom extension ...............728
19.5.4.1.1.3 Making Preparations on the Basic Crane Unit ..............................731
19.5.4.1.1.3.1Fitting the hoist rope on the run-in sheave on the main boom
head ..............................................................................................735
19.5.4.1.1.4 Folding the Main Boom Extension at the Side of the Rollway ...... 736
19.5.4.1.1.5 Folding the Main Boom Extension to the Front ............................ 742
19.5.4.1.1.6 Connecting the Electric Cables of the Main Boom Extension to
the Main Boom Head ....................................................................747
19.5.4.1.1.7 Fitting the tension plates in the 0° position ................................... 750
19.5.4.1.1.7.1Preparations for fitting / dismantling the tension plates ................ 754
19.5.4.1.1.7.2Fitting the tension plates and pinning the auxiliary cylinders ........754
19.5.4.1.1.7.3Pinning the tension plates for 0°- crane operation / relieving the
auxiliary cylinders of load ............................................................. 757
19.5.4.1.1.8 Fitting the tension plates in the 20°/40° position ...........................759
19.5.4.1.1.8.1Fitting the tension plates for 20° /40° crane operation and pin-
ning the auxiliary cylinders ........................................................... 763
19.5.4.1.1.8.2Lowering the main boom extension onto the ground ....................766
19.5.4.1.1.9 Fitting the adjusting cylinders (main boom extension with hy-
draulic continuous operating angle adjustment) ........................... 769
19.5.4.1.1.10Fitting the hoist rope and reeving the hook block ......................... 774
19.5.4.1.1.11Carrying out Remaining Work on the Basic Boom of the Main
Boom Extension ........................................................................... 777
19.5.4.1.1.12Carrying out Remaining Work on the Basic Crane Unit ............... 779
19.5.4.1.2 Folding from the Operating into the Transport Position ................780
19.5.4.1.2.1 Procedure ..................................................................................... 780
19.5.4.1.2.2 Carrying out preparations on the basic crane unit and the main
boom extension ............................................................................ 783
19.5.4.1.2.3 Moving the tension plates from the 0° position into the transport
position ......................................................................................... 787
19.5.4.1.2.3.1Engaging the auxiliary cylinder (0°) .............................................. 791
19.5.4.1.2.3.2Sliding in tension plates ................................................................793
19.5.4.1.2.4 Moving the tension plates from the 20°/40° position and placing
them in the transport position ....................................................... 795
19.5.4.1.2.4.1Engaging the auxiliary cylinder (20° / 40°). ...................................799
19.5.4.1.2.5 Placing the adjusting cylinders in the transport position ...............800
19.5.4.1.2.6 Carrying out preparations for folding up to the side of the basic
unit of the main boom extension ...................................................805
19.5.4.1.2.7 Carrying out preparations for folding up to the side of the main
boom .............................................................................................806
19.5.4.1.2.8 Folding the Main Boom Extension at the Side on the Main
Boom ............................................................................................ 810
19.5.4.1.2.9 Carrying out Remaining Work ...................................................... 817
19.5.4.2 MBE (21 m (68.9 ft)) Fitted in the Transport Position ................... 817
19.5.4.2.1 Folding over the MBE 11.4 m (37,4 ft) from the Transport into
the Operating Position .................................................................. 817
19.5.4.2.1.1 Fastening the Box Top Piece to the Main Boom .......................... 823
19.5.4.2.2 Folding from the Operating into the Transport Position ................825
19.5.5 Folding over the 21 m MBE (68.9 ft) .............................................827
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19.5.5.1 Folding over the MBE 21 m (68.9 ft) from the Transport into the
Operating Position ........................................................................ 827
19.5.5.1.1 Making Preparations for Folding over at the Main Boom Exten-
sion ............................................................................................... 833
19.5.5.1.2 Folding the Box Top Piece to the Front ........................................ 837
19.5.5.1.3 Connecting the Box Top Piece at the Front to the Basic Boom
MBE Electrically ............................................................................841
19.5.5.1.4 Fitting the hoist rope and reeving the hook block ......................... 841
19.5.5.1.5 Carrying out Remaining Work on the Box Top Piece ................... 846
19.5.5.2 Folding the 21 m MBE (68.9 ft) from the Operating into the
Transport Position ........................................................................ 848
19.5.5.2.1 Carrying out preparations on the basic crane unit and the main
boom extension ............................................................................ 853
19.5.5.2.2 Making Preparations at the Box Top Piece .................................. 857
19.5.5.2.3 Folding the Box Top Piece at the Side on the Basic Boom
MBE ..............................................................................................859
19.6 Transporting the Main Boom Extension Separately ..................... 862
19.6.1 Transport Instructions for Separate Transport ..............................862
19.6.2 Transport Dimensions / Weights, Attachment Points ................... 864
19.6.2.1 Transport Dimensions / Weights .................................................. 864
19.6.2.2 Attachment points .........................................................................865
19.6.3 Fitting and dismantling for separate transportation ...................... 867
19.6.3.1 General instructions and instructions on risks for fitting ............... 867
19.6.3.2 Fitting the 11.4 m MBE (37.4 ft) ....................................................868
19.6.3.2.1 Carrying out preparations on the main boom extension ...............872
19.6.3.2.2 Making Preparations on the Basic Crane Unit ..............................872
19.6.3.2.3 Fitting the basic boom of the main boom extension on the main
boom head in the 0°-position ........................................................874
19.6.3.2.3.1 Fitting the tension plates on the head of the main boom in the
0°position and pinning them ......................................................... 875
19.6.3.2.3.2 Connecting the Electric Cables of the Main Boom Extension to
the Main Boom Head ....................................................................877
19.6.3.2.4 Fitting the basic boom of the main boom extension on the main
boom head in the 20°/40°-position ............................................... 879
19.6.3.2.4.1 Fitting the tension plates on the head of the main boom and
pinning for 20°/40° crane operation. ............................................. 881
19.6.3.2.4.2 Lowering the main boom extension onto the ground ....................883
19.6.3.2.5 Fitting the basic boom of the hydraulically adjustable main
boom extension on the main boom head ..................................... 884
19.6.3.3 Fitting the 21 m MBE (68.9 ft) .......................................................891
19.6.3.3.1 Fitting the basic boom of the main boom extension and box top
piece on the main boom head in the 0°-position .......................... 894
19.6.3.3.1.1 Fitting the Box Top Piece at the Front on the Basic Boom of the
Main Boom Extension ...................................................................897
19.6.3.3.2 Fitting the basic boom of the main boom extension and box top
piece on the main boom head in the 20°/40° position .................. 898
19.6.3.3.2.1 Fitting the basic boom of the main boom extension ..................... 900
19.6.3.3.2.2 Removing the top bolt at the back on the basic boom of the
MBE ..............................................................................................901
19.6.3.3.3 Fitting the basic boom of the hydraulically adjustable main
boom extension and box top piece on the main boom head ........ 901
19.6.3.4 Fitting the 23.4 m MBE (76.8 ft) ....................................................903
19.6.3.4.1 Making Preparations on the Basic Crane Unit ..............................907
19.6.3.4.2 Fitting the intermediate section and the basic boom on the
main boom head in the 0°-position ............................................... 909
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19.6.3.4.2.1 Fitting the Intermediate Section on the Main Boom Head ............ 912
19.6.3.4.2.2 Connecting the Intermediate Section to the Main Boom Head
Electrically .................................................................................... 914
19.6.3.4.2.3 Fit the tension plates at the front on the intermediate section in
the 0° position and pin .................................................................. 916
19.6.3.4.2.4 Connecting the Main Boom Extension on the Intermediate Sec-
tion Electrically ..............................................................................918
19.6.3.4.3 Fitting the intermediate section and the basic boom MBE to the
main boom head in the 20°/40° position .......................................918
19.6.3.4.3.1 Fitting the tension plates at the front on the intermediate sec-
tion and pinning in place for 20° /40° crane operation ..................921
19.6.3.4.4 Fitting the intermediate section and basic boom of the hydraulic
MBE on the main boom head ....................................................... 922
19.6.3.4.4.1 Connecting the electric and hydraulic cables of the intermedi-
ate section to the main boom head .............................................. 925
19.6.3.4.4.2 Connecting the Main Boom Extension (HAVHY) on the Inter-
mediate Section Electrically ..........................................................929
19.6.3.5 Fitting the 33 m (108.3 ft) MBE .....................................................938
19.6.3.5.1 Fitting the intermediate section, basic boom and box top piece
on the main boom head in the 0°-position .................................... 943
19.6.3.5.2 Fitting the intermediate section, basic boom and box top piece
on the main boom head in the 20°/40° position ............................946
19.6.3.5.3 Fitting the intermediate section, basic boom of the hydraulic
MBE and box top piece on the main boom head ..........................948
19.6.3.6 Fitting the 35.4 m (116.1 ft) MBE ..................................................955
19.6.3.6.1 Fitting the intermediate sections and the basic boom MBE on
the main boom head .....................................................................957
19.6.3.6.1.1 Connecting the front intermediate section to the rear intermedi-
ate section electrically and hydraulically .......................................960
19.6.3.7 Fitting the 45 m (147.6 ft) MBE .....................................................964
19.6.3.7.1 Fitting the intermediate sections, basic boom MBE and box top
piece on the main boom head ...................................................... 967
19.6.3.8 Converting from One Length to Another .......................................975
19.7 Positioning / Reeving the Hoist Rope ........................................... 976
19.7.1 Fitting the Hoist Rope on the Main Boom Extension: ................... 977
19.7.2 Fitting the hoist rope on the main boom head .............................. 978
19.7.3 Fitting the front hoist rope on the rear intermediate section
(35.4 m / 116.1 ft and 45 m / 147.6 ft MBE) ................................. 979
19.7.4 Fitting the hoist rope at the front on the intermediate section to
which the basic boom MBE is attached (23.4 m / 76.8 ft MBE,
33 m / 108.3 ft MBE, 35.4 m / 116.1 ft MBE and 45 m / 147.6 ft
MBE) .............................................................................................979
19.7.5 Fitting the hoist rope to the rear rope sheave of the basic boom
MBE (all MBE variants) ................................................................ 980
19.7.6 Fitting the hoist rope at the front on the basic boom MBE (11.4
m / 37.4 ft MBE, 23.4 m / 76.8 ft MBE and 35.4m / 116.1ft
MBE) .............................................................................................981
19.7.7 Fitting the hoist rope at the front on the basic boom MBE (21
m / 68.9 ft MBE, 33 m / 108.3 ft MBE and 45 m / 147.6 ft
MBE) .............................................................................................982
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19.7.8 Fitting the hoist rope to the box top piece (21 m / 68.9 ft MBE,
33 m / 108.3 ft MBE and 45 m / 147.6 ft MBE) .............................983
19.8 Adjustment of the operating angle for fitted MBE ......................... 984
19.8.1 Adjusting the operating angle - Instructions on risks and gener-
al instructions ................................................................................984
19.8.2 On basic booms of the MBE with fixed operating angles:
change from 0 - degree to 20 -/ 40 - degree position (and vice
versa) ............................................................................................986
19.8.2.1 Making Preparations for Angling the Main Boom Extension ........ 990
19.8.2.2 Moving the tension plates from the 0° position into the 20° / 40°
position ......................................................................................... 992
19.8.2.2.1 Moving the bolts from the 0° position into the 20°/40° position
(on the main boom head) ............................................................. 995
19.8.2.2.2 Moving the bolts from the 0° position into the 20°/40° position
(on the head of the intermediate section) ..................................... 997
19.8.2.3 Moving the tension plates from the 20° / 40° position into the 0°
position ......................................................................................... 998
19.8.2.4 Carrying out the remaining work on the main boom and MBE ... 1000
19.8.3 Setting the Operating Angle on the Hydraulically Luffing MBE
("HAVHY") .................................................................................. 1003
19.8.3.1 Instructions on Risks and General Instructions .......................... 1003
19.8.3.2 Procedure ................................................................................... 1004
19.8.3.3 Display on crane control ............................................................. 1005
19.8.3.4 Setting the Operating Angle at the Radio Remote Control .........1006
19.9 Dealing with faults ...................................................................... 1007
19.9.1 Emergency Set down in the Case of Telescoping Problems ......1007
19.9.2 Retracting the hydraulic cylinders on the basic boom of the
MBE ............................................................................................1007
19.10 Main Boom Extension with Load Hook Camera / Hanging Light
(Optional) ....................................................................................1010
19.10.1 General Information / Operation ................................................. 1010
19.10.2 Assembling / Dismantling the Load Hook Camera ..................... 1011
19.10.3 Assembling / Dismantling the Hanging Light .............................. 1015
20 Radio Remote Control (Optional) ............................................1019

20.1 Intended use ...............................................................................1019
20.2 Safety Instructions ...................................................................... 1020
20.3 General .......................................................................................1024
20.4 Radio Receiver ........................................................................... 1025
20.5 Radio Transmitter ....................................................................... 1027
20.5.1 Radio transmitter, front, general ................................................. 1027
20.5.2 Radio transmitter, front, crane functions .....................................1028
20.5.3 Radio transmitter, lateral operating elements .............................1030
20.5.4 Screens in the displays ...............................................................1030
20.5.4.1 General .......................................................................................1030
20.5.4.2 Display, left ................................................................................. 1031
20.5.4.3 Display, right ...............................................................................1033
20.6 Control Lever Assignment .......................................................... 1034
20.7 Commissioning the Radio Remote Control ................................ 1035
20.8 Crane Operation Using Radio Remote Control .......................... 1043
20.9 Putting the Radio Remote Control Out of Operation .................. 1044
20.9.1 Standard Switching off Procedure .............................................. 1044
20.9.2 Shutting down Using the Quick Stop Switch .............................. 1046
20.9.3 Automatic Shut-down of the Transmitter .................................... 1047
20.10 Power Supply ............................................................................. 1048
20.10.1 Nickel Metal Hydride Accumulator Battery (Battery) .................. 1048
20.10.2 Battery Charging Device .............................................................1049
82640 2021-04-22 21
Table of contents
20.11 Troubleshooting ..........................................................................1051

20.12 servicing ..................................................................................... 1051
21 Emergency Operation (Optional) ............................................ 1053

21.1 General .......................................................................................1053
21.2 Emergency hydraulic lowering ....................................................1054
21.2.1 Emergency hydraulic lowering using an assisting crane ............ 1054
21.2.1.1 Intended use ...............................................................................1054
21.2.1.2 Safety Instructions ...................................................................... 1054
21.2.1.3 General information (hydraulic emergency lowering using an
assisting crane) .......................................................................... 1056
21.2.1.4 Connections on the hydraulic transformer ..................................1057
21.2.1.5 Equipment on the Crane .............................................................1058
21.2.1.6 Connecting the Hydraulic Transformer .......................................1059
21.2.1.7 Recovering a Small Load ........................................................... 1062
21.2.1.8 After Recovering a Small Load ...................................................1066
21.2.2 Emergency hydraulic lowering using the 8 kW power unit ......... 1068
21.2.2.1 General information (hydraulic emergency lowering using the 8
kW power unit) ............................................................................1068
21.2.2.2 Connections on the 8 kW power unit ..........................................1069
21.2.2.3 Connecting the Hydraulic Transformer .......................................1069
21.2.2.4 Recovering a Small Load ........................................................... 1072
21.2.2.5 After recovering a small load ...................................................... 1073
21.2.3 Interface for Drive of the Hydraulic Emergency Lowering (Op-
tional) ..........................................................................................1073
21.3 Electrical emergency control system .......................................... 1074
21.3.1 Intended use ...............................................................................1074
21.3.2 Safety Instructions ...................................................................... 1075
21.3.3 Components ............................................................................... 1076
21.3.4 Mobile Manual Control Panel ..................................................... 1077
21.3.4.1 Rough structure .......................................................................... 1077
21.3.4.2 Operating Elements of the Locking and Pinning Unit (LPU) .......1078
21.3.4.3 Position Sensor System of the LPU ........................................... 1078
21.3.4.4 State Sensor System of the LPU ................................................1079
21.3.4.5 Telescopic Section Identification ................................................ 1080
21.3.4.6 Function Elements ......................................................................1080
21.3.4.7 Crane Movements ...................................................................... 1081
21.3.4.8 Accumulator loading pressure "LPU" ......................................... 1082
21.3.5 manufacture ................................................................................1082
21.3.6 Carrying out crane movements using the electric emergency
control system ............................................................................ 1086
21.3.6.1 Safety Instructions ...................................................................... 1086
21.3.6.2 Slew gear ....................................................................................1086
21.3.6.3 Hoists ..........................................................................................1087
21.3.6.4 Luffing gear .................................................................................1087
21.3.6.5 Telescoping ................................................................................ 1088
21.3.6.5.1 General .......................................................................................1088
21.3.6.5.2 Telescoping the LPU .................................................................. 1088
21.3.6.5.3 LPU states .................................................................................. 1089
21.3.6.5.4 Telescopic Section Identification ................................................ 1090
21.3.6.5.5 Hydraulic oil supply to the LPU ...................................................1091
21.3.6.5.6 Move the LPU to the home position (unlocked and pinned,
max. telescoped in) .................................................................... 1091
21.3.6.5.6.1 General .......................................................................................1091
21.3.6.5.6.2 State 1: LPU "unlocked and pinned" .......................................... 1091
21.3.6.5.6.3 State 12: LPU "State change lock and pinned" .......................... 1091
21.3.6.5.6.4 State 2: LPU "locked and pinned" .............................................. 1092
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Table of contents
21.3.6.5.6.5 State 23: LPU "locked and state change pinning" ...................... 1092
21.3.6.5.6.6 State 3: LPU "locked and unpinned" .......................................... 1093
21.3.6.5.6.7 State 5: LPU "No information concerning the state available" ....1093
21.3.6.5.7 Retraction of the Boom from the LPU to the Basic Position ....... 1093
21.3.6.5.8 Example of manual telescoping procedure ................................ 1096
21.3.7 Fault Messages .......................................................................... 1099
22 Emergency Operation (Optional) ............................................ 1101

22.1 General .......................................................................................1101
22.2 Emergency Unit .......................................................................... 1102
22.2.1 Intended use ...............................................................................1102
22.2.2 Main Components of the Emergency Unit ..................................1102
22.2.3 Operating and control elements ................................................. 1103
22.2.4 Specifications ............................................................................. 1106
22.2.5 Transport and Storage ................................................................1107
22.2.6 Fault finding and troubleshooting control panel ..........................1107
22.2.6.1 General information on faults and displays ................................ 1107
22.2.6.2 Engine faults ...............................................................................1108
22.2.6.3 Faults in the exhaust gas aftertreatment system ........................1111
22.2.6.4 Suppressing the regeneration of the diesel particle filter ............1112
22.3 Connecting the Emergency Unit .................................................1113
22.4 Carrying out Emergency Operation ............................................ 1116
22.4.1 General .......................................................................................1116
22.4.2 Before starting the emergency unit's motor ................................ 1116
22.4.3 Starting the emergency unit motor ............................................. 1117
22.4.4 Setting crane control to emergency operation ............................1119
22.5 After Emergency Operation ........................................................ 1120
23 Dismantling and Assembly of the Main Boom (Optional) .... 1123

23.1 Safety Instructions ...................................................................... 1123
23.2 General .......................................................................................1125
23.3 Transport of the dismantled main boom ..................................... 1126
23.3.1 Transport dimensions and weights .............................................1126
23.3.2 Attachment points .......................................................................1127
23.3.3 Lashing eyes .............................................................................. 1127
23.4 Before Removal ..........................................................................1128
23.5 Dismantling .................................................................................1129
23.5.1 Perform Preparative Work .......................................................... 1129
23.5.2 Attaching the safety mast (optional) for anti-fall protection .........1131
23.5.3 Attaching the main boom ............................................................1134
23.5.4 Luffing cylinder headpin ..............................................................1139
23.5.4.1 Perform Preparative Work .......................................................... 1139
23.5.4.2 Supplying the mobile cylinder with hydraulic oil ......................... 1140
23.5.4.3 Pulling the Luffing Cylinder Headpin .......................................... 1142
23.5.5 Main Boom Foot Section Pins .................................................... 1145
23.5.5.1 Perform Preparative Work .......................................................... 1145
23.5.5.2 Pulling the Main Boom Foot Section Pin .................................... 1147
23.5.6 Lifting out the main boom ........................................................... 1150
23.5.7 Concluding Work ........................................................................ 1151
23.6 Fitting the main boom ................................................................. 1152
Index of figures ........................................................................ 1155
Index of tables ......................................................................... 1188
82640 2021-04-22 23
Table of contents
24 82640 2021-04-22
1 Safety Instructions
1.1 General
This section gives a general overview of risks which can occur in con-
nection with crane operation and driving the crane.
This information is referred to and dealt with in further detail in the
corresponding sections in the operating instructions as required.
Information on safely carrying out lubrication, service and mainte-
nance work can be found in the corresponding section in the lubrica-
tion and maintenance instructions. If there are separate assembly in-
structions, they apply accordingly.
1.2 Warning Information
1.2.1 General
The crane complies with state of the art technology and recognised
safety regulations. However, risks can occur during operation and
driving.
Warning information indicates these risks in these instructions.
82640 2021-04-22 25
1.2.2 Structure
The structure is explained using the example of the depicted warning
information.
Fig. 1: Safety note (z82353)
1 Pictogram 2 Sign for danger / risk

3 Signal word 4 Type and source of the danger
5 Possible consequences 6 Measures for prevention / bans
Item Function
1 Pictogram, optional: symbolises consequences, measures or
bans concerning a concrete type of risk; alternatively, the
general sign for danger/risk (such as item "2") appears in
large.
2 Sign for danger/risk, general: indicates the risk of injury to
persons
3 Signal word: indicates the extent of the risk and severity of
possible injury to persons
4 Type and source of the danger
5 Possible consequences
6 Measures for prevention / bans
Points "4" and "5" can also be combined.
26 82640 2021-04-22
1.2.3 Types
The following types of warning information are used in these instruc-
tions:
DANGER
Hazardous situation with a high level of risk, result-
ing in death or serious injury if not avoided.
WARNING
Hazardous situation with a moderate level of risk,
which could result in death or serious injury if not
avoided.
CAUTION
Hazardous situation with a low level of risk, which
could result in moderate or minor injuries if not avoi-
ded.
NOTE
Hazardous situation which could result in damage to goods or
property.
Particularly important or further information is indicated without a sig-

nal word in the following manner:
This is an example for an indication of particularly important or fur-

ther information.
1.2.4 Warning symbols

Symbol Meaning
General warning sign
Warning, explosive substances
82640 2021-04-22 27
Symbol Meaning
Warning, radioactive substances or ionising radiation
Warning, laser radiation
Warning, non-ionising radiation
Warning, magnetic field
Warning, obstacles at ground level
Warning, risk of falling
Warning, biohazard
Warning, low temperature/frost
Warning, risk of slipping
Warning, electrical voltage
Warning, forklift trucks
Warning, hanging load
28 82640 2021-04-22
Symbol Meaning
Warning, toxic substances
Warning, hot surface
Warning, automatic start-up
Warning, risk of crushing
Warning, obstacles at head height
Warning, flammable substances
Warning, sharp object(s)
Warning, corrosive substances
Warning, hand injuries
Warning, counter-rotating rollers
Warning of hazards associated with charging batteries
Warning, optical radiation
82640 2021-04-22 29
Symbol Meaning
Warning, oxidising substances
Warning, gas cylinders
Table 1: Warning symbols
1.3 Intended Use

The crane is designed for raising and lowering non-fixed loads.
The crane is designed exclusively for assembly operation.
Intended use also includes the observation of all capacity tables, the
operating instructions - in particular with regard to the specified as-
sembly sequence - and the lubrication and maintenance specifica-
tions.
Any other use or any further use such as e.g. handling general cargo,
pulling stuck loads free or grab operation, are not classified as in-
tended use. The manufacturer shall not be held liable for any dam-
age which results. The operator carries full responsibility for this type
of use.
If operation of the crane for general cargo handling or another type of
use is required, please contact the crane manufacturer.
The use of two hoists to raise the load (2-hook operation) is not per-
mitted. Special load cases are however permitted in consultation with
the crane manufacturer.
The crane is not intended for lifting people. It is prohibited to trans-
port people with personnel carrying equipment!
30 82640 2021-04-22
DANGER
Risk to life and limb when not used in accordance
with regulations.
In many cases, there have been serious injuries when
people have been transported using personnel carrying
equipment (or even on the hook or on loads). In these
cases, they have no control over crane movements and
are not protected against bumps or falls. Even the small-
est of errors can have fatal consequences.
Never use the mobile crane for entertainment purpo-
ses, e.g. for lifting persons for shows, "bungee jump-
ing" (leaping / bouncing from an elastic rope), "dinner-
in-the-sky" or lifting other equipment with people on
the equipment or underneath it (e.g. lifting of tents).
This is improper use of the crane and constitutes ex-
treme danger to life and limb.
The crane may only be used to lift people in a so-called "personnel

cage" and to keep them at that height as an exception in extraordi-
nary operating situations and when it is the least dangerous way of
carrying out the work.
This does not apply to the working platforms fitted to the crane
boom which are intended for lifting people, as they are covered by
international standards for mobile hoist operating platforms.
Such an exceptional use is only permitted if all the requirements

listed below are satisfied.
The crane operator carries the responsibility.
General requirements for using a personnel cage as an excep-
tion
- The use of mobile cranes for lifting persons is permitted by nation-
al law in the country of the crane's current operation. Specific regu-
lations for the use of personnel cages as stipulated by national law
are applied.
- The use of the crane for lifting persons is reported to the national
health and safety authority if required by national law (the use may
need special approval).
- The possibility of rescuing people in the personnel cage in the
case of an emergency has been evaluated prior to the job by
means of a job-specific risk assessment. Provisions for emergency
rescues must be taken if so required by national law.
- A pre-lift meeting has been held with all the relevant participating
people.
- The provisions for working in the vicinity of power lines according
to the job-site conditions and national law / regulations are ob-
served.
82640 2021-04-22 31
Requirements concerning Equipment for the exceptional case of

a personnel cage
- With the exception of the personnel cage being the load, the crane
is used as intended and described in the respective operating in-
structions.
- The crane is checked and no damage / defects are found prior to
lifting persons.
- The personnel cage fulfils the requirements in accordance with na-
tional law and / or standards and is used as intended.
- The personnel cage is thoroughly checked prior to lifting persons
and no defects are found.
- Any emergency rescue device as required by national law has
been checked and found to be operational.
- Hooks used must be equipped with a safety catch which prevent
the hook jaw from opening. It is required by national law to either
close the lock manually and to lock or to use an automatically op-
erated, spring-loaded safety catch.
Requirements concerning Tests before using a personnel cage
in exceptional circumstances
- Prior to lifting persons, an overload test lift (approval test) with an
overload of 125% of the lifting capacity of the personnel cage has
been carried out. This must be done at each new construction site
and after every modification or repair to verify the safe perform-
ance of the personnel cage and the lifting tackle (relocation of the
crane to a larger construction site does not require a new overload
test).
- Prior to lifting persons, a test lift has been carried out with an unoc-
cupied personnel cage, which has, however, been loaded with at
least the anticipated lift weight (simulating a loaded man basket),
in order to simulate the complete planned lifting cycle. This trial lift
must be done wherever the crane is set up on the construction site
for lifting persons.
Requirements for using a personnel cage as an exception
- The rope pull is limited to 50% of the maximum rope load.
- The crane is used at 50% of the maximum capacity of the relevant
load capacity table.
You must also observe the corresponding guideline ICSA N003 of

the International Crane Stakeholder Assembly. You can find this on
the FEM (European materials handling federation) homepage under
the "Cranes & Lifting Equipment" product group.
32 82640 2021-04-22
Operating cranes on vessels, barges and pontoons

The capacities listed in the capacity tables can only be raised if all
specifications in "Notes on crane operation"- supplied with the capaci-
ty tables - are complied with. This includes among other things:
- Crane is set on horizontally level ground (±0.5%)
- The ground must have sufficient bearing capacity for the resulting
ground pressures.
Since the operation on vessels, barges or pontoons generally cannot
comply with this condition, additional documentation (buoyancy and
resistance to capsize) must be provided by the operators (e.g. in ac-
cordance with EN 13852-2 ; floating cranes).
1.4 Working Conditions and Computed Design of the Crane
1.4.1 General
The crane has been constructed using state of the art technology and
in accordance with recognised safety regulations. Nevertheless, its
use can lead to hazards for the life and limb of the operator and third
parties, and/or damage to the machine and other objects.
Use the crane only when it is in full working order and only for its in-
tended use, paying attention at all times to safety and potential haz-
ards, and in observance of the operating instructions. In particular
have any malfunctions which might impair safety rectified immediate-
ly.
The term "Operating instructions" refers to the operating instruc-

tions, the assembly instructions (if separately at hand) and the lubri-
cation and maintenance instructions.
1.4.2 Classification of the Crane

The crane is classified in accordance with ISO 4301 and EN 13000
as listed below:
Operating class => U1

Collective class => Q2
Crane group => A1
All important components of the crane are designed and manufac-

tured for normal assembly operation. This assumes that crane opera-
tions under full load, crane operations with lower load and operating
breaks occur in a ratio that is typical for an assembly crane. More ex-
acting working conditions necessarily lead to a shorter service life for
the crane.
Working conditions or types of use other than assembly operation re-
quire the permission of the manufacturer and normally lead to a re-
duction in the lifting capacities.
82640 2021-04-22 33
1.4.3 Classification of the power units

The power units are also classified in accordance with ISO 4301-2
and FEM 1.001. They have been calculated and designed based on
specific working conditions which are laid down in European stand-
ards.
The winches of your crane are classified as follows:
Power unit group: M........

Load spectrum: Q ........ (L .......)
Factor of the load collective: Km = .......
Theoretical Service Life: D = .......
The individual values can be taken from the table "Monitoring the
winches" in the crane log book.
The classification of the power units is the basis for their evaluation
during the annual inspection (see Lubrication and Maintenance In-
structions).
1.4.4 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the configuration,
boom length and working radius. It is specified by the crane manufac-
turer in the load capacity tables.
The capacity tables supplied with the crane specify limit values which
may not be exceeded.
The limit of the winches' load bearing capacity is basically reached
when the rope force has reached its permitted value. Low loads with
a small amount of reeving can place the winch under just as much
load.
1.4.5 Required Ambient Conditions

Ambient temperature
The permitted temperature range for crane operation is -25°C to
+40°C (-13°F to +104°F) if the maximum and minimum temperatures
only occur a few days a year.
If temperatures are below -20°C (-4°F), the following also applies:
- Adapt consumables
The consumables may not cover the entire temperature range.
They must therefore be replaced if necessary.
To do so, observe the detailed specifications in the section "Con-
sumables and capacities" in the lubrication and maintenance in-
structions.
- Optional equipment
The crane must be equipped with auxiliary heating and a fuel pre-
heater.
34 82640 2021-04-22
The corresponding consumables and optional equipment can be

supplied.
- Warm-up phase
To do so, observe the relevant specifications in the operating in-
structions, section "Engine", and in the lubrication and mainte-
nance instructions, section "Consumables and capacities", under
"Specifications / legend for consumables tables".
The crane can be operated fully loaded up to 1000 m (3280 ft) above
mean sea level. It is not hazardous to operate the crane up to an op-
erating height of 2000 m (6560 ft) above mean sea level.
The crane can also be operated without danger with high / low rela-
tive air moisture.
Continuous operation in aggressive air (e.g. harbours, chemicals in-

dustry, steelworks etc.) combined with high relative air moisture can
require special care or maintenance work and an adapter kit / op-
tional equipment if necessary.
Increased dust concentration or use in desert regions requires

shorter intervals between lubrication and more frequent filter
changes. Dust concentration levels of up to 35 mg/m³ are permitted
for a short period of time.
The crane may be only operated up to specific wind speeds, de-
pending on boom length, equipment fitted and dynamic pressure.
WARNING
Risk of accidents with oncoming wind.
There is a risk of accidents if the permitted wind speeds
are exceeded.
Adhere to the relevant regulations in the operating in-
structions (see section "Working instructions" or
"Working with the crane equipment").
The ground on which the crane is supported on outriggers - or on

which it is parked or driven - must have sufficient load-bearing capaci-
ty. Detailed information on the load-bearing capacity of the ground
can be found in the section "Working instructions" or "Working with
the crane equipment" or "Outriggers", depending on the crane type.
The demands on the road for the various driving configurations are
described in the "Driving" section.
Use of the crane in a potentially explosive atmosphere or in oper-
ating conditions where combustible gas can be drawn in is only per-
mitted after corresponding conversion.
82640 2021-04-22 35
1.4.6 Service Life

Classification of the crane is based on a total operating life (service
life) of 20 years under the following conditions:
- the crane is operated as an assembly crane.
The capacity tables authorised for the crane are for assembly opera-
tion only. General cargo handling or grab operation can only be per-
mitted following express permission from the manufacturer under
suitable conditions.
- the entire number of the crane's load cycles in this time is less
than 32 000 (for example, 5 - 10 strokes / day on 200 days / year).
A "load cycle" encompasses all processes which begin when a load

is raised and end when the crane is ready to raise the next load.
- The type of load (the load spectrum) of the entire crane does not
indicate any proportions which are less favourable than the follow-
ing values:
- for 1/10 of the load cycles, the crane is placed under max. load
- for 4/10 of the load cycles with 50% of the max. load
- for 5/10 of the load cycles with 33% of the max. load
"Load" in this context refers to the sum of the load, load-handling

devices and lifting tackle (e.g.: load + hook block + sling ropes).
Under these conditions, assuming that maintenance work is carried

out properly, the theoretical service life can be more than 20 years.
Harder operating conditions naturally lead to a reduction in the serv-
ice life.
WARNING
The service life of components deviates from the
crane's service life.
Some components are not designed for the entire serv-
ice life of the crane.
For the winches, observe the regulations for deter-
mining the remaining theoretical service life in the
section "Inspections of the crane" in the lubrication
and maintenance instructions.
Replace certain components (e.g. ropes) with new
ones after a certain amount of time has passed.
Observe the instructions in the lubrication and main-
tenance instructions.
36 82640 2021-04-22
1.4.7 Scrapping / Disposal

If the crane (or components thereof) is/are scrapped, you must en-
sure professional disposal. It is particularly important that no poison-
ous materials (fuel, oil, etc.) or substances which are incompatible
with the environment (e. g., plastics) pollute the environment. The rel-
evant national regulations must be adhered to.
1.4.8 Standards and Calculation Regulations

The calculation of the crane corresponds with the requirements of
ISO 4301 and EN 13000.
For countries in which other regulations and standards apply, special-
case service life calculations can be carried out. If required, these cal-
culations must be specially ordered by the crane operator. The work-
ing conditions for the crane are not altered, however it may be neces-
sary to limit the lifting capacities.
1.4.9 Dangers to Air Traffic

As considerable heights are reached when the crane is operated, this
can lead to air traffic being endangered. For this reason, in particular
in the vicinity of airports, landing areas and air traffic control areas
(so-called protected zones), the crane may only be operated with the
permission of the authorities responsible for air traffic control.
For more information regarding Germany, contact the Deutsche Flug-
sicherung GmbH (DFS).
Observe respective national regulations.
1.5 Organisational Measures

In addition to the operating instructions, applicable national regula-
tions and any other binding regulations on the prevention of accidents
and protection of the environment must be followed and passed on.
These should be added to the operating instructions.
Such stipulations could involve, e. g., handling hazardous substan-

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

regulations valid in the country and on the operating site where the
crane is in use, the recognised technical regulations pertaining to safe
and correct working procedures must also be observed.
Supplement the operating instructions by any other required instruc-
tions, including supervisory and reporting duties for any special oper-
ating occurrences, e. g. with regard to work organisation, operating
procedures, allocated personnel, etc.
82640 2021-04-22 37
Ensure that all safety and warning signs on the crane are complete
and legible.
Safety guards on the crane must not be opened or removed during
crane operation.
Provide instructions on the location and use of fire extinguishing
equipment.
For crawler-mounted cranes, the supplied fire extinguisher is in the

area of the catwalk behind the crane operator’s cab.
For cranes with the chassis on wheels, the supplied fire extinguisher
is in a bracket in the driver's cab. It must be kept there during driving
or when the crane is not in operation. If there is a second holding
device in your crane outside of the cab, the fire extinguisher must be
stored there during crane operation. If there is no such holding de-
vice, ensure that the fire extinguisher can be accessed quickly and
easily at all times.
In case of poor visibility or darkness, the immediate area in front of

the crane operator's cab, the outriggers and the winches must be illu-
minated by the work lights, which are fitted on the machine (rear exte-
rior lighting, front exterior lighting, side exterior lighting). Other sur-
rounding areas (load, load path, slewing range, driving path, and simi-
lar) must be lit using suitable means, independently of the crane. The
responsibility for this lies with the crane operator.
1.6 Personnel Requirements

To make optimum use of a crane, without overloading it or failing to
use it to its full potential, the crane operator and the maintenance, as-
sembly and dismantling personnel must be thoroughly trained. The
crane operator / owner is responsible for providing this training.
Use only reliable, trained or instructed personnel for work on and with
the crane.
Make sure that only authorised personnel are allowed to carry out
work. Observe the minimum working age.
Personnel must be physically and mentally capable and may not be
under the influence of alcohol, drugs or medicine.
Clearly specify all areas of responsibility:
- for operation, configuration and maintenance.
- for the machine operator, also with regard to responsibility for ob-
serving road traffic regulations. Allow him to refuse instructions
from third parties which contravene safety regulations.
Personnel who are still being trained and instructed in the use of the
crane, or who are completing a general apprenticeship, may only be
allowed to work on the crane under the constant supervision of an ex-
perienced member of staff.
38 82640 2021-04-22
The crane operator must be familiar with the technical data, the ca-
pacity and the safety equipment of the crane, as well as the operating
elements and their assignment - before commencing work. Person-
nel who are responsible for work on the crane must have read the op-
erating instructions before commencing work, and in particular the
section on "Safety instructions". It is too late in the middle of crane
operations. This applies especially to personnel who only work on
the crane occasionally - e. g. for configuration or maintenance work
on the crane.
Check - at least now and then - to make sure that all personnel are
working safely and are aware of risks and are following the operating
instructions.
Personnel must have their hair tied back if it is long, and may not
wear loose clothing or jewellery, including rings. There is a risk of in-
jury, e. g. as a result of being caught or dragged in by moving parts.
1.7 Particular Hazards
1.7.1 High voltage

With high voltage lines, any direct contact with the boom or the hoist
rope is always dangerous. With high voltage lines above 1000 V cur-
rent can be transferred even as the lines are approached.
DANGER
Risk to life and limb when working in the vicinity of
high voltage lines.
Have the power to the lines switched off
Cover and / or have the danger zone cordoned off
DANGER
Risk to life and limb by electric shock.
Only electrical specialists may work on high voltage
lines.
DANGER
Electric shock due to insufficient safety clearance.
The safety clearance must still be available for unfav-
ourable crane or load positions.
Allow for possible swinging of the load or swinging
out of the free line as a result of the wind.
82640 2021-04-22 39
If the specified measures cannot be carried out, a sufficient safety

clearance must be maintained between the crane (hoist rope, lifting
tackle, hook block, load) and current-carrying lines. Risk to life and
limb!
Keep a clearance of at least 10 m (32.8 ft). If this is not possible, you
must obtain information on required minimum safety distances from
the electric power company responsible.
With extremely long boom equipment, these safety clearances are
very difficult to judge. To be on the safe side, increase the safety
clearance to 20 m (65.6 ft).
DANGER
Contact with high voltage power lines!
If, however, there is contact with high voltage power lines
and the crane operator leaves the crane or if another
person approaches and touches the crane, they will re-
ceive an electric shock.
Even the ground around the crane is carrying an electric
current. Therefore every step towards the crane or away
from the crane is potentially dangerous (step voltage).
Bring the crane out of the danger zone: drive it out,
swing it, adjust the boom system.
If this is not possible:
do not leave the crane or the cab.
Warn anyone in the vicinity against approaching or
touching the crane.
Arrange for the voltage to be switched off.
Only leave the crane when you are sure that the
touched/damaged line has definitely been disconnec-
ted from the power source.
40 82640 2021-04-22
1.7.2 High-frequency radiation
CAUTION
Electrical charge due to high-frequency radiation!
It can cause dangerous electrical charging if track-free
mobile cranes are used in the vicinity of transmission
systems (e. g. radio transmitters). People connecting the
charged components to ground will be violently and pain-
fully electrified at touch.
The crane's electrical system, particularly the load limit
device, cannot be considered to be functioning safely,
depending on the strength and frequency of the transmit-
ter.
You must communicate with the transmitter operator
before starting work. If required, switch off the trans-
mitter.
Connect the crane to ground. To protect the slewing
rim, fasten the grounding cable directly on to the su-
perstructure of the crane or on to the main boom.
Interference with the crane electrical system

The risk of the crane's electrical system, particularly the load limit de-
vice, being influenced by high-frequency radiation is minimised by
state of the art technology (shielding). However, it cannot be com-
pletely excluded. This is especially valid if the crane is used in the
close vicinity of high-frequency radiation sources (e. g. radar stations,
radio transmission stations, radio and television stations).
1.7.3 Lightning
If bad weather and storms appear imminent, deconfigure the crane
where possible and leave the crane. If this is not possible, lower the
load from the hook, switch off the engine and leave the crane.
Only remain in the crane operator's cab if you cannot carry out these
measures in good time.
82640 2021-04-22 41
DANGER
Risk to life and limb if you stay on the crane during a
thunderstorm.
If the crane operator must stay in the crane operator’s
cab during a thunderstorm, there is a risk of electric
shock.
stay in the crane operator’s cab.
Under no circumstance step on the crane or in its
near vicinity during a thunderstorm.
Warn any other people in the vicinity of the crane.
The general functions of the crane must be checked if it is suspected

that it has been struck by lightening. It is especially important that the
following is checked:
- Electrics in general, in particular:
- Load limit device; if it is defective a fault message appears on
the display.
- Limit switches; to see if they are functioning.
- Inductive proximity switches; to see if they are functioning.
- Luffing, assembly and outrigger cylinders with a visual check for
external damage caused by flashover voltages or melting. By re-
tracting and extending the relevant cylinders several times, check
if there are suspected internal leaks due to damaged seals.
- Hoists, especially for damage to ball and roller bearings.
1.7.4 Gas, dust, steam, smoke
DANGER
Risk to life when exhaust fumes are breathed in.
Do not breathe in any exhaust fumes.
Only operate combustion engines and fuel-operated
heaters in sufficiently ventilated spaces.
Before starting in enclosed spaces, make sure that
there is sufficient ventilation.
Follow the applicable regulations for the operating
site.
42 82640 2021-04-22
DANGER
Risk to life when exhaust fumes are breathed in.
The State of California advises that diesel engine ex-
haust and some of its constituents are known to cause
cancer, birth defects, as well as harm to genetic material.
Do not breathe in any exhaust fumes.
1.7.5 Crushing / collision

For the points listed below, please also refer to the detailed descrip-
tion in the corresponding sections of the operating instructions.
- During assembly of the main boom, fly jib and Superlift mast
- Hook block / load when slewing the superstructure
- During coupling and decoupling of the counterweight dolly
1.7.6 Becoming entangled / dragged in

- Head sheaves and deflection sheaves
- Hook blocks
- winches
- Slew ring toothing (slew pinion)
1.7.7 Crushing / shearing

- when telescoping the main boom in and out
- when lowering the main boom on the foot bearing of the super-
structure frame
- when slewing the superstructure
- when extending and retracting outriggers and cylinders
- when releasing the suspension lock following the outrigger proce-
dure in the vicinity of the wheels
- near the hook block or the load during uncontrolled movements
- when stacking the counterweights
- when fitting and removing hoist 2
- when fitting and removing the boom or superstructure
- when tilting/slewing the crane operator’s cab
- when fitting and removing / configuring additional equipment (op-
tional), such as e. g. main boom extension
- when coupling and decoupling the counterweight dolly.
82640 2021-04-22 43
1.7.8 Risks due to slipping, tripping, falling

Only the described catwalks and ladders may be used. There are suf-
ficient gripping devices there for holding on and attachment eyelets
for personal protective equipment. In addition, the catwalks are de-
signed to be slip-resistant (e. g. sanded areas, corrugated metal
plates, or similar).
If the crane has safety systems to protect against the risk of falling, fit
these systems and use them for reasons of safety. Adapt the person-
al protective equipment correctly according to the size of the person
using it.
1.8 Protection from physical effects

Noise
The crane complies with the limit values of the relevant EC directive
on noise emission in the environment by equipment for outdoor use.
The precise values for sound power levels (LWA) of the crane can be
found in the EC declaration of conformity (component part of the
crane log book) and on the corresponding adhesive label on the out-
side of the crane operator's cab.
The A-assessed equivalent permanent sound level at the crane oper-
ator's workplace in the crane operator's cab, averaged over the shift
duration of 8 hours, is below 70 dB(A). For this purpose, measure-
ments were taken during operation on construction sites using dosim-
eters. The measurements were taken at the ear position of the crane
operator using a sound level meter with a test microphone.
The structural measures for noise reduction must be supported by
the following behaviour:
- Actuate the operating elements smoothly.
- Keep covers on the drive motor and hydraulic system as well as
windows and doors of the crane operator's cab closed as much as
possible during regular operation. Make sure that warning signals,
warning calls or unusual noises remain audible.
- In special cases – e. g., when performing work on the drive motor
or hydraulic system with the covers open and the drive motor run-
ning – we recommend wearing hearing protection in the immediate
vicinity of the noise source.
Vibrations
The crane operator is protected against mechanical vibrations by
means of a shock-cushioning seat which can be adjusted to his
weight. The crane operator's seat offers infinite adjustment options for
the seat height and tilt, backrest and armrests. This means that the
seat can be adjusted to the optimum operating position for any crane
operator.
44 82640 2021-04-22
The weighted effective value of acceleration to which the upper body

is exposed is below 2.5 m/s2 (8.2 ft/s2). The weighted effective value
of acceleration to which the body (feet and seat) is exposed is below
0.5 m/s2 (1.6 ft/s2). Both values are therefore below the statutory
specifications.
1.9 Combination of Hazards with Combined Operation of Two or More Cranes
1.9.1 Operating Areas of Several Cranes Overlap

If the operating areas of several cranes overlap, there is a risk of colli-
sions. The operating company or its representative must:
- specify the working sequence in advance.
- make sure that there is a clear line of communication with the
crane operator!
If the crane operator does not have spoken or visual contact, suitable
measures must be taken (e.g. use of radios, spotters/banksmen,
etc.).
The communication connections for communicating with the crane
operators (e.g. walkie-talkies, etc.) must be inspected for reliable
functioning before beginning any work on the crane.
If banksmen are used, the corresponding signals must be agreed

between the banksmen and the crane operators (see section 1.14
Hand signals, side 61).
Crane operators must operate the crane in such a way that uncontrol-
led movements and subsequent collisions are avoided. They must re-
ceive suitable training and instructions to this end.
1.9.2 Several Cranes Raising a Load Together

If a load is to be raised by more than one crane, the operator of the
crane or his representative must first set up a working procedure and
appoint a supervisor, in whose presence the operations are carried
out.
The most important requirement for this type of operation is, however,
careful planning, covering the following points:
- The mass (the weight) and the centre of gravity of the load must
be known exactly.
- The load must be shaped so that no additional hazards are caused
by it during the operation.
- The other cranes which are taking part in the operation must have
nearly the same lifting capacity.
- Additional dynamic load effects when the load is raised and set
down and load effects as a result of environmental influences (e.g.
wind) must be allowed for during planning.
82640 2021-04-22 45
WARNING
Risk of overturning if the load is lowered unevenly.
The actual danger is during joint lowering of the load. If
the lowering speed is uneven, there is a risk of a slow
crane being overloaded.
Using reeving and control, create lowering speeds
which are as similar as possible for all cranes.
Never utilise the full load value in the capacity table.
Sufficient safety reserves must be provided for each
crane.
If there are any doubts concerning the accuracy of
the data, e.g. the accuracy of the details with regard
to weight and the position of the load's centre of grav-
ity, the safety reserves must be increased according-
ly.
Avoid oblique pull under all circumstances.

Before difficult operations, ask the crane manufacturer whether the

crane must be equipped with additional safety equipment (e.g. by lim-
iters) or whether the capacity must be limited beyond that for this op-
eration.
1.10 Driving Operation
1.10.1 Before Driving

In order to ensure the safety and operational readiness of the crane,
the checks and maintenance work must be carried out in accordance
with the lubrication and maintenance instructions.
In particular, check the effectiveness of the brakes, steering and sig-
nal and lighting equipment daily; if the crane is used infrequently,
check it every time before starting operation (or driving).
Before driving the crane, always make sure that there is no-one in the
danger zone of the crane. If necessary, give a warning sign (we rec-
ommend actuating the horn before starting the engine).
If you cannot see the hazardous area, a banksman must be used
(see 1.14 Hand signals, side 61)! This also applies if noise levels
are too high to allow normal verbal communication.
Keep the windows clean to maintain good visibility at all times.
46 82640 2021-04-22
Make sure that all accessories are stored safely and cannot cause an
accident.
When driving on public roads, highways and precincts, observe the
relevant traffic safety regulations and if required, place the crane in
the road travel state in line with traffic regulations beforehand.
In the case of axle loads, there is a differentiation between the tech-
nically possible axle loads (technical driveability) and the axle loads
permitted according to the road traffic regulations. "Technical drivea-
bility" is only permitted on construction sites or private roads (with the
exception of countries which permit axle loads over 12 t / 26.4 kip).
Axle loads over 12 t (26.4 kip) are not authorised for road travel in
countries subject to EU regulations (or to reduced axle loads). If the
crane is driven on the road with axle loads above 12 t (26.4 kip), then
the crane operator assumes sole responsibility. All components and
installations are designed and calculated for axle loads of
12 t (26.4 kip) at maximum speed. If this 12 t (26.4 kip) axle load is
exceeded, the service life of axles, wheel hubs, bearings, suspension
cylinders and brakes will be reduced. In particular, wear to the brake
linings and the risk of the brakes overheating and fading are in-
creased. The brake delay for the brakes (EEC: 50%) is reduced in
proportion to the increase in axle load or to the transportation weight
of the crane.
1.10.2 During Travel

When driving on the road, the main boom must be lying on the travel
support in the transport position and the telescopic sections must be
secured against undesired telescoping out.
For crane types with pinnings between the telescopic sections, these
must be pinned. For crane types with telescoping cylinders and rope
drives, the main boom must be secured against undesired telescop-
ing out using a rod or a rope.
When driving on inclines, always adapt the speed of the crane to the
conditions. Never shift gear once on the slope, but change to a lower
gear before reaching the slope.
When negotiating underpasses, bridges, tunnels, overhead power ca-
bles, etc. always make sure that there is sufficient clearance.
When towing, follow the towing regulations with respect to the prescri-
bed transport position, permitted speed and distance travelled.
Additional persons may only drive along when sitting in the specified
and regulated seats (with safety belts, etc.). For crane types which
have a chassis cab (driver's cab), no-one may be taken along in the
crane operator's cab.
82640 2021-04-22 47
Emergency exit from the cab:

For crane types which have a chassis cab, the passenger door may
be used as an emergency exit. For crane types which only have a
cab on the superstructure, the front window of the cab which can be
opened widely can be used as an emergency exit.
1.11 Crane Operation
1.11.1 Before Crane Operation

In order to ensure the safety and operational readiness of the crane,
the checks and maintenance work must be carried out in accordance
with the lubrication and maintenance instructions.
Check the load conditions again before commencing crane operation:
Is the mass (the weight) of the load and the operating procedure
known and is there sufficient lifting capacity, working radius and lifting
height? Compare the values with the load capacity table.
Using the crane's display systems, check: Load status, fluid statuses,
engine operation, hydraulic oil pressures and wind speeds.
Check whether outside conditions such as wind, snow, poor visibility,
unfavourable temperatures etc. could impair crane operation.
Make sure that the ground has sufficient load-bearing capacity (e.g.
for supporting the crane on outriggers). Maintain a safe distance be-
tween the supported crane and slopes and ditches. Depending on the
crane type, there are detailed specifications on both subjects in the
sections "Working instructions" or "Outriggers". In addition, check
whether there are any channels, covered ditches or cellars in the area
where the crane is to be operated and in which direction they are run-
ning. Furthermore, hidden dangers in the ground such as melting ice
or flooding must be taken into consideration.
Before commencing work, familiarise yourself at the operating site
with its surroundings. The working environment includes, for example,
obstructions in the operating and traffic areas, the load-bearing ca-
pacity of the ground and the necessary safety precautions required to
cordon off the construction site from public traffic areas.
To operate the crane, an unobstructed view of the crane, load and
load path must be ensured. If this is not ensured, banksmen must be
used. Either signals for communication must be agreed between the
banksman/person handling the load and the crane operator (see
1.14 Hand signals, side 61) or a communication system (e.g. voice
radio) must be used. If a communication system is used, it must be
provided by the crane operator.
Carry out the necessary measures to ensure that the crane is operat-
ed in a safe and functional condition.
Before commencing work, check all crane movements to make sure
that they are functioning properly.
48 82640 2021-04-22
Operate the crane only if all safety guards and safety-related equip-
ment are fitted and functional.
Check the effectiveness of brakes, signal and lighting equipment, limit
switches and overload cut-off devices daily, or in the case of cranes
which are seldom used, before the equipment is placed in operation.
If a radio remote control is used on the crane, radio transmitters, at-
mospheric interferences or other radio remote controls transmitting on
the same frequency can disrupt the radio transmission. For this rea-
son, the radio remote control and / or the radio transmission must be
checked for proper function before the actual operation. If interferen-
ces in radio transmission cannot be rectified by changing the operat-
ing frequency, the radio remote control must not be used during the
operation or interfering radio transmitters and other radio remote con-
trols must be switched off. Observe the charging state of the batter-
ies.
Before commencing work with the crane make sure that no-one is in
the hazardous area. If necessary, give a warning sign (we recom-
mend actuating the horn before starting the engine).
As oil can be emitted during maintenance and assembly work, suita-
ble collecting vessels and binding agents must be placed ready.
Wherever required or stipulated by regulations, personnel must wear
personal protective equipment (e.g. safety harnesses, safety clothing,
goggles, face mask etc.).
Remember that protective equipment does not offer 100% protec-

tion! A helmet can protect you against small falling objects, but not
against falling loads!
You must remain attentive and safety-conscious at all times.
The weight of the load must be known.
WARNING
Risk of overturning and breaking if an incorrect
weight is assumed.
It is difficult to calculate the load weight during disman-
tling work. If a load that is attached to the crane is re-
leased from its previous connection to other parts and is
too heavy, the crane will be unavoidably destroyed or will
overturn, regardless of an activated load limit device.
When dismantling hollow components (pipelines, ce-
ment silos etc.) allowance must be made for the
weight of possible residues inside these components.
When determining the size of the components that
are to be dismantled, never utilise the full values al-
lowed in the load capacity tables of the crane, but al-
low for a safety buffer.
82640 2021-04-22 49
Select the correct boom length and reeve the hoist rope in accord-
ance with the individual load case.
Before reeving and before starting crane work, check the status of all
accessible ropes (including the end connections), winches and
sheaves.
Select the lifting tackle in accordance with the weight of the load, the
type of attachment and the angle of inclination.
Pay attention to the rules and regulations for working with load-han-
dling equipment (attachment ropes etc.) and load handling devices
(lifting beams etc.). Never use lifting tackle and load-handling devices
if there is any doubt as to their lifting capacity. Check to make sure
that the lifting tackle and all load-handling devices are in perfect con-
dition.
Only hook blocks supplied by the crane manufacturer may be used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.
50 82640 2021-04-22
1.11.2 During Operation of the Crane
WARNING
Risk to life and limb for persons in the area at risk!
During power-operated erection and assembly work
only the crane operator may be on the crane (and he
must be in the crane operator's cab).
The crane operators of cranes which are controlled
using radio remote control must be outside of the
danger zone of the moving crane components and
the load.
Remaining personnel must remain clear of the haz-
ardous area on and around the crane. The only ex-
ception to this rule is when the counterweight is being
fitted and when a load is being attached or released
with the help of a fitter.
When stacking the counterweight, the fitter must
leave the crane and the slewing area as soon as the
configuration work is completed. During stacking, the
fitter must remain outside of the area at risk.
When attaching and disconnecting the load, particular
care must be taken due to hazards resulting from
swinging loads or hook blocks. The person attaching
the equipment must be proficient in handling hook
blocks. The fitter must leave the slewing or hazardous
area immediately after the procedure has been com-
pleted.
The fitter must be easily recognisable to the crane op-
erator. The person handling the load must wear one
or more means of identification, for example, jacket,
helmet, special collars, armbands, signalling discs.
These means of identification should be in a distinc-
tive colour and where possible of an identical design
and must be exclusive to the fitter.
The crane operator must give a warning signal when starting the drive
motor and before starting crane movements (horn). Stop work if peo-
ple fail to leave the hazardous area in spite of warning signals.
Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision. The load must never come into con-
tact with the framework of the crane (boom system, superstructure,
crane chassis, outriggers etc.).
The crane operator may only start movements if he has good visibility
of the hazardous area.
When working from the crane operator's cab, keep the windows clean
so that good visibility is ensured.
82640 2021-04-22 51
If the hazardous area cannot be seen directly by the crane operator,

suitable auxiliary equipment (e.g. mirrors, ultrasound equipment, TV
cameras, radio remote control) must be used or a banksman must be
employed (see 1.14 Hand signals, side 61).
It is prohibited to switch off the drive of the crane when a load is at-
tached and/or to leave the crane operator's cab to allow for immedi-
ate response or reaction when the crane is subjected to changing en-
vironmental conditions.
An exception is only permitted in emergencies. To avoid hazardous

situations, in the final instance the drive source (diesel engine) can
be switched off using the quick-off-button in the crane operator's
cab. First – where possible – movements that have been started
should be completed using the control levers.
Before raising a load, you must always make sure that the hook block
is positioned vertically over the load’s centre of gravity.
The load must be raised/lowered so that it does not place heavy dy-
namic demands on the crane.
Any lockable outrigger control boxes must be locked during crane op-
eration. The chassis cab must be locked in cranes types which have
one. The engine of the crane chassis must be switched off in crane
types with an engine in the crane chassis and crane superstructure.
The configured crane without load may only be left without the super-
vision of a trained crane operator if certain conditions are met (see
1.11.3 Disruption of Crane Operation - Parking and Leaving (Partially)
Erected Mobile Cranes Unsupervised, side 54 and "Parking (the
crane)").
Conveying of persons with the load or the load-handling equipment is
prohibited.
The crane may only be accessed and left following agreement with
the crane operator and only when the crane is at a standstill.
Observe all safety and hazard instructions on the crane.
Avoid any type of action that could possibly impair safety (e.g. that
could put the stability of the crane at risk).
Settings in crane control and relevant incidents on the crane are re-
corded by crane control (datalogger).
Never slew loads over people. Do NOT stand under suspended
loads.
When working from the crane operator's cab: Only start the crane en-
gine from the driver’s seat. Only actuate the control lever from the
cab.
52 82640 2021-04-22
The crane operator must only initiate, execute and finish crane move-
ments from the designated operating position. This is to prevent
(among other things) accidental crane movements being initiated
when entering and exiting the crane operator's cab. The operating po-
sition is monitored by a corresponding release switch system. The
crane operator may only assume the specified operating position if
the corresponding control lever is in the "Neutral position" and may
only leave it once the initiated crane movement has been completed.
Keep the control levers within reach as long as a load is suspended
on the crane or the crane is driven.
During all crane movements keep your eye especially on the load, or
if no load is fitted, the load-handling devices and the boom top sec-
tion. Watch the slewing radius of the counterweight, etc.
In all crane movements, approach the limit ranges especially slowly
and carefully. Limit ranges can be detected, e.g., in the load utilisation
display of the load limit device.
WARNING
Risk of accidents due to unintentional crane move-
ments!
Bridging or overriding bridging of the limit switches when
the control lever is fully extended results in sudden and
abrupt activation or braking of the corresponding crane
movement.
Hold the control levers in the "neutral position".
If shut-downs must be bridged to place the crane back in a safe oper-

ating condition, the control levers must then be in the "Neutral posi-
tion".
It is prohibited to pull loads at an angle or to drag loads.
It is prohibited to pull loads free that have become stuck.
It is prohibited to raise overloads by luffing in.
Monitor the rope drums to prevent the hoist ropes winding in opposite
directions on the rope drums.
Do not jump off the crane. Use the ladders and the grab handles pro-
vided.
Secure doors using the locks available to prevent them slamming
closed or open.
Check the crane at least once per shift for any visible signs of dam-
age and faults. Report any changes (including to operating behaviour)
immediately to the department/person responsible. If necessary,
switch off and safeguard the crane.
In case of malfunctions, shut down the crane immediately and secure
the crane. Have any faults rectified immediately.
82640 2021-04-22 53
Pay attention to the procedures for switching equipment on and off as

well as to monitoring displays as outlined in the operating instructions.
In case of poor visibility and darkness, always switch on the exterior
lighting. The interior lighting must be switched off to enable a proper
overview of the load and of the immediate vicinity of the crane.
Adhere to the options for reporting and fighting fires.
Pay attention to the weight and surface area of the load exposed to
the wind.
Loads that are in water are lighter for the crane than those in air (due
to buoyancy). When the load leaves the water, it becomes heavier. If
this results in the crane being overloaded the load limit device would
be triggered. There is a risk to the lifting tackle, however, if this is not
measured for the actual load weight.
Set the computer of the load limit device in accordance with the ca-
pacity tables supplied.
Deviating from that, crane control calculates the maximum permitted
capacities in relation to the superstructure position when raising loads
with slewing angle-dependent capacities (depending on crane type
and design).
Observe the permitted wind speeds.
For cranes with the chassis on wheels, the superstructure may only
be slewed when the crane is supported on outriggers. Observe that
slewing is only permitted for certain crane configurations (e.g. con-
cerning outrigger span, counterweight etc.)! For some crane types,
there are "Free on wheels" capacity tables. Only then is it permitted to
slew the superstructure when not supported on outriggers. Always
observe the specifications in the capacity tables.
Slewing of the superstructure in the overload range (load limit device
has shut down) is generally prohibited.
In an emergency the wide-opening front window of the cab can be
used as an exit.
1.11.3 Disruption of Crane Operation - Parking and Leaving (Partially) Erected Mo-
bile Cranes Unsupervised
1.11.3.1 Problems and Risks

Manufacturers of mobile cranes and operators using mobiles crane
are aware that it might not be possible under certain conditions to
fully retract the boom and the crane equipment or to lower them into
the position of rest to temporarily shut down the crane (for example,
at night) when at locations with limited space options.
Some examples of possible events which can occur when the crane
is left unsupervised are listed below. The associated potential risks
must be taken into consideration:
54 82640 2021-04-22
- The ground giving way:

- The ground could slip away due to heavy rainfall, landslides or
erosion
- Melting ice under the supports
- Bad weather:
- Storms and winds
- Thunderstorms
- Rain / floods
- Hydraulic cylinders of the crane:
- Slow retraction of the support cylinders, luffing cylinders and/or
telescoping cylinders when telescopic systems are unpinned
(for example, due to a change in the ambient and oil tempera-
ture or a leak).
- Vandalism.
If a qualified crane operator acquainted with the operating site deter-
mines that the boom of a crane cannot be lowered into the position of
rest, the additional instructions listed below must be adhered to.
1.11.3.2 General Instructions

A general rule is: If a configured crane can no longer be sufficiently
controlled, the boom and other equipment must be lowered. The fol-
lowing instructions are valid for all mobile cranes, regardless of type,
configuration, configuration mode and ambient conditions:
- The crane must be positioned in the smallest and most stable per-
mitted operative configuration which is possible in practise at the
operating site. This also applies to parameters such as the boom
angle, the slewing direction and the top section adjustment angle.
- The attached counterweight of a jib or a Superlift must be lowered
onto the ground.
- The engines must be switched off.
- A load may not remain attached on the hook.
- All levers must be switched in the neutral position or in a "locked"
position.
- All secondary systems, for example the heating system, the air
conditioning, etc. must be switched off.
- Close all windows.
- When the crane is left unsupervised, the energy supply and the
functional efficiency of the safety features and equipment (for ex-
ample, the aircraft warning lights, etc.) must be ensured.
- All keys must be kept in a safe place to prevent unauthorised use.
- The crane must be secured and the cab doors (of the chassis and
superstructure) must be locked to prevent unauthorised use.
82640 2021-04-22 55
- Lock any unused control platforms.

- Depending on the crane type, the mobile control platforms connec-
ted with the crane via cables must be removed and/or stored in a
safe location to prevent unauthorised use.
- To prevent unauthorised use, any cordless control platforms must
be stored in a safe location and it must ensured that the batteries
are charged or are being charged.
If the crane is erected and the conditions at the operating site do not
allow for complete lowering of the boom and/or the equipment into a
resting position, a qualified crane operator acquainted with the situa-
tion at the operating site and with the existing conditions and restric-
tions must decide in which the configuration the crane is to be left un-
supervised. Furthermore, the following instructions must be observed:
- Before leaving the crane unsupervised, an emergency plan must
be determined with which the crane can be placed in a safe posi-
tion in case of emergency (for example, unforeseen change in
weather or other possible events such as the ones described un-
der 1.11.3.1 Problems and Risks, side 54). This plan must pro-
vide sufficient space to place the technical equipment in a safe po-
sition.
- The crane must be left without a load attached, i.e. without the
load-handling devices as well.
- The hook block must be in the uppermost position, so that no con-
tact is possible between the cables and the boom or other obsta-
cles.
- The location and configuration of the crane may not cause any
risks for the surrounding area - for example, endangering road traf-
fic or causing a risk of collision with obstacles in the area; under
certain circumstances this requires a risk assessment before the
crane is left unsupervised.
- It must be checked whether accidental (slow) movements are pos-
sible, for example, due to internal or external leaks in all load-bear-
ing hydraulic cylinders and winches:
- support cylinders in vertical supports
- main boom luffing cylinders
- hydraulic cylinders for adjusting the equipment, if applicable
- hoist winch
- derricking winch, if applicable
- etc.
Slight movements can also be caused by a change in the oil temper-

ature (for example, temperature changes due to heating up caused
by sunlight or the hydraulic oil cooling down).
56 82640 2021-04-22
- The weather report must be obtained throughout the entire time in

which the crane is erected.
- When determining the parking location and the crane configura-
tion, changes to meteorological conditions such as wind, ice,
rain, floods and thunderstorms must be taken into consideration
before parking and leaving the crane unsupervised.
- If, due to unforeseen weather conditions, wind speeds exceed
the permitted values for an erected boom, the crane must be
secured as best as possible and everyone must be evacuated
from the affected area.

1.11.3.3 Specific Instructions for Mobile Hydraulic Cranes with Telescopic Boom
- If the crane is parked and left unsupervised, the boom must always
be retracted as much as possible and must be secured (for exam-
ple, pinned).
- If the predicted wind speed exceeds the maximum value listed in
the operating instructions for the selected configuration, the boom
must be telescoped in and lowered before the maximum permitted
wind speed for assembly and dismantling is reached.
1.11.3.4 Specific Instructions for Crawler-mounted Cranes with Equipment

- If the predicted wind speed exceeds the maximum value listed in
the operating instructions for the selected configuration, the boom
must be lowered before the maximum permitted wind speed for as-
sembly and dismantling is reached.
1.11.4 Following Crane Operation

Before you leave the crane:
- the load must be detached from the crane hook or placed onto the
ground.
- the engine must be switched off and all control levers must be put
in the neutral position or in the locked position.
- the heating must be switched off.
- the parking brake of the crane chassis must be applied (if not al-
ready occurred).
- the crane must be secured to prevent unauthorised use and acci-
dental movement.
If, for cranes with the chassis on wheels, the crane is parked on a
slope, the travel gear must be additionally secured with chocks, the
slew brake must be applied and the main boom must be secured.
82640 2021-04-22 57
Always lock all control desks that are fitted with a lock when they are
not being used. Depending on the crane type, there are mobile con-
trol panels on the crane which are connected with cables. Remove
them when they are no longer needed.
If your crane is equipped with a radio remote control, store it safely.
Ensure that the batteries are recharged if required.
Even when parking the crane, pay attention to the permitted wind
speeds (also for the time when the crane is stationary). If necessary,
telescope in and set down the boom system.
1.12 Power supply failure
1.12.1 General
If the power supply fails, all movements are stopped. An unintentional
restart is not possible. When the diesel engine comes to a standstill,
the driven hydraulic pumps also stop. The oil which is currently in cir-
culation also comes to a standstill. As soon as the control pressure
reaches zero, all actuators return spring-loaded to the zero position,
regardless of the position of the pilot control lever.
In the hydraulic circuits which are directly relevant to safety, there is
redundant braking of the winches and cylinders as a result of the
locked position or additional retaining brake.
1.12.2 Winches and cylinders

The oil column on the lever side of the winch motors and cylinders is
safeguarded by means of load-independent brake valves (lowering
brake valves). If the power supply fails, the winches and cylinders can
only be moved by connecting an emergency unit and an external en-
ergy source. Otherwise, contact Customer Service in such a case.
The lower brake valves are directly fitted to the winch motors and cyl-
inders (no hose lines).
If hoses or pipes should burst, therefore, there will be no dangerous
crane movements as a result.
In addition, in the case of a standstill the hydraulically actuated disc
brake of the slew gear is applied.
1.12.3 Driving the crane in the configured configuration

For cranes with the chassis on wheels, the load rests on the suspen-
sion cylinders when the crane is driven in the configured condition.
These are not equipped with pipe burst valves, in order to guarantee
problem-free suspension behaviour during driving of the crane. The
specifications in "Driving in the configured condition" must be strictly
adhered to in order to prevent endangerment.
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1.13 Assembling and dismantling crane components
DANGER
Risk of crushing when carrying out assembly and
dismantling work.
Although all possible protective and safety measures
have been provided, there is still a risk of crushing during
assembly and dismantling work.
In particular, pay attention to the following regula-
tions.
In addition, observe the corresponding specifications
in the operating and assembly instructions (if sepa-
rately available).
In these operating instructions, the standard, normal assembly se-

quence is described.
The equipment must be dismantled in exactly the reverse order (un-
less stated otherwise).
Crane components may not, under any circumstances, be assembled
and dismantled by untrained personnel. This also applies to staff pro-
viding temporary help. Incorrect assembly can result in danger to life
and limb.
Due to danger by slipping, stumbling and falling, you may not step on
the superstructure, boom and equipment (for example, main boom
extension). Exceptions are only permitted if access areas are provi-
ded. However, this requires additional safety measures. Safe meas-
ures for walking are then described in the corresponding section of
the operating instructions.
All assembly work is to be carried out with the help of suitable acces-
sories (ladders, hoist platforms, scaffolding, auxiliary crane etc.). The
assembly personnel must be sufficiently secured. Furthermore, per-
sons may only access operational areas where there is no risk of fall-
ing equipment/loads.
Normal assembly prescribes that all component parts which are
transported separately are transported near to the ground with suita-
ble auxiliary cranes and lifting tackle (ropes) - and are safely connec-
ted to the basic crane.
82640 2021-04-22 59
DANGER
Risk to life and limb if you stay in areas where loads/
equipment could fall!
During the assembly procedure, personnel must nev-
er walk or stand in the area where there is a risk of
the load falling or even directly beneath suspended
loads, until the planned procedure for securing the
load has been completed.
WARNING
Danger due to bumping / crushing during lateral
movements of suspended loads.
It is prohibited to be near suspended loads.
Before assembly personnel approach suspended loads, for example

counterweights, outrigger struts, intermediate sections, main boom
foot section and top pieces, luffing masts or fly jib, these loads must
be placed on the ground, on trestles or other supports with sufficient
load bearing capacity.
If, during assembly work, certain crane movements have to be carried
out, the crane operator must ensure that no-one is in the hazardous
area affected.
A fastening procedure is only completed once the suspended crane
element is firmly connected to the stable, set down crane component,
e.g. by knocking in pins of an intermediate section or by tightening all
screws of a screwed connection with the specified torque, etc.
A safe distance must be maintained from unavoidable crushing and
shearing points, in particular on outrigger struts, between the super-
structure and crane chassis, on cylinders, on the telescopic boom and
on the entire lattice mast fly jib and the Superlift mast, as long as a
component is suspended in the air during assembly and/or is not
safely secured and/or as long as the engine of the crane or of the
auxiliary assembly crane is running.
Connecting pins are always knocked in manually from the outside in-
wards during the assembly of individual elements, unless the operat-
ing instructions expressly state otherwise. Only when all pins of a
construction element have been knocked in is it possible to secure
them with auxiliary bolts and spring cotter pins.
Connecting pins may only be knocked out during the dismantling of
fly jib components or other parts when all individual components are
safely supported symmetrical to their centre of gravity. After release,
the responsible shift foreman must decide whether sudden fall-
ing or folding movements are to be expected due to the releas-
ing procedure. In case of doubt, a service specialist from the crane
manufacturer must be consulted.
60 82640 2021-04-22
In particular, knocking out pins / bolts must be carefully planned and it

must be ensured that no-one is standing inside the respective individ-
ual element, at risk of being crushed. The falling movement of a bolt
which has been knocked out, a released rope or another component
must be carefully planned and safeguarded.
On completion of work, make sure that no tools have been forgotten.
Falling or flung tools can cause risk to life and limb.
Sometimes it is required to bridge limiters (for example, limit
switches) when assembling and removing crane components. Under
certain circumstances, this can also lead to additional dangers. The
systems may therefore only be bridged if this is required in the oper-
ating instructions for a certain piece of work.
1.14 Hand signals

If the crane operator is unable to observe the use of the working
equipment (and danger zone), a banksman must be employed. He
must communicate with the crane operator: using e.g. hand signals
(as described below). This is also the case if normal verbal communi-
cation or voice radio is not possible due to increased noise levels.
CAUTION
Risk of accidents due to misunderstandings!
Only responsible and reliable persons who know the
hand signals may be employed as banksmen.
The banksman must be in a safe position from which
he can SEE THE LOAD and can himself be clearly
SEEN BY THE CRANE OPERATOR.
The banksman must be easily recognisable for the
crane operator. The banksman must wear one or
more suitable means of identification, for example,
jacket, helmet, collars, armbands, signalling discs.
These signs of identification must be in a distinctive
colour and uniform in design and must be worn exclu-
sively by the banksman.
If the load is attached by several people, only one
person may give the signals. These must be made
known to the crane operator.
If the crane operator does not fully understand a sig-
nal, he should not carry out any movement with the
crane. Before commencing work the crane operator
and spotter must work out a signal for this scenario.
A board listing the hand signals is attached to the machine in accord-

ance with OSHA 1926.1422 for cranes. The standard American hand
signals in accordance with ASME B30.5-2014 listed there are ex-
plained below.
82640 2021-04-22 61
CAUTION
Risk of accidents due to misunderstandings!
Depending on the industrial sector, country or even legal
regulations, there are different specifications concerning
the hand signals and their meanings.
Communicate about the hand signals before starting
work.
Directions given by hand signals are to be understood from the per-

son's point of view who is initiating the machine's movement.
The speed with which certain hand signals are given indicates how
fast or slowly the machine movement is to be carried out.
LOAD UP
Forearm raised vertically, index finger pointing upwards, hand moved
in a small horizontal circle.
LOAD DOWN
One arm stretched downward, index finger pointing downwards, hand
moved in a small horizontal circle.
USE MAIN ROPE

Tap on head with fist; then use normal signals.
62 82640 2021-04-22
USE AUXILIARY ROPE

Tap elbow with one hand; then use normal signals.
BOOM UP
Arm outstretched, fingers clenched to a fist, thumb pointing upward.
BOOM DOWN
Arm outstretched, fingers clenched to a fist, thumb pointing down-
ward.
MOVE SLOWLY
Give the movement signal with one hand and hold the other hand -
without moving it - in front of the hand issuing the movement signal.
(The example shows: Raise slowly.)
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BOOM UP, LOAD DOWN

Arm outstretched, thumb pointing upwards, clench and unclench fin-
gers for as long as the load movement is wanted.
BOOM DOWN, LOAD UP

Arm outstretched, thumb pointing downwards, clench and unclench
fingers for as long as the load movement is wanted.
SLEW
Outstretched arm, use a finger to point in the direction in which the
boom is to be moved.
MOVE
Arm outstretched to the front, opened and slightly raised hand, mak-
ing a pushing-away movement in the direction of travel.
64 82640 2021-04-22
STOP EVERYTHING
Place hands together in front of body.
MOVE (ON TWO CRAWLER TRACKS)

Both fists circling around each other in front of body to indicate for-
ward or reverse direction of travel. (Only for land-based cranes.)
MOVE (ON ONE CRAWLER TRACK)

Lock track on one side, indicate this using a raised fist. Other fist held
vertically in front of body, making circling motions, indicates direction
in which the other track is to be moved. (Only for land-based cranes.)
EXTEND BOOM
Signal with one hand. One hand in front of chest, tap chest with
thumb.
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RETRACT BOOM
Signal with one hand. One hand in front of chest, thumb pointing out-
wards, tap on chest with heel of hand.
EXTEND BOOM
Both fists in front of body, thumbs pointing outwards.
RETRACT BOOM
Both fists in front of body, thumbs pointing to each other.
STOP
Arm outstretched, palm of hand facing downwards, move arm hori-
zontally forward and back.
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EMERGENCY STOP
Both arms outstretched, palms of hands facing downward, move
arms horizontally forward and back.
82640 2021-04-22 67
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2 Structure of the Mobile Crane
2.1 Specifications
AC 250-5 AC 220-5 AC 160-5 AC 130-5
Length
Width see part 2, section 2 "Crane chassis" under "Technical data"
Height
Max. capacity See capacity tables
6 telescopic sec- 7 telescopic sec- 6 telescopic sec- 5 telescopic sec-
Max. main boom length tions = 70 m tions = 78 m tions = 68 m tions = 60 m
(229.7 ft) (255.9 ft) (223.1 ft) (196.8 ft)
Max. system length 33 m + 68.8 m 21 m + 78 m 33 m + 61.6 m 33 m + 53.5 m
with main boom exten- (108.3 ft (68.9 ft (108.3 ft (108.3 ft
sion + 225.7 ft) + 78NaN ft) + 202.1 ft) + 175.5 ft)
Length of hoist ropes 330 m (1082 ft)
Max. rope speed hoist 120 m/min (394 ft/min)
Operating voltage 24 V
82640 2021-04-22 69
2.2 Main Elements

The main elements of the crane and possible additional equipment
are listed below:
Fig. 2: Entire crane - main elements (schematic diagram)
1 Main boom 2 Luffing cylinder

3 Hoist rope 4 Hoist 1
5 Hoist 2 (Optional) 6 Counterweight
7 Crane operator's cab 8 Crane chassis
9 Hook block 10 Main boom extension (optional, shown folded in the
transport position on the main boom)
11 Assembly Jib (Optional) 12 Head sheave, can be folded sideways (optional)
13 Hook suspension gear (optional)
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Fuel tank for the crane operator's cab heater assembly
AC 250-5/AC 220-5
AC 160-5/AC 130-5
Fig. 3: Main elements of the crane
1 Switch box "X0002" with fuses 2 Superstructure frame

(central electrical unit), behind
cover
82640 2021-04-22 71
Fig. 4: Main elements of the crane
1 Slew gear (depending on the 2 Roller-bearing slewing ring

device design behind a trim)
2.3 Getting onto and off the Crane
2.3.1 General
You must get on (and subsequently, down from) the crane to do cer-
tain activities (e.g. enter the crane operator’s cab). When getting on
and off the crane and carrying out work at heights, suitable measures
must be taken at all times to prevent a risk of falling.
Work should always be carried out on the ground as long as possi-

ble. This can be done using suitable auxiliary equipment (e.g. using
an auxiliary rod to fit the hoist rope). This is the only way to 100%
eliminate a potential risk of falling.
Any personnel working with mobile cranes must be informed concern-

ing the required measures they must take to protect themselves from
slipping and falling off and to ensure they can get on and off safely.
These are listed below. The contractors must provide the information
to the employees accordingly.
72 82640 2021-04-22
WARNING
Risk to life and limb by falling if unsuitable auxiliary
equipment for getting on and off is used.
The auxiliary equipment described below must be
used in accordance with regulations to get on/off the
crane.
The crane is equipped with ladders and holding devices. In addition,

rails, catwalks and antifall protection systems are available for certain
components, depending on the crane design. The existing devices
must be used to get on and off the crane. Personnel must have at
least three points of contact at all times with the ladder/holding device
or crane to get onto/off the crane safely (e.g. 2 feet, 1 hand). Addition-
al suitable auxiliary equipment (platform ladders, hoist platforms, etc.)
ensuring safe access to the crane must be used in situations in which
it is not possible to get on / off the crane safely.
If ladders other than the ones supplied with the crane are used or if
the supplied ladders are used at different points than the designated
ones, the operators must ensure the ladders are supported and fixed
in place appropriately.
All areas which are authorised for getting onto / off and walking on
are designed so that they are slip resistant.
2.3.2 Overview of the ladders
Fig. 5: Overview of the ladders
1 Multi-purpose ladder, movable 2 Hinged ladders, two left and two

(in transport receptacle) right
With the optional "Chain box, rear left", the corresponding ladder is
not required.
82640 2021-04-22 73
2.3.3 Before getting on /off ladders
WARNING
Risk to life and limb / risk of injury due to slipping
and falling!
The regulations listed below must be observed.
- Ensure that all equipment described for getting on / off the crane:
- is fitted. This applies to the ladders themselves as well as to the
corresponding holding devices.
- is in the operative state required (e.g. folding ladder in the oper-
ating position).
- can be accessed and used without any restrictions (e.g. the
equipment must be free of oil / grease, snow / ice, dirt and grit).
- Wait until the crane comes to a standstill.
- Do not misuse control elements (such as e.g. control levers in the
crane operator’s cab) as grab handles / holding devices.
- Keep the crane clean and dry.
- Keep shoes and gloves clean and dry.
- Carry out a visual inspection to check for damage and safe use. If
faults are detected, ladders, steps or holding devices may no lon-
ger be used and must be replaced immediately.
- Never jump off the crane. Always use the designated ladders to
get off.
- When using the ladders, always face / always have the front of
your body facing the ladder and always use the three points of
contact.
- Ensure the height is sufficient.
- Observe the signs attached to the ladders.
- Adhere to the max. load – 150 kg (330 lbs).
- Fit and use personal safety equipment if it is not ensured that there
will be three points of contact.
- The crane must be aligned horizontally. If the crane is in the in-
clined position, the crane operator might need to take additional
measures.
- Repairs and maintenance on ladders must be carried out by an ex-
pert and in accordance with the manufacturer's instructions.
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2.3.4 Getting on and down from the crane using folding ladders
2.3.4.1 General
Fig. 6: Handles - crane operator’s cab
When using these ladders to get into the crane operator's cab, the
grab handles outside of and within the crane operator's cab must also
be used so that there are constantly three points of contact.
For detailed information on actually entering / exiting the crane oper-

ator’s cab, see "Entering / exiting the cab" in "Crane operator's cab"
in the operating instructions of the superstructure.
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2.3.4.2 Placing the Folding Ladders in the Operating Position
WARNING
Risk of accidents in the slewing range.
Before beginning the swinging and folding procedure,
ensure that no people or objects are in the area affec-
ted.
WARNING
Risk of crushing in the area of the ladder hinges!
There is a risk of crushing for fingers and hands when
gripping the ladder in the hinge area and subsequently
swinging it round.
Never handle the ladder in the hinge area, but at the
free end.
Wear protective clothing.
Fig. 7: Hinged ladder in the transport position (schematic diagram)
1 Folding ladder 2 Lock

3 Guide rails
The folding ladder to be used must first be placed in the operating po-
sition before getting onto it. This may only be done from the ground.
To accomplish this, proceed as follows:
1. Lift the folding ladder out of the lock on the free end of the lad-
der.
2. Swing the ladder away from the crane by 90° until the top bars fit
into the guide rails.
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Fig. 8: Folding ladder in the operating po-

sition
1 Folding ladder
2 Metal sheeting
3 Guide bolts
WARNING
Risk of falling if the ladder is not fitted properly.
You may not step onto the ladder if it has not been
locked correctly into the operating position. The guide
pin must lock onto the metal sheet as illustrated.
3. Fold the ladder onto the chassis so that the guide pin locks in
place on the metal sheet.
A stable ladder position and a suitable angle for going up and
down the ladder is ensured.
The ladder is in the operating position and can be used.
82640 2021-04-22 77
2.3.4.3 Using the Folding Ladder

The followings points should be observed when using the ladder:
- Do not exceed max. payload of the ladder (here: 150 kg / 330 lbs).
- Face / front of body facing the ladder
- There must be three points of contact at all times. This means that
either 2 hands and one foot or 2 feet and one hand must be in con-
tact with the ground, ladder / holding device or the crane at the
same time.
- The grab handles outside of and within the crane operator's cab
must also be used so that there are constantly three points of con-
tact when using this ladder.
- There could be other grab handles, depending on the machine de-
sign (e. g. where you get on from the ladder). The same applies to
these.
- Hold on tight (using the bars and ladder steps and the existing
grab handles).
- Objects which are carried when climbing a ladder should not be
heavy and should be easy to handle. Tools must be carried in /
fastened to a corresponding harness to keep your hands free.
- When working on the ladder, personnel must also be equipped
with suitable personal protective equipment and must attach them-
selves to one of the attachment eyelets designated for this pur-
pose.
2.3.4.4 Placing the Folding Ladders in the Transport Position
WARNING
There is a risk of crushing for fingers and hands
when handling the folding ladder.
Proceed with appropriate caution.
Wear protective clothing.
Fig. 9: Hinged ladder in the transport position (schematic diagram)
1 Folding ladder 2 Lock
78 82640 2021-04-22
Before driving the crane, all folding ladders must be placed in the
transport position and secured in the lock. It is sensible to proceed in
the reverse sequence to 2.3.4.2 Placing the Folding Ladders in the
Operating Position, side 76.
However, before folding the ladder up and away from the chassis, the
metal plate must first be placed in the depicted position manually.
2.3.5 Getting onto and down from the Crane Using Mobile Multi-purpose Ladders
WARNING
Risk of falling due to incorrect handling.
Inappropriate handling of the multi-purpose ladder may
result in someone falling. This can cause serious injuries
or death.
The following chapters for installing and using the
multi-purpose ladder should be observed.
In particular, follow the safety instructions listed below
on handling the multi-purpose ladder.
2.3.5.1 General
Fig. 10: Lashing strap for fastening the ladder
1 Multi-purpose ladder
In addition to the firmly fitted ladders, there is a mobile multi-purpose

ladder. It is used not just for getting onto and down from the crane,
but also particularly for carrying out assembly procedures (e.g. fitting
or folding the main boom extension).
It is stored in the transport position on the crane chassis and must be
secured against falling down using two lashing straps.
This ladder can be fitted and removed from the ground.
The weight of the ladder is approx. 8.5 kg (19 lbs).
82640 2021-04-22 79
This ladder can be used in two ways:
- as a step ladder; to do so, it must be unfolded and set up.
- as a leaning ladder; when used like this, it can be adjusted to dif-

ferent lengths.
If the multi-purpose ladder is used as a leaning ladder, the attach-

ment hooks on the top ladder end must be hung correctly into the cor-
responding grooves of the ladder bracket (see arrows).
The ladder bracket design shown here is fitted to the main boom ex-
tension as an example. There are further ladder brackets e.g. in the
area of the main boom head and at the back in the cover plate of the
superstructure frame.
When working on the ladder, personnel must also be equipped with

suitable personal protective equipment and must attach themselves
to one of the attachment eyelets designated for this purpose.
There is also an attachment eyelet on each ladder bracket - or in its

immediate vicinity - for attaching the personal protective equipment
hooks. For detailed information on these attachment eyelets, see
2.3.7 Attachment Eyelets for Personal Protective Equipment,
side 84.
The adjacent figure shows the ladder, correctly attached to a ladder

bracket, and personnel additionally equipped with personal protective
equipment and secured.
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2.3.5.2 Placing the Multi-purpose Ladder in Position and Setting it up

To do so, comply with the following points:
- The ladder must be set up in the correct set-up position, e.g. cor-
rect set-up angle for leaning ladders (inclination angle: approx.
1:4); rungs or steps horizontal and stepladder must be fully
opened.
- Locking devices, if fitted, must be fully locked before use.
- The ladder must be standing on a level, horizontal and immobile
base.
- A leaning ladder must be leaned against a level, firm surface and
must be secured before use, e.g. by fixing it in place or by using a
suitable device for ensuring stability.
- The ladder may never be placed in a new position from above.
- When placing the ladder in position, remember the risk of collision,
for example with pedestrians, vehicles or doors. Lock doors (not,
however, emergency exits) and windows in the operating range, if
possible.
- Determine all risks due to the electrical equipment in the operating
range, e.g. high voltage overhead lines or other exposed electrical
equipment.
- The ladder must be set up on its base, not on its rungs or steps.
- The ladder may not be set up on slippery surfaces (e.g. ice,
smooth surfaces or clearly contaminated and dirty firm surfaces),
unless additional measures have been taken to prevent the ladder
from slipping or to clean the contaminated surfaces sufficiently.
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2.3.5.3 Using the Multi-purpose Ladder

Particularly when using the multi-purpose ladder (stepladder or lean-
ing ladder), follow the specifications listed below:
- Do not lean out too far. Users should keep their belt buckle (navel)
between the bars and stand with both feet on the same step/rung.
- Do not step away from a leaning ladder at great heights without
securing yourself additionally, e. g. fastening or using a suitable
device for securing the stability.
- Do not use stepladders for climbing onto another level.
- Do not use the top three steps / rungs as a base.
- Do not use the top two steps / rungs of a stepladder without plat-
form and holding device for hands / knees as a base.
- Do not use the top four steps / rungs of a stepladder with fitted
sliding ladder as a base.
- Do not use the ladder outside if the weather conditions are unfav-
ourable, e. g. strong winds.
- Avoid excessive loading or stress to one side.
- Do not stay on the ladder too long without regular breaks (tired-
ness is a risk).
In addition, the generally valid specifications under 2.3.4.3 Using

the Folding Ladder, side 78 for ladder assemblies must be ob-
served.
2.3.6 Surfaces Permitted for Walking and Standing on the Crane Chassis
WARNING
Risk to life and limb due to stumbling and/or falling
when walking on the crane chassis.
Only step on the permitted surfaces.
Observe the listed specifications in the following pro-
cedures.
Before stepping onto the tread surfaces, ensure that
there are no tools or other accessories lying around
loosely. Tools belong in the toolbox.
Move with particular care in areas with obstacles,
such as e. g. holding devices.
Before accessing tread surfaces where there are lad-
ders in the transport position, first remove them or
move them into the operating position.
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Fig. 11: Permitted tread surfaces (AC 250-5/220-5)
Fig. 12: Permitted tread surfaces (AC 160-5)
Fig. 13: Permitted tread surfaces (AC 130-5)
The permitted tread surfaces on the crane chassis are shaded. They
are designed to be slip-resistant. You may only step onto these
surfaces.
Surfaces with cross-hatching may also be accessed in the standard
version. Optionally, these can also be occupied by a chain box, a
hook block support or an additional tank, depending on the crane
type. In this case, you may no longer access these surfaces.
Observe the following when accessing the tread surfaces:
- Keep the surfaces permitted for walking and standing free of oil/
grease, debris, snow/ice and obstacles.
- Only walk in the areas wearing clean shoes.
- Only walk in the areas with sufficient height.
- Only step onto the engine covering when the main boom has been
luffed up and the engine is cold.
- Do not trip over mounting parts.
- The maximum permitted point load for walking on these surfaces is
1500 N.
It is expressly prohibited to walk on (or load) these surfaces:
- roof of the driver's cab
- supports of the air filter
- silencers and tubes of the exhaust system
82640 2021-04-22 83
- wood and chain box cover (optional) on the rear of the crane chas-
sis – do not get into the box interior either
- slanted surfaces in the area of the engine covering
- Hydraulic Tank
- Surface for setting down the hook block - do not climb into it or
place any objects inside
- occupied surface for optional "Chain box, rear left"
2.3.7 Attachment Eyelets for Personal Protective Equipment
WARNING
Risk of accidents due to inappropriate usage of per-
sonal protective equipment!
All persons using personal protective equipment must
be trained accordingly and competently with regard to
selection, checks before use and correct application
of their personal protective equipment.
WARNING
Risk of overloading and breaking if the attachment
eyelets are used improperly!
All attachment eyelets marked with the corresponding
decals may only be used to attach the hooks of the
personal protective equipment.
Under no circumstances are they to be used to hang
individual crane component parts to an auxiliary
crane. The attached objects could fall down.
84 82640 2021-04-22
Fig. 14: Attachment eyelet PPE with plate
1 Ladder bracket 2 Attachment eyelet

3 Adhesive sign
There are attachment eyelets at various points of the crane – here

shown as a component part of a ladder bracket. They serve as at-
tachment points for the lock-on hook of suitable personal protective
equipment.
These attachment eyelets are marked with a decal for clear identifica-
tion.
The country-specific regulations concerning design and use of per-
sonal protective equipment must be observed.
2.4 Headlights
Depending on the design of the crane, headlights can be fitted at the
following points on the superstructure:
- Cab, bottom, front
- Cab, top, front and rear
- Basic case of the main boom, can be adjusted electrically from the
cab
- Hanging light on the head of the main boom / fly jib
Specifications for driving the crane:

- The headlights on the upper side of the cab must be folded in
during travel in order to comply with the dimensions of the equip-
ment specified in the crane documents.
- The pendant lamp on the main boom head must be removed
while the vehicle is in motion, as it extends into the driver's field
of vision.
82640 2021-04-22 85
2.5 Emergency Exit

The front window of the crane cab can be opened wide to the front. It
is therefore suitable as an emergency exit. The passenger door on
the driver's cab can be used as an emergency exit.
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3 Crane operator's cab
3.1 Overview of the crane operator's cab
3.1.1 Total overview
Fig. 15: Total overview
1 Elements in the front of the cab (see 3.1.2 Ele- 2 Control panel, front (see 3.1.3 Control panel,
ments at the front of the cab, side 89) front, side 89)
3 Roof console (see 3.1.4 Roof console, side 94) 4 Control console, right (see 3.1.5 Control console,
right, side 96)
5 Key-operated pushbutton for bridging the load limit 6 Auxiliary AC System (Optional)
device (function only for crane control software in
accordance with EN 13000) 1) (see section "Safety
equipment" under "Bridging the shut-down of all
movements (EN13000)")
1) = You can check whether the crane has been equipped with control software in accordance
with EN 13000 by selecting the "System set-up (user)" screen in crane control. In this case,
there is a corresponding note.
82640 2021-04-22 87
Fig. 16: Total overview
1 Operating elements, crane operator cab's door (see 2 Platforms (see 3.5.3 Retracting/extending the
3.1.6 Operating elements on the cab door, platform on the cab, side 111)
side 98)
3 Operating elements in the footwell (see 3.1.7 Op- 4 Control console, left (see 3.1.8 Control console,
erating elements in the footwell, side 99) left, side 99)
5 Crane operator's seat (see 3.1.9 Crane operator's
seat, side 101)
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3.1.2 Elements at the front of the cab
Fig. 17: Operating elements at the front of the cab
1 Warning light (see section 2 Loudspeakers (for announce-

"Safety equipment" under "Over- ments made to persons in the vi-
load cut-off by load limit device cinity of the crane operator’s
(LLD)") cab) (optional)
Depending on the equipment, the speaker (2) may also be located

on the cab roof.
3.1.3 Control panel, front
Fig. 18: Control panel, front
1 Operating elements in the in- 2 Operating panel of the crane

strument panel, front (see control (electronic crane informa-
3.1.3.1 Operating elements in tion system; see section "Safety
the instrument panel, front, equipment" under "Operating
side 90) and display elements")
3 Instrument panel, side (see 4 Connections under side instru-
3.1.3.2 Instrument panel, side, ment panel (see 3.1.3.3 Con-
side 91) nections under side instrument
panel, side 93)
82640 2021-04-22 89
3.1.3.1 Operating elements in the instrument panel, front
Fig. 19: Front instrument panel (schematic diagram)
1 Adjustment of crane control's 2 Ignition key

operating panel monitor
3 Ignition switch (see 3.1.3.1.1 4 Quick stop of the engine
Ignition Switch, side 90)
3.1.3.1.1 Ignition Switch

The key-operated switch of the ignition lock is designed as a four-po-
sition switch:
P "Off" position
The key can be removed, depending on the design of the igni-
tion switch.
0 "Off" position
Removable key.
I Operating position
The ignition is switched on.
II Engine start position
WARNING
Risk of starting by unauthorised persons!
Remove the key, even when leaving the vehicle for a
short period of time.
WARNING
Risk of accidents!
It is forbidden to shut off the motor when a load is at-
tached.
The interior lighting of the crane operator's cab and the hazard light
always functions, regardless of the position of the ignition key.
90 82640 2021-04-22
NOTE
Risk of batteries discharging!
Any electric consumers which are not required should be switch-
ed off when the engine is switched off.
When the operator leaves the crane with electrical consumers
switched on (e.g. hazard lights), the electrical supply must be
ensured, if necessary through additional steps (e.g. battery
charger).
3.1.3.2 Instrument panel, side
Fig. 20: Instrument panel, side
1 Multifunctional display (addition-

al display) (call-up of information
focus: engine, see chapter "En-
gine" under "Additional display")
1 Automatic levelling (option) 2 Function selection 'Vertically re-

tract / extend all supports' (op-
tional)
3 Direction button 'Vertically re- 4 Direction button 'Vertically ex-
tract all supports' (optional) tend all supports' (optional)
5 Function selection 'Front left 6 Function selection 'Rear left sup-
support, horizontal / vertical' (op- port, horizontal / vertical' (option-
tional) al)
7 Function selection 'Front right 8 Function selection 'Rear right
support, horizontal / vertical' (op- support, horizontal / vertical' (op-
tional) tional)
9 / 10 Direction button 'Horizontal sup-
port' (optional)
82640 2021-04-22 91
1 Counterweight up/down 2 Enable radio remote control (op-

tional)
3 Bridge the load-moment-reduc- 4 Bridging "hoist limit switch"
ing movement "Raise luffing
gear"
5 Setup button (function only for
control software in accordance
with EN 13000) 1) otherwise:
bridge the load limit device (in-
stead of via the key-operated
pushbutton on the outside on
the rear can wall) (see section
"Safety equipment" under
"Bridging with the "Setup" but-
ton")
1) = You can check whether the crane has been equipped with
control software in accordance with EN 13000 by selecting
the "System setup (user)" screen in crane control. In this
case, there is a corresponding note.
92 82640 2021-04-22
3.1.3.3 Connections under side instrument panel
Fig. 23: Connections under side instrument panel
1 Cigarette lighter and power sup- 2 Power supply 24 VDC

ply 24 VDC
3 Ethernet RJ45 CAT 5 − connec- 4 USB−connection for crane con-
tion for crane control trol
Connections (3) and (4) are service connections for servicing crane
control.
NOTE
Risk of malfunction in crane control!
Do not connect anything if not specifically instructed.
Do not charge any devices, for example, mobile phones, tablets,
etc. using them.
82640 2021-04-22 93
3.1.4 Roof console
3.1.4.1 Overview of the operating elements
Fig. 24: Roof console
1 Monitor camera surveillance 2 Load hook camera operating

(see "Cameras on the crane panel (see 9.3.1.3 Hook cam-
(optional)" in the section "Work- era, side 421
ing instructions")
3 Operating elements - instrument 4 Operating panel - radio/CD (op-
panel in roof console (see tional)
3.1.4.2 Operating elements - in-
strument panel in roof console,
side 95)
5 Microphone for announcements 6 Connection for microphone (item
to persons in the vicinity (option- 5) (optional)
al)
7 Power supply 24-V
Depending on the cameras on the crane, there may be several mon-

itors in the crane operator's cab (see chapter "Working instructions"
under "Cameras on the crane (optional)").
94 82640 2021-04-22
3.1.4.2 Operating elements - instrument panel in roof console
Fig. 25: Operating elements - heating system and air conditioning (schematic dia-
gram)
1 Fan 2 Thermostat
3 Fan air distribution 4 Air conditioning ON/OFF (option-
al)
5 Fresh air / recirculated air 6 Operating element - engine-inde-
pendent heating
Fig. 26: Operating elements - roof console, centre part
1 Rotaflare light 2 Dash board illumination

3 Hazard light (optional) 4 Lighting equipment: bottom out-
rigger support area; top rear/side
area (optional)
5 Retraction / extension of the 6 Roof window wipers, 2 stages
platform (see 3.5.3 Retracting/ (intermittent / continuous)
extending the platform on the
cab, side 111)
7 Windscreen washer system, 8 Wipers, front, 2 stages (intermit-
roof / front window tent / continuous)
82640 2021-04-22 95
Fig. 27: Operating elements - roof console, rear part
1 Lighting equipment - crane oper- 2 Lighting equipment - crane oper-

ator’s cab, bottom front ator’s cab, top front (optional)
3 Lighting equipment - crane oper- 4 Heating system, flameless (op-
ator’s cab, top rear (optional) tional)
5 Pendant light at the top section
of the boom system (optional)
3.1.5 Control console, right
3.1.5.1 Operating elements
Fig. 28: Control console, right
1 Arm console incl. storage com- 2 Control of the crane movements

partment under armrest (for set- (for the structure, see 3.1.5.2
ting the arm console, see Control lever, right, side 97; for
3.1.10 Setting the arm consoles, control lever assignments, use of
side 105) the control levers, see 8.1.7.11
"Joystick Modes" screen,
side 304)
3 Operating elements (see
3.1.5.3 Instrument panel ar-
rangement, right-hand control
console, side 98)
96 82640 2021-04-22
3.1.5.2 Control lever, right
Fig. 29: Control lever, right
1 Fine tuning (%) of movement 2 Vibration display: Hoist 1 rotating

speed
3 High speed hoist 1 4 High speed luffing gear
5 Release switch system crane
movements
WARNING
ments.
As several different variants can be selected for the
control lever assignment via the IC-1 (see 8.1.7.11
"Joystick Modes" screen, side 304), it is the respon-
sibility of the crane operator to check the current con-
trol lever assignment before initiating a crane move-
ment.
Other keys might be available, depending on the control lever de-

sign. These are without function.
82640 2021-04-22 97
3.1.5.3 Instrument panel arrangement, right-hand control console
Fig. 30: Instrument panel arrangement, right-hand control console
1 Engine START / STOP 2 Cab adjustment (for use, see

3.8 Tilting the crane operator’s
cab (optional), side 113)
3 Short wiping procedure (with
brief button operation, approx. 1
second): top: roof window; bot-
tom: front window
3.1.6 Operating elements on the cab door
Fig. 31: Manual operating elements on the cab door
1 Handle, interior 2 Door opener, interior

3 Door catch 4 Handle, exterior
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3.1.7 Operating elements in the footwell
Fig. 32: Operating elements in the footwell
1 Speed adjustment of the engine 2 Horn

3 Slew gear brake
3.1.8 Control console, left
3.1.8.1 Operating elements
Fig. 33: Control console, left
1 Arm console incl. storage com- 2 Control of the crane movements

partment under armrest (for set- (for the structure, see 3.1.8.2
ting the arm console, see Control lever, left, side 100; for
3.1.10 Setting the arm consoles, control lever assignments, use of
side 105) the control levers, see 8.1.7.11
"Joystick Modes" screen,
side 304)
3 Operating elements (see
3.1.8.3 Instrument panel ar-
rangement, left-hand control
console, side 101)
82640 2021-04-22 99
3.1.8.2 Control lever, left
Fig. 34: Control lever, left
1 Fine tuning of the movement 2 Vibration display: Hoist gear 2 is

speed - selecting crane move- turning (optional)
ment
3 Hoist gear 2 high speed (option- 4 without function
al)
5 Release switch system crane
movements
WARNING
ments.
As several different variants can be selected for the
control lever assignment via the IC-1 (see 8.1.7.11
"Joystick Modes" screen, side 304), it is the respon-
sibility of the crane operator to check the current con-
trol lever assignment before initiating a crane move-
ment.
Other keys might be available, depending on the control lever de-

sign. These are without function.
100 82640 2021-04-22

3.1.8.3 Instrument panel arrangement, left-hand control console
Fig. 35: Instrument panel arrangement, left-hand control console
1 Switch 1st basic case headlight 2 Adjust 1st basic case headlight
on / off (optional) (optional)
3 Switch 2nd basic case headlight 4 Adjust 2nd basic case headlight
on / off (optional) (optional)
5 Angle adjustment of hydraulical- 6 Switchover slew gear: open /
ly adjustable fly jib (option) closed circuit
7 Open / close the slew gear park-
ing brake
3.1.9 Crane operator's seat
3.1.9.1 General Instructions

The crane operator is protected against mechanical vibrations by
means of a pneumatically dampened seat.
Tips for sitting correctly
- Set the seat to your own requirements.
- Set the horizontal setting so that the pedals can be reached com-
fortably and can be pushed down effortlessly.
- In order to sit in a relaxed manner, your back must recline against
the backrest from your bottom to your shoulder blades.
WARNING
Risk of accidents!
For safety reasons, the seat may only be adjusted /
set when no crane movements have been initiated.
CAUTION
An incorrectly set seat a risk to your health.
Before starting work, set the seat so that is ideally
suited to your body, especially when you change driv-
ers.
82640 2021-04-22 101

WARNING
If the following warnings are not adhered to it can
cause serious injury.
The seat may only be fitted and repaired by qualified
personnel.
Have defective components repaired or replaced im-
mediately.
It is prohibited to make changes to the seat.
Fixtures and locks must be checked regularly.
Do not use damaged or faulty seats.
Broken steel components may not be welded.
Do not actuate several operating elements simultane-
ously.
All adjusting mechanisms must audibly engage. The
actuating levers must be operated the full actuating
path to prevent wear to the adjusting mechanism.
NOTE
Specifications on correct maintenance of the seat
Only use a slightly damp cloth without any strong clean agents
to clean the seat.
The cover fabric may not be wet through.
The seat is only suitable for a driver's weight of no more than
150 kg (330 lbs).
Ensure that the seat (especially the shock-cushioning seat) is
not blocked by objects in the vehicle. This can cause damage to
the seat.
If the seat heating is operated or connected incorrectly, the
heating can become overheated.
102 82640 2021-04-22

3.1.9.2 Setting the crane operator's seat
Fig. 36: Crane operator's seat
1 Belt buckle 2 2-point lap belt

3 Seat heating 4 Seat height setting
5 Seat cushion depth adjustment
Item Designation Symbol Function

1 Belt buckle (depending on the crane design)
2 2-point lap belt (depending on the crane design)
3 Heating Thermostatically controlled seat cushion and backrest heating. It
is switched on and off using the switch.
4 Seat height set-
Actuate the +/- button. The setting is carried out pneumatically, a
ting
compressor integrated in the seat is triggered.
5 Seat cushion Pull up the actuating lever and adjust the seat cushion in the lon-
depth adjust- gitudinal direction.
ment
82640 2021-04-22 103

Fig. 37: Crane operator's seat
1 Lumber vertebrae support 2 Height / tilt setting, front

3 Horizontal adjustment of the seat without armrests 4 Horizontal setting
5 Horizontal adjustment of the seat with armrests 6 Backrest setting
Item Designation Symbol Function

1 Lumber verte- The three chambers of the pneumatic lumbar vertebrae
brae support support can be aerated and vented independent of each
other using the corresponding button.
Front height Pull the lever up and change seat height / tilt by applying
2 and tilt setting or removing pressure in the front area of the seat cush-
ion.
3 Lever Horizontal adjustment of the seat without armrests
4 Display
Load display:
- Green: in case of load
- Yellow: if the amount of compressed air in the sus-
pension system has become too low
5 Lever Horizontal adjustment of the seat with armrests

6 Backrest set- Pull the handle up completely and bring the backrest into
ting the desired position by pressing the upper half of your
body appropriately.
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3.1.10 Setting the arm consoles
1. To set them in the longitudinal direction, pull the bottom lever,

thereby pushing the arm consoles forward and backward with the
seat.
Fig. 38: Setting the height and tilt of the arm console
- The arm consoles can be fastened to the side panel of the crane
operator's cab at 3 different heights.
- The fixtures on the arm consoles are designed so that the tilt of
the arm consoles can be set at the same time.
2. To set the height / tilt, loosen the screws (see detail in Fig. 38,
side 105) and fasten the arm consoles again.
3.2 Locking/unlocking the cab door from the outside
3.2.1 Locking/unlocking using the vehicle key
1. Turn the vehicle key clockwise.
The cab door is locked.
82640 2021-04-22 105

2. Turn the vehicle key anticlockwise.
The cab door is unlocked.
3.2.2 Locking/unlocking with remote control operation (optional)
1. Press the function button of the remote control twice briefly.
Door is locked.
The indicators on the chassis briefly light up twice when locking the
cab door using the remote control.
2. Press the function button of the remote control once briefly.
Door is unlocked.
- The door is not automatically locked again if it is not opened after

unlocking.
- The indicators on the chassis briefly light up when unlocking the
cab door using the remote control.
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3.2.2.1 Overview/structure of the key remote control (optional)
Fig. 39: Radio remote control - cab doors
1 Folding key 2 Push button for folding key

3 LED 4 LED
5 Crane operator’s cab door 6 Central locking
7 Driver's cab door
Item Function
1 Folding key
2 Push button for folding key
LED
confirms actuation of transmit button:
- green for opening procedures
3 - red for closing procedures
- blue if button (7) has been pressed for longer than 3 sec-
onds (only for Service).
LED
4 flashes green if a button is actuated and the radio key is in the
transmission/reception area
Crane operator’s cab door:
5 - Press 1 x briefly to unlock
- Press 2 x briefly to lock
6 Lock the crane operator cab and driver's cab doors

Driver's cab door:
7 - Press 1 x briefly to unlock
- Press 2 x briefly to lock
The battery in the key must be replaced if LEDs (3) and (4) flash si-
multaneously first in red, green and then blue.
82640 2021-04-22 107

3.3 Unlocking/opening the cab door from the inside
1. Unlocking the door: actuate the door opener.
2. Slide the cab door open using the grab handle.
3.4 Opening the cab door
1. Actuate the door handle - the door lock is opened.
2. Pull the grab handle and push the cab door open.
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3.5 Entry / exit
- Use the handles (arrows) to enter and exit safely.
- The cab door is automatically locked when completely open to pre-

vent accidental closing.
- It might be required to push the left-hand arm console back to en-

ter and exit comfortably (see 3.1.10 Setting the arm consoles,
side 105).
3.5.1 General
WARNING
Risk of falling!
Use handles and folding ladder / steps to enter and
exit. Do not jump out of the crane operator's cab.
Safety is diminished on the steps and at the entry
areas due to dirt and mud. This means you can slip
on the steps. Keep steps, entry areas and shoes free
of contamination (e.g. mud, clay, snow and ice).
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Fig. 40: Operating elements - entering/exiting the crane operator’s cab
1 Ignition key 2 Handles

3 Handle 4 Handle
5 Platform 6 Grab handle for sliding the cab
door open/closed
CAUTION
Danger!
The door to the crane operator's cab must be closed
so that the platform (see Fig. 40, side 110) can be
used across its full width.
3.5.2 Procedure
Requirements:
- The ignition in the driver's cab is switched on.
1. Completely extend the platform using the operating elements in
the operating boxes. See 3.5.3 Retracting/extending the plat-
form on the cab, side 111.
2. Unlock the cab door. See 3.2 Locking/unlocking the cab door
from the outside, side 105.
3. Open the cab door. See 3.4 Opening the cab door, side 108.
4. Depending on the position of the superstructure, get onto the
crane chassis using one of the crane chassis ladders (see sec-
tion "Structure of the mobile crane " under "Getting onto and off
the crane" or "Ladders, holding devices and rails").
5. Step into the cab via the platform. If required, fold up the left arm
console (see 3.1.10 Setting the arm consoles, side 105).
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The left arm console must be folded up when exiting the cab. Then
the work steps for entering the cab are carried out in the reverse se-
quence.
3.5.3 Retracting/extending the platform on the cab

Extend the platform (arrow) fully to get into / exit the crane operator's
cab. To do so, the ignition must be switched on or the engine must be
started.
WARNING
There is a risk of crushing and falling when extend-
ing and retracting the platform on the side of the
crane operator’s cab.
Only retract and extend the lateral platform if there is
a clear view of it.
Operation on the operating boxes
Fig. 41: Outrigger Controls
1 Button "Retract / extend lateral 2 Direction button, retraction/

platform, crane operator’s cab" extension of the support struts;
Retract lateral platform
3 Direction button, retraction/
extension of the outrigger struts;
Extend lateral platform
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Extending the lateral platform on the crane operator’s cab

Press the "Retract / extend lateral platform, crane operator’s cab" but-
ton (1) and the direction button (3) together until the platform is com-
pletely extended.
Retracting the lateral platform on the crane operator’s cab
Press the "Retract / extend lateral platform, crane operator’s cab" (1)
button and the direction button (2) together until the platform is com-
pletely retracted.
Operation in the crane operator’s cab
Alternatively, the platform can be retracted and extended using the
depicted rocker switch in the roof console of the crane operator's cab
(for arrangement of the rocker switches, see "Operating elements in
instrument panel in the roof console").
3.6 Closing the cab door
CAUTION
There is a risk of crushing between the door and the
cab frame when closing the cab door.
Use the intended grab handles to ensure that your
hands are not in the area at risk.
1. If the cab door is locked while completely open: Use the interior
or exterior door opener.
2. Closing the door:
- from the outside: on grab handle
- from the inside: on grab handle
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3.7 Exiting the cab in an emergency

Use the front window as an emergency exit (see 3.9.3 Front Win-
dow, side 115).
3.8 Tilting the crane operator’s cab (optional)
Fig. 42: Rocker switch - tilt crane operator's cab
To make it easier to follow work with the crane, the crane operator's
cab can be tilted backwards using hydraulic cylinders.
1. Press the rocker switch upwards.
The crane operator's cab tilts backwards.
Or
Press rocker switch downwards.
The crane operator's cab tilts forwards.
CAUTION
There is a risk of crushing when tilting the crane op-
erator's cab.
Persons must stay clear of the hazardous area!
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3.9 Opening / Closing Windows
3.9.1 Rear Window

The window in the rear cab wall is a sliding window.
When closed, the individual handle on the window element and the
fixed counterpart on the cab frame support must be locked together.
Press the grip together to open the rear window. The locking nose is
lifted and the window element can be closed/opened.
CAUTION
When closing, there is risk of crushing between the
window element and the door / cab frame.
3.9.2 Side window (in cab door)

The side window in the cab door is a sliding window.
When closed, the grip on the window element and the fixed counter-
part on the door frame are locked together.
Press the grip together to open the side window. The locking nose is
lifted and the window element can be closed/opened.
CAUTION
When closing the window, there is a risk of crushing
between the window element and the door frame.
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3.9.3 Front Window
3.9.3.1 Structure / function of the front window
Fig. 43: Front Window
1 Gas-operated positioner 2 Lock

3 Handle 4 Front Window
Item Designation Function

Gas-operated
1
positioner
2 Lock Unlock / lock the front window
3 Handle Opening / Closing front window
4 Front Window
3.9.3.2 Opening / Closing front window
Fig. 44: Opening the front window
1 Lock 2 Handle
1. To open the front window, press both locks (1) together with the
handles (2) and push the window open.
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NOTE
Risk of breakage!
When pressing the window open, do not let go of it until it is
completely open. This prevents the window from being knocked
hard in the final position.
CAUTION
There is a risk of crushing between the window ele-
ment and the cab frame when closing the window.
Use the intended handles to ensure that your hands
are not in the area at risk.
Fig. 45: Closing the front window
2. To close the front window, pull it down using both handles (see
arrows) and let the locks engage.
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3.10 Sunshade
The crane operator's cab is fitted with roll-down sunshades on the
roof window, rear window and side window. These can be activated
as required to avoid being dazzled by the sun or the crane operator's
cab becoming too warm.
Fig. 46: Sunshades - crane operator’s cab
1 Clip - window shade, roof win- 2 Cord to release the window

dow shade locks
3 Clips - vertical window shades

1 Shackle To open/close the sunshade of the roof win-
dow
2 String To release the locks on the window shades
in the side windows / rear window
3 Shackles To close the window shades in the side win-
dows / rear window
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Window shade on the roof window
Fig. 47: Sun shades in the roof window
1 Clip - window shade, roof win-

dow
To roll down the window shade on the roof window, take the shackle
(1) and slightly tilt the front rod of the window shade to the front/down
within the guide rails to release the lock. In this position, move the
window shade forward into the desired position and release the
shackle. The window shade is relocked in this position.
To roll it up, proceed analogously. The window shade automatically
rolls down after the lock is released.
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Vertical window shades
Fig. 48: Vertical window shades
1 Clips - vertical window shades 2 Cord to release the window

shade locks
The vertical window shades can be pulled down to the desired posi-
tion using the corresponding flap (1). Once the shade has been pulled
down to the required level, it stays in that position. In order to roll up
the window shades again, release the lock by pulling string (2). The
window shade is then rolled up fully.
Sunshade on the front window
Fig. 49: Sunshade, front
The sunshade in the front window can be pivoted around the existing
pivot points into the desired position, as required.
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3.11 Interior Lighting
Fig. 50: Interior cab lights
1 Lamp 2 Switch
There are two lamps (1) in the roof console which can be used as
reading lamps or for ambient lighting.
Switch to the desired function using the 3-position switch (2):
- Press to the left: Reading light ON
- Press to the right: Ambient lighting ON
- Middle position: Light OFF
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3.12 Racks
Fig. 51: Racks and storage options (schematic diagram)
1 Storage compartment on the top 2 Storage recess on the right-hand

of the instrument panel (with side of the cab
netting)
3 Ashtray 4 Storage compartment in the
right- and left-hand arm consoles
(under the armrest)
5 Storage area under the seat 6 Storage compartment under the
seat of the crane operator (be-
hind the flap)
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4.1 General
The superstructure does not have its own drive motor. Superstructure
operation is carried out using the engine of the crane chassis.
For detailed information on the engine, see the operating instructions
of the crane chassis under "Engine". This information, particularly the
safety instructions before starting operation of the engine, must be
observed.
Before starting operation, the operating instructions of the engine

manufacturer must be observed (see the part "Various").
The following points are primarily limited to the specifications which

particularly affect crane operation.
4.2 Damage-prevention measures
WARNING
Risk of accidents by not observing safety measures.
Not observing safety measures can cause injury to per-
sons, damage to the engine, components and cable set.
The safety measures in the operating instructions of
the crane chassis must be observed.
4.3 Control and display elements
4.3.1 Additional display
4.3.1.1 General
Fig. 52: Additional display
Screens at the additional display:

- For the operating screen with vehicle data and indicator lights, see
4.3.1.3 Operating screen, side 124
- For the "Engine/hydraulic data" screen, see 4.3.1.4 "Engine/
hydraulics data" screen, side 126
When the crane control of the superstructure is switched on, the dis-
play is automatically started.
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The green LED at the bottom right on the housing of the additional
screen is illuminated. After a few seconds, the operating screen will
appear.
4.3.1.2 Structure of the additional display
Fig. 53: Additional display
1 Screen 2 Function buttons (for switching

between displays)
3 Green status light: everything is 4 without function
in working order; flashing red:
communication fault
4.3.1.3 Operating screen
Fig. 54: Operating screen (schematic diagram)
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Figure Explanation
Fuel tank filling level (see 4.4.5.10 Filling level of the fuel tank, side 142)
AdBlue filling level (see 4.4.5.11 Filling level of the AdBlue / DEF tank, side 142)
Engine speed, analogue and digital (rpm x 1000) (schematic diagram)
Indicator light for diesel particulate filter (see "Operating restrictions and indicator
lights for the exhaust gas aftertreatment system") 4.5.2.2.1 ... Engine complies
with exhaust emission standard EM5, side 145 under "Regeneration of the diesel
particulate filter")
Indicator light for high exhaust gas temperature (see "Operating restrictions and in-
dicator lights for the exhaust gas aftertreatment system") 4.5.2.2.1 ... Engine com-
plies with exhaust emission standard EM5, side 145 under "Regeneration of the
diesel particulate filter")
Coolant temperature (see 4.4.5.8 Coolant temperature, side 141)
Hydraulic oil temperature (see 4.4.5.5 Hydraulic oil temperature, side 139)
Engine oil pressure indicator light (see 4.4.5.2 Engine oil pressure, side 138)
Coolant temperature indicator light (see 4.4.5.8 Coolant temperature, side 141)
Battery voltage indicator light
Engine malfunction alarm indicator light (see 4.4.5.3 Engine fault, side 138)
Engine malfunction warning indicator light (see 4.4.5.3 Engine fault, side 138)
Exhaust gas aftertreatment system indicator light (see 4.5.2.2.1 ... Engine com-
plies with exhaust emission standard EM5, side 145 or 4.5.2.2.2 ... Engine com-
plies with exhaust emission standard EM4/Tier4, side 148)
Exhaust gas aftertreatment system indicator light (see 4.5.2.2.1 ... Engine com-
plies with exhaust emission standard EM5, side 145 or 4.5.2.2.2 ... Engine com-
plies with exhaust emission standard EM4/Tier4, side 148)
The error indication that displays depends on the exhaust emission

standard complied with.
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4.3.1.4 "Engine/hydraulics data" screen
Fig. 55: Engine/hydraulics data
1 Battery voltage in Volt 2 Engine oil pressure

3 Engine oil filling level 4 Operating hours - engine
5 Change to vehicle data/indicator 6 Filling level hydraulic oil
lights (selection via the function
button below)
7 Access for customer service de- 8 Change to info screen diesel par-
partment only (selection via the ticulate filter (EM5 engine; selec-
function button below) tion via the function button be-
low)
4.3.1.5 Info screen "Diesel particulate filter" (DPF; EM5 engines only)
Call up the additional display on the "Motor/hydraulic data" screen.
Fig. 56: Info screen "Diesel particulate filter"
1 Zone of "DPF loading" (see 2 "Remaining time manual regen-

Tab. 2, side 147) eration"
3 Change to "Engine/hydraulic da-
ta" screen (selection via the
function button below)
For detailed information on the diesel particulate filter, see

4.5.2.2.1 ... Engine complies with exhaust emission standard EM5,
side 145.
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4.3.2 Engine Display in the Crane Control Screen
4.3.2.1 "Engine display" screen
4.3.2.1.1 Calling up the "Engine display" screen
Fig. 57: Crane control "Engine display" screen (schematic diagram)
1 Engine data (see 4.3.2.1.2 2 Engine/exhaust gas aftertreat-

Display of engine data, ment indicator lights (see
side 128) 4.3.2.1.3 Display indicator lights,
side 128)
3 Automotive driving (see
4.3.2.2 "Automotive driving"
screen / setting the engine
speed manually, side 129)
Press the key shown in the quick menu of crane control to call up the
"Engine display" screen.
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4.3.2.1.2 Display of engine data
Fig. 58: Engine data
Display Meaning
Engine speed
Operating hours
Supply - reducing agent (only for engines

with SCR exhaust gas aftertreatment sys-
tem)
4.3.2.1.3 Display indicator lights
Fig. 59: Indicator lights "Engine display" screen
There are indicator lights on faults in the area of the engine/exhaust

gas aftertreatment system only for engines with exhaust gas after-
treatment system SCR.
To troubleshoot errors in the engine/exhaust gas aftertreatment

area, the corresponding indicator lights should be consulted on the
additional display.
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4.3.2.2 "Automotive driving" screen / setting the engine speed manually
Fig. 60: Crane control menu "Automotive driving"
1 Calling up the "Automotive driv-

ing" screen
Actuate the key shown in the engine display to call up the "Automo-
tive driving" screen.
4.3.2.2.1 Switching on/off "Automotive driving"
Fig. 61: "Automotive driving" screen
1 Switching on/off "Automotive

driving"
During "Automotive driving", the engine speed is automatically adap-

ted depending on the load. This ensures comfortable working as the
engine speed does not have to be additionally activated by the crane
operator.
Switching on "Automotive driving"
Press the displayed key to switch on "Automotive driving". It is high-
lighted in green.
Switching off "Automotive driving"

Press the displayed key again to switch off "Automotive driving".
When switched off, the key background reverts to grey.
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Speed limit during "Automotive driving"

The maximum achievable engine speed can be limited, for example,
for noise protection reasons. Similar to the procedure for manually
setting the engine speed (see 4.3.2.2.2 Manually Setting the Engine
Speed, side 130), the maximum achievable engine speed can be set
("Slider to the left").
Fig. 62: Pedal for speed adjustment
The engine speed can be increased by actuating the pedal for

speed adjustment ("accelerator pedal", see arrow) if a higher engine
speed is desired for a short period of time during operation.
4.3.2.2.2 Manually Setting the Engine Speed
Fig. 63: "Automotive driving" screen
1 Slide control switch - engine

speed
When "Automotive driving" is switched off, the engine speed can be

regulated between the minimum and maximum values by actuating
the arrows or moving the displayed slide control switch. The current
speed is shown directly under the slide control switch.
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4.4 Starting the Engine
4.4.1 Checks before Starting the Engine

1. Before starting, check (on the outside on the crane):
- the hydraulic oil level
- the coolant level.
For the procedure, see the lubrication and maintenance instructions,

under "Engine".
2. Furthermore, you must also check:

- the fuel supply in the additional screen.
- the engine oil level in the additional screen.
- the supply of the reduction agent (only for engines with ex-
haust gas aftertreatment system) in the crane control screen
or in the additional screen.
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4.4.2 Starting Procedure
4.4.2.1 Safety Regulations during the Starting Procedure
WARNING
Risk of accidents due to abrupt movements.
Starting the engine can cause the crane to move abrupt-
ly, which can cause injury to persons and damage to
property.
Before starting the engine, ensure that the control
levers are in the neutral position.
Fig. 64: Foot switch - horn in the cab
WARNING
Risk of accidents in the hazardous area!
Serious injury to persons and damage to property can
occur in the hazardous area and beyond the crane oper-
ator's field of vision.
Only authorised persons may be in the hazardous
area of the crane (e.g. people attaching/detaching the
load, banksmen, etc.). The crane operator or appoin-
ted safety personnel must monitor this.
Before operating the crane, anyone possibly outside
of the crane operator's field of vision within the
crane's collision and crushing area must be warned.
To do so, activate the horn using the foot switch ev-
ery time before starting the engine or initiating crane
movements (see arrow).
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NOTE
Risk of damage to the engine if the regulations are not ob-
served.
Only operate the crane within the permitted ambient tempera-
ture range (see 1.4.5 Required Ambient Conditions, side 34).
Only use suitable consumables (e.g. engine oil, transmission oil,
etc.) for the corresponding ambient temperature range (see the
lubrication and maintenance instructions under "Consumables").
Connect the vehicle batteries carefully.
4.4.2.2 Starting the Engine (Starting Operation)
WARNING
Risk of injury due to using starter spray.
Using starter spray can cause an explosion in the intake
manifold which can lead to burns and injuries.
Starter spray or similar devices may not be used for
jump starting.
DANGER
Danger due to operating the engine in enclosed
spaces.
Operating the engine in enclosed spaces leads to as-
phyxiation, poisoning or death, as the exhaust fumes
contain carbon monoxide and nitrogen oxide. Both are
poisonous.
Only start the engine in well ventilated areas.
When operating the engine in enclosed spaces, suita-
ble exhaust systems for exhaust gases and gases
from crankcase ventilation are required.
1. Ensure the safety regulations described are adhered to (see

4.4.2.1 Safety Regulations during the Starting Procedure,
side 132).
2. For cranes with a battery isolating switch (optional): Connect the
crane's electrical system with the vehicle batteries by activating
the battery isolating switch in the chassis cab (see the operating
instructions of the crane chassis under "Engine").
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4 motor
3. Switch on the ignition. To do so, insert the ignition key into the
ignition lock and turn clockwise up to the first stop (position "I").
This starts the crane control.
WARNING
Risk of accidents in the hazardous area!
occur in the hazardous area and beyond the crane oper-
ator's field of vision.
Activate the horn before crane operation to warn peo-
ple.
4. Actuate the horn using the foot switch.
5. Place the pedal for speed adjustment in the idling position.
Alternatively, the engine speed can also be adjusted using crane

control. To do so, call up the "Automotive driving" screen (see
4.3.2.2 "Automotive driving" screen / setting the engine speed man-
ually, side 129).
6. Continue to turn the ignition key up to the stop (position "II") and
hold in this position (max. 30 s) until the engine starts.
After power take off has been released (drive gearbox of the crane
chassis), the hydraulic pumps of the superstructure start up.
If there is no release, crane control issues the collective fault mes-
sage 9002 " Fehler UW Antriebsstrang STOP" ("Fault chassis drive
train STOP"). In very rare cases, the power take off is not enabled
because of an incorrect gear tooth position. In that case, turn off the
engine and repeat the starting procedure.
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NOTE
Risk of damage due to actuating the starter incorrectly.
Once the engine has started running, release the ignition key.
Never actuate the starter with the engine running.
Instructions in case of starting problems:

- Before attempting to start the engine again, turn the ignition key
back to the first stop.
- The starter may only be actuated twice for maximum 30 seconds.
Wait at least 5 minutes before attempting another start.
- If the engine starter does not turn or turns too slowly: charge up
the batteries or perform a jump start (see 4.4.4 Battery Charg-
ing Device (Optional), side 136 or 4.4.3 Jump Starting with Ex-
ternal Batteries, side 136).
- If the engine does not start, determine the cause of the fault us-
ing the operating instructions of the engine manufacturer.
4.4.2.3 Starting the Engine (with the Ignition Already Switched on)
Fig. 65: Dual button - Engine START/STOP
If the engine has been switched off using the dual button with the igni-
tion switched on (see 4.6.1 Switching the Engine off under Normal
Conditions (with the Ignition Switched on), side 150), it can also be
restarted using the dual button.
NOTE
Risk of damage due to actuating the starter incorrectly.
Observe the corresponding specifications on the duration of the
starting procedure and for instructions on start-up problems (see
"Starting the engine (operational start)").
Release the dual button immediately after the engine has star-
ted running.
Never actuate the starter with the engine running.
1. To do so, press the right side of the dual button without actuating
the pedal for speed adjustment until the engine is running.
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4.4.2.4 Starting at Low Temperatures

The environmental regulations valid on location must be adhered to.
Use fuel preheater and engine heating to prevent starting problems
and white smoke.
At low engine speeds and average load, the formation of white smoke
is limited and the cold engine reaches its operating temperature more
quickly than when warming up without load.
Do not let the engine run at idle speed longer than absolutely neces-
sary.
At extreme sub-zero temperatures, do not subject the cold engine to
full load.
Before the engine may be operated at higher load, the hydraulic oil
must be brought to normal operating temperature (see "Warming up
the hydraulic system" in this section). At lower engine speeds, (<
1000 min-1/rpm) warm up the hydraulic oil until the tank temperature
is higher than the lower operating temperature depending on the oil
type.
4.4.3 Jump Starting with External Batteries

For detailed information on this subject, see the operating instructions
of the crane chassis, section "Engine" under "Jump starting".
4.4.4 Battery Charging Device (Optional)

For detailed information on this subject, see the operating instructions
of the crane chassis, section "Engine" under "Battery charger (option-
al)".
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4.4.5 After starting the engine
4.4.5.1 General
Fig. 66: Displays
1 Additional display 2 Display of crane control
Certain checks must be carried out. This is done either in the addi-
tional screen (1) or in the crane control screen (2).
NOTE
Risk of damage for the engine if operation is continued.
Switch the engine off immediately if:
- the oil pressure drops abnormally or exhibits major fluctua-
tions.
- decreasing performance and speed without the position of
the speed adjustment pedal being changed
- heavily smoking exhaust
- abnormally rising coolant and oil temperatures
- sudden abnormal noises in the engine or turbocharger.
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4.4.5.2 Engine oil pressure

Check the additional display on the "Motor/hydraulic data" screen.
NOTE
Risk of damage when operating the engine without oil pres-
sure.
Do not rev up the engine if there is no engine oil pressure dis-
played. If, after 10 seconds. no engine oil pressure is displayed,
switch off the engine and determine the cause of the fault.
After reaching the operating temperature and speed, the oil pressure
is normally approx. 3 - 6 bar (43.5 - 87 psi). It may not fall below the
following values:
- 0.7 bar (10.2 psi) for speeds below 1000 rpm-1
- 2.5 bar (36.3 psi) for speeds over 1000 rpm-1.
If the pressure falls below these values, switch the engine off and de-
termine the cause.
If the minimum permissible value is not reached, the symbol on the
left will be shown on the additional display.
High oil pressure (above 6 bar / 87 psi) is normal when starting a

cold engine.
4.4.5.3 Engine fault

If the engine control unit reports an engine fault, a "warning" or
"alarm" is displayed on the additional display.
For a "warning", the indicated symbol appears. In addition, an error
message is displayed in the crane control display (Group error, E ....
Fault chassis drive train warning).
WARNING
Risk of accidents in the event of non-compliance.
If a warning occurs from the engine control unit, the oper-
ating safety of the drive motor is at risk.
Rectify the fault or have it rectified as soon as possi-
ble.
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For an "alarm", the indicated symbol appears. In addition, an error

message is displayed in the crane control display (Group error, E ....
Fault chassis drive train STOP).
WARNING
Risk of accidents in the event of non-compliance.
If an alarm occurs from the engine control unit, the oper-
ating safety of the crane is at risk.
Switch off the engine.
Rectify the fault immediately (or have the fault recti-
fied).
4.4.5.4 Air filter state

If there is a fault message relating to the air filter in the crane control
display in the form of the depicted symbols (see "Fault messages"
screen in section "Safety equipment"): Service the air filter. See the
section "Cooling, intake and exhaust system" under "Intake system"
in the lubrication and maintenance instructions.
4.4.5.5 Hydraulic oil temperature

Check the additional display on the "Operating mask".
The hydraulic oil temperature may not exceed a certain "upper oper-
ating temperature". This depends on the hydraulic oil used. For this
reason, observe the corresponding specifications (see 4.7 Hydraul-
ic System, side 152).
NOTE
Danger of the hydraulic oil overheating!
If the hydraulic oil temperature is too high, do not stop the en-
gine. Instead, allow it to run at low speed without a load until the
hydraulic oil returns to the permitted temperature range.
4.4.5.6 Filling level hydraulic oil

Detailed specifications on checking the hydraulic oil level and top-

ping up if required can be found in the respective points in the lubri-
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Transport condition
The displayed percentage must be as follows when the crane is in the
transport condition (main boom telescoped in and set down on the
boom support device, struts / outrigger cylinders retracted:
AC 250-5 AC 220-5 AC 160-5 AC 130-5

Display max 100 % 100 % 100 % 100 %
Display min 96 % 96 % 91 % 91 %
Superstructure Operation
During superstructure operation, the percentage must not drop below
the following value:
AC 250-5 AC 220-5 AC 160-5 AC 130-5

Display min 35 % 35 % 37 % 39 %
Fault message
If in the superstructure on the display of the crane control, the fault
message (collective fault E ...... "Error carrier miscellaneous warning")
is issued, this can be caused by a number of issues such as a hy-
draulic oil level which is too low.
A definite identification of the cause of the fault for this fault message
in the superstructure is only possible on the driver information system
in the driver's cab (crane chassis).
When the fault message regarding the hydraulic oil level is displayed,
stop crane operation and top up hydraulic oil (max. approx. 30 - 40 l /
8 - 10 gal; this corresponds to the display about 4%). The fault mes-
sage is then switched off again.
If required, check for leaks. Check the oil level again for crane in
transport condition according to corresponding description in the lubri-
4.4.5.7 Hydraulic filter state

If an error message relating to the hydraulic filters appears in the
crane control display in the form of the depicted symbols when the
hydraulic oil is warm from operation (see "Error messages" screen in
section "Safety equipment"): service the high-pressure hydraulic filter,
see the lubrication and maintenance instructions under "Hydraulic
system".
This only applies when the hydraulic oil is at operating temperature.

Due to technical reasons, when temperatures are low, this error
message can appear even if there is no error.
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4.4.5.8 Coolant temperature

After the maximum permissible value is exceeded, the display (sym-

bol and temperature display) for the coolant temperature is displayed
in red.
At the same time, the corresponding indicator light is illuminated in

red on the additional screen.
NOTE
Danger of the engine overheating!
Excessive coolant temperatures could cause damage to the engine.
Switch the engine off immediately in case of an error message
or coolant loss. Determine the cause of the error. Crane opera-
tion is only permitted once the fault has been rectified.
4.4.5.9 Engine oil filling level

The depicted display symbolises a dipstick. The vertical line on the
left marks the "min" level, the line on the right marks the "max" level.
Permitted levels are displayed in green, prohibited levels are dis-
played in red.
If the depicted symbol appears, it is not possible to display the oil lev-
el (e.g. if the engine is running).
If the oil level is too low, the error message ".....fault chassis drive
train..." appears on the crane control display. The error that actually
exists can only be determined using the corresponding displays and
error messages on the driver information system in the chassis cab.
NOTE
Errors at the chassis during crane operation put the operating
safety of the crane at risk!
Rectify any chassis errors before proceeding. If necessary, in-
terrupt crane work until the error has been rectified.
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4.4.5.10 Filling level of the fuel tank

If approx. 90% of the supply has been used, the colour of the corre-
sponding display changes from white to yellow (symbol and percent-
age display).
4.4.5.11 Filling level of the AdBlue / DEF tank

Only for engines with exhaust gas aftertreatment SCR systems.
Check the additional display on the "Operating mask". If the
AdBlue/DEF supply is sufficient, the percentage display is shown in
white.
If the filling level is in the reserve range, the percentage display is

shown in yellow (here: 10%).
Alternatively, check the filling level in the crane control screen on the
"Engine display" screen.
It is legally prohibited to start the engine without AdBlue / DEF.
NOTE
Risk of damage for the SCR system in case of operation with-
out AdBlue/DEF!
Never operate the engine without AdBlue/DEF.
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4.5 Engine during Operation
4.5.1 Setting the Required Engine Speed
WARNING
Risk to life and limb when operating the engine in an
environment at risk of explosions!
Electrical and mechanical components of the engine can
cause sparks to form and ignite explosive materials. This
can cause death, serious injury to persons and extensive
damage to property.
When operating the engine, ensure that there are no
explosive materials in the vicinity.
WARNING
Risk of injury due to mobile parts.
Components in the engine compartment carry out move-
ments during operation. Body parts, clothing or dropped
tools can get caught in rotating parts (e.g. fan) and cause
serious injuries or loss of limbs.
Do not reach into the engine compartment during op-
eration.
Always cover rotating parts.
WARNING
Risk of burning due to hot surfaces.
There are components with high surface temperatures in
the engine compartment. This can cause severe burns
when touched.
Always cover hot surfaces.
Before reaching into the engine compartment, let the
engine cool down to ambient temperatures as much
as possible.
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Fig. 67: Engine operating elements in the cab
The speed of the drive engine must be continuously adapted to the

current load to cover the hydraulic oil requirements during crane oper-
ation.
The engine's speed can be adapted in two ways:
Automatically Manual
Setting "Automotive driving" in 1. Using the pedal (see arrow

crane control (see 4.3.2.2 "Au- in Fig. 67, side 144
tomotive driving" screen / setting 2. Using the engine display
the engine speed manually, (see "Engine information"
side 129) screen)
In general, the engine speed must be adapted automatically using

"Automotive driving". This ensures comfortable working as the en-
gine speed does not have to be additionally activated by the crane
operator.
4.5.2 Checking the operation functions while the crane is in operation
4.5.2.1 General
During crane operation, the crane operator must constantly check the
indicator lights and display instruments for messages.
4.5.2.2 Operating restrictions and indicator lights for exhaust gas aftertreatment
system
The following parameters monitored by the electronic system in en-
gines with the exhaust gas aftertreatment system:
- The display, filling level and quality of the reduction agent AdBlue /
DEF
- The efficiency factor of the catalytic converter in relation to the per-
mitted tolerance limits of nitrogen oxide emission (NOx)
- Amount of soot in the diesel particulate filter (if present)
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Errors/messages from the exhaust gas aftertreatment system are

shown in the additional display.
Note on the engine designation in relation to fulfilled exhaust emis-

sion standard:
- Without exhaust gas aftertreatment system:
- EM3a: DC13 076A
- With exhaust gas aftertreatment system:
- EM4/Tier4: DC13 085A
- EM5: DC13 313A
4.5.2.2.1 ... Engine complies with exhaust emission standard EM5

Operating restriction due to low reduction middle state
AdBlue/
indicator lights DEF fill Operating restrictions
level
illuminated 10 % none
illuminated
Torque is reduced by 1% per mi-
2.5 % nute to 75% of the maximum tor-
que.
flashing
illuminated Torque is reduced by 1% per mi-

nute to 50% of the maximum tor-
0% que. Engine speed is lowered to
flashing rap- 60% of the nominal engine
idly speed.
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Operating restriction due to a fault in the SCR system
indicator lights Operating restrictions
illuminated none
illuminated
Torque is reduced by 1% per minute to
75% of the maximum torque.
flashing
illuminated
Torque is reduced by 1% per minute to
50% of the maximum torque. Engine speed
is lowered to 60% of the nominal engine
speed.
flashing rapidly
After the error has been fixed and the engine control unit has re-
ceived a message that the exhaust gas aftertreatment system is func-
tioning again (i.e. the fault code has been confirmed in SDP3) the tor-
que returns to a normal level.
Regeneration of the diesel particulate filter
The diesel particulate filter is automatically regenerated. When a cer-
tain amount of soot is collected, the engine transitions into a periodi-
cal and automatic program to reduce the amount of soot. The engine
can be used without effecting operation.
Once the diesel particulate filter is full, it must, however, be manually
regenerated.
For further information on the diesel particulate filter, see the operat-
ing instructions of the crane chassis in the "Engine" section.
The soot load is displayed on the "Diesel particulate filter" info screen.
For uncritical loading, "Zone 0" is displayed. In case of high soot load,
the display changes directly to "Zone 2". As the soot load increases,
the display rises to "Zone 5". See the description in the following ta-
ble.
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indicator lights Description
Soot load high (Zone 2)

illuminated Automatic regeneration possible, manual re-
generation possible.
Soot load very high (Zone 3)

illuminated Automatic regeneration required, manual re-
generation recommended.
flashing
Soot load critical (Zone 4)
Manual regeneration absolutely required, auto-
matic regeneration no longer possible.
illuminated
flashing
Soot load too high (Zone 5)

Workshop/diagnosis required, output reduction,
manual regeneration no longer possible
illuminated
High exhaust temperature

illuminated Regeneration of the diesel particulate filter is
carried out.
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4.5.2.2.2 ... Engine complies with exhaust emission standard EM4/Tier4

Level of AdBlue/DEF too low
AdBlue/
Operating restric-
Indicator light DEF fill
tions
level
Percentage
display in
yellow
20 % none
illuminated
Percentage
display in
Torque is reduced by
yellow
1% per minute to
10 %
70% of the maximum
flashing torque
Percentage
display in
yellow Torque is reduced to
0% 0% (low idling speed)
flashing rap- within 2-10 minutes
idly
Engine returns to normal torque when reducing agent is filled to a

level of at least 20%.
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Malfunction in the SCR (selective catalytic reduction) system
Indicator light Time Operating restrictions
Fault detec-
illuminated none
ted
illuminated
Torque is reduced by 1 % per
After 30 mi-
minute to 70 % of the maxi-
nutes
mum torque
flashing slowly
illuminated
Torque is reduced to 0% (low
After 4 hours idling speed) within 2-10 mi-
nutes
flashing rapid-
ly
After the fault was remedied, the torque will be returned to its normal
level.
If a new fault occurs within 40 operating hours of the first one, the
warning light will light up. After 30 minutes, the warning light flashes
quickly and the torque is reduced to 0% (low idling speed) within 30
minutes.
If the torque is reduced to 0% (low idling speed), the engine control

unit will not detect that the SCR system is working again. The sys-
tem must be replaced by a service technician to ensure normal
speed can be resumed.
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4.6 Switch off the engine
4.6.1 Switching the Engine off under Normal Conditions (with the Ignition Switched
on)
Fig. 68: Dual button - Engine START/STOP
Proceed as follows if the engine is to be switched off, but crane con-

trol is to remain in operation:
1. Press and hold down the dual button in the left-hand area until
the engine is switched off. Crane control remains active.
WARNING
Risk of accidents when the crane is operated unau-
thorised.
The crane is ready for operation in this state.
Do not leave the cab.
When leaving the cab, remove the ignition key and
lock the cab.
4.6.2 Switching the Engine off under Normal Conditions (End of Operation)
NOTE
Risk of damage when switching off an overheated engine.
There could be damage to the turbocharger and continued boiling.
After operation at full engine output, high coolant and / or hy-
draulic oil temperature, let the engine run without load at idle
speed for several minutes so that the temperature can drop
back to the permitted range.
Do not switch off the power supply before the engine has come
to a standstill.
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1. When operating with the engine speed set manually: Place the
pedal for speed adjustment in the idling position.
2. Turn the ignition key anti-clockwise (in position "P" or “0").
For further information on the ignition switch, see "Ignition switch" in

the section "Cab".
3. Remove the ignition key, leave the cab and lock it.
4.6.3 Switching off the Engine in an Emergency
4.6.3.1 Standard design

In an emergency, the engine can be switched off by pressing the
quick stop button in the crane operator's cab. Depending on the crane
design, there are other quick stop buttons on the chassis near the
outrigger controls.
NOTE
Risk of damage to the engine and add-on parts.
Only use the quick stop button in an emergency.
1. Press the quick stop button.
The drive motor is switched off.
The quick stop button locks in the actuated position.
The quick stop button must be unlocked before another engine start.
For this, the upper part must be slewed or pulled depending on the
design of the quick-stop pushbutton.
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4.6.3.2 Quick stop equipment with air shut-off valves (optional)

This device makes it possible to shut down the engine in an emergen-
cy, for example, during suction of flammable gases. An air shut-off
valve is fitted in the air suction channel for this purpose. It can be ac-
tuated using the quick stop button, among other things, as in the
standard design.
NOTE
Risk of damage if the engine is started with a closed air shut-
off valve.
Before the engine is started again, the air shut-off valve must be
unlocked manually and the airways must be checked.
For detailed information, see the operating instructions of the crane

chassis in the section "Engine" under "Unlocking the air shut-off
valve".
4.7 Hydraulic System
4.7.1 General
The hydraulic oil used must be suitable for the respective working
temperature.
The relevant temperature specifications for all authorised hydraulic
oils can be found in the table below.
Detailed information on hydraulic oil can be found in the lubrication

and maintenance instructions under "Consumables and capacities".
(1) (2) (3) (4)

Authorised hydraulic oils (°C)
°C °C °C °C
Fuchs Renolin Xtreme Temp 46 Plus -16 -12 +95 +35 (+45)
Fuchs Renolin Xtreme Temp 32 Plus -23 -19 +85 +30 (+40)
Shell Tellus STX 46 ** Tellus S3 V 46 -18 -14 +91 +30 (+40)
Shell Donax TM Spirax S1 ATF TASA -20 -15 +88 +35 (+50)
Shell Donax TA Spirax S2 ATF AX -25 -19 +87 +35 (+50)
Shell Donax TX Spirax S4 ATF HDX -28 -22 +88 +35 (+50)
Shell Tellus Arctic 32 ** Tellus S4 VX 32 -36 -31 ≤+70 +10 (+15)
Aeroshell Fluid 4 ** Aeroshell Fluid 41 -60 -53 ≤+50 -10 (-5)
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(1) Starting ambient temperature = oil temperature

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

** particularly specified consumables. All specifications refer to these
lubricants.
(1) (2) (3) (4)

Authorised hydraulic oils (°F)
°F °F °F °F
+95
Fuchs Renolin Xtreme Temp 46 Plus +3.2 +10.4 203
(+113)
+86
Fuchs Renolin Xtreme Temp 32 Plus -9.4 -2.2 +185
(+104)
+86
Shell Tellus STX 46 ** Tellus S3 V 46 -0.4 +6.8 +196
(+104)
Shell Tellus STX 32 ** Tellus S3 V 32 -11.2 -4 +174 +68 (+86)
+113
Shell Tellus STX 68 ** Tellus S3 V 68 +12.2 +21.2 +210
(+122)
+95
Shell Donax TM Spirax S1 ATF TASA -4 +5 +190
(+122)
+95
Shell Donax TA Spirax S2 ATF AX -13 -2.2 +189
(+122)
+95
Shell Donax TX Spirax S4 ATF HDX -18 -7.6 +190
(+122)
≤
Shell Tellus Arctic 32 ** Tellus S4 VX 32 -33 -24 +50 (+59)
+158
≤
Aeroshell Fluid 4 ** Aeroshell Fluid 41 -76 -63 +14 (+23)
+122
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(1) Starting ambient temperature = oil temperature

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

** particularly specified consumables. All specifications refer to these
lubricants.
4.7.2 Warming up the Hydraulic System

The system must first warm up if the hydraulic oil temperature is be-
low the corresponding "lower operating temperature". To do so, start
the engine and increase the speed slowly from idling to 1200 min-1/
rpm.
The hydraulic system must warm up for at least 10 minutes when

starting operation at "starting ambient temperature".
The hydraulic pumps may only be placed under load when the "lower
operating temperature" has been reached.
First drive all crane movements repeatedly without load.
The operating temperature is shown on the additional display in the

"Operating mask".
In the event of unusual noises, the crane must be shut down immedi-
ately.
NOTE
Risk of damage if not observed.
Instructions must be complied with, otherwise safe crane opera-
tion is not ensured.
Hydraulic components can become damaged.
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4.7.3 Hydraulic system in operation

If the hydraulic oil is too warm, crane operation must be stopped mo-
mentarily. Leave the diesel engine running at low speed so that the
hydraulic oil can be cooled down via the oil cooler.
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5 Supporting the Crane on Outriggers from the Crane Operator’s Cab (Optional)
5.1 General Instructions and Warnings
WARNING
There is a risk of accidents if safety instructions are
not observed.
Observe the specifications from "General informa-
tion / important instructions" under "Outriggers" in the
operating instructions of the crane chassis.
Generally, the outriggers must be set using the operating elements in

the outrigger controls on the side on the chassis (see the operating
instructions of the crane chassis in "Outriggers" under "Operating sta-
tions on the chassis"). However, it is possible to operate the outrig-
gers from the crane operator's cab for later levelling.
WARNING
There is a risk of crushing between the components
of the outriggers and the ground and/or any other
constructional limits.
The supports may only be moved if the crane opera-
tor has a direct view of the relevant support via mir-
rors or cameras.
Check all mirror positions before operating the outrig-
gers.
If required, banksmen must support the crane opera-
tor.
WARNING
There is a risk of crushing in the area between the
tyres and the base if the crane is lowered directly on-
to the tyres when retracting the outriggers.
Before lowering, make sure that this area is com-
pletely free of people.
WARNING
There is a risk of overturning if the crane is operated
without it being horizontally aligned.
Align the crane horizontally before raising loads.
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5.2 Control elements
1 Automatic levelling 2 Function selection Vertically re-

tract / extend all supports
3 Direction button Vertically retract 4 Direction button Vertically extend
all supports all supports
5 Function selection Front left 6 Function selection Rear left sup-
support, horizontal / vertical port, horizontal / vertical
7 Function selection Front right 8 Function selection Rear right
support, horizontal / vertical support, horizontal / vertical
9 / 10 Direction button Horizontal sup-
port
5.3 Procedure for supporting on outriggers

Requirements
-Engine running
-Crane control is set according to the assembly state of the crane.
-Crane supported on outriggers or
-Locking bolt of the support struts unpinned and support plate in the
operating position
- 5.1 General Instructions and Warnings, side 157 read and un-
derstood.
The basic procedure for supporting the crane on outriggers is de-

scribed in section "Outriggers" in the operating instructions for the
crane chassis.
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Actuate the hydraulic cylinders of the outriggers using the control ele-
ments described under 5.2 Control elements, side 158. To carry out
a movement, the dual button for selecting the movement / function
(e.g. support cylinder at front left) and a dual button for selecting the
movement direction (e.g. extend vertically) must be pressed simulta-
neously and held (depicted dual buttons show a described example).
For safety reasons, only one support can be retracted or extended

horizontally at once.
Use the tilt display on the crane control of the superstructure for lev-
elling.
To extend and retract all support cylinders at the same time, press
the "ALL" button and the corresponding side of the dual button for
carrying out vertical movement (e.g. extend) simultaneously and hold.
Observe the warning information and the descriptions described in
section "Retracting and extending all support cylinders" in the operat-
ing instructions of the crane chassis.
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6 Slewing the Superstructure
6.1 General
6.1.1 General Instructions on Risks
Fig. 71: Outrigger support area (sche-

Fig. 70: Plate - Risk of overturning
matic diagram)
DANGER
Risk of overturning!
After supporting the crane on outriggers and fitting
the counterweight, check the outrigger support area
BEFORE the superstructure may be slewed.
Observe the specifications in the capacity tables.
When the outrigger support area is reduced, only fit
the maximum permitted counterweight listed in the
capacity table.
If the support base is symmetrical, slewing the super-
structure is only permitted in working radius ranges
for which there are capacity values in the capacity ta-
bles.
Slewing the superstructure in the overload range
(LLD has switched off) is prohibited.
If "Slewing angle-dependent capacities" (optional) has been set, it is

possible to determine whether slewing the superstructure is possible
and permitted using the simulation screen and the operating screen
"Slewing angle-dependent capacities". If slewing is not permitted, the
load limit device switches the slewing movement off.
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WARNING
Risk of crushing between the superstructure and the
chassis and between the rear end of the superstruc-
ture (counterweight) and any obstacles in the vicini-
ty.
It is therefore PROHIBITED at all times for anyone to
be in the slewing area.
CAUTION
Risk of accidents!
Never slew over people.
Do not jump from the slewing crane.
Dolly or dolly preparation

For machines which are equipped with a dolly or dolly preparation,
the slew gear brake must not be blocked in the open state when driv-
ing the crane function and the ball valve of the luffing gear must be
open.
WARNING
Risk of accidents!
Observe the description of the dolly or dolly prepara-
tion in this section and in the operating instructions of
the crane chassis at "Driving".
Position monitoring of the counterweight

It is prohibited to slew the superstructure if the counterweight has not
been raised to its final position. The counterweight could drop due to,
e.g. extreme temperature fluctuations, after a longer machine stand-
still time or due to leaks. In these cases, crane controls stops the
slewing movement.
NOTE
Risk of collision and damage due to dropped counterweight.
Determine cause of the fault and rectify.
Raise the counterweight completely.
During crane operation, check at regular intervals whether the
counterweight has dropped.
Only when it is safe to assume that there is no risk of collision may

monitoring by crane control be bridged in case of a fault. To do so,
the see the corresponding description in the section "Counterweight".
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6.1.2 System Description
Fig. 72: Schematic structure of the slew gear
1 Hydraulic motor 2 Slewing gear transmission

3 Slew gear pinion (under cover) 4 Ring gear
The figure shows the schematic structure of the slew gear. The drive
unit consists of a hydraulic motor (1), the slew gearbox (2) and the
slew gear pinion (3). The ring gear (4) is firmly connected to the chas-
sis at the slewing rim. The slew gear pinion (3) is supported by the
ring gear (4) and creates the slewing movement of the superstructure.
Depending on the crane type, the drive unit is on the right- or left-
hand side of the superstructure (possibly under a cover).
Drive
The slew gear which is for slewing the superstructure is driven by a
hydraulic motor (1).
Depending on whether the slew gear is activated hydraulically, there
are different operating modes of the slewing circuit (open, closed
slewing circuit).
The slewing movement is initiated by the control lever in the crane
operator's cab (observe control lever assignment!). The movement
speed can be regulated at the control levers (see section "Safety
equipment" under "Fine tuning the movement speed").
Retaining brake / slew gear parking brake
The slew gear has a parking brake that is closed via spring force. To
turn the superstructure the parking brake has to be opened hydrauli-
cally.
Service Brake
The hydraulic oil drainage of the slew gear motor is throttled by a foot
pedal in the crane operator's cab.
In the open slew gear circuit, the slewing movement is braked by ac-
tivating the service brake's pedal.
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Preparation for Dolly (Optional)

The main boom can be set down on a trailer (dolly) during driving so
that it is possible to drive the crane with smaller axle loads.
The parking brake / slew gear parking brake must be blocked me-
chanically in the open position so that the crane can then be steered.
A special design is required for the slew gear brake to do so.
6.1.3 Operating Modes of the Slewing Circuit

Depending on the preferred method of operation, the slew gear can
be operated optionally in the closed or in the open circuit.
Fig. 73: "Switch-over slew gear" switch
The operating mode is selected with the displayed switch.
Only the position of the switch indicates to which operating mode

the slewing circuit has been switched.
6.1.3.1 Closed Circuit
The displayed switch is not actuated in the closed circuit (indicator

light in the switch is not illuminated).
In a closed circuit, the speed of the slewing movement depends di-
rectly on the movement of the corresponding control lever. Therefore,
it is possible to:
- Specifically decrease the slewing speed by taking the control lever
back or even
- Directly stop the slewing movement by taking the control lever
back into the neutral position.
For set capacities dependent on slewing angles (optional), the slew
gear is operated in closed circuit.
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6.1.3.2 Open Circuit
The displayed switch is actuated / pressed down in the open circuit

(indicator light in the switch is illuminated).
In the open circuit, the slewing movement is not stopped abruptly if
the corresponding control lever has been brought back into the neu-
tral position. The movement slowly runs its course and comes to a
stop during freewheeling. It is also possible to place the boom head in
a vertical position over the load without any problems.
Fig. 76: "Slew gear brake" foot pedal (schematic diagram)
The depicted pedal of the slew gear brake must be pressed down in
relation to the desired braking effect for targeted braking of the slew-
ing movement.
In this type of open circuit it is possible to counter the effects of a side

wind, for example, by countersteering the control lever.
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6.1.4 Slewing Angle / Slewing Direction

Crane configuration
The slewing angle indicates the position of the superstructure to the
crane chassis.
Fig. 77: Slewing angle / slewing direction (schematic diagram)
The positive slewing direction is clockwise.

In the example shown (schematic diagram), the superstructure is in
the 0° position, i.e. the superstructure (main boom) is positioned to
the rear, against the direction of travel. In order to slew the super-
structure to the 90° position, for example, it would have to be rotated
a quarter turn to the right (clockwise).
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Display of the "Crane operation" screen
Fig. 78: Display of "Current slewing angle"
Display consists of the current slewing angle and two combined semi-
circular arrows. The arrow tips indicate the corresponding slewing an-
gle. The colours of the semi-circular arrows indicate if slewing is pos-
sible or blocked.
Symbol Colour Meaning
Green Slewing to the left possible
red Slewing to the left blocked
Green Slewing to the right possible
red Slewing to the right blocked
The part of the arrow not relevant for the current description is shown
as a dotted line.
Display for persons in the area at risk (country-specific):
- by an acoustic warning signal (sound interrupted)
- by additional flashing lights on both sides of the superstructure
6.2 Initiating a Slewing Movement

Requirements:
- Crane assembled with the corresponding outrigger support area
and supported on outriggers horizontally.
- Engine running. All parameters selected at crane control in accord-
ance with the actual crane configuration.
82640 2021-04-22 167

Procedure:
WARNING
Risk of accidents due to carrying out unintentional
crane movements.
It is the crane operator's responsibility to check the
current control lever assignment before initiating a
crane movement.
1. Select the mode for the corresponding task for the control lever
assignment. The current mode (here: 1) is displayed in the up-
permost line of the "Crane operation" screen.
Detailed specifications on selection and scope of the different

modes can be found under 8.1.7.11.4 Control Lever Assignments
(6 Modes), side 309.
2. Raise the main boom so that it cannot become entangled with

other parts of the crane (see 11.1.1 General Safety Instruc-
tions, side 511).
You must differentiate whether the slew gear is in the "Open circuit"
or in the "Closed circuit" for the further procedure.
Fig. 79: Switch "Open / close the slew gear parking brake"
CAUTION
Risk of accidents!
Note the differences between operating in the "Open
circuit" and the "Closed circuit".
3. Actuate the depicted switch to open the slew gear parking brake.
The indicator light in the switch is illuminated.
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Slew gear in the "Open circuit"

The slew gear parking brake is opened.
Fig. 80: "Slew gear brake" foot pedal
CAUTION
Risk of accidents due to unintentional slewing move-
ment or independent trailing of the superstructure
due to the effects of the wind or an oblique position
of the crane.
Brake or stop the superstructure carefully using the
dynamic brake with the foot pedal depicted in
Fig. 80, side 169.
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Slew gear in the "Closed circuit"

The slew gear parking brake is only actually opened when the slew-
ing movement is initiated in the next step.
Fig. 81: Control levers - crane operator’s Fig. 82: Switch "Open / close the slew
cab gear parking brake"
WARNING
Risk of accidents!
Observe the warning information and other specifica-
tions on the release switch system in section "Safety
equipment" under "Release switch system for crane
movements".
WARNING
There is a risk of crushing and collision if speeds or
accelerations at which movements are carried out
are not adapted when the respective movement is
switched off due to the load or hook block swinging
out.
Carry out crane movements at adapted speeds or ac-
celerations.
NOTE
Risk of damage!
Never carry out a slewing movement without first opening the
slew gear brake (switch off Fig. 82, side 170).
4. Initiate the slewing movement by actuating one of the buttons of

the "Release switch system" and carefully moving the control lev-
er (see Fig. 81, side 170) in the corresponding direction.
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6.3 Selecting the slewing speed

The slew gear is electrically pre-controlled. The slewing speed de-
pends on the engine speed and the movement of the corresponding
control lever.
WARNING
There is a risk of accidents due to inappropriate
slewing speeds, particularly when operating the fly
jib or under special local conditions.
Operate the slewing gear and slewing brake with
care.
Select appropriate slewing speeds.
Brake carefully.
Make sure you have a low slewing speed (lower range) in the follow-
ing cases:
- when working with loads > 30% of the load capacity
- completely extended main boom
- fitted fly jib
Fine tuning of the movement speed
In order to be able to control the movement more sensitively, the
max. movement speed can be set with the control lever fully steered
(within the technical limits). See 8.4.1 Fine tuning of the movement
speed, side 354.
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6.4 Braking the Slewing Movement
Fig. 83: Switch "Open / close the slew Fig. 84: Foot pedal "Slew gear brake"
gear parking brake" (schematic diagram)
The slew gear has two braking systems:

- Slewing gear parking brake: Static parking brake, spring-loaded,
for opening / closing the slew gear. This brake is actuated using
the switch shown in Fig. 83, side 172.
- Service brake: The hydraulic oil drainage of the slew gear motor is
throttled using the foot pedal in the crane operator's cab shown in
Fig. 84, side 172. The effect of the dynamic brake is identical for
the open and closed circuits.
WARNING
Risk of accidents!
Before leaving the crane operator's cab, e.g. during
work breaks or at the end of work, the slew gear park-
ing brake must be closed.
The control lever automatically returns to the neutral position when it

is released. The crane movement that was initiated is stopped.
WARNING
There is a risk of accidents if the movement is stop-
ped too quickly or the movement is switched in the
opposite direction too quickly.
Only initiate the counter movement after a movement
standstill.
Do not release the control lever too abruptly.
1. Slowly place the control lever to which the slewing movement is

assigned in the neutral position.
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Slew gear in the "Open circuit"

In the open circuit, the slewing movement gradually runs out. It must
be brought to a standstill - if desired - using the foot pedal or held with
the control lever.
Slew gear in the "Closed circuit"

In the closed circuit, the slewing movement is directly brought to a
standstill due to the fixed oil column. If the control lever is in the neu-
tral position and the movement has run its course, the slew gear park-
ing brake is automatically closed.
Fig. 85: Switch "Open / close the slew

gear parking brake"
2. Close the slew gear parking brake. Actuate the depicted switch
to close the slew gear parking brake.
The indicator light in the switch goes out.
6.5 Preparation for Dolly (Optional)

If the crane is prepared for driving with dolly (optional), the brake of
the slew gear mechanism can be locked in the open state.
DANGER
Risk of accidents due to the unchecked movement of
the superstructure!
Unchecked movement of the superstructure can lead to
death, serious injuries and tipping over of the crane.
The brake may not be blocked during crane opera-
tion.
Before crane operation, check that the brake of the
slew gearbox is not blocked in the open state.
Also observe the corresponding warning signs on the
slew gear and in both cabs (see also the section
"Structure of the mobile crane" under "Decals").
82640 2021-04-22 173

Fig. 86: Slew gearbox (schematic diagram)
1 Slew gearbox 2 Shift lever

3 Padlock
During crane operation, shift lever (2) on the brake of the slew gear-
box (1) must be pulled out. Additionally, shift lever (2) must be se-
cured with padlock (3).
Depending on the crane design, the slew gearbox is under a cover.
6.6 Superstructure locking device (optional)

This crane can be equipped with a manual superstructure locking de-
vice. In this case, the crane may only be rotated if the corresponding
pin between the superstructure and crane chassis is unpinned (see
the description "Unpinning the superstructure and crane chassis" in
section "Driving in the configured condition" )
6.7 Monitoring the Right-hand Side of the Superstructure
6.7.1 Monitoring Using A Mirror (Optional)
Fig. 87: Mirror on the right-hand side of the superstructure frame (schematic dia-
gram)
Depending on the machine type, the mirror is fixed to a stand-alone

bracket or to a tool box support.
There is a mirror on the right-hand side of the superstructure frame. It

must be set up before crane operation.
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Depending on the position of the main boom, the view to the mirror
can be obstructed by the main boom or the luffing cylinder.
WARNING
Risk of crushing when slewing the superstructure!
A banksman must be used when slewing the super-
structure in main boom positions in which the view to
the mirror is obstructed.
6.7.2 Monitoring Using the Camera (Optional)
Fig. 88: Camera on the superstructure frame (schematic diagram)
Depending on the type of machine, the camera is fixed to a stand-

alone bracket or to a tool box support.
See 9.3 Cameras on the crane (option), side 417.
82640 2021-04-22 175

176 82640 2021-04-22

7 Counterweight
7 Counterweight
7.1 General
When planning a load case, the required counterweight combination
is determined using the capacity tables. This counterweight combina-
tion represents an important part of the crane configuration, especial-
ly for safe crane operation.
The crane operator is responsible for making sure that the required
counterweight combination is actually fitted and that the load limit de-
vice is set accordingly.
DANGER
Risk of accidents due to incorrectly set crane con-
trol.
Check that actual fitted counterweight combination
corresponds with the one set on the crane control.
For cranes with optional automatic counterweight detection or prepa-

ration for raising loads with slewing angle-dependent capacities, the
actually fitted counterweight combination is shown as a suggestion in
crane control.
To do so, observe the detailed description under "Automatic counter-
weight detection (Optional)" in section "Safety equipment".
DANGER
Risk of accidents due to incorrect counterweight
combination.
Fit all components of the specified counterweight
combination correctly.
Only fit the counterweight combinations listed in this
section.
Only fit counterweight elements which are marked
with the construction number of the respective crane
to ensure faultless accuracy of fit.
All counterweight plates and saddle weights are marked with the fol-
lowing specifications:
- Identification number XXX XXX XX + index x
- Serial number, consecutive, starting with 0 (for initial sample)
- Nominal weight in xxxxx kg / xxxxx lbs
- Manufacturer abbreviation or logo.
In addition, there is a sign with the crane's construction number.
82640 2021-04-22 177

7 Counterweight
7.2 Counterweight Combinations
7.2.1 General
The individual elements for all permitted counterweight combinations
are listed below from which the respective counterweight combination
must be assembled.
The 5600 kg (12.3 kip) counterweight plate is available in two ver-

sions that differ slightly in their appearance. The relevant dimen-
sions (width, depth, height) and the mass are identical.
7.2.2 Counterweight Combination 0 t (0 kip)

For the 0 t (0 kip) counterweight combination, no counterweight ele-
ments and no hoist 2 are required.
7.2.3 Counterweight Combination 5.1 t (11.2 kip)
Fig. 89: Counterweight Combination 5.1 t (11.2 kip)
1 Counterweight plate 5075 kg

(11.2 kip)
1 Counterweight plate 5075 kg 2 Counterweight plate 8000 kg

(11.2 kip) (17.6 kip)
178 82640 2021-04-22

7 Counterweight

(11.2 kip) (17.6 kip)
(12.3 kip)

(11.2 kip) (17.6 kip)
(24.6 kip)
82640 2021-04-22 179

7 Counterweight
7.2.7 Counterweight Combination 29,9 t (65.9 kip)
Fig. 93: Counterweight Combination 29,9 t (65.9 kip)

(11.2 kip) (17.6 kip)
(24.6 kip) (12.3 kip)

(11.2 kip) (17.6 kip)
(24.6 kip), x 2
180 82640 2021-04-22

7 Counterweight

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (12.3 kip)
7.2.10 Counterweight Combination 46 t (101.4 kip)
Fig. 96: Counterweight Combination 46 t (101.4 kip)

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (23.2 kip)
82640 2021-04-22 181

7 Counterweight

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (23.2 kip)
(12.3 kip)
7.2.12 Counterweight Combination 70,2 t (154.8 kip)
Fig. 98: Counterweight Combination 70,2 t (154.8 kip)

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (23.2 kip)
5 Counterweight plate 5600 kg 6 Saddle weight 9300 kg (20.5
(12.3 kip) kip), x 2
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7 Counterweight
7.3 Fitting the Counterweight
7.3.1 General
The counterweight elements are set down on the crane chassis with
the help of an additionally trained person, who, as an exception, is on
the crane with the crane operator during this procedure.
DANGER
Risk of crushing by the counterweight elements if
you are in the endangered area.
When fitting and removing individual counterweight ele-
ments, there is a risk of crushing between the individual
counterweight elements, between the counterweight and
the superstructure frame as well as between the counter-
weight and the crane chassis (counterweight support).
When turning the crane, there is a risk of crushing be-
tween the counterweight and obstacles in the vicinity.
You must observe the specifications in 1.13 As-
sembling and dismantling crane components, side 59
to prevent this risk.
In particular, maintain sufficient safety clearance.
Leave the crane and/or the endangered area immedi-
ately after completing the setting down procedure.
The crane operator must have constant visual contact
with the assembly assistant and must ensure that no-
one else is in the endangered area. Before the super-
structure is rotated, the crane operator must make
sure that this person has left the crane and the en-
dangered area.
DANGER
Risk of accidents if you are in the endangered area.
It is prohibited to walk or stand beneath suspended
loads or in areas where loads/equipment could fall.
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7 Counterweight
Fitting the counterweight is described using the largest possible coun-

terweight combination of 70.2 t (154.8 kip) as an example.
As a general rule, all counterweight combinations can be fitted using
your own crane.
The fitting procedure consists of two processes which follow each
other:
- Setting down the counterweight combination on the crane chassis
(see section "Counterweight under "Setting down the counter-
weight combination on the crane chassis")
- Fitting the counterweight combination on the superstructure frame
(see 7.3.4 Fitting the Counterweight Combination to the Super-
structure Frame, side 204).
7.3.2 Anti-fall Protection Using a Safety Mast (Optional)
7.3.2.1 General
By using the safety mast, the assembly assistant can secure himself
against falling with suitable personal protective equipment in order to
get onto or down from the counterweight stack and to walk on the
counterweight stack.
WARNING
Risk of accidents due to personnel not being quali-
fied.
The safety mast may only be used by trained and
qualified personnel.
WARNING
Risk of accidents when the additional safety instruc-
tions are not observed.
In addition, you must observe the instructions of the
manufacturers of each individual component of the
anti-fall protection system.
The instructions of the manufacturer of the safety mast can be found

in the part "Various".
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7 Counterweight
Detailed specifications on the safe use of the components can be

found in the manufacturer’s instructions, which cover the points listed
below, among other things:
- intended use
- prohibited improper use
- permitted / required combinations of the different components
- limits of use
- period of use
- requirements for users
- behaviour after a fall
- necessity of defining effective rescue measures before operation
- status check before every operation, repair, routine tests
- transport, care, storage.
WARNING
Risk of accidents when the additional safety instruc-
tions are not observed.
Also observe the information and specifications which
are found directly on the individual components of the
anti-fall protection system.
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7 Counterweight
7.3.2.2 Using anti-fall protection
DANGER
Risk of accidents when the requirements are not sat-
isfied.
The requirements listed in the section "Counter-
weight" under "Setting down the counterweight com-
bination on the crane chassis" must be satisfied.
Fig. 101: Set-up location of the multi-pur-

Fig. 100: Multi-purpose ladder
pose ladder
1. Set up the multi-purpose ladder so that it is possible to get on

and - later, off - behind the counterweight stack which has been
set down (see arrow in Fig. 101, side 186).
DANGER
Risk of accidents when safety instructions are not
observed!
For correct and safe use of this ladder, you must ob-
serve section "Assembly of the mobile crane" under
"Getting on and off using the mobile multi-purpose
ladder".
2. An assembly assistant must get onto the crane using the folding
ladder (see arrow).
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7 Counterweight
Fig. 102: Safety mast
1 Safety mast 2 Ratchet lashing straps
3. Release safety mast (1) from the transport position. To do so, re-
move both ratchet lashing straps (2).
The safety mast weighs approx. 12 kg (26 lbs).
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7 Counterweight
Fig. 103: Safety mast (schematic diagram)
3 Locking bar 4 Bracket
4. Carry the safety mast to bracket (4), fit it as shown and secure it
in the depicted position using locking bar (3). To do so:
4.1. If no counterweight plates are fitted: simply walk over the
free area of the counterweight support.
4.2. If counterweight plates are fitted:
- Hand down the mast
- Get down using the ladder assembly
- Using the multi-purpose ladder behind the counter-
weight plates, get back on
- Have the mast handed back up.
CAUTION
Risk of burning due to hot exhaust!
Maintain sufficient distance.
In this position, the safety mast can be used for securing before it
must be moved into the corresponding counterweight plate, and the
procedure for getting on the counterweight stack is carried out as
described below. You will also find detailed specifications there on
using the safety mast.
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7 Counterweight
5. First fit counterweight plates (1) and (2) (see section "Counter-
weight" under "Setting down the counterweight combination on
the crane chassis"). To release (or attach) the lifting tackle, the
assembly assistant must not enter the area at risk of falling ob-
jects at the edge of the crane chassis.
In the procedure below, the safety mast can be used after fitting or for
removing counterweight plate(s) (3), (4) and (5) and for fitting and re-
moving saddle weights (6) (for assignment of the counterweight ele-
ments, see 7.2.12 Counterweight Combination 70,2 t (154.8 kip),
side 182). This means in principle:
- Fit the mast in the counterweight plate
- Secure yourself to the mast (attach)
- Step onto the counterweight stack once you are secured
- Release/attach lifting tackle; guide saddle weights
- Step off the counterweight stack, still secured
- Remove the mast
- Fit / lift off the next counterweight plate, etc.
A description is given below, which uses the example of the complete
counterweight stack (counterweight combination 51.2 t / 113.8 kip or
70.2 t / 154.8 kip with laterally fitted saddle weights).
1 Safety mast 4 Bracket
6. Unlock safety mast (1), lift it out of bracket (4) and insert it fully in
the corresponding hole (ø 104 mm/4.1 in) of the uppermost
counterweight plate - as illustrated.
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7 Counterweight
Fig. 105: Safety mast fully inserted into

the receptacle
1 Safety mast
2 Receptacle for safety mast
7. Ensure that the actual safety mast (1) is full inserted - to the red
marking ring (see arrow) - into the receptacle(2).
1 Safety mast 3 Attachment Points
8. Attach the hook of the safety device of the suitable personal pro-
tective equipment to one of the two attachment points (3) at the
top end of mast (1) - as illustrated.
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7 Counterweight
If the attachment points at the top of the mast cannot be reached,

the bottom attachment point on the mast adapter component can al-
so be used to secure yourself temporarily while getting on. However,
in this case the personal protective equipment must have an addi-
tional lock-on hook, so that after getting on, the assembly assistant
is secured at all times when attaching himself as required to the high
attachment point.
This low attachment point is emphatically not suitable for securing
oneself when walking on the counterweight stack.
9. Use the grab handle on the safety mast to get onto the counter-
weight stack, while secured - as illustrated.
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7 Counterweight
Fig. 108: Safety mast
The assembly assistant can then move around on the counterweight

stack - while secured - e.g. to help during fitting or removal of a sad-
dle weight, as illustrated.
10. After completing work, get off the counterweight stack while still
secured, detach the lock-on hook and remove the mast.
NOTE
Risk of damage when slewing the superstructure.
If the safety mast has not been removed, there can be collisions
with it when slewing the superstructure.
The safety mast must be removed.
11. Hand the mast down, get off using the multi-purpose ladder and
remove the multi-purpose ladder.
12. Place the mast back in the transport position. To do so, proceed
as described under "Using the anti-fall protection" for the oppo-
site procedure, but in the reverse sequence.
DANGER
Risk of crushing if the assembly assistant stays in
the endangered area.
After completing the assembly procedure, the assem-
bly assistant must leave the crane and the area at
risk.
Only after this is done may the fitting procedure be
continued as described under 7.3.4 Fitting the
Counterweight Combination to the Superstructure
Frame, side 204.
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7 Counterweight
7.3.3 Setting Down the Counterweight Combination on the Crane Chassis

1. Support the crane on outriggers and align. Select the support
width in accordance with the following operation of the crane.
DANGER
Risk of accidents when the crane is not supported
on outriggers.
Always support the crane on outriggers to fit and re-
move or reconfigure the counterweight combinations.
To do so, observe the section "Outriggers" of the op-
erating instructions of the crane chassis.
DANGER
Risk of overturning when slewing the superstructure
with reduced support widths.
When the support width is reduced, the maximum coun-
terweight which may be fitted is limited. If a larger coun-
terweight is fitted, there is a risk of overturning to the rear
during slewing.
Observe the corresponding specifications in the ca-
pacity tables.
2. Drive up counterweight element(s) on the low-loader up to the

crane.
3. Set the load limit device to the current load case. In order to fit
the counterweight elements, counterweight combination 0 t /
0 kip must be set at crane control.
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7 Counterweight
Detailed instructions on setting the load limit device to the current

crane configuration can be found in the section "Safety equipment"
under the "Operating mode selection" screen.
DANGER
Risk of accidents when attaching the counterweight
elements.
You must take the safety instructions listed in the fol-
lowing into consideration when attaching the counter-
weight elements!
All counterweight elements must be attached at the prescribed at-

tachment points. None of the attachment points may be loaded over
the max. permitted values!
This means for the 5600 kg (12.3 kip) counterweight plate and the
two saddle weights that each one may only be loaded with the dead
weight of the individual element.
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7 Counterweight
The following applies to the other counterweight plates:
Fig. 109: Counterweight plate with attachment hooks
1 Counterweight plate 11 Attachment hooks
- Attachment hooks (11) on counterweight plate (1): max. 15 t

(33 kip) per hook (in accordance with the corresponding marking
on the hook).
Fig. 110: Counterweight plate with attachment hooks
3 Counterweight plate 33 Attachment hooks
- Attachment bollards in accordance with the specification of the

max. permitted load attached to the respective bollard, i.e. for
counterweight plates (2), (3) and (4) max. 8.5 t (18.7 kip) per bol-
lard (e. g. "33" for plate "3").
The specifications on the bollards could be 4 t (8.8 kip) or 6 t

(13.3 kip) for production-related reasons.
As an exception, 2 counterweight plates can be attached simultane-
ously as described below in this case.
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7 Counterweight
Fig. 111: Counterweight plates, in pairs Fig. 112: Counterweight plates, in pairs
(11.2 kip) (24.6 kip), x 2
(17.6 kip) (23.2 kip)
(12.3 kip)
For this reason, it is also possible to attach 2 counterweight plates at

the same time.
Fig. 113: Counterweight plate with lifting tackle
Only use lifting tackle which is suitable for the counterweight ele-
ments to be raised and is sufficiently dimensioned.
In particular, only flat lifting slings made of plastic may be used for at-
tachment to the cast bollards.
Ensure that the attached counterweight element is not crooked and
does not swing out during raising.
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7 Counterweight
Fig. 114: Attached counterweight plate
1 Counterweight plate 21 Hydraulic Tank
NOTE
Risk of damage for the hydraulic tank!
When approaching the position over the counterweight support,
you must prevent the counterweight from swinging out, so that it
cannot hit the hydraulic tank (21) under any circumstances,
which could damage it.
4. Attach counterweight plate (1) with your own crane to the corre-
sponding attachment hooks on the draw bars with 4 falls - as il-
lustrated - and position it centrally over the counterweight sup-
port of the crane chassis (angular indicator 180°).
DANGER
Risk of crushing between the counterweight plate
and the crane chassis or between the counterweight
elements.
Maintain sufficient safety clearances. To do so, stay
in the area between the counterweight which has
been set down and the cab of the crane chassis.
DANGER
Risk of accidents if you are in the endangered area.
5. A trained assembly assistant must get on the crane chassis to

align and remove the counterweight elements.
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7 Counterweight
Fig. 115: Attached counterweight plate
1 Counterweight plate 17 Baffle plates

18 Spigots 19 Guide plates
6. Set counterweight plate (1) down on the counterweight support

of the crane chassis. Then gradually lower the counterweight
plate over the slope of the guide plates (19) until it is completely
set down (end position is not illustrated). The correct positioning
of the counterweight plate is ensured through the guide plates
(19) and the retraction of the corresponding grooves of the coun-
terweight plates in the spigots (18).
Protect deflector plates (17) from damage during the raising and set-
ting down of components adjacent to the counterweight plates.
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7 Counterweight
Fig. 116: Counterweight plates

(11.2 kip) (17.6 kip)
(12.3 kip)
7. One after the other, attach the necessary counterweight plates to

your own crane using 4 falls and lower onto the counterweight
plate(s) which have already been set down so that the draw bars
of counterweight plate (1) are within the corresponding grooves
of the counterweight plate to be fitted.
Make sure that the counterweight plates are fitted correctly.
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7 Counterweight
Fig. 117: Counterweight plates

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (23.2 kip)
(12.3 kip)
Once all counterweight plates (1) - (5) have been stacked on top of
each other as shown in the figure, the 51.6 t (113.8 kip) counter-
weight combination has been set down on the counterweight support.
Make sure that the counterweight plates are fitted correctly.
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7 Counterweight
Fig. 118: Attached counterweight plates

(11.2 kip) (17.6 kip)
(24.6 kip), x 2 (23.2 kip)
(12.3 kip)
The attachment hooks of counterweight plate (1) are designed so that

the counterweight stack can be attached to them and raised com-
pletely up to this maximum counterweight combination 51.6 t
(113.8 kip).
To do so, a suitable 4-strand suspension tackle must be used. Its ca-
pacity must be designed so that it is not overloaded even when only
taking the load with 3 falls.
DANGER
Risk of accidents due to incorrect attachment of the
counterweight elements.
For this load case, you must observe the specifica-
tions of the corresponding 0 t capacity table (e. g.
with regard to the achievable radius, rope load, re-
quired number of falls, etc.).
You may only attach to the attachment hooks of
counterweight plate (1) as illustrated.
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7 Counterweight
Fig. 119: Counterweight plates with saddle weight
4 Counterweight plate 10500 kg 6 Saddle weight 9300 kg (20.5

(23.2 kip) kip), x 2
Counterweight plate (4) is designed so that saddle weights can be at-

tached on the sides.
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7 Counterweight
Fig. 120: Assembly assistant climbing up onto the counterweight stack
An assembly assistant must get onto the counterweight stack to sup-

port assembly of these counterweights.
DANGER
Risk of falling when working without suitable auxili-
ary equipment.
It is essential that you move slowly and carefully.
It is essential that you maintain a sufficient safety dis-
tance from the outer edges.
Use additional anti-fall protection (e. g. safety mast
(optional), see 7.3.2 Anti-fall Protection Using a
Safety Mast (Optional), side 184.
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7 Counterweight
Fig. 121: Counterweight plates with saddle weight
1 Counterweight plate 2 Counterweight plate

3 Counterweight plate 4 Counterweight plate
5 Counterweight plate 6 Saddle weight
8. Attach one of the two saddle weights (6) using your own crane.
This is done at the cast-iron bollards with two falls.
9. Attach the saddle weight with two attachment lugs to the cast-
iron recesses on counterweight plate (4).
10. Attach the second saddle weight (6) analogously on the other
side. This is shown in the figure opposite.
If these two saddle weights are attached, the process of set-
ting down the largest possible 70.2 t (154.8 kip) counterweight
combination onto the counterweight support is complete.
DANGER
the endangered area.
After completing the setting down procedure, the as-
sembly assistant must leave the crane and the area
at risk.
Only then can the fitting procedure be continued as
described on the following pages!
7.3.4 Fitting the Counterweight Combination to the Superstructure Frame
7.3.4.1 General
NOTE
Risk of damage to the counterweight lift cylinders.!
When fitting the counterweight combination, ensure that the
counterweight lift cylinders are always retracted correctly (com-
pletely) during slewing.
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7 Counterweight
Requirements
- desired counterweight combination set down as described in sec-
tion "Counterweight" under "Setting down the counterweight com-
bination on the crane chassis".
- the crane operator has made sure that no-one is on the super-
structure or in the endangered area.
DANGER
Risk of crushing if people stay in the endangered
area.
If this is not taken into consideration, there is a risk of
crushing for these persons as soon as a slewing move-
ment is initiated in the following procedure.
You must leave the endangered area.
- the "Slew" movement play an important part in fitting the counter-

weight. For this reason, observe the detailed information on this
subject in the section "Slewing the superstructure".
The fitting procedure can either be carried out automatically (optional,
from 7.3.4.2 Automatic Fitting, side 205) or manually (from
7.3.4.4 Manual Fitting, side 211).
If there is the option of "Automatic fitting", it should be used.
7.3.4.2 Automatic Fitting
1. Check which mode has been selected for the assignment of the
control levers. The current mode (here: 1) is displayed by the
corresponding symbol in the top line of the IC-1 display.
Fig. 122: Slewing the Superstructure
2. Slew the superstructure until a position of approx. 10° is ach-

ieved.
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7 Counterweight
Fig. 123: "Counterweight display" screen
3. Call up the "Counterweight display" screen. Press the depicted

key in the "Quick menu" screen to do so.
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7 Counterweight
"Counterweight display" screen
1 Display counterweight 2.1 Status display "not bridged"

2.2 Status display "bridged" 3.1 Status display "manual"
3.2 Status display "automatic"
Item Symbol Explanation
1 Display: symbolic depiction of the fitted counterweight
Status display: "Monitoring by control active" / button: switch to "Monitoring by

2.1
control bridged"
Status display: "Monitoring by control bridged" / button: switch to "Monitoring by

2.2
control active"
only for the option "Automatic fitting":
3.1 Status display: "Counterweight fitting – manual operation" / button: switch to
"Counterweight fitting – automatic operation"
3.2 only for the option "Automatic fitting":
Status display: "Counterweight fitting – automatic operation" / button: switch to
"Counterweight fitting – manual operation"
After switching the ignition on / off, symbol (3.1) always appears. If only the
displayed screen is changed (without switching the ignition on / off), the respec-
tive selected configuration remains.
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7 Counterweight
4 Status display 5 Angular indicator

6 Current position of the superstructure 7 Current hydraulic pressure
Display of the condition of the counterweight cylinders using percentages relating

4
to extension state and arrow symbols
Cylinders completely retracted
Cylinders retracting
Cylinders extending
Cylinders completely extended
Slewing angle display: only shows the angle range of 0°/360° +/- approx. 5°
5
which is crucial for fitting
6 Vertical bar: shows the current position of the superstructure (here: 0°)
7 Current hydraulic pressure in the counterweight cylinders
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7 Counterweight
After switching the ignition on/off, manual operation is preselected

when the "Counterweight display" screen is opened. A new selection
must be made.
4. Select "Automatic operation". Press the corresponding button to
do so. It changes in appearance as illustrated.
Automatic mode can only be selected when the counterweight lift

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

must slew to the left to do so. To do so, press one of the keys of
the release switch system and carefully steer the corresponding
control lever at the same time. During the entire fitting procedure,
the control lever must now be held in this direction.
The current slewing angle can be seen in the slewing angle display
within the angle range of 0°/360° +/- approx. 5°. The counterweight lift
cylinders can only be retracted into the counterweight stack with a su-
perstructure position within the angle window (approx. 4°) with a
green background.
During automatic operation, the slew gear operates in a closed cir-

cuit (see the section "Slewing the superstructure"). This setting can-
not be changed.
To ensure sufficient sensitivity, the engine speed is regulated by the
control system.
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7 Counterweight
The only thing the crane operator must actively do is determine the
slewing direction by moving the control lever correspondingly and
holding the control lever in this position. The remaining procedure is
then automatic and can be observed in the control screen.
The automatic process can be interrupted at any time by releasing

the control lever and can be reinstated by actuating the controls
again.
When the control lever is actuated the following steps are carried out
automatically:
- The superstructure is slewed to the 4° position.
- The counterweight lift cylinders are extended into the counter-
weight stack.
- The superstructure is slewed to 0° with the counterweight lift cylin-
ders lowered within the counterweight stack.
- The counterweight stack is raised into the end position.
6. When the movement is switched off and the engine speed has
been reduced, release the control lever, i. e. place in the neutral
position.
The actual automatic fitting procedure is concluded.

However, before a crane movement may be initiated, further
tasks must first be completed as well: To do so, observe 7.3.4.3
Required tasks in addition to automatic, side 210.
7.3.4.3 Required tasks in addition to automatic

After the actual automatic fitting procedure has been completed, the
following tasks must first be completed additionally before a crane
movement may be initiated.
- Check that the counterweight combination has been completely
raised.
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7 Counterweight
- Check that the counterweight combination is positioned central to

the superstructure frame.
WARNING
Risk of accidents if the counterweight is not fitted
correctly.
The raising procedure must be repeated again if
BOTH conditions are not fulfilled.
WARNING
Risk of accidents due to self-actuating lowering of
the counterweight.
Check regularly to ensure that the raised counter-
weight has not lowered itself on its own (e.g. due to
extreme temperature shifts after the machine has
stood still for a longer period of time or due to leaks).
In such a case, completely raise the counterweight
again.
- Set the load limit device to the changed crane configuration with
regard to the fitted counterweight. Detailed information on setting
the operating mode can be found in the section "Safety equipment"
under "Selecting the operating mode" screen.
- Check the crane levelling. Detailed information on this can be
found in the operating instructions of the crane chassis in the sec-
tion "Outriggers".
WARNING
Risk of accidents if the additional tasks are not car-
ried out.
Crane movements may only be initiated once all
these tasks have been completed.
7.3.4.4 Manual Fitting

First proceed as already described for automatic fitting in the first 3
work steps under 7.3.4.2 Automatic Fitting, side 205. Also observe
the description of the screen "Counterweight display" which can be
found there.
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7 Counterweight
Fig. 127: "Manual fitting" screen
1. Select "Manual operation":

1.1. After switching the ignition on/off, manual operation is
already preselected when the "Counterweight display"
screen is opened. The corresponding symbol appears
as illustrated.
1.2. If "Automatic operation" was set, a new selection must

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

you must slew to the left to do so.
The current slewing angle can be seen in the slewing angle display
within the angle range of 0°/360° +/- approx. 5°. The counterweight lift
cylinders can only be retracted into the counterweight stack with a su-
perstructure position within the angle window (approx. 4°) with a
green background.
3. Extend counterweight lift cylinders. To do so, press the bottom

half of the depicted luminous pushbutton and hold it in this posi-
tion.
In the status display of the counterweight lift cylinders, the

"Downward arrow" is shown to indicate "Counterweight lift cyl-
inders extending". The percentage (here: 90%) is changed
successively from 0% (completely retracted) up to approx.
100% (completely extended).
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7 Counterweight
Fig. 128: Mushroom-shaped ends of the

piston rods (schematic diagram)
1 Mushroom-shaped ends of the
piston rods
2 Receptacle
If the counterweight lift cylinders are completely extended into the

counterweight stack, the mushroom-shaped ends (1) of the piston
rods are at the side next to the appropriately designed receptacles (2)
of the draw bars of the counterweight base plate.
The percentage display (here: 100%) does not change any more. The
arrow between the two cylinder symbols is shown with a horizontal
line at the bottom. The counterweight lift cylinders are completely ex-
tended.
4. End the movement "Extend counterweight lift cylinders". To do

so, release the depicted luminous pushbutton.
Slewing of the superstructure is enabled. The depicted slewing sym-

bol is shown in green/red. Slewing is only possible in the direction of
the green arrow.
Subsequently, slewing takes place within the counterweight stack.

5. Slew the superstructure from the current 4°-position in the 0°/
360° direction to the left. The slewing speed is automatically re-
duced.
Observe the angle display. As soon as the 0°/360° position is ach-
ieved, stop the slewing movement. The angle display displays 0°.
During this slewing procedure, the mushroom-shaped ends of the pis-

ton rods of the counterweight lift cylinder are retracted into the corre-
spondingly designed receptacles of the draw bars of the counter-
weight plate.
Only in this 0°/360° ±0.1° position is it permitted to raise the counter-
weight combination.
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7 Counterweight
Fig. 129: "Manual fitting" screen
6. Retract counterweight lift cylinders in order to raise the counter-

weight combination. To do so, press the top half of the depicted
luminous pushbutton and hold it in this position.
The "Upward arrow" is shown in the status display of the

counterweight lift cylinders. The percentage at the counter-
weight cylinders' symbols (here: 90%) is reduced successive-
ly.
The pressure display indicates the pressure in the counter-

weight lift cylinders and changes depending on the mass of
the attached counterweight combination (here: e. g. 0 bar /
0 psi).
7. Press the luminous pushbutton until raising is switched off. En-

gine speed is reduced.
Authorisation for slewing is given as soon as the counterweight

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

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

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

nation on the superstructure frame.
However, before a crane movement may be initiated, first all tasks
must be additionally carried out as after automatic fitting. To do so,
you must observe 7.3.4.3 Required tasks in addition to automatic,
side 210.
DANGER
Risk of accidents if the additional tasks are not car-
ried out.
Crane movements may only be initiated once all
these tasks have been completed.
7.4 Removing the counterweight

As with the fitting procedure, the following basic requirements must
be satisfied:
- Crane supported on outriggers/aligned
- Load limit device is set correctly (0 t/0 lbs tables).
The equipment is removed as it is fitted, in the reverse order.
7.5 Behaviour in Case of a Fault / Bridging Control

When fitting the counterweight - as well as in manual operation - all
crane movements are monitored by control. The controller only ena-
bles such movements (e.g. slewing, lowering / raising counterweight
lift cylinders) which would not cause any damage at this point.
In exceptional cases - e.g. in the case of faults or defects - the crane
control can be bridged — only specifically with regard to fitting/
dismantling the counterweight. Monitoring the fitting procedure for the
counterweight is then completely suspended.
WARNING
Risk of accidents due to a bridged crane control!
When bridged, control does not monitor anymore. Only
the crane operator decides which movements are safe
and therefore can be carried out.
The crane operator may bridge only if he is acquain-
ted with the counterweight assembly in accordance
with the operating instructions and he is aware of the
existing dangers.
82640 2021-04-22 215

7 Counterweight
DANGER
Risk of crushing for the auxiliary personnel within
the area at risk.
If it becomes necessary – in an exceptional case – for
auxiliary personnel to step onto the crane again to rectify
faults, there is a risk of crushing.
Proceed with particular care.
Maintain constant contact with the crane operator.
Do not enter the area at risk of objects falling.
1. Press the depicted key in the "Counterweight display" to bridge.
A screen appears indicating that the safety devices are to be

deactivated.
Depending on the software version, the "Warning" screen ("Atten-

tion! Safety devices of the crane are deactivated! Are you sure?") or
the "Info" screen ("Are you sure?") appears.
2. Press the depicted key if bridging is not to be carried out after all.
Bridging is interrupted; the original screen reappears un-

changed.
Or
216 82640 2021-04-22

7 Counterweight
Press the depicted key if existing dangers are to be consciously

risked.
Only then will bridging actually be activated.
The bridged state is shown in two places. The originally acti-

vated key in the "Counterweight display" screen changes in
appearance into a red warning symbol.
Fig. 130: Display: Counterweight control

bridged
In addition, the depicted warning symbol is shown in the crane

display area. This ensures that the bridged state is always dis-
played even when the "Counterweight display" screen has
been exited (the "bridged" state remains).
3. Press the displayed key again in order to cancel overriding.
The symbol changes back to the state "not bridged".
The depicted warning symbol in the crane display area disap-

pears.
82640 2021-04-22 217

7 Counterweight
7.6 Dimensions
7.6.1 Slewing Radius and Width
Fig. 131: Standard Counterweight
Slewing radius (ap-

Width
Type of counterweight prox.)
m ft mm ft
Standard Counterweight 5 16.4 3470 11.4
Fig. 132: Standard counterweight + saddle weights
Slewing radius (ap-

Width
Type of counterweight prox.)
m ft mm ft
Standard counterweight + saddle weights 5 16.4 6330 20.8
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7 Counterweight
7.6.2 Transport Dimensions and Weights of the Counterweight Elements
Fig. 133: Counterweight Elements
1 Counterweight plate 5075 kg (11.2 kip) 2 Counterweight plate 8000 kg (17.6 kip)
3 Counterweight plate 11155 kg (24.6 kip), x 2
Weight Width Depth Height

Item
kg kip mm ft mm ft mm ft
1 5075 11.2 2990 9.8 2222 7.3 60 / 1135 0.2 / 3.7
2 8000 17.6 2990 9.8 2270 7.4 197 0.6
3 11155 24.6 3480 11.4 2270 7.4 230 0.8
82640 2021-04-22 219

7 Counterweight
Fig. 134: Counterweight Elements
4 Counterweight plate 10500 kg (23.2 kip) 5 Counterweight plate 5600 kg (12.3 kip)
6 Saddle weight 9300 kg (20.5 kip), x 2
Weight Width Depth Height

Item
kg kip mm ft mm ft mm ft
4 10500 23.2 3480 11.4 2200 7.2 373 1.2
5 5600 12.3 2990 9.8 2200 7.2 220 0.7
6 9300 20.5 1734 5.7 1675 5.5 890 2.9
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8 Safety Equipment
8 Safety Equipment
8.1 IC-1 Crane Control
8.1.1 General specifications on the IC-1 crane control system

The crane control system IC-1 (Intelligent Control System) combines
several devices which provide the crane operator with essential infor-
mation for operating the crane within the parameters specified by the
manufacturer:
- Overload cut-off device (load limit device LLD)
- Telescoping information system
- Display of numerous crane functions, for example, supporting
force, tilt, crane configuration, lifting capacities etc.
- Warning (optical and acoustic) in case of prohibited conditions
- Display of system diagnostics
This crane control (incl. load limit device) is an operating aid. It pro-
vides the crane operator with essential information concerning crane
data such as length and angle of the boom, sheave head height,
nominal capacity, the total load suspended from the boom, etc. and
gives warning when an overload condition is being approached or
when the hook block gets too close to the boom head.
DANGER
This safety device is no substitute for the judgement
and experience of the crane operator or application
of recognised safe working procedures for crane op-
eration.
The crane operator is not relieved of his responsibility
for safe crane operation.
DANGER
Risk of influencing crane control!
The danger that the load limit device is influenced by
high-frequency radiation is minimised as far as the
technology allows it (shields).
It cannot, however, be completely excluded – in par-
ticular under extreme conditions, for example near
powerful transmitters.
82640 2021-04-22 221

8 Safety Equipment
CAUTION
It is essential for the operating safety of the crane
that the crane control functions in its original condi-
tion.
Necessary updates must be obtained from the cus-
tomer service department of the crane manufacturer.
8.1.2 Overload Cut-off Using the Load Limit Device (LLD)
8.1.2.1 Normal Operation
8.1.2.1.1 Function
To protect the crane from overload, the crane control system has a
load limiting device. If the load limit device has triggered, the following
crane movements will be switched off:
- Luffing up
- Luffing down
- raise hoist
- Telescoping out
DANGER
Risk of accidents! Risk of overturning!
It is absolutely forbidden to bridge the load limit de-
vice to overload the crane above its load bearing ca-
pacity!
It is prohibited to raise a load with the load limit de-
vice overridden.
DANGER
Risk of accidents!
The load limit device should only be triggered in an
emergency.
Under no circumstances may it be used as a stand-
ard operating tool!
This means that the crane operator must be satisfied,
before raising the load, that the capacity of the crane
is not exceeded by the load to be lifted.
Loads which are too heavy and exceed the capacity
of the crane may not be picked up, even though a
load limit device is fitted.
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8 Safety Equipment
DANGER
Risk of accidents! Risk of overturning!
Even without load, the boom must only be moved
within those ranges for which capacities are specified.
You can find detailed information on the status display of the load
limit device under "Display of status information on the crane state".
Before raising a load, its weight must be known. The safety equip-
ment may not be used to determine the weight!
To ensure that the load limit device functions properly it must:
- be set by the crane operator according to the crane configuration
before beginning work (as soon as the configuration state has
been reached) after ignition / engine has been switched on.
- be reset by the crane operator after changing the crane configura-
tion.
DANGER
Risk of accidents! The crane operator is responsible
for the correct setting!
This is done by selecting the operating mode (de-
tailed description under "Selecting the operating
mode" screen).
Only when the load limit device has been correctly set
by the crane operator in accordance with the current
operating mode/crane configuration, can it operate
automatically!
82640 2021-04-22 223

8 Safety Equipment
DANGER
Risk of accidents – limits of the load limit device! De-
spite a functional load limit device that is correctly
set in accordance with the crane configuration, the
load limit device can become ineffective in particular
cases / operating errors:
insufficient capacity of the ground at the set-up site of
the crane
support errors
not adhering to the designated telescoping sequen-
ces
influence of the wind
diagonal pull
dynamic influences, e.g. by crane movements that
are too fast and end with an abrupt stop
dismantling work when loads are unscrewed / burnt
off after attachment, then hang freely from the crane
and prove to be too heavy
raising overloads with the luffing gear
several cranes working together.
NOTE
The crane operator must observe these system limits when set-
ting up and operating the crane.
DANGER
Danger of crushing! Despite using automatic safety
devices, swinging of the load cannot always be pre-
vented when shutting down.
It can only be avoided by adjusting the acceleration /
speed of all crane movements! Also watch the contin-
uous load utilisation display with advanced warning at
90% of the permissible load utilisation prior to shut-
down.
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8 Safety Equipment
8.1.2.1.2 Displays, Warnings and Interventions of the Control System

There is a differentiation between the "EN 13000" design (see
8.1.2.1.2.1 "EN 13000" Version, side 225) and the "Non-EN 13000"
design (see 8.1.2.1.2.2 "Non-EN 13000" Design, side 228).
You can check whether the crane is equipped with control software
in accordance with EN 13000 by selecting the "System setup (user)"
screen in crane control (see 8.1.7.3 Calling up the "System setup
(user)" screen, side 264). In this case, a corresponding note can be
found there.
8.1.2.1.2.1 "EN 13000" Version

Signals for people in
Signals for crane operators in the cab the crane's danger
zone Speed at
Load utilisa- which crane
tion Warning movements
"Crane operation" screen / Warning light at the Warning are executed
"Displays" buzzer front of the siren
cab
Normal range
(below 90%) illuminated
unlimited
in green
Advanced
warning
range Sound in- illuminated unlimited
(90% – 100%) terrupted in yellow
Overload
range
Continu- illuminated Sound in- stopped
(from 100%)
ous tone in red terrupted
interrupted signal uninterrupted signal
The overload data is recorded.

All acoustic warnings listed here can be acknowledged / switched off in the crane operator's
cab after 5 seconds (see 8.1.6.1.4 Base line, side 251).
82640 2021-04-22 225

8 Safety Equipment
Configuring
Fig. 135: Configuring
If a crane movement (for example, luffing up) is carried out outside of

the capacity table to achieve the planned operating position, the
"Configure" symbol - which is highlighted in the figure - appears.
In addition, the load utilisation display of the load limit device is shown
in red (with 3 stars).
DANGER
Risk of accidents by raising loads in configuration
operation!
No capacities are enabled in configuration operation.
Raising loads is prohibited.
DANGER
The crane may only be configured in an erected state
(outriggers, counterweight etc.) for which there are
load capacity tables.
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8 Safety Equipment
Displays, Warnings and Interventions of the Control System

(Configuring)

zone Speed at
cab
Normal range
illuminated
unlimited
in green
Overload
range Continu- illuminated Sound in- stopped
The overload data is recorded.

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8 Safety Equipment
8.1.2.1.2.2 "Non-EN 13000" Design

zone Speed at
cab
Normal range
(below 90%) illuminated
unlimited
in green
Advanced
warning
range Sound in- illuminated Sound in- unlimited
(90% – 100%) terrupted in yellow terrupted
Overload
range
Continu- illuminated Continu-
(from 100%) stopped
ous tone in red ous tone
The overload data is recorded with the overload recorder (optional) activated.
228 82640 2021-04-22

8 Safety Equipment
Configuring
Fig. 136: Configuring
If a crane movement (for example, luffing up) is carried out outside of

the capacity table to achieve the planned operating position, the
"Configure" symbol - which is highlighted in the figure - appears.
In addition, the load utilisation display of the load limit device is shown
in red (with 3 stars).
DANGER
Risk of accidents by raising loads in configuration
operation!
No capacities are enabled in configuration operation.
Raising loads is prohibited.
DANGER
The crane may only be configured in an assembly
state (outriggers, counterweight, etc.) for which there
are capacity tables!
82640 2021-04-22 229

8 Safety Equipment

(Configuring)

zone Speed at
cab
Normal range
illuminated
unlimited
in green
Overload
range Continu- illuminated Continu- stopped
ous tone in red ous tone
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8 Safety Equipment
8.1.2.2 Bridging the Load Limit Device

After the crane movements have been switched off by the load limit
device, bridging this safety equipment is permissible only for special
operative states and in emergency situations.
DANGER
Risk of accidents!
Bridging may only be initiated if the control levers are
in the neutral position and/or the initiated crane
movement has been completed.
DANGER
Risk of accidents!
The bridging of the load limit device may not, under
any circumstances, be used for the purpose of being
able to use the crane for operations which exceed its
load carrying limit!
8.1.2.2.1 Bridging with the key-operated "Setup" pushbutton

Bridging with the key-operated "Setup" pushbutton can only be done
in the "EN 13000" version.
You can check whether the crane has been equipped with control
software in accordance with EN 13000 by selecting the "System set-
up (user)" screen in crane control (see 8.1.7.3 Calling up the "Sys-
tem setup (user)" screen, side 264). In this case, a corresponding
note can be found there.
Press the depicted key-operated "Setup" pushbutton to bridge. To ac-

complish this, rotate the key for this key-operated push button clock-
wise and then release it.
Effects of the bridging

- The permitted work load of the max. load moment is briefly in-
creased from 100% to 110%.
- The increased permitted work load continues to be monitored.
Crane movements are enabled and/or switched off accordingly.
- The speed of all of the crane movements is limited to a maximum
of 15% of the permitted speed in the case of the respective load.
By pressing the key-operated "Setup" pushbutton, no movements are
permitted which could lead to component failure or loss of stability.
82640 2021-04-22 231

8 Safety Equipment
Cancelling bridging is done:
- by pressing the depicted key-operated "Setup" pushbutton again
- by setting the control levers into neutral position. Bridging is then

cancelled with a delay (after 10 seconds). If a new crane move-
ment is initiated within these 10 seconds, bridging will remain ac-
tive.
- with an engine stop.
8.1.2.2.1.1 Displays, warnings and interventions of the control system ("Set-up" key-
operated pushbutton actuated)
zone Speed at
cab
Normal range
(below 90%) Continu- illuminated reduced to
ous tone in green 15%
Advanced
warning
range Continu- illuminated reduced to
(90% – 100%) ous tone in yellow 15%
All data is recorded when bridging with the key-operated "Setup" pushbut-
ton.
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8 Safety Equipment

zone Speed at
cab
Overload
range
Continu- flashes in reduced to
(100% - 110%)
ous tone yellow 15%
Overload
range
Continu- illuminated Sound in- stopped
(from 110%)
All data is recorded when bridging with the key-operated "Setup" pushbut-
ton.
8.1.2.2.2 Bridging shutdown of the "Luff up" movement
8.1.2.2.2.1 Function
If a prohibited overload condition has occurred, then the "Luff up"
movement will also be shut down by the load limit device. Only lower-
ing the load on the hook is still permitted.
Once an overload condition has been switched off by the load limit
device, this movement can be carried out to move a freely suspended
load out of the overload range again, back into the normal operating
range.
The depicted key-operated pushbutton can then be used to bridge the
load limit device to enable the "luff up" movement.
To do so, the key in the depicted key-operated pushbutton must be
turned in the clockwise direction and held in this position.
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8 Safety Equipment
DANGER
Risk of overturning! Risk of breakage! There is no
monitoring of the crane if a load is raised with the
load limit device overridden.
It is prohibited to lock the key-operated push button
mechanically!
DANGER
Risk of accidents! This movement is only permitted if
it does not create any dangerous scenarios, but the
crane is placed in a safe state. The crane movement
is executed without the crane controls monitoring
whether or not the executed movement leads to any
dangers! Make sure that this is the case before
pressing the key-operated pushbutton!
If the load is still touching the ground and raising was
switched off, the load is too heavy.
In this case, activating the "Luff up" movement is not
permitted!
If the "luff up" movement is switched off due to the
permissible minimum radius being reached, then this
movement cannot be bridged to prevent the crane
from overturning to the rear.
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8.1.2.2.2.2 Displays, Warnings and Interventions of the Control System

You must differentiate between the "EN 13000" and "Non-EN 13000"
designs.
screen ( 8.1.7.3 Calling up the "System setup (user)" screen,
side 264) in crane control. In this case, a corresponding note can
be found there.

zone Speed at
cab
across all
load utilisa-
tion areas Continu- unlimited
ous tone
"EN 13000" design: All data is recorded when bridging with the key-operated pushbutton
"Bridge raise luffing gear".
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8.1.2.2.3 Bridging the Shut-down of All Movements
DANGER
Risk of accidents! The load limit device may only be
bridged in exceptional cases, for example, for re-
pairs, when fitting a rope or for similar situations. All
crane movements will then be carried out without
crane control monitoring whether the executed
movement leads to any risks.
This may only be carried out by authorised persons
who are fully familiar with operation of the crane.
Under no circumstances may the load limit device be
overridden to increase the load moment.
It is prohibited to raise a load with the load limit de-
vice overridden.
There is a differentiation between the "EN 13000" design (see

8.1.2.2.3.1 "EN 13000" Version, side 236) and the "Non-EN 13000"
design (see 8.1.2.2.3.2 "Non-EN 13000" Design, side 239).
screen in crane control (see 8.1.7.3 Calling up the "System setup
(user)" screen, side 264). In this case, a corresponding note can be
found there.
8.1.2.2.3.1 "EN 13000" Version

The depicted box with the key-operated pushbutton for bridging the
load limit device is at the back of the cab of the superstructure.
Fig. 137: Key-operated pushbutton for bridging the LLD (schematic diagram)
Proceed in accordance with the following steps in order to bridge:

1. Step onto the step next to the crane operator's cab with the re-
quired key.
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2. Attach yourself to the top of the crane operator’s cab to the han-
dle between the two mounting plates using personal protective
equipment (e.g. safety harness).
Hold onto the handles with your left hand and carry out tasks using
your right hand.
Fig. 138: Box - key-operated pushbutton
1 Position lock 2 Cover

3 Key-operated pushbutton 4 Key
3. Open the box. Proceed as follows:

3.1. Press position lock (1) in the direction of the rear cab wall
to unlock the cover of the box (see figure box key-operat-
ed pushbutton "a").
3.2. Fold cover (2) back completely and insert key (4) in the
key-operated pushbutton (3) (see figure box key-operated
pushbutton "b").
3.3. Turn key (4) clockwise up to the stop and then let it return
to its initial position (see figure box key-operated pushbut-
ton "c")..
Effects of the bridging
- The permitted work load of the maximum load moment will not
longer be limited (and thus also no longer monitored).
- All crane movements will be enabled accordingly.
- the speed of the crane movements "luff down, luff up, raise
hoist, telescope out" will all be limited to a max. of 15% of the
permitted speed for the load case concerned.
Cancelling bridging is done:
- by pressing key-operated pushbutton (3) again (see figure box
key-operated pushbutton "b").
- automatically after 30 minutes
- with engine stop.
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zone Speed at
cab
Load-mo-
ment-reduc-
ing move-
ments
over all load Luffing gear

utilisation down, luffing
ranges Continu- flashing red Continu-
gear up, raise
ous tone ous tone
hoist, tele-
scope out re-
duced to
15 %
The warning buzzer can be acknowledged / switched off in the crane operator’s cab after 5
seconds (see 8.1.6.1.4 Base line, side 251). The warning siren cannot be switched off.
All data is recorded during crane operation with crane control bridged.
Fig. 139: Key-operated pushbutton for bridging the LLD (schematic diagram)
After ending the bridging

Once bridging has ended, the key for the bridging pushbutton must
be removed again and stored in accordance with regulations. The de-
picted box on the outside of the rear cab wall must be closed again.
To do so, proceed as described under 8.1.2.2.3.1 "EN 13000" Ver-
sion, side 236 in the reverse sequence.
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8.1.2.2.3.2 "Non-EN 13000" Design

The load limit device can be bridged using the depicted key-operated
pushbutton.
To do so, the key in the depicted key-operated pushbutton must be
turned in the clockwise direction and held in this position.
The bridging will stay in effect for as long as the key-operated push
button is kept in this position.
DANGER
Risk of overturning! Risk of breakage! There is no
monitoring of the crane if a load is raised with the
load limit device overridden.
mechanically!
Fig. 140: Box - key-operated pushbutton
The key-operated pushbutton (see arrow in Fig. 140, side 239) is

at the rear of the cab (see 8.1.2.2.3.1 "EN 13000" Version,
side 236), but it is not activated.
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8 Safety Equipment

zone Speed at
cab
over all load

utilisation
Continu- illuminated Continu-
ranges unlimited
ous tone in red (*) ous tone
Depending on special national regulations, the red lamp in the warning light could possibly
(*)
also flash in this state.
8.1.3 Operating elements and display elements

Operating panel of the crane control (IC-1 screen) (also observe the
specifications under 8.2 Care, maintenance, repairs and disposal,
side 351).
This computer has a colour screen. There are different profiles avail-
able for setting the screen (colour) ( 8.1.7.4 "Colour profile set-
tings" screen, side 265). The brightness of the screen display can
be set individually. All keys in the screen display are activated by
tapping on the symbol directly with your finger (touchscreen) (
8.1.4 Operating Crane Control (IC-1), side 242).
Left- and right-hand control levers

- Control of the crane movements
- Operation of the release switch system for crane movements
- Speed setting for crane movements
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8.1.3.1 Operating Panel of Crane Control (Structure)
Fig. 141: Operating panel of crane control (schematic diagram)
1 Monitor 2 On / Off
3 brightness "+" (manual) 4 brightness "-" (manual)
5 Status LED (green)

Touch-sensitive
1 screen (touch Operation of Crane Control
screen)
For any restart of the IC−1 which may be required: Switch off the ignition,
2 On / off key
press the key. Switch the ignition on again.
3 Key brightness "+" (manual)
4 Key brightness "-" (manual)
Operating condition display
LED off: no power supply
LED lights up: Computer start procedure / normal operation / run-on time
5 LED
LED flashes (0.2 s on/0.8 s off): Temperature sensor is faulty
LED flashes (0.5 s on/0.5 s off): Ambient temperature outside of the per-
mitted range
The computer is not ready for operation if the temperature of the op-
erating panel of the crane control is outside of the permitted operat-
ing temperature (-30° to +50°C / -22° to +122° F). The temperature
in the cab must then be adjusted using the heating system or air
conditioning until the control panel of crane control is within the per-
mitted temperature limits.
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8.1.4 Operating Crane Control (IC-1)

In this system, the functions are carried out by "tapping on" buttons
symbolically depicted in crane control's control panel (touchscreen).
The display changes to another screen by tapping on a buttons (see
the example on the left). There is a symbol on the button indicating
the function (example: switch to "Operating mode selection" screen;
Fig. 142, side 242).
Fig. 142: "Selecting the operating mode" screen (schematic diagram)
There is a "header" in the individual screens in which the name of the

corresponding screen can be found (example: "Main menu").
In most screens, there is a button with the "Exit symbol". The screen
can be exited by pressing this button. If settings were changed in a
screen, the changed settings are not saved.
Settings can be changed in screens in which there is a "Save sym-

bol". If settings were changed, the changed settings are saved.
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Fig. 143: "Selecting the operating mode" screen
Tapping on a corresponding button (for example: arrow in Fig. 143,

side 243 "A") that is marked as illustrated on the left opens a list of
selection options in the selected area (pull-down menu; for example:
Fig. 143, side 243 "B"). A value must then be selected from the se-
lection list. If the set value is not to be changed, the previous value
must be selected again from the selection list.
Operation at ambient temperatures over +50 °C (+122 °F)

To prevent the display from malfunctioning, the crane operator's cab
must be cooled with the air conditioning before and during crane op-
eration if ambient temperatures are above +50 °C (+122 °F). You
must avoid direct sunlight on the display. An appropriate cooling
down period should be prescribed if necessary for the period before
work begins.
8.1.5 System start / switching the system off

Automatic system start
Fig. 144: Start screen (schematic dia- Fig. 145: "Selecting the operating mode"
gram) screen (schematic diagram)
When ignition is switched on, the crane control of the superstructure

is automatically started ( Fig. 144, side 243).
When crane control is ready for operation, the "Selecting the operat-
ing mode" screen ( Fig. 145, side 243) is shown.
If the assembly or operating conditions are unchanged, the "Selecting
the operating mode" screen can be exited using the "Exit" key.
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8 Safety Equipment
If the assembly or operating conditions have changed, the specifica-

tions in the "Selecting the operating mode" screen must be changed
accordingly.
In this case, the "Selecting the operating mode" screen must be exi-
ted using the "Save" key so that the changes are transmitted to con-
trol.
Fig. 146: "Crane operation" screen
In both cases, the "Crane operation" screen appears.

Central screens - "Crane operation" and "Main menu"
Fig. 147: "Main menu"screen
The "Crane operation" screen ( Fig. 146, side 244) (see "Crane op-
eration" screen) and the "Main menu" screen ( Fig. 147, side 244)
are mainly used as a starting point for using the superstructure crane
control.
The required functions can be selected from these screens by calling
up the corresponding screens. The description of the screens used
can be found under "Submenus".
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Switching off (Power Control)
Fig. 148: Power Control
After switching off the ignition, the display changes to the "Power con-
trol" screen. The time to computer switch-off is shown here. If the igni-
tion is switched on again within this time, crane control is ready for
operation again. Then the "Selecting the operating mode" screen ap-
pears.
Fig. 149: IC-1 screen
If necessary, restart the crane control with the ignition switched off by
switching off the operating panel on the on/off switch (see arrow).
Switch the ignition on again.
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8.1.6 Central Screens
8.1.6.1 "Crane operation" screen
1 Current configuration information 2 Load utilisation display

3 Function-dependent screen 4 Base line
5 Status information 6 Load and radius
Item Explanation
1 Display of current configuration information
(see 8.1.6.1.1 Display of current configuration information, side 247)
2 Load utilisation display
(see 8.1.6.1.2 Load utilisation display, side 249)
3 Function-dependent screens (Here: Quick menu)
(see 8.1.6.1.3 Function-dependent screens (Here: Quick menu), side 250)
4 Base line
(see 8.1.6.1.4 Base line, side 251)
5 Display of status information on the crane condition
(see 8.1.6.1.5 Display of status information on the crane condition, side 252)
6 Display of load and radius
(see 8.1.6.1.6 Display of load and radius, side 258)
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8 Safety Equipment
The "Crane operation" screen appears after confirming or exiting the

"Selecting the operating mode" screen. The parameters which are rel-
evant during crane operation are displayed in this screen.
DANGER
Risk of accidents due to incorrectly set crane con-
trol. The crane could overturn or parts of the crane
could break during crane operation with crane con-
trol set incorrectly.
If deviations are determined between the values dis-
played in the "Crane operation" screen and the actual
assembly state, set the operating mode correctly (see
8.1.7.8 "Selecting the operating mode" screen,
side 271).
The areas of the "Crane operation" screen are described in the fol-
lowing sections.
8.1.6.1.1 Display of current configuration information
Fig. 151: Display of current configuration information
1 Abbreviation of the crane configuration
Item Explanation
HA Main boom (max. wind speed vT = 9.81 m/s (21.9 mph))
HA-W125 *) Main boom (max. wind speed vT = 12.5 m/s (28.0 mph))
HA-W150 *) Main boom (max. wind speed vT = 15 m/s (33.6 mph))
HA-0° Main boom, special case 0° (to the rear)
MBE Main boom extension
HAV-VA Main boom extension, hinged, with fixed part (adapter)
HAVHY Hydraulic main boom extension
HAVHY-VA Main boom extension, hinged hydraulically, with fixed part (adapter)
MS Assembly jib
*) (*) - available, depending on crane type and design.
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8 Safety Equipment
1 Counterweight 2 Outrigger support area

3 Reeving number
Item Symbol Colour Explanation

1 Counterweight combination
When saving/leaving the "Select operating mode" screen, if a different
red counterweight combination is set than the one detected by the crane
control, the counterweight symbol will be highlighted in red in the header.
2 Outrigger support area
Symbol in case of symmetric outrigger support area. The extension state
of the support is displayed as a numerical value above the symbol.
If – when saving / exiting the "Operating mode selection" screen – anoth-
er support width is set than the one detected by crane control or if the
red
extension state of at least one support is incorrect, the supports symbol
is displayed highlighted in red.
The corresponding symbol is displayed above the supports symbol if

"Capacities dependent on slewing angles" (optional) is set.
3
Reeving number
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1 Selected length code no. (LK) 2 Current tilt

3 Allocation of the control levers 4 Time

1 Selected length code no. (LK)
White Selected length code not achieved
Green Selected length code achieved
2 Current tilt
(see also 8.1.7.24 "Outrigger support area" screen, side 326)
3
Allocation of the control levers
(see 8.1.7.11.4 Control Lever Assignments (6 Modes), side 309)
4 Time
8.1.6.1.2 Load utilisation display
Fig. 154: Load utilisation display (schematic diagram)
Continuously changing display of the current load utilisation as a "bar

display" with percentage or overload display.
Detailed information can be found in the description of the load limit
device under 8.1.2.1.2 Displays, Warnings and Interventions of the
Control System, side 225.
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8 Safety Equipment
8.1.6.1.3 Function-dependent screens (Here: Quick menu)
Fig. 155: "Quick menu" screen
Various contents / screens are assigned to this area, depending on

the function carried out. The "Quick menu" screen is displayed after
confirming / exiting the "Selecting the operating mode" screen once
crane control has been switched on.
"Quick menu" screen
Calling up the "Selecting the operating mode" screen (see 8.1.7.8
"Selecting the operating mode" screen, side 271)
Calling up the "Telescoping display" screen (see 10.4.2.2.1.1 Call-

ing up the "Tele Display" Screen, side 450)
Calling up the "Operating range limit" screen (see 8.1.7.10 "Operat-

ing range limit" screen (optional), side 295)
Calling up the "Counterweight display" screen (see the section "Coun-

terweight" under "Fitting the counterweight combination on the super-
structure frame")
Calling up the "Outrigger support area" screen (see 8.1.7.24 "Out-

rigger support area" screen, side 326)
Calling up the "Engine display" screen (see the section "Engine" un-
der "Engine display in the crane control screen").
Calling up the operating screen "Capacities dependent on slewing an-

gles" (optional) (see 8.1.7.26 Operating screen "Capacities depend-
ent on slewing angles" / capacity radar (optional), side 327)
Call up the "IC-1 Remote" screen ("Teleservice"; optional) (see

8.1.7.27 "IC-1 Remote" screen ("Teleservice"; optional), side 329)
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8.1.6.1.4 Base line
Fig. 157: Quick menu (schematic dia-

Fig. 156: Base line (schematic diagram)
gram)
1 Area "Quick menu"
Key: Exit
Depending on which content / screen is displayed in area (1), the fol-
lowing screen appears after exiting:
- "Quick menu" screen is displayed: "Main menu" screen appears.
- A different screen than "Quick menu" screen (e.g. "Telescoping
display") is displayed: "Quick menu" screen appears in area (1). If
settings were changed, the changed settings are not saved.
Fault messages key

The crane's control system indicates errors. Calling up the "Fault
messages" screen (see 8.1.7.21 "Fault messages" screen,
side 324).
Button: warning buzzer

After the warning buzzer sounds, it can be acknowledged by pressing
the loudspeaker symbol, and is switched off in doing so. The loud-
speaker symbol disappears after acknowledgement.
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8 Safety Equipment
8.1.6.1.5 Display of status information on the crane condition
Fig. 158: Displays crane operation screen
1 Hook height 2 Hook height / zero point difference

3 Load limit device 4 Hoist limit switch
5 Support force/support basis 6 Lower limit switch 1

1 Button: Set the hook height (item 2) to zero
2 Display: Difference of the hook height to the set zero point
Green Green frame: valid value
Red red frame: invalid value
(see 8.1.16 Hook Height - Moving Repeatedly to a Saved Height,

side 346).
3 Display: Load limit device
Red Load limit device is switched off and is not overridden.
Black The load limit device is bridged.
At the same time, the STOP symbol appears.
4 Display: Hoist limit switch
Red Hoist limit switch is triggered and not overridden.
Black Hoist limit switch has been overridden.
5 Warning: support force / outrigger support area
red
Minimum support pressure has not been reached 1)
6 red Display: Lower limit switch 1 (hoist 1) is triggered
1) = Optional
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1 Counterweight control bridged 2 Lower limit switch 2

3 Current wind speed 4 Warning symbols

1 Display: Counterweight control bridged
(see the section "Counterweight")
2 Display: Lower limit switch 2 (hoist 2, 1)) is triggered

3 Display: Current wind speed
4 Display: Warning symbol
Prewarning range: 90%-99% of the permissible crane load reached.
The load limit device has shut down.

OR
The load limit device is bridged.
1) = Optional
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8 Safety Equipment
1 Operating Range Limits 2 Radio remote control active

3 Emergency operation 4 High speed
Item Explanation
1 Display: Operating range limit 1) active
(see 8.1.7.10 "Operating range limit" screen (optional), side 295)
2 Display: Radio remote control 1) active
See section "Radio remote control"; operation at crane control's operating panel no longer
possible.
3 Display: The emergency hydraulic lowering or emergency operation function has been activa-
ted
(see the section "Emergency actuation" (optional) under "Recovering a small load" and the
section "Emergency operation" (optional) under "Carrying out emergency operation")
4 Display: High speed
(see 8.4.2 High speed, side 355)
1) = Optional
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1 Crane symbol 2 Support force, front right

3 Support force, rear right 4 Support force, rear left
5 Support force, front left
Item Explanation
1 Display: Crane symbol 1)
Assignment of the supports for alignment on the crane chassis with selected operating
screen "Capacities dependent on slewing angles" (see 8.1.7.26 Operating screen "Capaci-
ties dependent on slewing angles" / capacity radar (optional), side 327)
2 Display: Support force, front right 1)
for selected operating screen "Capacities dependent on slewing angles" (see 8.1.7.26 Op-
erating screen "Capacities dependent on slewing angles" / capacity radar (optional),
side 327)
3 Display: Support force, rear right 1)
side 327)
4 Display: Support force, rear left 1)
side 327)
5 Display: Support force, front left 1)
side 327)
1) = Optional
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8 Safety Equipment
1 Main boom length 2 Main boom foot section angle

3 Current slewing angle 4 Slew gear operation in an open circuit
5 Symbol 6 Hoist movement
Item Explanation
1 Display: Main boom length
2 Display: Main boom foot angle relative to the horizontal
3 Display: Current slewing angle
(see 6 Slewing the Superstructure, side 161)
4 Display: Slew gear operation in an open circuit
(see 6 Slewing the Superstructure, side 161)
5 Display: Symbol of the selected crane configuration
Here: symbol of the crane configuration "HA" (main boom)
For other crane configurations, a symbol corresponding with the crane con-
figuration appears.
If further information is displayed in this screen for such a crane configura-
tion, the relevant explanations can be found in the corresponding section.
6 Display: Hoist movement (here: hoist 1 winds up/down) (here: winds up)
The winding process of the hoist is symbolised by the number of displayed

Red arrow tips switching continuously between 1 - 2 and 3 (i.e. seems to "run
through")
For a control lever assignment with both hoists the corresponding symbols
are displayed side by side.
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1 Max. / min. main boom angle reached 2 Main boom head angle
3 current load radius 4 max. / min. limit radius achieved
5 Current head height

1 Display: max. / min. main boom angle achieved
Red LLD shuts down.
Black LLD - shut-down of the crane movement "Luff up" bridged.
2 Display: Main boom head angle relative to the horizontal

3 Display: Current load radius
4 Display: max. / min. limit radius achieved
Red LBM shuts down.
5 Display: Current head height
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8 Safety Equipment
8.1.6.1.6 Display of load and radius
Fig. 164: Display of load and radius
1 Net load 2 Maximum load

3 Current total load (gross load) 4 Actual radius
5 Maximum radius
Item Display Colour Explanation

1 Net load; here: 2.7 t
The current load is tared by actuating the "Net" key (see 8.1.8 Load
Monitoring Device, side 332).
2 Maximum load (for the set crane configuration); here: 13.0 t
The depicted configuration symbol is displayed during configuration.
Raising loads is then prohibited
(see 8.1.2.1 Normal Operation, side 222).
3 Current total load (gross load); here: 3.7 t
It comprises load, hook block, all load handling devices and any fitted
additional equipment.
4 Actual radius; here: 3.4 m
The area which is still available and/or shut-downs is/are indicated here
by the background colours.
White OK
Yellow Prewarning
red Shut-down
5 maximum radius; here: 12.3 m
for the selected operating mode or selected LC with current load
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8.1.6.2 "Main menu"screen

You can call up the "Main menu" screen by activating the displayed
button below the "Quick menu" screen.
System setup
Fig. 165: "Main menu"screen - "System setup"
Calling up the "System setup (user)" screen, (see 8.1.7.3 Calling up

the "System setup (user)" screen, side 264)
Calling up the "Colour profile settings" screen (see 8.1.7.4 "Colour

profile settings" screen, side 265)
Call up the "IC-1 Remote" screen ("Teleservice"; optional) (see

8.1.7.5 "Setup IC-1 Remote" screen ("Setup Teleservice"; optional),
side 266)
Calling up the "System setup (extended)" screen (see "System setup

(extended)" screen)
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8 Safety Equipment
Crane operation
Fig. 166: "Main menu" screen - "Crane operation"
Calling up the "Crane operation" screen (see 8.1.7.7 Calling up the

"Crane operation" screen, side 271)
Calling up the "Selecting the operating mode" screen (see "Selecting

the operating mode" screen)
Calling up the "Operating range limit" screen (optional) (see "Operat-

ing range limit" screen (optional))
Calling up the "Joystick Modes" screen (see 8.1.7.11 "Joystick

Modes" screen, side 304 screen)
Service
Fig. 167: "Main menu"screen - Service
Calling up the "Parameter Setup" screen (see 8.1.7.12 "Parameter

settings" screen, side 310)
Calling up the "Datalogger" screen (see 8.1.7.13 "Datalogger"

screen (optional), side 312)
Calling up the "Operating hours meter" screen (see 8.1.7.14 "Oper-

ating hour meter" screen, side 316)
Activating / deactivating "Hydraulic emergency lowering" (optional,

see the section "Emergency actuation" under "Recovering a small
load" or "Emergency operation" (optional, see the section "Emergen-
cy operation" under "Carrying out emergency operation")).
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Diagnosis
Fig. 168: "Main menu"screen - "Diagnosis"
Calling up the "Function display" screen (see corresponding point)
Calling up the diagnostics screen "I/O View" (see 8.1.7.17 "I/O

view" screen, side 319)
Calling up the diagnostics screen "CAN View" (see 8.1.7.18 "CAN

View" Screen, side 320)
Calling up the diagnostics screen "Load-Sensing View" (see

8.1.7.19 "Load Sensing View" screen, side 321)
Calling up the diagnostics screen of the control levers "Joystick Diag-

nostics" (see 8.1.7.20 "Joystick diagnostics" screen, side 324)
The crane's control system indicates errors. Calling up the "Fault

messages" screen (see 8.1.7.21 "Fault messages" screen,
side 324)
Functions which are not enabled although available as an option are

displayed in grey.
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8 Safety Equipment
8.1.7 Submenus
8.1.7.1 General
Fig. 169: Main Menu Fig. 170: Quick menu
The submenus which can be called up from the "Main menu"

( Fig. 169, side 262, schematic diagram) and/or the "Quick menu"
( Fig. 170, side 262, schematic diagram) are described below. The
sequence is based at first on the arrangement of the symbols in the
"Main menu" screen ( Fig. 169, side 262 from the top left to the bot-
tom right). If the function can be called up from the "Main menu" as
well as from the "Quick menu", then the position of the corresponding
button is also shown in the "Quick menu". Then, the keys are descri-
bed which can only be found in the "Quick menu" ( Fig. 170,
side 262).
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8.1.7.2 Submenus - basic structure
Fig. 171: Submenus
1 Header 2 function-dependent content of the screen

3 Base Line

1 Header
Name of the corresponding screen entered
2 function-dependent content of the screen
3 Base Line
The keys / buttons listed below are often used in submenus:
Button: Exit
The screen can be exited by pressing this key / button. If settings were
changed in a screen, the changed settings are not saved.
Button: Error messages

The crane's control system indicates errors. Calling up the "Error messag-
es" screen (see 8.1.7.21 "Fault messages" screen, side 324)
Button: Save
If changes or entries are made in a screen which are to be transmitted to
control, the screen must be exited by confirming this key / button.
Load utilisation display
If crane movements can also be driven for testing purposes while a screen
is visible, the load utilisation display of the load limit device is also shown.
The crane operator is therefore continually informed of the current load
utilisation of the crane.
There can be further keys / buttons in the "Base line". These keys /
buttons are specific to the function of the corresponding screen.
They are therefore described under the corresponding screen.
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8.1.7.3 Calling up the "System setup (user)" screen

Press the button displayed in the main menu under system settings to
call up the "System settings (user)" screen.
"Info" area
Fig. 172: "System setup (user)" screen
Crane type (see explanations on "Specifications in the ca-

pacity table" in this section)
Tables Load capacity table set
75 corresponds to EN 13000
85 corresponds to 85%
MTC version Display of the current software version
MTC firmware Display of the current MTC firmware version
IC-1 Remote Display of the current Teleservice software ver-
sion (dependent on the software version)
Construction
Display of the construction number of the crane
number
EN 13000 Display of conformity with regard to EN 13000
Software in accordance with
Active:
EN13000
Software not in accordance with
not active:
EN 13000
HMI version Display of the current version of the user inter-
face
ENV MTC: Display of the current MTC environment version
Note on specification of crane type

If the fault message "E1060 Wrong crane type HMI or control" ap-
pears and if the crane type is shown in red in this screen, our cus-
tomer service team must be informed.
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"Settings" area
Fig. 173: "System setup (user)" screen
Language Selection of language setting.

Units Selection of the unit depiction
You can select between "Metric" and "Feet".
Date Setting possibility for the date
Time Depending on the configuration: display of the time
taken from the tachograph or setting option for the
time
The keys which can be found or can appear in the bottom of the
screen ("Base line") are described in the section 8.1.7.2 Subme-
nus - basic structure, side 263.
8.1.7.4 "Colour profile settings" screen

call up the "Colour profile settings" screen.
Fig. 174: "Colour profile settings" screen
This screen makes it possible to set the different colour profiles:

Standard
Night
Day
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8.1.7.5 "Setup IC-1 Remote" screen ("Setup Teleservice"; optional)

call up the "Setup IC-1 Remote" ("Setup Teleservice") screen.
Fig. 175: "Setup IC-1 Remote" screen ("Setup Teleservice") (schematic diagram)
1 Mobile connection settings 2 WLAN network display/selection
Mobile connection settings

If the crane has the option "IC-1 Remote" ("Teleservice"), the medium
installed is equipped with a SIM card. As long as the SIM card is not
changed, no data entry is necessary.
Changing the SIM card
It is recommended to have the change carried out by a service em-

ployee of the crane manufacturer.
The following data must be entered:

APN (Access Point Name)
PIN (PIN number of the SIM card)
IMSI (International Mobile Subscriber Identity)
Only when all three entries have been made can the values be con-
firmed via the save key. The modem now tries to connect to these ac-
cess data. If you leave the dialogue without "Saving", the entries are
deleted.
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The new "mobile setup" settings of the SIM card are only initialized
when the modem is restarted. Switch off the ignition and wait until all
LED's on the modem are off. This may take a while due to the follow-
up time of the crane control or the internal buffer battery. Only then
can the ignition be switched on again.
Notes on the input values:
The APN depends on the country and the operator.
Examples are:
- internet-t-mobile for T-Mobile in Germany
- general.t-mobile.uk for T-Mobile in the UK
- web.vodafone.de for Vodafone in Germany
- ISP.CINGULAR for AT&T (With acceleration USA)
The IMSI number consists of a maximum of 15 digits. However, only
the first five or six digits need to be entered here.
For this reason, the entry of the number of characters is restricted.
The first three digits of the IMSI number stand for "Mobile Country
Code" (MCC).
The following two or three digits stand for "Mobile Network Code"
(MNC).
Examples are:
- 262 01 ... MMC 262 for Germany, MNC 01 for T-Mobile,
- 262 02 ... MMC 262 for Germany, MNC 02 for Vodafone D2,
- 310 240 ... MMC 310 for USA, MNC 240 for Voicestream
Information about APN and IMSI entries can be obtained from mo-
bile operators or from various forums and specifications on the Inter-
net.
WLAN network display/selection

In the "Wifi Setup" area, the WIFI networks found by the modem are
displayed and can be selected by "tapping".
If a password is required for the WIFI network, an input keyboard is

displayed which can be used to enter the password.
For more information on "IC-1 Remote" ("Teleservice"), see section

8.1.15 IC-1 Remote ("Teleservice"; optional), side 345.
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8.1.7.6 "System setup (extended)" screen

call up the "System settings (extended)" screen.
Fig. 176: "System setup (extended)" screen
This screen makes it possible to carry out service activities.

Access only for customer services
These keys are used for service work. A PIN is required to use them.
Press the depicted key to call up the "Software" screen. The software
version of the input / output boxes can be viewed here and a software
update can be carried out if required. See the description further be-
low in this section.
Depending on the software version, calibration of the crane control

visual display computer can be carried out as described further be-
low.
The keys which can be found or can appear in the bottom of the
screen ("Base line") are described in the section 8.1.7.2 Subme-
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View software version of the input / output boxes / software up-

date
Fig. 177: "System setup (extended)" screen
Press the depicted key to call up the "Software" screen.

Depending on the software version, this screen has one or several
pages. If the screen has several pages, there are buttons on the right-
and/or left-hand side of the screen which make it possible to switch
between the individual pages.
Normally, the software levels of the input and output boxes corre-
spond with each other. The "Update" key is shown greyed out.
An automatic software update might be required after repairs to crane

control. In this case, the "Update" key can be selected.
Press the displayed key to do so.
Calibration of the crane control visual display computer

Calibration of the display must be carried out if - in exceptional cases
- the desired function can no longer be activated by touching the cor-
responding key (active button) in the crane control visual display com-
puter.
The calibration can be carried out as described below, depending on
the software version. Please consult our customer service department
in the case of a software version which does not permit this proce-
dure.
Actuate the displayed key in the "System settings (extended)" screen.
The "Info" screen appears.
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Press the key shown on the left to carry out the calibration.
If calibration is not to be carried out after all, the procedure can be

cancelled by pressing the key shown on the left.
NOTE
Maloperation due to faulty calibration.
It can lead to maloperation in the display at a later time if the
calibration is carried out incorrectly. The crane operator must be
aware of this risk.
Touch the symbol shown ("calibration target") in the screen for cali-
bration. After touching, the next screen appears.
The actual calibration is completed after touching the last position.

The screen must be exited by pressing the "Accept" key.
The "Server" screen appears.
Actuate this key to exit the "Server" screen in order to continue crane
operation.
After actuating this key and entering a service pin number, all crane
data stored in the system is deleted. This may only be done after con-
sultation and with the agreement of our service department.
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8.1.7.7 Calling up the "Crane operation" screen
Fig. 178: Calling up the "Crane operation" screen
Press the button shown in the main menu under Crane operation set-
tings to call up the "Crane operation" screen (right-hand side with
"Quick menu" screen) (see "Crane operation" screen).
8.1.7.8 "Selecting the operating mode" screen
8.1.7.8.1 General
This screen appears:

- after every restart, as soon as the IC-1 has run through the starting
procedure
Fig. 180: Calling up the "Selecting the operating mode" screen
- if the displayed button is actuated in the "Main menu" screen or

"Crane operation" screen (in the Quick menu).
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8.1.7.8.2 Individual parameters of the "Selecting the operating mode" screen
The individual parameters which are relevant for operating modes /

crane configuration are listed as symbols in this screen. The selection
window for parameter selection is next to the symbol on the right-
hand side. The set parameter is visible there. The meaning of the
symbols can be found in the following table:
Abbreviation of the crane configuration (see "Display of current con-
figuration information")
Length of the fly jib (optional)
Angling of the fly jib
Counterweight combination
In cranes with optional "Capacities dependent on slewing angles" or
optional counterweight recording, the actually fitted counterweight
combination is displayed here as a suggestion by crane control. For
warning information and specifications which must be observed, see
8.1.12 Automatic Counterweight Recording (Optional), side 337.
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If a symmetrical support base is set, the selected support width is dis-

played here as a numerical value.
alternative:
In order to set the optional "Capacities dependent on slewing angles",
the symbol displayed on the left must be selected as a parameter in-
stead of the numerical value of a symmetrical support base. "Capaci-
ties dependent on slewing angles" can (depending on the crane de-
sign) only be selected in main boom operation (crane configurations:
"HA...").
Number of the reeved rope lines
"Table view" key (see "Table view" screen)
The "Table view" key appears if a "Symmetric outrigger support

area" is selected from the support selection options.
Simulation "Capacities dependent on slewing angles" key (optional)

(see Simulation screen "Capacities dependent on slewing angles"
(optional))
The 'Simulation "Capacities dependent on slewing angles"' key ap-

pears if "Capacities dependent on slewing angles" is selected for the
outrigger's selection option.
"Radio remote control" key (for radio remote control (optional) (see
the section "Radio remote control"))
The buttons which in addition can be found or can appear in the bot-
tom of the screen (base line) are described under 8.1.7.2 Subme-
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8.1.7.8.3 Important specifications on the "Operating mode selection" screen
DANGER
Risk of accidents! All parameters must be selected
by the crane operator in such a way that they corre-
spond to the actual status of the crane! This respon-
sibility lies with the crane operator alone!
It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the
crane operation!
After restarting crane control, the parameters of the last set operating
mode are preset.
Fig. 182: "Operating mode selection" screen
1 Header 2 Selection area

3 "Exit" button
The screen can be exited by pressing the displayed button (3) if the
specification shown in the top line (1) or in the selection area (2) cor-
respond with the actual state of the crane when the screen appears.
The "Crane operation" screen appears.
Exiting the screen using button (3) discards the settings that were
just carried out and the previous configuration will remain set.
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If the specifications shown are not consistent with the crane status,
the operating mode must be reset. Proceed as follows for setting/
changing the parameters:
Starting at the first parameter "Abbreviations of the crane configura-

tion", using the depicted arrow button, open the corresponding pull-
down menu and select the crane configuration in accordance with the
desired equipment (e.g. "MB" for main boom operation).
The corresponding abbreviations are on all capacity tables. The

meaning of all abbreviations can be found under "Display of current
configuration information".
Depending on the number of corresponding selection elements, these

pull down menus are opened with or without scroll bars. An element
in the list must then always be selected in the pull-down menu so that
the pull-down menu can be closed again. This must even be done if
you decide to keep the original selection after opening the pull-down
menu.
The selection of the crane configuration determines the content of all
other parameters. Proceed in the same manner for all other parame-
ters that must be changed.
Selection elements which only contain one parameter can not be
changed. Its text is shown in grey.
If, when a parameter is changed, another one is also automatically
modified by the system (for example, a fictive outrigger support area
of 1.2 m), this value is displayed in red font. Values in "red" must be
confirmed by the user; this means the button must be actuated again.
If the crane is equipped with an outrigger support area display, the

support width with which the crane is currently set up is displayed as
a suggested value.
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If the current assembly state deviates from the previous settings, the
current support width or the smallest support width for the set coun-
terweight configuration is preset in relation to the set counterweight
configuration. The preset support width is then displayed in red letter-
ing / digits. As previously described, values in red must be confirmed
by the user, i.e. the button must be actuated again.
If - when saving / exiting the "Operating mode selection" screen - an-
other support width is set than the one detected by crane control or if
the extension state of at least one support is incorrect, a correspond-
ing entry is made in the datalogger. In addition, an acoustic signal
goes off.
1 Selection area 2 "Save" button
If all areas in selection area (1) are filled in correctly in accordance

with the actual configuration of the crane, you exit the screen to take
over the newly set values by actuating the depicted button (2). The
set configuration is transmitted to control.
- The operating mode must not be changed when under load.

- For the "EN 13000 version", the operating mode cannot be
changed when under load.
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Fig. 185: Check of entered parameter values
After completing the transmission, the "Crane operation" screen ap-

pears. The parameter values just selected appear there in the left-
hand area of the top line.
DANGER
Risk of accidents!
If these values are not consistent with the actual
crane state, crane operation is not permissible!
8.1.7.8.4 "Table view" screen
8.1.7.8.4.1 General instructions on this screen

The "Table view" screen within the "Selecting the operating mode"
screen is called up by pressing the displayed key. The values in the
"Table view" screen correspond with the values in the capacity tables.
The capacities indicated in the capacity tables correspond 100% with

the permissible maximum load of the individual crane configuration.
DANGER
Risk of crane overturning and/or risk of crane com-
ponents or auxiliary equipment breaking if the load
capacities specified in the capacity tables are excee-
ded!
Only attach permissible loads to the crane.
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The following details can be found in the load capacity tables stored
in the system:
Fig. 186: "Table view" screen
1 Pinned lifting capacities 2 Number of the length code (LC)

3 Main boom length 4 Scroll bar
5 ID no. of the capacity table
Item Explanation
1 Pinned lifting capacities
2 Number of the length code (LC)
3 Main boom length
4 Scroll bar
5 ID no. of the capacity table
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1 Current angle step 2 Calling up the "Search configuration for load case"
screen
3 Calling up the "Length code LC" screen

1 Display of current angle step
for luffing boom extensions, the current angle step (e. g. 40°) is also displayed.
By pressing this key, the other angle steps can be called up one after the other.
2 Key for calling up the "Search configuration for load case" screen
(see 8.1.7.8.4.2 "Search configuration for load case" screen, side 280)
3 Key for calling up the "Length code LC" screen
(see 8.1.7.8.4.3 "Length code LC" screen, side 283)
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1 Calling up the unpinned capacities 2 Horizontal capacities

3 Minimum reeving 4 Radius
Item Explanation
1 Key for calling up the unpinned capacities
(only for operating mode "HA")
See “Telescoping" section under “Capacities in the unpinned state”.
2 Horizontal capacities
The capacity tables contain values for raising loads in the virtually "horizontal main boom po-
sition" ("Horizontal capacity"). In this case, the angle of the main boom must be at least two
degrees to the horizontal.
3 Minimum reeving
4 Radius
For capacity tables with special capacities, an additional line

("...STL") with the corresponding capacity values is displayed under
the horizontal capacities (2).
Please refer to the capacity tables which you receive with the crane –
either on paper or as a CD-ROM – for more specifications on capaci-
ties. Please also note the 8.1.13.1 Specifications in the capacity ta-
bles, side 339.
8.1.7.8.4.2 "Search configuration for load case" screen

Press the depicted key to call up the "Search configuration for load
case" screen.
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Fig. 189: "Search configuration for load case" input screen
If the load and the load radius are known, possible configurations for
raising the load can be displayed.
Proceed as follows:
1. Tap input field below "Load (t/kip)".
A numeric pad appears where the required load can be en-
tered - within the limits specified in the head of the numeric
pad. If the entry is outside the permissible range, it will be
shown in red.
By pressing this key, the cursor is moved one position to the left and
the character that was there is removed.
2. Select the load.

3. Either discard or accept the entry by pressing the corresponding
key:
discard entry
accept entry and return to start screen
4. Select radius. Proceed analog to the procedure described for the

load.
If both fields for load and radius are filled with the desired entries,
start Search by activating the displayed key.
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Fig. 190: "Configurations" screen
All configurations found are entered in the corresponding field (bottom

marked area).
The entire selection is opened by pressing the arrow key.
The desired configuration can be selected by tapping. If you open the

"Select operating mode" screen, the selected configuration is dis-
played as a suggestion.
Fig. 191: "Configurations" screen
An entry such as (e.g. Fig. 191, side 282)

HAV-VA (23.4 / 0.0) / 41.10 / 5.54 means:
- Abbreviation of the crane configuration with fly jib "MBE-VA": main
boom extension, hinged with rigid section (adapter)
The meaning of all abbreviations can be found under "Display of

current configuration information".
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- the details in brackets are only relevant when working with addi-
tional equipment:
Value in brackets Example given Meaning

Length 1 23.4 m / 76.8 ft Length of the rigging
Angle 0.0° Angling of the fly jib
- Counterweight configuration: 41.1 t (90.6 tilt)

- Outrigger support area: 5.54 m (18.2 ft)
8.1.7.8.4.3 "Length code LC" screen
Fig. 192: "Length code LK" screen (schematic diagram)
The "Length code LC" screen can be called up within the "Table view"
screen by actuating the "LK" ("LC") key. The possible extension
states of the main boom with details of the length code (LC), main
boom length, extension state of the individual telescopic sections and
possible capacities are listed here in relation to the currently set con-
figuration.
8.1.7.9 Simulation screen "Capacities dependent on slewing angles" (optional)

Press the depicted key to call up the simulation screen "Capacities
dependent on slewing angles" (optional).
This screen is a preview screen and is for planning crane operation.

"Capacities dependent on slewing angles" can (depending on the
crane design) only be selected in main boom operation (crane config-
urations: "HA...").
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8.1.7.9.1 Structure of the simulation screen "Capacities dependent on slewing an-

gles"
Fig. 193: Simulation screen "Capacities dependent on slewing angles" (schematic

diagram)
1 Input Area 2 Result Display Area

3 Base line
The simulation screen "Capacities dependent on slewing angles" can

be divided into 3 sections:
Item Explanation
1 Input Area
(see 8.1.7.9.1.1 Input Area, side 284)
2 Result Display Area
(see 8.1.7.9.1.2 Result Display Area, side 289)
3 Base line
(see 8.1.7.9.1.3 Base line, side 292)
8.1.7.9.1.1 Input Area

The basic structure of the input area is described here. Depending on
the crane type, the available crane configurations, length codes,
counterweight combinations and extension states of the supports are
displayed and/or can be selected. At the end of this section, crane-
specific examples of this area of the simulation screen can be found
for clarification.
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Fig. 194: Simulation screen "Capacities dependent on slewing angles"
1 Abbreviation of the crane configuration 2 Selected length code (LK)

3 Counterweight selection
Item Explanation
1 Key/Display: Abbreviation of the crane configuration (available depending on crane type and
design)
When touched, a pull-down menu for crane configuration selection is opened.
HA Main boom (max. wind speed vT = 9.81 m/s (21.9 mph))
HA-W125 Main boom (max. wind speed vT = 12.5 m/s (28.0 mph))
HA-W150 Main boom (max. wind speed vT = 15 m/s (33.6 mph))
2 Key/display: Selected length code (LC)
When touched, the "Length code (LC) selection" screen appears for selection of another
length code (LC). The description of this screen is in section "Telescoping".
3 Key/display: Counterweight selection
When touched, a pull-down menu for counterweight combination selection is opened.
As many bars are shown as telescopic sections are on the main

boom for the symbolic depiction of the selected length code (2).
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1 Support, front right 2 Support, rear right

3 Crane symbol
Item Explanation
1 Key / display: Front right support
To enter the extension state
The selected outrigger support area has a green background. The extension state is dis-
played as a numerical value under the supports symbol. (Support on the crane symbol
marked as "C")
2 Key / display: Rear right support
marked as "A")
3 Display: Crane symbol
enables assignment of individual struts to the chassis
The angles entered correspond with the respective display in crane control.
As many selection options are displayed as supports' extension

states available on the crane chassis for the symbolic depiction of
items (1) and (2). The different extension states can be selected by
tapping on them several times.
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1 Support, rear left 2 Support, front left
Item Explanation
1 Key / display: Rear left support
marked as "B")
2 Key / display: Front left support
marked as "D")
As many selection options are displayed as supports' extension

states available on the crane chassis for the symbolic depiction of
items (1) and (2). The different extension states can be selected by
tapping on them several times.
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Crane-specific examples of the input area
Fig. 197: Example AC 250-5 Fig. 198: Example AC 220-5
Fig. 199: Example AC 160-5 Fig. 200: Example AC 130-5
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8.1.7.9.1.2 Result Display Area
Fig. 201: Simulation screen "Capacities dependent on slewing angles" - "Input area"
1 Display area

1 Display area
The colours in the display area indicate the distribution of the permitted capacities
possible in the current assembly state of the crane. It is possible to assign the
colour to the possible capacity together with the bar display (1) in Fig. 204,
side 291.
Orange to Range of the permitted capacity between 1 t (2.2 kip) and max. capacity for this
green crane assembly state
Prohibited operating range: raising loads in this range would lead to the crane be-
grey
ing overloaded or overturning
The assignment of the display area to the crane can be recognised in Fig. 202,
side 289.
Fig. 202: Assignment of the display area to the crane.
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1 Current load point
Item Explanation
1 Display: Current load point
Current load point for the display of the maximum load at this point (see display: Maximum
load)
is selected by touching the screen
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1 Bar display 2 Maximum radius

3 Slewing angle 4 Load radius
5 Maximum load
Item Explanation
1 Bar display
The bar display enables the assignment of the possible capacities to the colours in the dis-
play area (1).
2 Display: Maximum radius
Maximum radius which can be achieved in the set LC of the main boom
3 Display: Slewing angle
Slewing angle of the superstructure to the chassis in relation to the current load point
4 Display: Load radius
Load radius in relation to the current load point
5 Display: "Maximum load"
The maximum load pertains to the current load radius (3) and the current slewing angle of the
superstructure
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8.1.7.9.1.3 Base line
Fig. 205: Simulation screen "Capacities dependent on slewing angles" - "Base line" (schematic diagram)
1 Carrying out the simulation calculation
Item Explanation
1 Key: Carry out simulation calculation
All other displays and keys that can be found in the base line are de-
scribed under 8.1.6.1.4 Base line, side 251.
8.1.7.9.2 Carrying out the simulation calculation

A simulation calculation of the possible crane capacities can be car-
ried out using the simulation screen "Capacities dependent on slew-
ing angles" (see Structure of the simulation screen "Capacities de-
pendent on slewing angles"). Length code (LC), counterweight config-
uration and extension state of the supports of the current crane as-
sembly state are taken over in this screen as presettings.
1 Display area 2 Current load point

3 Bar display 4 Slewing angle
5 Load radius 6 Maximum load
Before the simulation calculation, items (1) and (2) are not displayed
and the values of items (3), (4), (5) and (6) are filled with "0".
1. If the simulation calculation for the current crane assembly state
is to be carried out, the work procedure can be continued directly
with work step 3.
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1 Abbreviation of the crane config- 2 Selected length code (LK)

uration (depending on crane
type and design)
3 Counterweight selection 4 Supports
2. If the simulation calculation is not to be carried out for the current

assembly state, adapt length code (LC) (2), counterweight con-
figuration (3) and extension states (4) of the supports. If load ca-
pacity tables with a different max. wind speed are available, they
can be selected in crane configuration (1).
The assignment of the respective support symbol to the support on

the chassis is described in "Input area".

3 Carrying out the simulation cal-
culation
3. Carry out simulation calculation. To do so, activate key (3).

Coloured profiles are shown in the circular display area (1)
and in bar display (2) after completing the simulation calcula-
tion.
The simulation calculation can take a few seconds.
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3 Slewing angle 4 Load radius
5 Maximum load
4. Touch touchscreen in the circular display area (1) at the desired

load point (2) to display the maximum capacity at this load point.
After touching the touchscreen, the maximum capacity value
(5), load radius (4) and slewing angle (3) between the super-
structure and the chassis at the desired load point is dis-
played.
Press the depicted key to exit the screen. No settings are taken over.
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8.1.7.10 "Operating range limit" screen (optional)
8.1.7.10.1 General instructions on this screen
Fig. 210: Calling up the "Operating range limit" screen
Activate the depicted key to call up the "Operating range limit" screen.
This is where operating area limits can be observed, defined and acti-
vated/deactivated.
If the initiated movement approaches a fixed limit, the movement is

slowed down until it comes to a stop.
The set limits are always adhered to. The crane operator can there-
fore switch the operating range limits briefly off and on again without
losing any data.
DANGER
This safety device is no substitute for the judgement
and experience of the crane operator or application
of recognised safe working procedures for crane op-
eration.
The crane operator is not relieved of his responsibility
for safe crane operation.
NOTE
Make sure that you deactivate the activated limits as soon as
work in a limited operating range has been completed!
Otherwise, it could cause unintentional and sudden shutdown
during the next crane operation without limits, causing the hook
block/load to swing out widely.
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8.1.7.10.2 Structure of the "Operating range limit" screen
Fig. 211: "Operating range limits" screen
1 Active operating range limits 2 Height of the main boom head

3 Current values relating to load
and radius
Item Explanation
1 Active operating range limits
The operating range defined by the active operating range
limits is shown as a green area. The black square (1) shows
the current position of the main boom head.
2 Actual and max. permitted height of the main boom head de-
picted in a bar diagram
3 Current values relating to load and radius
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1 Slewing angle limit 2 Radius limit

3 Operating range limit by virtual 4 Height limit
wall
Item Explanation
1 Slewing angle limit
(see 8.1.7.10.4 Slewing angle limit, side 300)
2 Radius limit
(see 8.1.7.10.5 Radius limit, side 301)
3 Operating range limit by virtual wall
(see 8.1.7.10.6 Limits by a virtual wall, side 302)
4 Height limit
(see 8.1.7.10.7 Height limit, side 304)
The keys which in addition can be found or can appear in the bottom
of the screen are described in the section 8.1.7.2 Submenus - ba-
sic structure, side 263.
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8.1.7.10.3 Procedure for Defining, Activating and Deactivating Operating Range Lim-
its
1 Active operating range limits
When selecting the "Operating range limit" screen, the entire field (1)
is displayed green if no operating range limits have been activated.
Procedure
1. Defining an operating range limit. Move to the crane position for
defining the operating range limit. Teach slewing angle, radius,
wall point and/or max. height. Move to second crane position and
teach when required by the definition of the operating range limit.
The key for teaching is described in the corresponding section of
the respective operating range limit.
WARNING
Risk of damage if the operating range limits are set
too close to the danger zone / projecting edge.
Ensure that the selected teach points ensure suffi-
cient distance to the danger zone even in extreme sit-
uations (e.g. when the hook block swings out after
the crane movement has been switched off).
2. Place the crane in a permitted position.
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Fig. 214: Keys for activating / deactivating the operating range limits
3. Activating / deactivating an operating range limit. To do so, acti-

vate the operating range limit with the corresponding key. The
key for activating / deactivating is described in the corresponding
section of the respective operating range limit. The background
colour of the key changes, depending on whether the operating
range limit has been activated or deactivated.
Background col-
Symbol Meaning
our
Operating range limit deactivated

Grey
(here: "Slewing angle limit" example)
Operating range limit activate

Green
(here: "Slewing angle limit" example)
4. Exit the screen using the displayed key.
Changed settings are saved.
5. After setting the limits, first make sure in a "test run" that the
shut-down occurs at the intended positions.
Display in the "Crane operation" screen
If one of the limits (e.g., slewing angle limit) is active, the depicted
symbol appears in the "Crane operation" screen. This symbol is for
information purposes only and cannot be activated.
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8.1.7.10.4 Slewing angle limit
Fig. 215: "Operating range limit" screen - slewing angle limit
Activating / deactivating the slewing angle limit

(for the visual differentiation of the two states "Activated" / "Deactiva-
ted", see 8.1.7.10.3 Procedure for Defining, Activating and Deacti-
vating Operating Range Limits, side 298)
Teaching the left-hand slewing angle

To do so, move to the left-hand limit point and press this button. The
angle setting above the key is overwritten by the current slewing an-
gle.
Teaching the right-hand slewing angle

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

deactivating the operating range limit under 8.1.7.10.3 Procedure
for Defining, Activating and Deactivating Operating Range Limits,
side 298.
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8.1.7.10.5 Radius limit
Fig. 216: "Operating range limit" screen - radius limits
Activating / deactivating the max. radius limit

Teaching the max. radius
Activating / deactivating the min. radius limit
Teaching the min. radius

side 298.
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8.1.7.10.6 Limits by a virtual wall
Fig. 217: "Operating range limit" screen - "Virtual wall"
1 Wall point 1 X / Y Coordinates
Activating / deactivating the limit by a virtual wall

Teaching the 1st wall point (1)

To do so, move to the desired wall point with the hook block and
press this key. A red point (1) appears in the figure. The co-ordinates
for this point (here: "10.00" as a value for the x-axis, "+5.00" as a val-
ue for the y-axis) are displayed.
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Fig. 218: "Operating range limit" screen - "Virtual wall"
1 Wall point 2 X / Y Coordinates
Teaching the 2nd wall point (1)

To do so, move to the desired wall point with the hook block and
press this key. A blue point (1) appears in the figure. The co-ordinates
for this point (here: "+5.00" as a value for the x-axis, "+10.00" as a
value for the y-axis) are displayed.
The 2nd wall point must be at least 8 m (26.3 ft) from the 1st wall
point. Otherwise the range is highlighted in red with the co-ordinate
information.
Fig. 219: Taught points
When activating the limit, the two taught points are automatically
connected with a line in Fig. 219, side 303 in the marked area.
The resulting permitted operating range is displayed as a green
area.

side 298.
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Switching over the permitted operating range

If the other side of the wall is to be defined as the permitted operating
range, press this key; its appearance changes, i.e. it has a green
background.
Observe the description of the procedure for defining, activating and

side 298.
8.1.7.10.7 Height limit
Fig. 220: "Operating range limit" screen - height limit
Activating / deactivating the height limit

Teaching the max. height

side 298.
8.1.7.11 "Joystick Modes" screen
8.1.7.11.1 General
Press the button displayed in the main menu under the settings for
crane operation to call up the "Joystick modes" screen.
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8.1.7.11.2 Structure of the "Joystick modes" / "Control lever assignment" screens
Fig. 221: Structure of the "Joystick modes" screen
1 "Current assignment of the control levers" display

1 Display: Current assignment of the control levers
"Slew gear"
superstructure slews to the left
superstructure slews to the right
"Telescoping main boom"
telescope in/out to entered LC
telescope to LC1 (completely retracted)
The specifications on telescoping listed here refer to automatic telescoping.
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1 "Current assignment of the control levers" display
Continued from item (1)

1 "Luffing gear (main boom)"
main boom luffs up
main boom luffs down
"Hoists" (here: example hoist gear 1)
hoist unreels
hoist reels in
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1 "Current assignment of the control levers" display 2 "Selection of control levers assignment" buttons
Item Symbol Function / explanation

Buttons / displays: Selection assignment of the control levers
(Modes 1 - 6; Description of modes, see 8.1.7.11.4 Control Lever Assignments
(6 Modes), side 309)
Mode can be selected
Mode is selected. Control lever assignment can be identified by symbols under

2
(1).
Mode cannot be selected.
Only the modes can be selected for which the crane has the corresponding tech-
nical equipment (for example, without hoist gear 2, only modes 1, 4 and 6 can be
selected).
The buttons, which can be found or can appear at the bottom of the
screen, are described under 8.1.7.2 Submenus - basic structure,
side 263.
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8.1.7.11.3 Display / Change to the Control Lever Assignment
1 "Current assignment of the con- 2 "Selection of control levers as-

trol levers" display signment" keys
For item (1), the symbol of the current crane movement is depicted on
the axes of the two coordinate axes.
The corresponding mode is displayed "green" under (2) at the corre-
sponding key (here: "Mode 1").
Press the key of the desired mode (e.g. mode 4) under (2) to change
the control lever assignment.
This key / display is shown "green".
The symbolic display of the control lever assignment (1) is changed

accordingly and indicates the changed control lever assignment.
DANGER
crane movements!
Before initiating a crane movement, the crane opera-
tor must ascertain what the current control lever as-
signment is.
Display of the control lever assignment in the "Crane operation"

screen
The mode no. of the current control lever setting is shown in the top
line of the IC-1 display.
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8.1.7.11.4 Control Lever Assignments (6 Modes)
Fig. 225: Control levers
There are six different options for standard control lever assignment
(modes 1 - 6).
Control lever, left Control lever, right

Mode
Legend:
Control lever: horizontal steering direc-

Control lever: vertical steering direction (v)
tion (h)
Slewing Telescoping main boom
Hoist 1 Hoist gear 2
Luffing
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8.1.7.12 "Parameter settings" screen

Press the button shown in the main menu under Service settings to
call up the "Parameters" screen.
Fig. 226: "Parameter settings" screen
In this screen, execution of the movement speed can be selected de-

pending on the control lever movement for the crane movements
slewing, luffing, hoist gear 1 and hoist gear 2.
The following progressivity profiles are available for selection:
Display Control Description
progressive
Ratio of execution of
movement speed de-
Moderately progressive
pending on control
lever movement
linear
Table 2: Parameter settings
Profiles can be fixed for three crane operators. In Fig. 226,

side 310, crane operator "1" is active.
As crane movements can also be driven for testing purposes, the de-
picted load utilisation display of the load limit device is also shown in
the top part of the screen. The crane operator is therefore continually
informed of the current working radius of the crane.
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8.1.7.12.1 Change profile
Fig. 227: "Parameter settings" screen
1. Activate symbol of the desired crane operator - it gets a green

background (here: crane operator "1").
2. Actuate the progressivity of control to be changed until the de-

sired progressivity appears (see Tab. 2, side 310 "Parameter
settings").
3. Press the displayed button to save the change.
Or
Exit the screen without changing the profile
The buttons, which in addition can be found or can appear at the

bottom of the screen, are described under 8.1.7.2 Submenus - ba-
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8.1.7.13 "Datalogger" screen (optional)
8.1.7.13.1 Call-up and Display

The datalogger saves relevant events of crane control. A correspond-
ing display can be viewed using the "Datalogger screen" selection
button shown.
call up the "Datalogger" screen.
Fig. 228: "Datalogger" screen
1 Current operating mode 2 Event table

3 "Copy and download datalog-
ger" button (optional) (see
8.1.7.13.3 Copy and download
datalogger file (optional),
side 315)
DANGER
Risk of accidents!
If a fault message concerning the datalogger is dis-
played, the fault must be rectified immediately. To do
so, please consult the crane manufacturer's customer
service team.
8.1.7.13.2 Event table
- The current operating mode is displayed in the event table as the

most recent event at the end of the table.
- Please consult the customer service team of the crane manufac-
turer to interpret the displayed data.
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Legend - Event table
Data Display / meaning

Datum Date the event occurred
Time Specifying the time of the event
LMB-Stop 0 = Enabled
1 = Not enabled
UE_RT_EU 0 = Configuration button 110% (EN 13000)
not activated
1 = Configuration button 110% (EN 13000)
activated
UE_LMB 0 = Load limit device override button not op-
erated (EN 13000: key-operated push-
button cab rear panel; non-EN 13000:
key-operated pushbutton in dashboard)
1 = Load limit device override button operat-
ed (EN 13000: key-operated pushbutton
cab rear panel; non-EN 13000: key-oper-
ated pushbutton in dashboard)
UE_HES 0% = Hoist limit switch (HLS)
not actuated / not bridged
1 = Hoist limit switch (HLS)
not actuated / bridged
10 = Hoist limit switch (HLS)
actuated / not bridged
-(11): = Hoist limit switch (HLS)
actuated / bridged
UE-AUF 0 = Bridging key UP (luff up) not actuated
1 = Bridging key UP (luff up) actuated
Tele-manual 0 = Tele automatic active
1 = TeleManual active
LK Selected length code
LK-rel The relevant length code for the load calculation
LK-err Length code achieved
Reeving Hoist rope reeving
Load Current crane load utilisation [%]
MAX Maximum capacity [0.1 t]
Last (Load) Current load [0.1 t]
Radius Current radius [0.1 m]
Radius-REL Radius relevant for load calculation [0.1 m]
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HA-Winkel Current main boom angle [0.1°]
HA-Kopfwinkel Current main boom head angle [0.1°]
HAV-Winkel Current angle of the main boom extension (MBE)
[0.1°]
HA_Laenge Current main boom length [0.1 m]
SVE-Laenge Current extension length of the telescoping cylin-
der [mm]
LPU state Current LPU state
1 = unlocked and pinned
12 = State change lock and pinned
2 = locked and pinned
23 = locked and state change pinning
3 = locked and unpinned
5 = "Locking/pinning unknown" state
Drehwinkel Current superstructure slewing angle [0.1°]
HA height Current main boom height [0.1 m]
ORL 0 = Operating range limits not activated
1 = Operating range limits activated
RRC 0 = Radio remote control not activated
1 = Radio remote control activated
Anst-HW1 Control value hoist movement HW 1 (-200 to 200)
Anst-HW2 Control value hoist movement HW 2 (-200 to 200)
Anst-DW Control value slewing gear movement (-200 to
200)
Anst-WW Control value luffing gear movement (-200 to
200)
Anst-Tele Control value telescoping movement (-200 to
200)
HMI-Maskenindex Number of the screen displayed during the event
0 = Warning - support force not active
W−STDruck
1 = Warning - support force active
0 = Fault outrigger support area not active
E−STBasis
1 = Fault outrigger support area active
STB−VR Measured outrigger support area, front right [cm]
STB−VL Measured outrigger support area, front left [cm]
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STB−HR Measured outrigger support area, rear right [cm]
STB−HL Measured outrigger support area, rear left [cm]
GGW−gem Measured counterweight [0.1 t]
Where required, the measured units of the displayed values are lis-
ted in brackets.
Example: The numerical value "70" is displayed for the "GGW-gem"
value. The measured unit is "0.1 t". Accordingly, this value would
correspond with 7 t (15.4 kip).
8.1.7.13.3 Copy and download datalogger file (optional)

This section describes how the datalogger file can be copied as a
"text file" and downloaded onto a USB stick.
1. Insert the USB stick into the USB port on the right below the front
control panel.
Fig. 229: "Datalogger" screen
2. Call up "Datalogger" screen.

If the crane is prepared for copying the datalogger file, the
corresponding button is in the footer (see arrow).
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Fig. 230: "Info" screen
3. Press the depicted button in the "Datalogger" screen.
During the download, the "Info": "Kopiere ausgewählte Datei

auf den USB-Stick." ("Copy selected file onto USB stick.")
screen appears. The "Info" screen disappears again after suc-
cessful download.
Fig. 231: "Info" screen
If there is a fault during transfer, the "Info": "Es ist ein Fehler aufge-
treten! ("A fault has occurred!) Die Datei wurde nicht kopiert." (The
file has not been copied.") screen appears.
8.1.7.14 "Operating hour meter" screen

call up the "Operating hours meter" screen.
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Fig. 232: "Operating hour meter" screen
Display operating hours Slew Gear
Display operating hours Luffing gear
Display operating hours tele unit
Display of operating hours for hoist 1
Display of the operating hours for hoist 2 (optional)
Display of operating hours of the engine in superstructure operation

(optional)
The buttons which can be found or can appear at the bottom of the
screen are described under 8.1.7.2 Submenus - basic structure,
side 263.
8.1.7.15 Activating / deactivating the "Emergency hydraulic lowering" / "Emergency

operation" functions (options)
Press the buttons shown in the main menu under Service settings to
activate or deactivate the "Emergency hydraulic lowering" and "Emer-
gency operation" functions.
All specifications on this option can be found in the section "Emergen-

cy actuation" and the section "Emergency operation".
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8.1.7.16 "Function display" screen

Press the button shown in the main menu under diagnostics settings
to call up the "Function display" screen.
Fig. 233: "Function display" screen
If there are malfunctions, all input and output parameters required for
a movement can be displayed in this screen to carry out a compari-
son of the setpoint and actual values.
The crane movement is selected using the keys on the left-hand side
of the screen.
Slew superstructure display
Hoist 1 display
Hoist 2 display (optional)
Telescoping display
Luffing gear display
Configure counterweight display
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The selected key is given a green background colour (here: "Slew su-
perstructure").
For screens with several pages: buttons for scrolling through the pa-
ges (forward and back).
The keys which can be found or can appear at the bottom of the
side 263. The key / button for "Dismantling the main boom" is an ex-
ception and is described on the following pages.
"Dismantling the main boom" button
Fig. 234: "Dismantling the main boom" button
If the crane is equipped with equipment for quick dismantling of the

main boom, there is another button at the bottom of the screen when
the "Telescoping" crane movement has been selected. The meaning
and use of this button is described in the section "Dismantling and fit-
ting the main boom (optional)".
8.1.7.17 "I/O view" screen

Press the button shown in the main menu under Diagnostics settings
to call up the "I/O view" screen for diagnosis of the individual inputs
and outputs of the control unit.
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Fig. 235: "I/O view" screen
The required element is selected using the keys shown on the left.
In this example, this is "A0701".
The keys which can be found or can appear at the bottom of the
side 263.
8.1.7.18 "CAN View" Screen

Press the button shown in the main menu under Diagnostics settings
to call up the "CAN View" screen for diagnosis of the status of the in-
dividual bus participants for the CAN buses.
Fig. 236: "CAN View" screen (schematic diagram)
1 Selection of desired bus 2 List of bus participants

3 Status of respective bus partici-
pant
In this example, this "CAN 1".
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Status display Meaning
Operational Colour "green", ok
Colour "red", participant not

not available
available
All CAN participants which are not active in the bus are marked with a
red dot. This can have two causes:
- Participants such as for example the radio remote control are not
active as the crane is not equipped with the corresponding equip-
ment; therefore no fault is present.
- Participants are not active due to a fault. In this case, please con-
sult our customer service team.
The buttons that can be found or can appear at the bottom of the
side 263.
8.1.7.19 "Load Sensing View" screen

Actuate the key displayed in the main menu under diagnosis settings
to call up the "Load Sensing View" screen for system diagnosis.
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The depiction for pump P1 appears:
Fig. 237: "Load Sensing View" screen
1 Crane movements symbols 2 Load pressure

3 Pump pressure 4 Pressure difference

1 Symbols of the crane movements, which can be assigned to the pump
(telescoping, luffing, hoist 1, hoist 2 (optional))
2 Load pressure
3 Pump pressure
4 Pressure difference
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Fig. 238: "Load Sensing View" screen
1 Display of sliders 2 "Load sensing" switched off

3 "Load sensing"

1 Symbolic depiction of the sliders ("z")
2 "Load sensing" symbol switched off
By switching off "Load sensing", the "Load sensing" elements can be switched off
during troubleshooting, for example, eliminating them as potential fault sources.
3 "Load sensing" key
switched on
switched off
The buttons, which in addition can be found or can appear at the

bottom of the screen, are described under 8.1.7.2 Submenus - ba-
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8.1.7.20 "Joystick diagnostics" screen

Press the button displayed in the main menu under the Diagnostics
settings to call up the "Joystick diagnostics" screen for diagnosis of
the control lever.
Fig. 239: "Joystick diagnostics" screen
The function can be checked by moving the control lever.
The buttons that can be found or can appear at the bottom of the
side 263.
8.1.7.21 "Fault messages" screen

Warning information and tips shown when faults occur
If there is a fault in crane control, a corresponding message appears
in every screen with fault display. When dealing with faults, observe
the warning information and specifications on this subject under
8.1.17.2 Error messages are displayed on a visual display computer,
side 347.
Calling up the "Fault messages" screen
Press the "Fault display" key in the currently displayed screen to call
up the list of existing faults (see Fig. 240, side 325).
As an example, the fault display in the "Main menu" screen is shown.
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Content of the "Fault messages" screen

The faults with fault codes and descriptive text are listed here:
Fig. 240: "Fault messages" screen
If a fault's descriptive text is too long to be displayed in its entirety,

an auxiliary window can be called up by tapping on the correspond-
ing line. Then the entire text is displayed.
Acknowledging fault messages

The displayed fault messages are "acknowledged" with this key, i.e. it
is confirmed that the crane operator has acknowledged them.
If the "Error messages" screen is exited without the error messages

being "acknowledged", they will still be displayed as new error mes-
sages in the other screens.
8.1.7.22 "Telescoping display" screen

Press the button shown in the quick menu to call up the "Telescoping
display". Detailed information on this subject can be found in the "Tel-
escoping" section.
8.1.7.23 "Counterweight display" screen

Press the button displayed in the quick menu to call up the "Counter-
weight display" screen. Detailed information on this subject can be
found in the section "Counterweight".
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8.1.7.24 "Outrigger support area" screen

Press the button displayed in the quick menu to call up the "Outrigger
support area" screen.
Fig. 241: "Outrigger support area" display (schematic diagram)
1 current support force (option: 2 current support width (option:

support pressure display) outrigger support area display)
3 Current tilt
Assignment of the displays

Item
Support Crane
1 Current support force
(Option: see operating instructions for
the crane chassis in the "Outriggers"
section under "Support pressure dis-
play (optional)")
2 current extension state of the support
(Option: Outrigger support area display
(see "Outrigger support area display
(depending on crane design)")
3 Current tilt
- Depending on the crane type and equipment, the displays vary in

the "outrigger support area" screen.
- When displaying the gradient, the display starts at a gradient of
1.5°. The inner circle describes a gradient of 0.5°.
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The screen is exited using the depicted key in the "Crane operation"
screen.
The "Crane operation" screen with the partial screen "Quick menu"
appears.
8.1.7.25 "Engine display" screen

Press the button displayed in the quick menu to call up the "Engine
display" screen. Detailed information on this subject can be found in
the "Engine" section.
8.1.7.26 Operating screen "Capacities dependent on slewing angles" / capacity radar

(optional)
Press the button displayed in the quick menu to call up the "Capacity
radar" screen.
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Fig. 242: "Capacity radar" screen
1 Angle segment 2 Maximum radius which can be achieved in this LK

3 Current load point

1 Display: angle segment
+/− 25° of the current superstructure position
Green Normal range: load utilisation less than 90%
Yellow Advanced warning range: load utilisation between 90% and 100%
red Overload range: load utilisation above 100%; crane control switches off
2 Display: maximum radius which can be achieved in this LK
3 Display: Current load point
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Fig. 243: "Capacity radar" screen
1 Speed reduction luffing movement 2 Bar diagrams for speed reduction

3 Speed reduction slewing movement

1 Display: symbolic depiction of the direction of the luffing movement
2 Display: speed characteristics
dynamic speed adjustment of the crane movement symbolically
shown in the corresponding display (items 1 and 3)
Blue No speed reduction
white-blue Speed reduced (increasing white share - increased speed reduction)
red Movement blocked

3 Display: symbolic depiction of the direction of the slewing movement
8.1.7.27 "IC-1 Remote" screen ("Teleservice"; optional)

Press the button displayed in the quick menu to call up the "IC-1 Re-
mote" screen ("Teleservice").
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Fig. 244: "IC-1 Remote" screen ("Teleservice") (schematic diagram)
1 Provider/cell phone provider dis- 2 Active mobile phone connection

play, SIM card used display
3 Active WIFI connection display 4 Quality of mobile phone connec-
tion display
5 Quality of the connected WIFI 6 Display for reception status for a
connection display "Global Navigation Satellite Sys-
tem" (GNSS) e.g. GPS
7 Display for GNSS lettering (as- 8 Charge status of the internal bat-
signment to (6)) tery (available depending on the
software version)
9 Field for error messages (availa- 10 Scroll bar (available depending
ble depending on software ver- on the text length of the error
sion) messages)
If the text "No APN" appears while the active mobile connection (2)
("Mobile") is displayed, no SIM card is configured.
The connection status of the mobile or wireless connection is dis-

played as follows:
Connection active
Connection not active
No connection available
Very poor connection
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Sufficient connection
Good connection
Excellent connection
The reception status to a Global Navigation Satellite System (GNSS)

is displayed as follows:
Connection available
Connection available but poor reception
No connection available
The charging status of the battery is displayed as follows:
Battery status not available

Battery is charged
Battery is charged.
Battery is discharged
Battery is discharged and the device switches
off
To set up the mobile and wireless connection, see the 8.1.7.5

"Setup IC-1 Remote" screen ("Setup Teleservice"; optional),
side 266.
For more information on "IC-1 Remote" ("Teleservice"), see section

8.1.15 IC-1 Remote ("Teleservice"; optional), side 345.
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8.1.8 Load Monitoring Device

With the help of the computer of the load limit device, it is possible to
check the weight of the raised load (net load).
DANGER
Risk of accidents!
The load monitoring assembly may not be used to
calculate the load, but is used to check the weights of
loads that have been previously calculated in order to
calculate better the load hoist and to avoid potentially
hazardous situations!
Fig. 245: "Maximum load" display
Before raising the load, the maximum load corresponding to the oper-
ating state must be determined. It is shown, depending on the selec-
ted operating mode, on the display under "MAX (t/kip)" on the screen
"Crane operation".
Load monitoring
Fig. 246: "Net load" display
1. If the hook block is suspended freely (without load, with load-

handling devices), press the key of the net display "NET (t/kip)".
The lifting tackle is tared and set at 0.0 t (0.0 kip) net load.
2. Raise the load with the hoist.

The net display then shows the net load (actual load on the
hook without the load handling device).
The gross load comprises - apart from the load weight - the weight
of the hook block and all load handling devices. The net load is the
actual load on the hook block without the load handling equipment.
Display errors are possible because of outside factors, e.g. wind,
which have an effect on both the crane and the load.
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8.1.9 Tilt display

Before every operation of the crane, the crane must be supported on
outriggers and horizontally aligned. Observe the corresponding speci-
fications in the operating instructions of the crane chassis under "Out-
riggers".
DANGER
Operation of the crane is only permitted when the
crane is aligned horizontally! Align the supported
crane so that the maximum deviation is less than 0.1°
after aligning it (levelling).
The current tilt is permanently displayed in the "Crane operation"

screen by means of the symbol shown.
The gradient is shown in more detail in the "Outrigger support area"

screen.
8.1.10 Support Force Display (Optional)

The support forces are optionally registered via pressure contacts in
the vertical support cylinders and displayed in the "Outrigger support
area" screen (see 8.1.7.24 "Outrigger support area" screen,
side 326).
DANGER
RISK OF ACCIDENTS!
When supporting on outriggers, observe the proce-
dure described in the "Outriggers" section in the oper-
ating instructions of the crane chassis.
If the vertical support cylinders - contrary to the pre-
scribed procedure - are extended fully up to the stop,
the supporting forces displayed will be inaccurate.
The support force display shows tolerance values. The display value
can differ from the actual value by up to approx. 10% (plus / minus).
Keep this in mind, for example in relation with limited load-carrying
capacity of the ground.
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Fig. 247: "Outrigger support area" screen

(schematic diagram)
Depending on the crane type and equipment, the displays vary in

The current and maximum occurring forces (see arrow in the figure
"Outrigger support area screen") are displayed as a numerical value
and as a display bar in the "Outrigger support area" screen for each
of the 4 supports.
A symbolic crane is displayed between the 4 support pressure dis-
plays (see arrow in Fig. "Outrigger support area screen") so that it is
possible to assign the respective support force value to the corre-
sponding support: the front supports are shown above, the rear sup-
ports below.
The display bars are depicted in red for support forces from approx.
90% of the permitted maximum value.
If a support force of 1 t (2.2 kip) is not reached, "STB" appears in red
in the "Crane operation" screen. In addition, the warning buzzer goes
off.
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8.1.11 Outrigger support area display (depending on crane design)

If the crane is equipped with an outrigger support area display, there
is a length measuring device at each support to register the extension
state of each support.
Display in the "Outrigger support area" screen

(schematic diagram)

In the “outrigger support area” screen, (see 8.1.7.24 "Outrigger sup-

port area" screen, side 326) numerical values are displayed (see ar-
row in Fig. "Outrigger support area screen": rear right, rear left, front
left, front right), which designate the extension state of each support.
DANGER
Risk of overturning due to incorrect extension state
of the supports.
The displays are for information purposes only. There
is no shut-down if the crane is not properly supported.
When supporting the crane, ensure the supports
have the correct extension state.
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DANGER
Risk of accidents due to the supports being assem-
bled incorrectly!
Only the extension position of the support is dis-
played in the outrigger support area display. It does
not monitor whether the pins to be fitted in the sup-
ports are fitted correctly and are secured against fall-
ing out.
Support the crane on outriggers as described under
"Outriggers" (operating instructions of the crane chas-
sis).
Current support width (see arrow)

(schematic diagram)

If a numerical value is displayed, it is an extension state in accord-

ance with one of the support variants described in "Outriggers" (oper-
ating instructions of the crane chassis).
If dashes are displayed, the support is not in an extension state in ac-

cordance with one of the support variants described in "Outriggers"
(operating instructions of the crane chassis). In this case, place the
support in an extension state which is in accordance with one of the
described support variants.
If three question marks are shown, there is a fault in the length meas-
uring device. In this case, check the length measuring device.
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Display in the "Selecting the operating mode" screen

The measured outrigger support area is displayed when calling up the
"Selecting the operating mode" screen. The extension state is dis-
played in red lettering if the last settings deviate from the just meas-
ured values. The selection must either be confirmed or adapted by
changing the configuration.
The crane operator must ensure that the assembly state of the sup-
ports corresponds with the specifications which are to be made in this
screen. In particular, it must be checked whether each support is in
an assembly state in accordance with one of the support variants de-
scribed in "Outriggers" (operating instructions of the crane chassis).
DANGER
There is a risk of accidents if crane control calcu-
lates with incorrect parameters.
Ensure that the parameters set in crane control corre-
spond with the actual assembly state.
Ensure that all supports are in an assembly state in
accordance with a support variant described in "Out-
riggers" (operating instructions of the crane chassis).
If this extension state shown in red is to be entered at crane control, it

must first be selected and therefore confirmed before the "Selecting
the operating mode" screen is exited with "Save".
Display in the "Crane operation" screen
If the extension state of the supports deviates from the parameters
set on the "Operating mode selection" screen, a warning appears in
the "Crane operation" screen. In addition, the warning buzzer goes
off.
A supports symbol highlighted in red appears as a warning with the
current configuration information.
8.1.12 Automatic Counterweight Recording (Optional)

The weight of the counterweight combination is entered in the "Oper-
ating mode selection" screen (see the corresponding description in
this section).
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In cranes with optional counterweight recording, the detected counter-

weight combination is displayed here as a suggestion.
Counterweight recording is also activated as standard in cranes with
optional "Capacities dependent on slewing angles".
When saving/leaving the "Select operating mode" screen, if a differ-
ent counterweight combination is set than the one detected by the
crane control, the counterweight symbol will be highlighted in red in
the header.
Counterweight recording is an operating aid.
DANGER
There is a risk of accidents if crane control calcu-
lates with incorrect parameters!
Ensure that the counterweight combination detected
by crane control corresponds with the actually fitted
counterweight combination.
Depending on the crane type, counterweight elements can be perma-

nently carried along on the superstructure. Technical requirements for
automatic counterweight detection on a crane type like this are de-
scribed in the section "Counterweight" under "Technical requirements
for automatic counterweight recording (optional)".
The steps listed below must be carried out to make it possible to con-
tinue work when there is a fault in the counterweight recording sensor
system:
- When a symmetric outrigger support area has been set, a value
detected by crane control that is incorrect can be overwritten man-
ually with the correct value.
- The fitting procedure must be carried out again if the optional "Ca-
pacities dependent on slewing angles" is set. This means that the
counterweight combination must be set down on the chassis frame
again and must be fitted again. If an incorrect counterweight com-
bination is displayed in the "Selection of the operating mode"
screen, no loads may be raised with "Capacities dependent on
slewing angles" selected. The fault in the counterweight detection
sensor system must be rectified first.
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DANGER
Risk of overturning! The crane can overturn when
working with a counterweight combination incorrect-
ly set in crane control.
If the displayed suggested counterweight combination
is manually overwritten, ensure that the counter-
weight combination actually fitted is entered.
The crane operator is responsible for the correct se-
lection.
8.1.13 Lifting loads with capacity values from the capacity table
The capacity values in the capacity tables are only valid for a sym-
metric support base (all supports in the same extension state). There
is an indication in each capacity table as to how the crane must be
supported on outriggers so that loads may be raised according to this
table. The symmetric support base listed in the capacity table is set
as parameter in the "Operating mode selection" screen (see "Operat-
ing mode selection" screen).
DANGER
Risk of overturning if crane control has been set in-
correctly!
If symmetrical outriggers are set, all supports must be
in the same extension state which is set in the "Oper-
ating mode selection" screen.
8.1.13.1 Specifications in the capacity tables

The capacities indicated in the capacity tables correspond 100% with
the permissible maximum load of the individual crane configuration.
The capacity table described in the following is only a sample.
DANGER
Risk of accident due to working with incorrect ca-
pacity tables!
Only the capacity tables which are supplied with the
crane may be used for Crane operation!
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The following examples show where which specifications can be

found in the capacity table:
Fig. 250: Capacity table sample - top area
1 Crane type 2 Lifting capacities on the main boom

3 Abbreviation of the crane configuration 4 Permitted slewing area
5 Support length 6 Support width
7 Counterweight
Item Explanation
1 Crane type:
- P82350_70 = AC 250-5
- P82350_78 = AC 220-5
- P38400 = AC 160-5
- P35300 = AC 130-5
2 Lifting capacities on the main boom

All telescopic sections pinned
(here: "HA" for main boom operation)
The meaning of all abbreviations can be found under 8.1.6.1.1 Display of current
configuration information, side 247.
4 Permitted slewing area
5 Support length
6 Support width
7 Counterweight
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Fig. 251: Capacity table sample - middle area
1 Main boom length 2 Load radius up to centre of slew ring

3 Capacity (pinned)
Item Explanation
1 Main boom length
2 Load radius up to centre of slew ring
3 Capacity (pinned)
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Fig. 252: Capacity table sample - bottom area
1 Horizontal capacity 2 Reeving number of the hoist rope

3 Length code no. (LK) of the extension sequence 4 Extension state of the telescopic sections
5 Restrictions / notes on dangers 6 ID no. / page no. of the capacity table
Item Explanation
1 Horizontal capacity
2 Reeving number of the hoist rope
3 Length code no. (LK) of the extension sequence
4 Extension state of the telescopic sections
5 Restrictions / notes on dangers
6 ID no. / page no. of the capacity table
Characteristics:
- The capacity tables contain values for raising loads in the virtually
"horizontal main boom position" ("Horizontal capacity"). In this
case, the angle of the main boom head must be at least two de-
grees to the horizontal.
- Depending on the application of the capacity table, the individual
elements (e.g. "Slewing area") can be arranged differently than
shown in the example.
- Some capacity tables feature the term "Capacity class". This value
can be used for the comparison of individual crane types.
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Capacity tables with special capacities
Fig. 253: Sample of capacity with special capacity
1 Counterweight 2 Special capacity values

3 Information on special capacity values
Item Explanation
1 Counterweight
2 Special capacity values
3 Information on special capacity values
Arranging the capacity values

The columns for the capacity values in the capacity table are listed
according to the length code, in increasing order. The columns of the
capacity values on crane control's operating panel are arranged ac-
cording to ascending main boom lengths.
8.1.14 Raising loads with "Capacities dependent on slewing angles" (optional)

Depending on the crane type and design, raising loads is possible in
the following operating modes:
- HA
- HA-W125
- HA-W150
In these operating modes, the crane control calculates the maximum
permissible load capacities depending on the superstructure position.
In many positions, this results in higher capacity values than indicated
in the corresponding 360°capacity table. In this function, outrigger
support areas / support bases are permitted in which the supports are
not in the same extension states.
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With this crane type, the supports must be in an extension state as

described in the operating instructions for the chassis in the section
on "Outrigger" under "Support variants".
DANGER
Risk of overturning due to interpreting the capacity
values incorrectly!
If capacities dependent on slewing angles are set in
the "Operating mode selection" screen, only the cal-
culations of crane control are valid regarding the pos-
sible capacities or shutdown points. The specifica-
tions in the capacity table are invalid here.
The slew gear is operated in a closed circuit (see the "Slewing the su-
perstructure" section).
"Capacities dependent on slewing angles" must be set as parameter
in the "Operating mode selection" screen (see "Operating mode se-
lection" screen ).
During crane operation, the operating screen "Capacities dependent
on slewing angles" (see Operating screen "Capacities dependent on
slewing angles") must be selected. The ranges / areas in which rais-
ing loads is possible or is blocked is marked in colour in the displayed
angle segment. When a blocked range / area is approached, the
speed of the slewing movement of the superstructure and of the luff-
ing movement of the main boom is continuously reduced to prevent
the crane from being overloaded. The movement is blocked com-
pletely when the blocked range / area has been reached.
The simulation screen "Capacities dependent on slewing angles" can

be used to plan crane operation beforehand or at the crane's set-up
location (see Simulation screen "Capacities dependent on slewing
angles"). After the relevant calculation has been made, the crane ca-
pacities possible for the current or entered assembly state and/or the
blocked ranges / areas are depicted in colour.
Special characteristics for the load limit device (LLD) in counties

in which EN 13000 is not valid
As shown in the description of the load limit device (see "Overload
cut-off by the load limit device (LLD)"), there are differences between
the "EN 13000" version and the "Non-EN 13000" version regarding
displays, warnings and interventions in control.
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The differences listed below apply if "Capacities dependent on slew-

ing angles" is set in countries in which EN 13000 is not valid:
- The key-operated pushbuttons of the different bridgings function
as described for the "EN 13000" setting.
- The crane movements are carried out for bridging at the speed de-
scribed for the "EN 13000" setting.
- The visual signals of the warning lights at the front of the cab are
displayed as described for the "EN 13000" setting.
The acoustic signals within and outside of the crane operator’s cab
remain as described for the "Non-EN 13000" setting.
8.1.15 IC-1 Remote ("Teleservice"; optional)

If the crane is equipped with the "IC-1 Remote" ("Teleservice") option,
data is sent to a data server via a mobile network. For this purpose, a
modem equipped with a SIM card is located in the vehicle. Optionally,
a WIFI connection can also be established. More detailed information
on the data sent can be obtained from the service department.
The relevant status information is displayed in the "IC-1 Remote"
screen ("Teleservice"; optional) (see 8.1.7.27 "IC-1 Remote" screen
("Teleservice"; optional), side 329).
Setting and configuration activities are described in the "Setup - IC-1

Remote" screen ("Setup Teleservice)" screen (see " 8.1.7.5 "Setup
IC-1 Remote" screen ("Setup Teleservice"; optional), side 266.
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8.1.16 Hook Height - Moving Repeatedly to a Saved Height

This option can be used to move repeatedly to a saved hook height
with hoist 1 (see arrow). This is helpful, for example, when lifting
loads into areas on buildings which are not visible. This equipment is
not suitable for precise measurement of the actual hook height. To
some extent, the displayed height difference deviates greatly from the
actual height difference.
Fig. 254: "Hook height" button
1 "Hook height" button 2 Hook height / zero point differ-

ence
Button (1) is used to save a hook height. The displayed value is then
set to zero in display (2).
A green frame is shown around the display which indicates that the
value is "valid".
The displayed value is no longer correct for technical reasons due to

telescoping and luffing the main boom.
The frame around the display is shown in red.
Displayed value Meaning

0.0 m (0.0 ft) Saved hook height is reached
negative value Hook block is below the saved hook height
positive value Hook block is above the saved hook height
Fig. 255: "Hook height" button
1 "Hook height" button 2 Hook height / zero point differ-

ence
If main boom length and main boom angle are brought back to the
length or angle in place when button (1) was touched, the frame
around display (2) is shown in green again. The displayed value is
valid again.
The function can also be used with a fitted fly jib (e. g. main boom ex-
tension, assembly jib).
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The saved hook height remains saved even after the ignition has
been switched off.
8.1.17 Procedure in the Event of Faults
8.1.17.1 Fault-free Operation

If operation is free of malfunctions, the currently set menus and
screens will be shown on the crane control system's visual display
computer. The crane can be moved with the aid of the control lever.
8.1.17.2 Error messages are displayed on a visual display computer

If a fault occurs in the crane's control system, in each screen which
displays faults, a button with a corresponding symbol will appear. As
an example, the fault display in the "Main menu" screen is shown
here.
Fig. 256: "Error messages" screen
The fault must be identified without delay. Depending on the fault

concerned, the crane operator must judge whether it is possible to
continue working with the crane or whether the fault must first be
fixed.
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DANGER
Risk of accidents! Death or serious injury may result
if work continues with the crane after safety-relevant
faults occur or faults whose effect on the crane or its
operation are not clear.
Immediately cease to operate the crane if safety-rele-
vant or unclear faults occur.
If necessary, contact the crane manufacturer's cus-
tomer service department.
Have the fault remedied by suitably qualified special-
ist personnel (e.g. customer service). If personnel
who are not qualified try to rectify faults, it can cause
serious injury to people and / or damage to objects.
Different symbols appear, depending on the fault status:

There are new (not yet acknowledged) faults or faults no longer exist
or both at the same time. The symbol flashes.
There are old, already "acknowledged" Error messages.
To identify the fault in the currently displayed screen, actuate the "Er-
ror display" button to call up the "Error messages" screen (see
8.1.7.21 "Fault messages" screen, side 324 screen).
If there are faults which cannot be rectified before crane operation is
continued, observe the section "What to do for safety-relevant faults
whose cause cannot be directly remedied" (see 8.1.17.3 What to do
for safety-relevant faults whose cause cannot be directly remedied,
side 349).
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8.1.17.3 What to do for safety-relevant faults whose cause cannot be directly rem-
edied
Depending on which faults exist the load can still be set down using
the hoist.
The main boom can be telescoped in by means of actuation of the
corresponding control lever in the telescoping-in device (dependent
on the control lever function configuration).
If no crane movements can be actuated, the crane must be controlled
or emergency lowered using the electrical emergency control system
(see the section "Emergency actuation" under "Electric emergency
actuation"). If this is not possible either, the crane and/or the load
must be emergency lowered using an auxiliary crane. In this event,
please contact our customer service department! The faults must be
rectified before crane operation can be continued.
DANGER
Risk of accidents! Death or serious injury may result
if work continues with the crane, after safety-relevant
faults occur or faults whose effect on the crane or its
operation are not clear.
Immediately cease to operate the crane if safety-rele-
vant or unclear faults occur.
If necessary, contact the crane manufacturer's cus-
tomer service department.
Have the fault rectified by suitably qualified specialist
personnel (e.g. customer service). If personnel who
are not qualified try to rectify faults, it can cause seri-
ous injury to people and / or damage to objects!
8.1.17.4 Failure of the Screen – Display Screen Is Black

The function of the load limit device is ensured.
What is to be done?
1. Set down the load.
2. Have the service department search for the fault and rectify it.
DANGER
Risk of accidents! No crane operation is permissible
when the display fails!
Rectify the fault before crane operation may be re-
sumed.
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8.1.17.5 Connection Problems – Crane Control's Control Panel to Crane Control
Fig. 257: Display of connection problems
If there is no connection between crane control's control panel and

the other components of crane control, this message appears: "Keine
Verbindung zur Steuerung! ("No connection to control!). Ohne Verbin-
dung fortfahren zur Diagnose." (Continue without connection to diag-
nosis".).
In this case, contact the crane manufacturer's service department.
8.1.17.6 Total Failure of Crane Control

If crane control has failed, but the engine and the hydraulic system
are intact, the load can be set down with the optional electrical emer-
gency control (see the section emergency control system) and the
crane can be placed in a safe configuration.
DANGER
Danger! There is no monitoring by the limit switches
during emergency operation with the "Electrical
emergency control". The load limit device and oper-
ating range limits are also inoperative.
tions on the electrical emergency control system (see
the section "Emergency actuation"). The faults must
be rectified before crane operation can be continued.
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8.2 Care, maintenance, repairs and disposal
NOTE
Risk of damage due to mechanical influences.
The screen must be protected from mechanical damage.
Only touch the screen with clean fingers or alternatively using
clean soft gloves with the version with the plastic screen.
Protect the screen from contamination.
Do not touch the screen with sharp/pointed or hard objects such
as ballpoint pens, screwdrivers, knives/blades, etc.
Do not apply unnecessary high pressure on the screen to oper-
ate it.
Nothing may fall against or press against the screen (e.g. man-
uals or files, screwdrivers in pockets, etc.).
Do not stick anything on the monitor. Do not stick any stickers -
or anything similar - on the screen.
NOTE
Risk of damage when cleaning the screen with the incorrect
cleaning agents.
The screen can be destroyed or discoloured.
Use mild soap suds, for example, as a cleaner.
Use a clean, non-abrasive cloth for cleaning.
Put the cleaning agent on the cloth and not directly on the sur-
face of the screen.
Do not use any harsh / abrasive cleaning agents (such as e.g.
any cleaning agents containing ammonia / sulphur or scouring
agents).
The operating unit of crane control is maintenance-free.

The unit may only be repaired by the manufacturer.
Disposal must be in accordance with the national environmental regu-
lations.
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8.3 Release switch system for crane movements
8.3.1 General
ments from the designated operating position.
This is to prevent (among other things) accidental crane movements
being initiated when entering and exiting the crane operator's cab.
The operating position is monitored by a corresponding release
switch system.
The crane operator may only assume the designated operating posi-
tion if the corresponding control lever is in the "Neutral position" and
may only leave it once the initiated crane movement has been com-
pleted.
The left-hand armrest can be folded away to make it easier to enter
and exit. Crane movements are only possible if the left-hand armrest
is folded down.
8.3.2 Assignment of the Release Buttons
Fig. 258: Assignment of the release buttons (schematic diagram)
There are release buttons at the following points:

- in both control levers
- Seat contact button in the crane operator's seat
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8.3.3 Activating the Release Buttons

The buttons may only be pressed or released and you may only sit on
or get up from the crane operator's seat if the control levers are in the
"Neutral position" and/or the initiated working movement has been
completed. The release buttons can be activated alternately during a
crane movement.
WARNING
Risk of accidents! It can cause the crane movement
to be initiated abruptly if the release buttons are ac-
tuated while the control lever is steered. It can cause
the crane movement to be stopped abruptly if a re-
lease button is released while the control lever is
steered without another release button simultane-
ously actuated.
Only initiate a crane movement when the release
switch has been activated.
When a crane movement is being executed, only let
go of one release button if another one has been acti-
vated.
Only let go of the release buttons, or get up from the
crane operator's seat, if the working movement has
been completed.
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8.4 Speed
8.4.1 Fine tuning of the movement speed
First press one of the rocker switches (see arrows) briefly to fine tune
the speed of different movements with the screen "Crane operation"
selected. Instead of the "Quick Menu" screen, the "Percent setting"
screen appears for 5 seconds.
Fig. 260: Movement speed in percent
As long as the "Percentage setting" screen is displayed, a displayed

percentage value, and therefore the speed, can be changed as fol-
lows:
- Select the crane movement to be changed using the rocker switch

(see arrow) in the left-hand control lever. The crane movement val-
ue that can be changed has a yellow background.
- Change the speed by percent using the rocker switch (see arrow)
in the right-hand control lever. The value is reduced or increased
depending on whether the self-return rocker switch is pressed to
the left or right. The minimum value that can be set is 20%.
If there is no adjustment to the percentage values, the "Percentage

setting" screen disappears again after 5 seconds.
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Fig. 261: Movement speed in percent
The speeds of the following movements can be set:

Turning the superstructure
Reeling in and unreeling hoist 1
Luffing the main boom up and down
Reeling in and unreeling hoist 2 (optional)
WARNING
There is a risk of accidents if crane movements are
carried out in an inappropriately quick manner.
Ensure an appropriate speed of movement.
8.4.2 High speed

The luffing gear and the hoists are electrically pilot-controlled. The
speed of the controlled movement depends on the engine speed and
the steering of the corresponding control lever.
A high speed mode can be activated to raise the main boom (luffing
up) and to reel in and unreel the hoist. To do so, press the corre-
sponding pushbutton in the control levers. The "Percentage setting"
screen appears on the right-hand side of the IC-1 display for 5 sec-
onds. The high speed mode remains activated until the corresponding
pushbutton is pressed again.
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8 Safety Equipment
Assignment of the push buttons
1 Activate high speed mode for 2 Activate high speed mode for
hoist 2 (optional) hoist 1
3 Activate high speed mode for
luffing gear
The high-speed mode cannot be activated for the movements "Luff-

ing gear down", "Slewing the superstructure" and "Telescoping the
main boom".
Fig. 263: Movement speed in percent for high speed mode
If the high speed mode is activated for one of the movements listed,
the "Percentage settings" screen is shown for 5 seconds. The depic-
ted arrow symbol is displayed there for each activated high speed
mode. In addition, the depicted arrow symbol is displayed during the
entire activation time in the "Crane operation" screen.
CAUTION
Risk of accidents!
Performance of crane movements in high speed
mode if only permitted if the load utilisation situation
allows it. Please observe the relevant instructions in
the section in which the crane movement is descri-
bed.
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WARNING
Switching to high speed mode is not permitted in the
following cases:
when working with loads > 30% of the capacity
with a fly jib fitted
to raise the fully or partially extended main boom
DANGER
Risk of overturning due to dynamics!
It is only permitted to activate the luffing gear in high
speed mode during main boom operation without
loads well before shutdown by the load limit device
(at latest up to the advanced warning).
8.5 Limit switches
8.5.1 Hoist Limit Switches
8.5.1.1 Function
Hoist limit switches are safety devices that limit the upwards move-
ment of hoist ropes and hook blocks. This prevents collisions be-
tween the hook block and boom head and therefore possible damage
to these parts and/or to the hoist rope, which could cause the load to
be dropped.
For this reason, the crane may only be operated with fully functional
hoist limit switches that have not been triggered.
DANGER
Risk of accidents!
Activate the hoist limit switch daily and check that it
functions properly!
If a hoist limit switch is triggered (and not bridged), the warning "HES"
(HLS) appears in red in the "Crane operation" screen. The warning
buzzer goes off.
In addition, the warning light could light up red depending on the

country.
The following crane movements are shut down:
- raise hoists
- Extend telescopic sections
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8 Safety Equipment
- Lower luffing gear and raise luffing gear.

Then either lower the hoist or retract to end this prohibited condition.
8.5.1.2 Bridging the Hoist Limit Switches

The hoist limit switches may only be bridged in exceptional cases
(e.g. fitting hoist ropes). Crane control does not monitor the lift height
when the hoist limit switch is bridged.
Bridging may only be initiated if the control levers are in the neutral
position and/or the initiated working movement has been completed.
There is a risk of damage to the crane components if a load is

raised with the hoist limit switch bridged. Crane operation with the
limit switches bridged is prohibited.
As described, when the hoist limit switches are triggered and not
bridged, the letters "HLS" appear in red in the "Crane operation"
screen.
The depicted key-operated push button is used to override the hoist

limit switches "Raise hoists".
DANGER
There is a risk of overturning and breakage when
working with safety equipment which has been put
out of function.
mechanically!
If the key-operated pushbutton is actuated (hoist limit switch bridged),

"HLS" is displayed in black.
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There is a differentiation between the "EN 13000" design ( 8.5.1.3

"EN 13000" Version, side 359) and the "Non-EN 13000" design
8.5.1.4 "Non-EN 13000" Design, side 359) in the description below.
screen ( 8.1.7.3 Calling up the "System setup (user)" screen,
side 264) at crane control. In this case, a corresponding note can be
found there.
8.5.1.3 "EN 13000" Version

The following must be observed when bridging the hoist limit switch in
the "EN 13000" design:
- The hoist limit switch can only be bridged if the hoist limit switch
has been started up.
- The speed of the hoist movement "Raise hoists" is reduced to
15 %.
- If the hoist limit switch is relieved in the following crane operation,
the overriding of the hoist limit switch is cancelled.
- If the hoist limit switch is triggered again, the displayed key-operat-

ed pushbutton must first be turned back to the standby position to
bridge again. Then the hoist limit switch can be bridged again as
described above.
- For configuration movements with the main boom in a horizontal
position or tilted downwards, the hoist limit switch can be perma-
nently bridged without switching the key switch back to the standby
position.
8.5.1.4 "Non-EN 13000" Design

It is always possible to bridge the hoist limit switches in the "Non-EN
13000" design, independent of whether they have been started or
not.
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8 Safety Equipment
8.5.2 Lower Limit Switches
8.5.2.1 Function
Lower limit switches are safety devices that switch off unreeling of the
hoist rope once it has been unreeled with 3 turns remaining on the
drum. This prevents the rope being wound back on in the opposite di-
rection.
There is one lower limit switch for hoist gear 1 (LLS1) and one for
hoist gear 2 (LLS2).
If a lower limit switch is triggered, "LLS2" or "LLS2" appears in red in
the "Crane operation" screen. The warning buzzer goes off. "Lower
hoist" is switched off. Only "raise hoist" is possible.
8.5.2.2 Malfunction
If the hoist rope is wound back in the opposite direction, for example,
due to operator error or a malfunction, this may result in damage to
the hoist rope at the tensioning point on the hoist. The hoist rope will
then have to be removed completely and the end of the rope exam-
ined for rope breakage at the tensioning point.
DANGER
Risk of accident when working with a damaged hoist
rope.
If the hoist rope is wound back in the opposite direc-
tion, it must be examined for damage in the tension-
ing area.
8.5.2.3 Bridging the Lower Limit Switches
DANGER
There is a risk of accidents in case of crane opera-
tion with the limit switches bridged.
Crane operation with the limit switches bridged is pro-
hibited.
The lower limit switches may only be bridged in ex-
ceptional situations, e.g. when configuring the crane
(fitting or changing equipment parts, fitting ropes,
etc.).
In this exceptional case, please consult our customer
service department.
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8.6 Electric Safety Chain
8.6.1 Wind speed indicator (anemometer) and hazard light (optional)

The crane is either supplied with a wind speed indicator (anemome-
ter) on its own or optionally with a wind speed indicator (anemometer)
and hazard light on a mutual bracket.
Using the wind speed indicator
DANGER
If the crane is operated at prohibited high wind
speeds, it will be at risk of overturning!
If an anemometer rotor is not fitted to the top section
of the main boom / boom system, adherence to the
permitted wind speeds cannot be monitored in the
display of crane control.
In this case, adherence to the permitted wind speed
must be monitored in a different manner (e.g. external
wind speed indicator at the height of the top section
of the main boom / boom system).
Using the hazard light

The hazard light can always be used if there is a risk of collision with
other obstacles in the air. For example, this can be the case when the
slewing ranges of several cranes overlap. For this reason, the hazard
light can be fitted at the highest designated point of the boom system
at night and also by day if there are bad visual conditions. National
regulations are valid for designating aviation obstacles.
Equipment (e.g. main boom extension) on the main boom head
If equipment (e. g. main boom extension) is fitted on the main boom
head, the wind speed indicator and hazard light (optional) incl. the
corresponding bracket must be dismantled. Then the wind speed indi-
cator and hazard light (optional) are fitted on the respective top sec-
tion of the boom system, depending on the case of operation. The rel-
evant section in these operating instructions indicates at which point
the wind speed indicator and hazard light (optional) are fitted. See the
corresponding section in this section or in the section "Main boom ex-
tension" for assembling / dismantling the wind speed indicator, haz-
ard light (optional) incl. the corresponding bracket on the head of the
main boom.
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8 Safety Equipment
8.6.1.1 Operation with the wind speed indicator and hazard light (optional) on the ad-
justable bracket
Fig. 264: Wind speed indicator on adjustable bracket
1 Hazard light (optional) 2 Wind speed indicator

3 Holding plate 4 Wing nut
Assembly
Fit wind speed indicator (2) and hazard light (1, option) on the main
boom head (if not already fitted). To do so, fasten bracket (3) on the
left-hand side of the main boom head using the two wing nuts (4) and
connect it electrically as described under" Connecting the distribution
box on the main boom head".
The cable must be laid so that it is not clamped or pinched and can-
not get stuck on obstacles during telescoping, for example.
Dismantling
For dismantling, loosen wing nuts (4) and then, after removing brack-
et (3), screw them back onto the threaded bolt firmly.
Transport position
The wind speed indicator with hazard light (optional) must be placed
in the transport position for driving on public roads, so that the exter-
nal dimensions of the crane listed in the official vehicle documents
are not exceeded.
The figure on the left shows the transport position of the wind speed
indicator with hazard light (optional) on the head of the main boom.
Moving the wind speed indicator / hazard light (optional) from

the transport into the operating position
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Fig. 265: Adjusting the wind speed indicator
1 Stay bar 2 Locking bolts

3 Holding plate 4 Grip
5 Forelock 6 Guide and adjustment plate
1. Hold stay bar (1) at grip (4) and remove forelock (5) (see "A" in
the figure above).
2. Push up the stay bar (1) in the guide of the guide and adjustment
plate (6) until the bore in the rod (1) is flush with the bore in the
guide (see "A" in figure above).
3. Pin the forelock (5) again and lock it (see "B" in figure above).
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8 Safety Equipment
Fig. 266: Adjusting the wind speed indicator
1 Guide and adjustment plate 2 Locking bolts

3 Holding plate X1 Pinning, transport position
X2 Pinning, non-angled main boom X3 Pinning, angled main boom ex-
extension tension
4. Set the required angle by means of the locking bolt (2) attached
to the guide and adjustment plate (1). To do so, pull the locking
bolt (2) and let it engage in one of the holes of the holding plate
(3) marked with "X".
Position Function
X1 Transport position
X2 - Operation with main boom
- Operation with the main boom extension not angled
X3 Operation with the main boom extension at an angle
The figure on the left shows the operating position of the wind speed
indicator with hazard light (optional).
Proceed in the opposite sequence to move the wind speed indica-

tor / hazard light (optional) from the operating into the transport posi-
tion.
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8 Safety Equipment
8.6.2 Connecting the Distribution Box on the Main Boom Head
Fig. 267: Distribution box on the main boom head
A Socket - anemometer rotor A1 Bridging plug

C Socket - CANBUS C1 CANBUS terminating plug
Assign the sockets as follows for main boom operation:
X550
Socket Assignment
A Plug of the anemometer rotor and of the optional hazard
light
alternative:
Bridging plug (A1)
C CANBUS terminating plug (C1)
Plug each plug into the corresponding socket and turn the union nut
clockwise until it locks in place.
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8 Safety Equipment
8.6.3 Using the hoist limit switch
8.6.3.1 Operating principle
Fig. 268: Overview of the hoist limit switch (schematic diagram)
1 Hoist Limit Switches 2 Shift weight

3 Hoist rope 4 Hook block
Hoist limit switch (1) prevents the reeved hook block (4) from colliding
with the head of the main boom or of the fly jib. Shift weight (2) is fas-
tened to hoist limit switch (1). Hoist rope (3) is fed through shift weight
(2). If the hook block is pulled up too high, shift weight (2) - and there-
fore the electric switch fitted in hoist limit switch (1) - is relieved of
load. Crane control locks movement functions.
WARNING
It can result in death or serious injuries if the hook
block collides with the head of the main boom during
hoist operation.
Due to the anticipated damage, parts of wreckage can
fall down.
Before hoist operation, place the hoist limit switch in
the functional state (see 8.6.3.3.2 Placing the hoist
limit switch in the functional state, side 368).
Before hoist operation, check that the hoist rope has
been fed through the shift weight and that the shift
weight is hanging freely while this is done. This
means that the electric switch fitted in the hoist limit
switch is pulled.
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8 Safety Equipment
8.6.3.2 Where are hoist limit switches located

There is a hoist limit switch fitted on the head of the main boom. If the
crane is delivered with a fly jib (e.g. assembly jib), an additional hoist
limit switch is delivered as well. It is used on the respective fly jib.
Generally no hook block is reeved on the main boom during hoist op-
eration with one fly jib. This means that the hoist limit switch shift
weight of the main boom head can swing around freely. To prevent
risks of injury and damage relating to this, this shift weight must either
be removed or placed in the park position.
Handling the shift weight is described 8.6.3.4 Shift weight of the
hoist limit switch, side 370.
8.6.3.3 Hoist Limit Switches
8.6.3.3.1 Structure of the hoist limit switch
Fig. 269: Component parts of the hoist limit switch
1 Housing of the hoist limit switch 2 Restrainer

with electric switch
3 Jumper wire
Fig. 269, side 367 shows the hoist limit switch in the functional
state.
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8 Safety Equipment
8.6.3.3.2 Placing the hoist limit switch in the functional state
1. Pull the jumper wire downward.
2. Pull away the pulled jumper wire to the side.
3. Pull off the restrainer.
4. Let the restrainer hang.
The hoist limit switch is now in the functional state.
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8 Safety Equipment
Fig. 270: Restrainer in the park position
Depending on the design, the restrainer can be pegged in the park

position onto the housing of the electric switch.
8.6.3.3.3 Bridging the hoist limit switch (putting it out of operation)
1. Pull away the jumper wire to the side.
2. Fit the restrainer on the housing of the hoist limit switch.
3. Feed the pulled jumper wire through the longitudinal groove of

the restrainer and place it in the vertical position.
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8 Safety Equipment
4. Let go of the jumper wire.
The jumper wire is tensioned at the restrainer where it bulges

out. This bridges the hoist limit switch, i.e. it is put out of func-
tion.
8.6.3.4 Shift weight of the hoist limit switch

Function position
As described under 8.6.3.1 Operating principle, side 366, the shift
weight of the hoist limit switch is fitted on the hoist rope with the hoist
rope reeved (see also the section "Reeving" under "Reeving / unreev-
ing the hoist rope").
Transport condition
If the hoist limit switch weight is not fitted on the hoist rope, it must be
placed in the park position or be removed. The hoist limit switch
weight is shown in the park position in Fig. 271, side 371 (schemat-
ic diagram).
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8 Safety Equipment
Fig. 271: Hoist limit switch weight (schematic diagram)
1 Locking spring 2 Hoist limit switch weight
Hoist limit switch weight (2) is slid over the corresponding bearing pin
and secured against falling out by a locking spring (1). To do so, the
hoist limit switch weight (2) must be rotated so that locking spring (1)
can be inserted through the two eyelets of the hoist limit switch weight
halves.
The hoist limit switch weight of the main boom must be placed in the
park position during fly jib operation and/or possibly when driving the
crane.
CAUTION
Risk of injury due to freely swinging hoist limit
switch weight!
Place the hoist limit switch weight in the park position
when it is not being used.
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9 Working Instructions
9.1 Operation Planning / Monitoring Safety Measures
9.1.1 General Information on Operational Planning / Monitoring Safety Measures

Detailed operational planning must be carried out before starting
work, i.e. before a load is picked up.
Only experienced and competent personnel may carry out planning
and operation.
For every crane operation that is planned, the crane operator / opera-
tion planner must place ready a suitable crane with sufficient lifting
capacity, hoist height and working radius.
The load weight must be known. The crane must not be taken for a
device to determine the load weight.
Section "Safety instructions" in particular provides additional instruc-
tions for planning crane operation.
When planning any crane set-up/assembly, the ambient conditions
(for example, the meteorological data, including weather forecasts,
important ambient conditions) must be taken into consideration during
all phases,i.e. assembly, operation, parking and dismantling. See also
9.1.3 Ambient Conditions, side 377).
A mobile crane may only be operated as long as the maximum per-
missible wind speeds (3-second wind gusts) indicated in the capacity
tables are not exceeded. If wind speeds increase, the crane must be
placed in a safe position by either setting down the boom (the boom
system) or by transferring it to a park position.
The park position indicated by the manufacturer has been optimised
so that the machine can withstand high wind speeds. It is possible
that the crane moves into positions which expose it more to the ef-
fects of the wind when the boom / boom system is being set down, or
moved into the park position; therefore, the boom / boom system
must be set down or placed in the park position in good time so that
the permissible wind speed is not exceeded during this procedure.
See the detailed information under "Permissible maximum wind
speed values when assembling / erecting the boom system, crane
operation, crane out of operation ("Parking")".
Delays in hoist operation must be anticipated particularly when raising
loads which are susceptible to wind or which are wind-critical. If these
possible delays are not sufficiently taken into consideration during
planning, there is a danger that avoidable risks of accident are accep-
ted due to the pressure of meeting deadlines.
The crane must be assembled in a state which is suitable for the sub-
sequent load case and for which there is a capacity table for the sym-
metric support base. See also 9.1.2 Crane Capacity and Capacity
Tables, side 376.
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With a symmetric support base, all supports are in the same assem-
bly state described in the chassis section "Support base".
DANGER
Risk of overturning due to too heavy counterweight
combination attached!
There is a risk of overturning to the rear if a counter-
weight combination is fitted by accident which is too
heavy for the support base.
In this case, the superstructure may not be slewed.
For cranes with optional slewing angle dependent capacities, all sup-
ports must be in an assembly state as described in section "Outrig-
gers" of the corresponding operating instructions. However, not all
supports have to be in the same assembly state.
If a counterweight combination that is too heavy is fitted for the sup-
port state, it might not be possible to turn the superstructure, because
the crane control is blocking the slewing movement.
DANGER
If the superstructure is still slewed by bypassing the
crane control, there is a risk of overturning!
In this case, the superstructure may not be slewed.
Wind speed, shape and size of the load have a substantial effect on
the stability and loading of mobile cranes. This must be taken into
consideration during operational planning. For example, if the wind
speed is doubled, this causes the wind force to be increased 4-fold.
The wind speed increases with height. The shape of the load affects
wind resistance. Section "Wind on the crane and on the load" de-
scribes what must be taken into consideration during operational
planning concerning the wind and its effects.
Driving and safety information on the wind conditions which is indica-
ted in the capacity tables and in the operating instructions must be
read carefully and must be observed to prevent accidents.
A suitable software (Cranimation) can be used to plan operation. This
software must only be operated by trained personnel.
The capacities listed in the capacity tables can only be raised if all
specifications in "Notes on crane operation"- supplied with the capaci-
ty tables - are complied with. This includes among other things:
- The crane is on horizontal, level ground (±0.5%)
- The ground must have sufficient bearing capacity for the resulting
ground pressures.
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DANGER
Two-hook operation is not secured by the load limit de-
vice and can lead to overloading and overturning of the
crane.
It is prohibited to raise a load on the main boom and
on the fly jib simultaneously.
It is prohibited to raise a load on the main boom with
the main boom extension fitted in the operating posi-
tion (loaded or unloaded).
The possible capacities are reduced when raising a load on the main
boom with the main boom extension fitted in the transport position.
The corresponding crane configuration must be set in crane control.
The weight of the hook blocks and lifting tackle must be subtracted
from the values in the capacity tables.
NOTE
With regard to "Hook block weights" and "Minimum loads", ob-
serve the "Instructions on operating the crane", which are sup-
plied with the capacity tables.
When picking up loads from great heights or winding onto the top
rope layers of a winch with high cable pull, the rope that is being
reeled in/out can cut into the rope in the rope layers beneath, damag-
ing the rope. See 9.1.6 Picking up Loads from a Great Height or
Winding onto the Top Rope Layers of the Winches, side 382).
For repair work during which particularly wind-critical loads are to be
raised, for example,replacing rotor blades or replacing an entire rotor
in a wind turbine, a smaller crane might be used than the one used to
set up the entire system for the first time. During the initial assembly,
the size of the cranewas set to the weight of the heavy nacelle, for ex-
ample, for a wind turbine. In this case, there is a risk that the crane
used for maintenance purposes reaches the limits of its nominal ca-
pacity during the raising procedure and is overloaded due to the addi-
tional wind load, which was not taken into consideration during plan-
ning.
The configured crane without load may only remain without the super-
vision of a trained crane operator if certain conditions are met (see
"Permissible maximum wind speed values for assembling / erecting
the boom system, crane operation, crane out of operation ("Park-
ing")") and the operating instructions, section "Parking").
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Within the construction site, mobile cranes can be driven in the con-
figured condition from one operational site to another operational site.
In this case, depending on the configuration, the crane is driven with
the counterweight and if fitted, with fly jib, with the main boom gener-
ally telescoped in. The vehicle's centre of gravity is then higher than
when driving the mobile crane in the transport condition. There can
be axle loads of up to 27 t (59.5 kip). Lateral inclination causes the
crane's centre of gravity to move away from the centre line of the
crane. This leads to the tyres on one axle side, and therefore the
ground underneath, to be subjected to an increased load. Even a
crane tyre which is loaded normally, with an axle load of 12 t
(26.4 kip), with a nominal tyre pressure of 10 bar (145 psi), has a lo-
calized load under the tyres of 100 t/m2 (142 psi). Special require-
ments for capacity and gradient are therefore placed on the driving
routes. Specifications on the ground conditions and gradient of the
road surface are in the description for "Driving in the configured con-
dition".
The driving routes must be designed so that they can safely support
the crane in its specific configuration. If driving routes are to be re-
built, the person responsible for their construction must be informed
concerning the planned axles loads, which far exceed the standard
driving condition.
Driving in the configured condition is described in "Driving in the con-
figured condition".
9.1.2 Crane Capacity and Capacity Tables

The capacity of a mobile crane in a certain configuration is restricted
by different influencing factors (e. g. structural component strength,
stability of the crane as a whole). The permitted capacity to take up a
load in relation to the configuration is registered as a combination of
the permitted load with the corresponding radius. This combination of
load/radius is monitored by the load monitoring assembly of the crane
(load limit device LLD). A detailed description of the load monitoring
assembly can be found in section "Safety equipment".
For symmetric support bases, the capacities programmed in the load
limit device are supplied with the crane in the form of extensive tables
"on paper" or on a CD-ROM. An example of such a "capacity table" is
shown in section "Safety equipment" in the section "Capacity table on
paper or CD-ROM".
Crane control automatically calculates values even for differing boom
positions. This is called interpolation of intermediate values.
The permitted capacity values from the capacity tables are only valid
up to a certain wind speed (see 9.2.4.2 Wind Specifications in the
Capacity Tables, side 388). Observe the specifications on the wind
speeds in the "Notes on crane operation" which can be found in the
capacity table set supplied with the crane.
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It might be necessary to reduce the capacity or wind speed permitted

for a configuration (according to crane control or the capacity table) if
the assumptions concerning the wind used for the calculation are ex-
ceeded (see 9.2.4 Determining the Permitted Wind Speed for
Crane Operation, side 387). The crane operator is responsible for
this task-specific evaluation.
DANGER
Risk of accidents!
Planning and carrying out a hoist procedure with loads
which exceed the permitted capacities, including e. g.
foreseeable wind effects, as well as bridging the overload
cut-off device of the crane, can cause accidents resulting
in injuries or even death.
Observe the notes on 9.1.1 General Information on
Operational Planning / Monitoring Safety Measures,
side 373.
9.1.3 Ambient Conditions

- The ground must have sufficient load-bearing capacity to take the
maximum occurring support pressures. If necessary, increase the
support area by stacking suitable materials under the support
plates.
Specifications on the maximum occurring support pressures, for cal-

culation of the required support surfaces and for safety distances to
slopes and ditches can be found in the "Outriggers" section of the
corresponding operating instructions.
- No live power lines in the operating area of the crane.

- No obstacles which hinder the necessary crane movements. Main-
tain sufficient safety clearances in order to prevent the risk of
crushing (e. g. on the counterweight).
- Location selected so that the crane operation can be carried out
with as small a working radius as possible.
- In case of bad visibility or darkness, the immediate area in front of
the crane operator’s cab, including the load, the outriggers and the
winches, must be illuminated. If the work lights on the machine are
insufficient for the specific assembly state, the area (load, load
path, slewing range, driving route, etc.) must be illuminated, inde-
pendent of the crane. The responsibility for this lies with the crane
operator.
- Consult the relevant weather station concerning the expected wind
forces and weather conditions for the time period during which the
crane is to be used. The effect of wind on operational planning is
described in this section in the segment "Wind forces on the crane
and on the load".
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- Lateral deformation of telescopic booms through solar radiation:

Because of continuous one-sided solar radiation, temperature dif-
ferences arise between the left and right sides of the boom. This
results in a difference between the lengths of the right and left
sides. The result is a lateral deformation of the unloaded boom
which is clearly visible.
Example:
- Assumed temperature difference: 30 °C / +86 °F)
- Boom length: 60 m /197 ft
- Boom width 0.6 m / 2 ft
In this case, the anticipated lateral deformation is approx. 1 m /
3.3 ft.
When utilising the maximum capacities, a visual inspection is re-
quired to ensure that there is no lateral deformation when unloa-
ded.
DANGER
Risk of accidents due to overloading components.
Turn the crane to ensure that both boom sides have
approximately the same temperature.
- If the crane is to be driven in the configured condition, the ground

must be level and have sufficient load-bearing capacity. To do so,
see the description on "Driving in the configured condition".
9.1.4 State of the Crane during Crane Operation

- Crane supported on outriggers correctly and horizontally aligned.
- With symmetric support base, all four support struts are extended
to the support base area specified in the respective capacity table.
- For cranes with slewing angle-dependent capacities, all four sup-
port struts are placed in an extension state as described in the
section "Outriggers".
- all four outrigger struts locked with pins to prevent them from shift-
ing.
- all four vertical support cylinders are extended so that all axles are
relieved of loads i.e. no tyres are in contact with the ground. Raise
the axles additionally if the adjustment length of the vertical sup-
port cylinders is not sufficient.
- support plates locked.
- Crane control/LLD set in accordance with the crane assembly
state.
- Engine sufficiently supplied with fuel and AdBlue for the duration of
crane operation (engine with exhaust gas aftertreatment system).
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In operating conditions during which the crane operator is not in the

driver's cab or the crane operator’s cab (e. g. crane operation with
radio remote control), the corresponding display cannot be read off
during operation.
9.1.5 Crane Operation
DANGER
Risk of accidents!
Before starting the engine or initiating crane move-
ments, the crane operator must sound the horn every
time to warn persons who are in the vicinity of the
crane.
The crane may only be put into operation if the driver's cab (crane
chassis) is closed (except when driving the crane from the driver's
cab).
Four crane movements can be carried out simultaneously and inde-
pendently of one other.
Electrical connections / electrical safety chain
In order to create the electric connections correctly during main boom
operation (closing the safety chain), refer to the "Safety equipment"
section at "Electric safety chain".
The procedures for operating the crane with additional equipment

are contained in the individual sections (e.g. main boom extension).
DANGER
Risk of accidents if used incorrectly.
The forbidden procedures listed below are expressly
prohibited.
The load must be raised/lowered so that it does not place heavy dy-
namic demands on the crane. For this reason, remember in particu-
lar:
- DO NOT let loads fall suddenly
- DO NOT raise loads quickly
- DO NOT cancel/stop crane movements abruptly.
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Load sensing / automotive driving

The engine speed is automatically adapted with regard to the per-
formance requirements of the hydraulic system during "automotive
driving". This ensures comfortable operation as the engine speed
does not have to be controlled by the crane operator and the crane
can still be in an efficient operating state at any time (energy con-
sumption). If the control levers are not operated, the engine will run at
idle speed. The speed will increase depending on the load. (see the
section "Engine").
Before raising a load, the individual parameters of the corresponding
configuration must be entered in the operating mode pre-selection
screen of crane control of the superstructure.
Some capacity tables require a permitted minimum radius which must
be adhered to. If the permitted minimum radius is not reached, the
corresponding crane movements are switched off.
DANGER
Risk of falling backward if the minimum radius is not
reached!
This minimum radius must not be undercut!
There is one capacity table that only allows operation of the crane
with the superstructure in the 0° position, that is, the superstructure to
the rear. In this case:
- Slew the superstructure to a position of 0° +/- 2°
- Select the operating mode "HA-0".
DANGER
Risk of overturning due to incorrectly set crane con-
trol.
Set crane control in accordance with the crane as-
sembly state.
If the main boom is extended to its final operating length and pinned,
the Locking and Pinning Unit must be fully retracted.
The designation number for the length code then has a green back-
ground in the telescoping display.
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Fig. 272: Main boom
1 Hook block 2 Luffing cylinder
NOTE
Risk of damage due to swinging movements of the hook block!
If the main boom is in the high position and is telescoped in
fully, the crane movements must be carried out with the appro-
priate care and at low speeds. In particular you avoid swinging
movements of the hook block (1) this way, that could cause col-
lisions with the luffing cylinder (2).
When the load is being carried, keep it as close to the ground as pos-
sible.
Avoid excessive operating speeds which could cause the load to
swing. Large loads must be guided from the ground with ropes.
Operate the slewing gear and slewing brake with care. Select a low
slewing speed! Brake carefully. This applies especially to operation
with the main boom extension or fly jib or special site conditions.
DANGER
Risk of crushing due to load swinging out.
Despite using automatic safety devices, swinging of the
load cannot always be prevented when shutting down.
Carry out all crane movements at adapted accelera-
tion / speed.
82640 2021-04-22 381

DANGER
Risk of accidents if ambient conditions change!
It must always be possible to respond at all times if a
load is attached.
Do not switch off the drive of the crane.
Do not leave the crane operator’s cab.
An exception is only permitted in emergencies. To prevent dangerous

situations, the drive source (diesel engine) can be switched off using
the quick stop switch in the crane operator's cab as a last resort. First
– where possible – movements that have been started should be
completed using the control levers.
ments from the designated operating position. The operating position
is monitored by a corresponding release switch system.
DANGER
Risk of accidents due to crane movements starting
or braking abruptly.
The crane operator may only assume the operating
position if the control levers are in the "Neutral posi-
tion".
The crane operator may only exit the operating posi-
tion if initiated working movements have been com-
pleted.
9.1.6 Picking up Loads from a Great Height or Winding onto the Top Rope Layers of
the Winches
When picking up loads from great heights or winding onto the top
rope layers of a winch with high cable pull, the rope that is being
reeled in/out can cut into the rope in the rope layers beneath, damag-
ing the rope.
Possible causes:
- the rope has been reeled onto the winch with too little preliminary
tension,
- the rope assembly has become loose due to winch use,
- due to contraction and wear, rope has reached or exceeded the
lower rope diameter tolerance.
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Possible remedy:
- If the rope diameter is still within the permitted tolerance, a safe
method is to wind up the rope in a controlled and neat manner with
a preliminary tension of 10% of the nominal cable pull (or 2% of
the minimum breaking force according to the crane log book) per
fall. The reeving must be selected so that the entire rope can be
unreeled with the main boom completely extended. A correspond-
ing additional weight is attached to the hook block for winding up.
The rope may not be reeled in high speed mode.
- Another option is to reduce the cable pull. To do so, the hook block
must be reeved with as high a number of falls as possible.
- A rope with a diameter which falls short of the diameter tolerance
must be replaced.
9.2 Wind on the Crane and on the Load
9.2.1 Planning / carrying out a crane operation (with regard to wind)

Responsibility of the crane operator
The wind represents a high potential for risks during crane operation.
The wind acts on the crane and the load.
The crane operator is responsible for ensuring that the crane is not
subjected to any prohibited high wind speeds. In case of doubt, the
crane operator decides whether the wind conditions are still within the
permitted limits or whether crane operation must be stopped.
Comparison of the permitted wind speed with the anticipated
wind speed
Crane operation includes assembly, crane operation and dismantling
of the crane.
For loads which have a low mass in relation to their surface area ex-
posed to wind (AW) (for example, rotor blades or rotor component as-
semblies), the actual permitted wind speeds are often much lower
than the maximum permitted wind speeds according to the crane ca-
pacity tables.
But even for more compact loads, a reduction in the actual permitted
wind speed might be required.
For this reason, a comparison of the permitted wind speed (see
9.2.4 Determining the Permitted Wind Speed for Crane Operation,
side 387) for the specific load lifting operation with the wind
speed to be anticipated during crane operation at the highest
point of the boom must be carried out before every crane opera-
tion (see 9.2.4.4 Determining the wind speed anticipated from the
weather forecast at the highest point of the boom, side 403) must be
carried out.
If the wind speed anticipated at the highest point of the boom ex-
ceeds the permitted wind speed during the crane operation, the lift
may not be carried out.
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DANGER
Risk of breaking or overturning when working with
wind speeds which are too high!
Only raise the load if it is ensured that the permitted
wind speed is not exceeded during the entire crane
operation.
For this reason, delays must be anticipated in hoist operation. The

risk of such delays must be included in the planning.
Dynamic pressure in relation to the wind speed

For information purposes, there are tables in the section 9.2.4.4.6
Dynamic Pressure in Relation to Height above Ground Level,
side 411, which indicate the so-called "quasi-static" dynamic pres-
sure in relation to the wind speed according to the Beaufort scale and
height above ground level. This can be used to evaluate how the dy-
namic pressure, and therefore the forces working on the load and the
boom system, change in relation to height.
Planning to set down the crane in an emergency
DANGER
Risk of overturning if there is strong wind!
At the work site, make sure that there is sufficient
space in the vicinity of the crane so that the main
boom can be telescoped in and any additional equip-
ment can be lowered to the ground if a (strong) wind
suddenly occurs.
If it is not possible to lower the boom system onto the
ground due to local conditions, a suitable and safe
procedure for placing the boom system in a safe state
must be planned in case there is (strong) wind.
Further information on this can be found in the operating instructions

in the section "Parking".
Carrying out a crane operation
The weather conditions must be observed during crane operation.
To check the wind speed, the crane is equipped with a wind meter
(anemometer). See 9.2.6 Measuring the Wind Speed, side 415.
"Permitted maximum wind speed values for assembling / erecting the
boom system, crane operation, crane out of operation ("Parking")" de-
scribes the performance when exposed to wind before, during and af-
ter crane operation.
384 82640 2021-04-22

9.2.2 Terms / Definitions
The arrows in the following diagram represent the wind.
Fig. 273: Representation of "wind"
m - Hoist load in t (kip)

Ap - Projection surface in m2 (ft2)
cw - Drag coefficient (wind resistance coefficient)
A table with typical body shapes and the corresponding wind
resistance coefficients (cw) can be found in the 9.2.4.3.3
Table with Typical Body Shapes and Corresponding Wind
Resistance Coefficients, side 402).
Aw - Surface area exposed to wind in m2 (ft2)
= product of projection surface (AP) and wind resistance co-
efficient (cw)
AW = AP * cw
vperm. - max. wind speed permitted for crane operation of a 3-sec-
ond wind gust at the highest point of the boom system in m/s
or mph. (see 9.2.4 Determining the Permitted Wind Speed
for Crane Operation, side 387)
vT - max. wind speed according to the capacity table in m/s
(mph)
va - possible decreased wind speed calculated for crane opera-
tion in m/s (mph), taking mass (m), projection surface (AP)
and wind resistance coefficient (cw) into account (see
9.2.4.3.1 Calculation of the Permitted Wind Speed, side 396
or 9.2.4.3.2 Wind Speed Reduction Diagram, side 399)
vz - anticipated wind speed vz determined from weather forecast
at the highest point of the boom system (see 9.2.4.4 De-
termining the wind speed anticipated from the weather fore-
cast at the highest point of the boom, side 403)
9.2.3 Wind Effects on the Crane and the Load

The wind speed and direction, as well as the shape and size of the
load, have a great effect on the stability and loading of cranes.
82640 2021-04-22 385

If the wind speed is doubled, the wind load is increased 4-fold. The
wind speed increases with increasing height above ground level. The
shape of the load influences the wind resistance and therefore the
wind load acting on the crane (see 9.2.4 Determining the Permitted
Wind Speed for Crane Operation, side 387).
If not otherwise indicated, the support force specifications made avail-
able are calculated without taking into account the effect of wind
forces and deformation.
When the wind acts on the load, the load can swing out in the direc-
tion of the wind. This means that the force of the load no longer acts
vertically downward on the boom. Depending on the wind speed, load
surface area exposed to wind and wind direction, the radius of the
load can increase or prohibited lateral forces can act on the crane
boom.
If the load created by swinging out approaches the range of the

maximum permitted load for the respective configuration, the load
limit device (LLD) could be switched on and off constantly.
The wind can hit the crane and the load from the front, the back and
the side. All 3 directions must be taken into consideration for the
crane and the load and they influence the crane in different ways:
- Wind from the front: Wind from the front does not decrease the
load of the hook, the hoist rope, the rope sheaves or the hoist
winch, as the load continues to act with its force of gravity. If wind
is coming from the front, the boom system is relieved of load, as
the wind acts on the surface area of the boom exposed to wind,
thereby reducing the dead weight of the boom. The load display
value of the load limit device (LLD) is below the actual hoist load.
The corresponding shutdown limit of the load limit device (LLD) is
at a larger radius than indicated in the capacity table. This means
that the crane is overloaded at the shutdown point.
DANGER
Risk of accidents due to wind loads from the front!
When raising the load, remember that the load on the
crane is actually higher than indicated in the load dis-
play.
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- Side wind: Side winds acting on the crane boom and the load are
particularly critical for the crane. The additional load due to side
wind is not detected or displayed by the load limit device (LLD).
The load display is similar to the display for operations without
wind. This can lead to the crane being overloaded with regard to
its steadiness and stability.
DANGER
Risk of accidents due to side winds.
When raising the load, remember that the load on the
crane is actually higher than indicated in the load dis-
play.
- Tailwind: The boom system is loaded additionally in case of tail-

wind. The load display of the overload cut-off device is higher than
the actual payload. The overload cut-off of the load limit device
(LLD) is triggered for a load that is smaller than the maximum per-
mitted load listed in the capacity table.
A hoist operation (particularly when raising loads with large surface
areas exposed to wind) must never be planned so that it is just at the
capacity tolerance limits.
If the load is swung during a hoist operation, all wind directions dis-
cussed can influence the load state even if the wind direction is un-
changed. Improvements in quality and technology concerning the
best available technology of cranes, a crane operator with several
years professional experience and qualifications regarding the effects
of the wind, as well as professional operational planning carried out
well in advance all contribute towards greatly reducing the risk of ac-
cidents.
9.2.4 Determining the Permitted Wind Speed for Crane Operation
9.2.4.1 General
Shape and condition of the load and the lifting height have an effect
on the crane. In this regard, and for the resulting risks, see the sec-
tion 9.2.3 Wind Effects on the Crane and the Load, side 385).
The capacity tables are only valid up to a maximum wind speed (see
9.2.4.2 Wind Specifications in the Capacity Tables, side 388). If the
relation between the load and the surface area exposed to wind is
disadvantageous, this maximum wind speed must be decreased.
The following values must be known or found out before hoist opera-
tion:
- the weight of the load (m)
- The maximum projection surface (AP) of the load (e. g. of the ro-
tor / rotor component groups; see below)
- the drag coefficient (cw)
82640 2021-04-22 387

- the predicted wind speed (vz) at the highest point of the boom sys-
tem (3-second wind gust speed)
Fig. 274: Projection surface
The maximum projection surface (AP) is calculated as shown in the

figure.
In the figure above ( Fig. 274, side 388), the same load is attached
in two ways. the arrows in the figure represent the wind.
In the left-hand half of the figure, the load is attached to create a pro-
jection surface which is as small as possible. In the right-hand half of
the figure, the same load is attached in a way that creates a larger
projection surface.
Section 9.2.4.3 Simplified Procedure for Determining the Permitted
Wind Speed for Crane Operation, side 390 provides a simplified cal-
culation procedure for calculating the permitted wind speed for crane
operation.
9.2.4.2 Wind Specifications in the Capacity Tables

Capacity tables are only valid up to a certain wind speed vT (for ex-
ample 9.8 m/s; 21.9 mph) (see the specifications in the notes on
crane operation or in the capacity tables).
When calculating the capacity values, a projection surface (Ap) of the
raised load of 1.0 m2/t (4.88 ft2/kip) with a drag coefficient of the
raised load of cW = 1.2 is assumed as standard (for the terms, see
9.2.2 Terms / Definitions, side 385).
Often, the wind and wind gusts are underestimated during hoist oper-
ation with cranes. When raising loads with a large surface area ex-
posed to the wind, such as for example, rotor blades or entire rotor
units of wind turbines, the actual conditions can deviate greatly from
the assumptions of the wind loads calculation.
In fact, rotor blades or rotor component groups generally have a
much larger projection surface than 1 m2/ t (4.88 ft2/kip). This is often
higher by a factor of 5 to 10. The typical coefficient cW of a complete
rotor component group is frequently equal to 1.5 to 1.8 and not equal
to the value 1.2 as assumed in the capacity calculation.
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For this reason, the maximum wind speeds of the capacity table when
raising rotor blades, rotor component groups or other constructions
with large surface areas exposed to wind are often invalid. The per-
mitted wind speeds when raising these components must be lower
than when raising tower sections, a nacelle or other heavy elements.
In relation to the EN 13000 version, the wind speed listed in the ca-
pacity tables is the so-called "3-second wind gust", measured at the
highest point of the boom system. It is not the median wind speed,
measured at a height of 10 m (33 ft) over a time period of 10 minutes,
as specified by most weather stations.
The wind speed of a "3-second wind gust" can be double and even
more, i. e. taking into consideration the median wind speed at a
height of 10 m (33 ft) can mean that the actual conditions are greatly
underestimated.
82640 2021-04-22 389

9.2.4.3 Simplified Procedure for Determining the Permitted Wind Speed for Crane
Operation
Fig. 275: Calculation procedure
390 82640 2021-04-22

A simplified calculation procedure for calculating the permitted wind

speed is introduced in this section. The procedure for determining the
permitted wind speed is shown in the figure "Calculation procedure".
This calculation procedure covers all individual cases and must there-
fore be considered conservative. Precise calculations can result in
higher permitted wind speeds. The crane manufacturer can provide
precise calculations.
Caption (for the flow chart)
m - Hoist load in t (kip)

Ap - Projection surface in m2 (ft2)
cw - Drag coefficient (wind resistance coefficient)
A table with typical body shapes and the corresponding wind
resistance coefficients (cw) can be found in the 9.2.4.3.3
Table with Typical Body Shapes and Corresponding Wind
Resistance Coefficients, side 402).
vperm. - max. wind speed of a 3-second wind gust permitted for
crane operation at the highest point of the boom system in
m/s or mph. The permitted wind speed may not be higher
than the maximum wind speed according to the capacity ta-
ble (vT) in m/s (mph).
vT - max. wind speed according to the capacity table in m/s
(mph)
va - possible decreased wind speed calculated for crane opera-
tion in m/s (mph), taking mass (m), projection surface (AP)
and wind resistance coefficient (cw) into account (see
9.2.4.3.1 Calculation of the Permitted Wind Speed, side 396
or 9.2.4.3.2 Wind Speed Reduction Diagram, side 399)
x - factor depending on the units of measurement used. See be-
low, "Explanations concerning the second branch / decision
element".
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392 82640 2021-04-22

Explanations concerning the second branch / decision element

In the flow chart ( Fig. 276, side 392), the mass (m) is set in relation
to the projection surface (AP) in the second branch / decision ele-
ment.
The factor "x" listed in the formula refers to the relation between the
maximum drag coefficient 2.4 and the standard drag coefficient 1.2,
which is used for the load assumption.
Depending on the units of measurement with which the calculation is

carried out, factor "x" must be selected in the table below:
Calculation in Factor "x"

t and m2 2
kip and ft2 0.41

Table 3: Calculation table
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394 82640 2021-04-22

Permitted wind speed vperm

The permitted wind speed (vperm) for crane operation is the minimum
of the maximum wind speed from the capacity table (vT) and the wind
speed (va) determined for crane operation and possibly decreased,
taking into consideration mass (m), projection surface (AP) and wind
resistance coefficient (cw).
The possibly decreased wind speed (va) determined for crane opera-
tion, can be calculated mathematically (see 9.2.4.3.1 Calculation of
the Permitted Wind Speed, side 396) or using a so-called "Wind
speed reduction diagram” (see 9.2.4.3.2 Wind Speed Reduction Di-
agram, side 399).
The calculated permitted wind speed (vperm.) for crane operation is
not programmed in the crane control / load limit device (LLD). There
is no warning when the calculated permitted wind speed (vperm.) is
exceeded.
DANGER
Risk of tilting and breaking!
There is a risk of overturning and breaking when loads
are raised with prohibited high wind speeds.
The crane operator must monitor compliance with the
maximum permitted wind speed in the operating pan-
el of crane control.
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If the permitted wind speed (vperm.) is reached or exceeded, the load

must be set down on the ground as quickly as possible.
As it is often very difficult or even impossible to set a load which is
already suspended back on the ground, it is extremely important that
the wind conditions are known beforehand for the entire duration of
the hoist procedure. This is possible by obtaining a detailed weather
forecast. The duration of the crane operation includes the hoist proce-
dure and configuration and deconfiguration.
The crane must be slewed by 360° before hoist operation while un-
loaded so that it is possible to evaluate the actual wind conditions at
the construction site. While this is done, the current wind speed dis-
play must be monitored at the top section of the boom system in the
operating panel display of crane control. As the anemometer could be
in the wind shadow of the load (e. g. wind turbine) or of the crane
structure, the maximum wind speed could change when the crane is
slewed.
DANGER
There is a risk of overturning when raising loads
when wind speeds are too high.
Before starting the lifting procedure, check the wind
conditions by slewing the superstructure by 360° and
simultaneously monitoring the anemometer.
9.2.4.3.1 Calculation of the Permitted Wind Speed

The permitted wind speed (vperm.) for crane operation is the minimum
of the wind speed from the capacity table (vT) and the possibly de-
creased wind speed determined for the hoist operation (va).
Fig. 278: Calculation of the permitted wind speed in m/s
The reduced wind speed (va) is calculated from the mass (m), projec-
tion surface (AP) and wind resistance coefficient (cw). Remember that
the calculation formula listed below is a numerical equation. In numer-
ical equations, the values must be indicated in a certain unit of meas-
urement for the result to be correct.
396 82640 2021-04-22

- metric: in m/s with mass (m) in metric tonnes (t) and projection sur-
face (AP) in square metres (m2)
Fig. 279: lowered wind speed in m/s
- imperial: in mph with mass (m) in kip and projection surface (AP) in
ft2
Fig. 280: lowered wind speed in mph
Example 1
A load with a weight m of 85 t (187.4 kip) has a cw-value of 1.2 and a
projection surface AP of 50 m2 (538 ft2). In this example, a maximum
wind speed (vT) of 9.8 m/s (21.9 mph) is permitted according to the
capacity table. Calculation of possibly reduced wind speed (va):
Calculation of possibly reduced wind speed (va):
- in m/s:
Fig. 281: Example 1: lowered wind speed in m/s
- in mph:
Fig. 282: Example 1: lowered wind speed in mph
Calculation of the permitted wind speed (vperm):

- in m/s:
Fig. 283: Example 1: Calculation of the permitted wind speed in m/s
- in mph:
Fig. 284: Example 1: Calculation of the permitted wind speed in mph
82640 2021-04-22 397

Result:
The permitted wind speed (vperm.) for this load case remains 9.8 m/s
(21.9 mph) as indicated in the capacity table.
Example 2
A load with a weight of 50 t (110.2 kip) has a cw-value of 1.3 and a
projection surface of 77 m2 (829 ft2). In this example, a maximum
wind speed (vT) of 9.8 m/s (21.9 mph) is permitted according to the
capacity table.
Calculation of possibly reduced wind speed (va):
- in m/s:
Fig. 285: Example 2: lowered wind speed in m/s
- in mph:
Fig. 286: Example 2: lowered wind speed in mph
Calculation of the permitted wind speed (vperm):

- in m/s:
Fig. 287: Example 2: Calculation of the permitted wind speed in m/s
- in mph:
Fig. 288: Example 2: Calculation of the permitted wind speed in mph
Result:
The permitted wind speed (vperm.) for this load case, compared with
the value (vT) of 9.8 m/s (21.9 mph) indicated in the capacity table,
must be reduced to approx. 7.6 m/s (17 mph).
398 82640 2021-04-22

9.2.4.3.2 Wind Speed Reduction Diagram
Fig. 289: Wind Speed Reduction Diagram
The wind speed reduction diagram shows by how much the permitted
wind speed (vperm.) must be reduced depending on the relation of
surface area exposed to wind (AW) to hoist load (m). If projection sur-
face (AP) is multiplied with wind resistance coefficient (cw), the result
is the surface area exposed to wind (AW).
There are wind speed reduction diagrams for every maximum wind
speed (vT) listed in the capacity tables / notes on crane operation.
In this section, the wind speed reduction diagram is shown for the
wind speed (vT) of 9.8 m/s (21.9 mph) as an example and is also il-
lustrated with examples.
This, and if required, wind speed reduction diagrams for other maxi-
mum wind speeds (vT) can be found and are described with the ca-
pacity tables in the "Notes on crane operation".
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Example 1
Fig. 290: Diagram example 1
The dotted lines in the wind speed reduction diagram show exam-
ple 1.

projection surface of 50 m2 (538 ft2). With a drag coefficient cw of 1.2
and a projection surface of 50 m2 (538 ft2), the surface area exposed
to wind is 60 m2 (646 ft2) (AW1). In this example, a maximum wind
speed (vT) of 9.8 m/s (21.9 mph) is permitted according to the capaci-
ty table. Therefore, the wind speed reduction diagram must be used
with the value 9.8 m/s (21.9 mph). Now, a vertical line must be drawn
upwards to the value of the surface area exposed to wind AW1 of
60 m2 (646 ft2) in the wind force diagram 9.8 m/s (21.9 mph). A hori-
zontal line must be drawn to the right to the hoist load of 85 t
(187.4 kip). The two lines intersect in front of the gradient 9.8 m/s
(21.9 mph).
Result:
The permitted wind speed (vperm.) for this load case remains 9.8 m/s
(21.9 mph) as indicated in the capacity table.
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Example 2
Fig. 291: Diagram example 2
The continuous lines in the wind speed reduction diagram show ex-
ample 2.

projection surface of 77 m2 (829 ft2). With a drag coefficient cw of 1.3
and a projection surface of 77 m2 (829 ft2), the surface area exposed
to wind is 77 m2 x 1.3 = 100 m2 (829 ft2 x 1.3 = 1076 ft2) (AW2). In
this example, a maximum wind speed (vT) of 9.8 m/s (21.9 mph) is
permitted according to the capacity table. Therefore, the wind force
diagram must be used with the value 9.8 m/s (21.9 mph). Now, a ver-
tical line must be drawn upwards to the value of the surface area ex-
posed to wind AW2 of 100 m2 (1076 ft2) in the wind force diagram
9.8 m/s (21.9 mph). A horizontal line must be drawn to the right to the
hoist load of 50 t (110.2 kip). The two lines intersect between the gra-
dient 8 m/s (17.9 mph) and the gradient 7 m/s (15.7 mph).
Result:
The permitted wind speed (vperm.) for this load case must be reduced
to approx. 7.6 m/s (17 mph), compared with the value (vT) of 9.8 m/s
(21.9 mph) indicated in the capacity table.
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9.2.4.3.3 Table with Typical Body Shapes and Corresponding Wind Resistance Coef-
ficients
Body shape Resistance coefficient CW Comments
1,1 to 2,0
0,3 to 0,4
0,6 to 1,0
0,8 to 1,2
0,2 to 0,3
0,05 to 0,1 Rotor blades
about 1,6 Rotor blades
Table 4: Typical body shapes and resistance coefficients
402 82640 2021-04-22

9.2.4.4 Determining the wind speed anticipated from the weather forecast at the
highest point of the boom
9.2.4.4.1 General / Procedure

An important part of operational planning is obtaining information from
the weather station responsible concerning the wind conditions to be
anticipated throughout the duration of the operation.
You must remember that, for example, wind speeds of squalls with
heavy showers and thunderstorms can exceed the predicted maxi-
mum wind speeds.
In practise, wind values from weather stations are usually median
wind speed values within a time period of 10 minutes at a height of
10 m (33 ft). See 9.2.4.4.2 "Beaufort Scale", side 404.
The speed of wind gusts (gusts of wind) is higher than the median
wind speed which is measured over a time period of 10 minutes. The
so-called "3-second wind gust speed" is important for the effect on
the crane. See 9.2.4.4.3 Wind Gusts, side 405.
In addition, the contours of the landscape and the properties of the
surface of the ground affect the wind speed. The properties of the
surface of the ground can be divided into roughness classes 0 to 4.
The wind values of the weather station are specified for roughness
class 2 (agricultural land with some houses and high hedgerows,
within a distance of min. 500 m (1640 ft)). This means that if the sur-
face at the operational site belongs to a lower roughness class, the
wind speed is higher than the value predicted by the weather station.
See 9.2.4.4.4 Term "Surface Roughness", side 406.
To determine the wind speed vz relevant for crane operation at the
height of the top section of the boom system, the tables in 9.2.4.4.5
Determining the Anticipated Wind Speed in Relation to Height above
Ground Level, side 407 are used.
82640 2021-04-22 403

9.2.4.4.2 "Beaufort Scale"

Generally, wind speeds are classified using the so-called "Beaufort
scale" in "bft.". This is a scale of 0 to 12 in accordance with phenom-
enological criteria (by observing natural phenomena). The wind
strengths can be determined with the help of typical visual effects and
nature observations on and of the landscape. In practise, the Beaufort
force refers to the median value within a time period of 10 minutes at
a height of 10 m (33.0 ft). Beaufort values are within the range of 0
(wind calm) to 12 (hurricane).
Wind speed (average value over 10

Wind strength
min)
Effects of the wind
Beaufort
Description m/s(mph) km/h(mph)
scale
0 - 0,2 1 Wind calm, smoke rises verti-
0 Calm
(0-0.45) (0.62) cally
Wind motion only visible in
0,3 - 1,5 1-5
1 Light air smoke, but no wind vane
(0.67-3.4) (0.62-3.1)
movement
Wind felt on exposed skin,
1,6 - 3,3 6 - 11
2 Light breeze leaves rustle, wind vane
(3.6-7.4) (3.7-6.8)
movement
Gentle 3,4 - 5,4 12 - 19 Leaves and smaller twigs in
3
breeze (7.6-12.1) (7.5-11.8) motion, light flags extended
Dust and loose paper raised,
Moderate 5,5 - 7,9 20 - 28
4 twigs and small branches in
breeze (12.3-17.7) (12.4-17.4)
motion
Small trees begin to sway,
Fresh 8,0 - 10,7 29 - 38
5 white horses are formed on
breeze (17.9-23.9) (18.0-23.6)
the sea
Table 5: Beaufort scale
Continued on the next page
404 82640 2021-04-22

Wind speed (average value over 10

Wind strength
min)
Effects of the wind
Beaufort Descrip-
m/s(mph) km/h(mph)
scale tion
Large branches in motion,
Strong 10,8 - 13,8 39 - 49 whistling heard in overhead
6
breeze (24.2-30.9) (24.2-30.4) lines, umbrella use becomes
difficult
Whole trees in motion, effort
13,9 - 17,1 50 - 61
7 Near gale needed to walk against the
(31.1-38.3) (31.1-37.9)
wind
Twigs broken from trees, pro-
17,2 - 20,7 62 - 74
8 Gale gress on foot outside is serious-
(38.5-46.3) (38.5-46.0)
ly impeded
Some damage to buildings
20,8 - 24,4 75 - 88
9 Strong gale (smoke hoods and roof tiles are
(46.5-54.6) (46.6-54.7)
torn off)
24,5 - 28,4 89 - 102 Trees are uprooted, extensive
10 Storm
(54.8-63.5) (55.3-63.4) damage to buildings
Violent 28,5 - 32,6 103 - 117 Widespread damage (very sel-
11
storm (63.8-72.9) (64.0-72.7) dom inland)
32,7 (73.1) 118 (73.3) Considerable and widespread
12 Hurricane
and more and more damage
Table 6: Beaufort scale
9.2.4.4.3 Wind Gusts

A strong gust of wind which is active within a wind or storm system is
known as a 'wind gust'. Often, people listening to the weather forecast
are surprised to hear of wind speeds of e. g. 33 km/h (20.5 mph), as
they estimate the wind to be much stronger. In actual fact, wind gusts
are gusts which are much stronger and are independent of the me-
dian wind speed. This means that a wind gust can reach 60 km/h
(37.3 mph) or more, while the median values are much lower (e. g.
33 km/h / 20.5 mph).
The speed of a wind gust is the median value of the wind speed
which is measured for the duration of 3 seconds. The speed of the
wind gust is higher than the median wind speed which is measured
over a time period of 10 minutes. Furthermore, the direction of the
wind can change by up to approx. 30 degrees during a wind gust,
which can cause additional undesired side effects.
Particularly dangerous are local wind gusts that can occur in connec-
tion with heavy rainfall and storms, for example.
82640 2021-04-22 405

9.2.4.4.4 Term "Surface Roughness"

The wind is no longer affected by the surface properties of the ground
high above the ground level, at a height of approx. 1 km (3280 ft).
The wind speeds in the lower air layers are reduced by the friction re-
sistance of the ground. A distinction is made between the ground
roughness, the effect of obstacles and the influence of contours in the
landscape, which is also known as "orography" of the terrain. These
roughness classes are between 0 (water surface) and 4 (cities with
very high buildings).
Fig. 292: Effect of the roughness of the ground
The figure above shows the effect of the roughness class of the
ground on the wind speed. The wind speed (X) is the same in all 3
depictions.
Figure ("a") symbolically depicts the city centre, figure ("b") shows the
city outskirts and figure ("c") represents the conditions in open
spaces. The roughness class becomes lower from the city centre to
the city outskirts to open spaces. The respective curve shows the
speed profile of the wind. Above each curve, the wind flows unaffec-
ted by the ground properties.
It can be seen that the zone where the wind flows unaffected by the
ground properties starts at a lower height in the case of a lower level
of ground roughness.
406 82640 2021-04-22

Technicians often refer to roughness classes in the wind industry

when wind conditions of a landscape are to be evaluated. Normally,
the more pronounced the roughness of the ground, the more the wind
is slowed down.
A few examples for roughness classes are listed below:
Roughness
Description
class
0 Water surface
0,5 Open terrain, smooth surface, e. g. runways
Agricultural area, no fences, no hedgerows, scattered
1
houses
Agricultural area with some houses and high hedge-
1,5
rows, within a distance of min. 1.25 km (4100 ft)
2
rows, within a distance of min. 500 m (1640 ft)
2,5
rows, within a distance of min. 250 m (820 ft)
Agricultural area with many trees, high hedgerows and
3
buildings, uneven terrain, villages, small cities
3,5 Large cities with tall buildings
4 Cities with very tall buildings
Table 7: Roughness classes
The values of the weather station and the calculations of the wind
speed are based on roughness class 2. If the roughness classes are
lower at the operation site, you must remember that the wind speed
is higher than the values given by the weather station.
9.2.4.4.5 Determining the Anticipated Wind Speed in Relation to Height above

Ground Level
The tables "Wind speeds in relation to height above ground" descri-
bed below are used to calculate the anticipated wind speed at the
highest point of the boom system:
- Wind speed in m/s: see 9.2.4.4.5.1 Table "Wind Speed in Rela-
tion to Height above Ground Level" in m/s, side 407.
- Wind speed in mph: see 9.2.4.4.5.2 Table "Wind Speed in Rela-
tion to Height above Ground Level" in mph, side 409.
9.2.4.4.5.1 Table "Wind Speed in Relation to Height above Ground Level" in m/s
The table shows the relation between the 3-second wind gust speed
v(z), depending on the median wind speed ⊽ according to the Beau-
fort scale, and the height z.
82640 2021-04-22 407

Beaufort degree 3 4 5 6 7 8 9 10
⊽ [m/s] 5,4b 7,9b 10.1a1 10,7b 13,8b 14.3a2 17,1b 20,7b 24,4b 28,4b
z [m] v(z) [m/s]
10 7,6 11,1 14,1 15,0 19,3 20,0 23,9 29,0 34,2 39,8
20 8,1 11,9 15,2 16,1 20,7 21,5 25,7 31,1 36,6 42,7
30 8,5 12,4 15,8 16,8 21,6 22,4 26,8 32,4 38,2 44,5
40 8,7 12,8 16.3 17,3 22,3 23,1 27,6 33,4 39,4 45,8
50 8,9 13,1 16,7 17,7 22,8 23,6 28,3 34,2 40,3 46,9
60 9,1 13.3 17,0 18,0 23,3 24,1 28,8 34,9 41,1 47,9
70 9,3 13,5 17,3 18,3 23,6 24,5 29,3 35,5 41,8 48,7
80 9,4 13,7 17,6 18,6 24,0 24,8 29,7 36,0 42,4 49,4
90 9,5 13,9 17,8 18,8 24,3 25,1 30,1 36,4 42,9 50,0
100 9,6 14,1 18,0 19,1 24,6 25,4 30,4 36,9 43,4 50,6
110 9,7 14,2 18,2 19,2 24,8 25,7 30,8 37,2 43,9 51,1
120 9,8 14.3 18,3 19,4 25,1 25,9 31,1 37,6 44,3 51,6
130 9,9 14,5 18,5 19,6 25,3 26,2 31,3 37,9 44,7 52,0
140 10,0 14,6 18,7 19,8 25,5 26,4 31,6 38,2 45,1 52,5
150 10,0 14,7 18,8 19,9 25,7 26,6 31,8 38,5 45,4 52,9
160 10,1 14,8 18,9 20,1 25,9 26,8 32,1 38,8 45,7 53,2
170 10,2 14,9 19,1 20,2 26,0 27,0 32,3 39,1 46,0 53,6
180 10,3 15,0 19,2 20,3 26,2 27,1 32,5 39,3 46,3 53,9
190 10,3 15,1 19,3 20,4 26,4 27,3 32,7 39,5 46,6 54,2
200 10,4 15,2 19,4 20,6 26,5 27,4 32,8 39,8 46,9 54,6
a Wind levels for a crane in operation:

1 light ⊽ = 10.1 [m/s] => for z = 10 [m] => q (z) = 125 [N/m2]
2 normal ⊽ = 14.3 [m/s] => for z = 10 [m] => q (z) = 250 [N/m2]
b Top limit of the Beaufort level
Table 8: Relation between the 3-second wind gust speed and wind speed
⊽ [m/s]: wind speed, averaged over 10 min at a height of 10 m (top limit of the Beaufort level)
z [m]: Height over level ground
v(z) [m/s]: speed of a 3-second wind gust, effective at height z, decisive for calculation
q(z) [N/m2]: Quasi-static dynamic pressure, effective at height z, see 9.2.4.4.6 Dynamic Pressure
in Relation to Height above Ground Level, side 411 determined from v(z)
408 82640 2021-04-22

9.2.4.4.5.2 Table "Wind Speed in Relation to Height above Ground Level" in mph
The table shows the relation between the 3-second wind gust speed
v(z), depending on the median wind speed ⊽ according to the Beau-
fort scale, and the height z.
⊽ [mph] 12.1b 17.7b 22.6a1 23.9b 30.9b 32.0a2 38.3b 46.3b 54.6b 63.5b
z [ft] v (z) [mph]
33 17.0 24.8 31.5 33.6 43.2 44.7 53.5 64.9 76.5 89.0
66 18.1 26.6 34.0 36.0 46.3 48.1 57.5 69.6 81.9 95.5
98 19.0 27.7 35.3 37.6 48.3 50.1 59.9 72.5 85.5 99.5
131 19.5 28.6 36.5 38.7 49.9 51.7 61.7 74.7 88.1 102.5
164 19.9 29.3 37.4 39.6 51.0 52.8 63.3 76.5 90.1 104.9
197 20.4 29.8 38.0 40.3 52.1 53.9 64.4 78.1 91.9 107.1
230 20.8 30.2 38.7 40.9 52.8 54.8 65.5 79.4 93.5 108.9
262 21.0 30.6 39.4 41.6 53.7 55.5 66.4 80.5 94.8 110.5
295 21.3 31.1 39.8 42.1 54.4 56.1 67.3 81.4 96.0 111.8
328 21.5 31.5 40.3 42.7 55.0 56.8 68.0 82.5 97.1 113.2
361 21.7 31.8 40.7 42.9 55.5 57.5 68.9 83.2 98.2 114.3
394 21.9 32.0 40.9 43.4 56.1 57.9 69.6 84.1 99.1 115.4
427 22.1 32.4 41.4 43.8 56.6 58.6 70.0 84.8 100.0 116.3
459 22.4 32.7 41.8 44.3 57.0 59.1 70.7 85.5 100.9 117.4
492 22.4 32.9 42.1 44.5 57.5 59.5 71.1 86.1 101.6 118.3
525 22.6 33.1 42.3 45.0 57.9 59.9 71.8 86.8 102.2 119.0
558 22.8 33.3 42.7 45.2 58.2 60.4 72.3 87.5 102.9 119.9
591 23.0 33.6 42.9 45.4 58.6 60.6 72.7 87.9 103.6 120.6
623 23.0 33.8 43.2 45.6 59.1 61.1 73.1 88.4 104.2 121.2
656 23.3 34.0 43.4 46.1 59.3 61.3 73.4 89.0 104.9 122.1

1 light ⊽ = 22.6 [mph] => for z = 32.8 [ft] => q (z) = 2.61 [lbF/ft2]
2 normal ⊽ = 32.0 [mph] => for z = 32.8 [ft] => q (z) = 5.22 [lbF/ft2]
Table 9: Relation between the 3-second wind gust speed and wind speed
⊽ [mph]: wind speed, averaged over 10 min at a height of 32.8 m (top limit of the Beaufort level)
z [ft]: Height over level ground
82640 2021-04-22 409

v(z) [mph]: speed of a 3-second wind gust, effective at height z, decisive for calculation
q(z) [lbF/ft2]: Quasi-static dynamic pressure, effective at height z, see 9.2.4.4.6 Dynamic Pressure
in Relation to Height above Ground Level, side 411 determined from v(z)
9.2.4.4.5.3 Example
Fig. 293: Beaufort table
1 wind speed 2 Maximum lifting height

3 3-second wind gust speed
You receive (e. g. from the weather station) a wind speed value of
6.2 m/s (13.9 mph) at 10 m (33 ft) above the ground level, calculated
over 10 minutes. According to the Beaufort table (see 9.2.4.4.2
"Beaufort Scale", side 404) this corresponds to a wind speed (1) with
a Beaufort value of 4.
You have a maximum lifting height (2) of e. g. 50 m (164 ft). The 3-
second gust wind speed can now be read out using the table "Wind
speeds in relation to height above ground level" (see 9.2.4.4.5.1
Table "Wind Speed in Relation to Height above Ground Level" in m/s,
side 407 in m/s or 9.2.4.4.5.2 Table "Wind Speed in Relation to
Height above Ground Level" in mph, side 409 in mph).
According to the table, the 3-second wind gust speed (3; vz) is
13.1 m/s (29.3 mph) for a maximum lifting height (2) of 50 m (164 ft)
and a wind speed (1) with a Beaufort value of 4. As this exceeds the
maximum permitted wind gust speed (vT) of 9.8 m/s (21.9 mph) ac-
cording to the capacity table, the load lift may not be carried out.
410 82640 2021-04-22

9.2.4.4.6 Dynamic Pressure in Relation to Height above Ground Level

At this point, for information purposes, the so-called "quasi-static" dy-
namic pressure in relation to the wind speed according the Beaufort
scale and the height above ground level is printed. This can be used
to evaluate how the dynamic pressure, and therefore the forces work-
ing on the load and the boom system, change in relation to height.
9.2.4.4.6.1 Table "Dynamic Pressure in Relation to Height above Ground Level" in

m/s
⊽ [m/s] 5,4b 7,9b 10.1a1 10,7b 13,8b 14.3a2 17,1b 20,7b 24,4b 28,4b
z [m] q (z) [N/m2]
10 35,7 76,5 125,0 140,3 233,3 250,0 358,2 524,9 729,3 988,0
20 41,1 88,0 143,8 161,4 268,5 287,7 412,2 604,1 839,4 1137,1
30 44,7 95,7 156,4 175,5 292,0 312,9 448,3 657,0 912,8 1236,6
40 47,5 101,6 166,1 186,4 310,1 332,3 476,2 697,8 969,6 1313,5
50 49,8 106,5 174,2 195,5 325,1 348,4 499,2 731,5 1016,4 1376,9
60 51,8 110,8 181,0 203,2 338,0 362,2 519,0 760,5 1056,6 1431,4
70 53,5 114,5 187,1 210,0 349,3 374,3 536,4 786,0 1092,1 1479,5
80 55,0 117,8 192,6 216,1 359,5 385,2 552,0 808,9 1123,9 1522,6
90 56,5 120,8 197,5 221,7 368,8 395,1 566,2 829,7 1152,8 1561,8
100 57,8 123,6 202,1 226,8 377,3 404,3 579,3 848,9 1179,5 1597,9
110 59,0 126,2 206,3 231,6 385,2 412,7 591,4 866,7 1204,2 1631,3
120 60,1 128,6 210,3 236,0 392,6 420,6 602,8 883,3 1227,2 1662,6
130 61,2 130,9 214,0 240,2 399,5 428,1 613,4 898,8 1248,9 1691,9
140 62,2 133,1 217,5 244,1 406,0 435,1 623,4 913,6 1269,3 1719,6
150 63,1 135,1 220,8 247,8 412,2 441,7 632,9 927,5 1288,7 1745,9
160 64,0 137,0 224,0 251,4 418,1 448,0 642,0 940,8 1307,1 1770,8
170 64,9 138,9 227,0 254,8 423,7 454,1 650,6 953,4 1324,7 1794,7
180 65,7 140,6 229,9 258,0 429,1 459,8 658,9 965,5 1341,6 1817,5
190 66,5 142,3 232,6 261,1 434,3 465,4 666,8 977,2 1357,7 1839,3
200 67,3 144,0 235,3 264,1 439,3 470,7 674,5 988,3 1373,2 1860,4
82640 2021-04-22 411


1 light ⊽ = 10.1 [m/s] => for z = 10 [m] => q (z) = 125 [N/m2]
2 normal ⊽ = 14.3 [m/s] => for z = 10 [m] => q (z) = 250 [N/m2]
Table 10: Dynamic pressure in relation to height above ground in m/s
⊽ [m/s]: wind speed, averaged over 10 min at a height of 10 m (top limit of the Beaufort level)
z [m]: Height over level ground
v(z) [m/s]: speed of a 3-second wind gust, effective at height z, decisive for calculation
q(z) [N/m2]: Quasi-static dynamic pressure, effective at height z, calculated from v(z)
9.2.4.4.6.2 Table "Dynamic Pressure in Relation to Height above Ground Level" in

mph
⊽ [mph] 12.1b 17.7b 22.6a1 23.9b 30.9b 32.0a2 38.3b 46.3b 54.6b 63.5b
z [ft] q (z) [lbF/ft2]
33 0.75 1.60 2.61 2.93 4.87 5.22 7.48 10.96 15.23 20.63
66 0.86 1.84 3.00 3.37 5.61 6.01 8.61 12.62 17.53 23.75
98 0.93 2.00 3.27 3.67 6.10 6.54 9.36 13.72 19.06 25.83
131 0.99 2.12 3.47 3.89 6.48 6.94 9.95 14.57 20.25 27.43
164 1.04 2.22 3.64 4.08 6.79 7.28 10.43 15.28 21.23 28.76
197 1.08 2.31 3.78 4.24 7.06 7.56 10.84 15.88 22.07 29.90
230 1.12 2.39 3.91 4.39 7.30 7.82 11.20 16.42 22.81 30.90
262 1.15 2.46 4.02 4.51 7.51 8.05 11.53 16.89 23.47 31.80
295 1.18 2.52 4.12 4.63 7.70 8.25 11.83 17.33 24.08 32.62
328 1.21 2.58 4.22 4.74 7.88 8.44 12.10 17.73 24.63 33.37
361 1.23 2.64 4.31 4.84 8.05 8.62 12.35 18.10 25.15 34.07
394 1.26 2.69 4.39 4.93 8.20 8.78 12.59 18.45 25.63 34.72
427 1.28 2.73 4.47 5.02 8.34 8.94 12.81 18.77 26.08 35.34
459 1.30 2.78 4.54 5.10 8.48 9.09 13.02 19.08 26.51 35.91
492 1.32 2.82 4.61 5.18 8.61 9.23 13.22 19.37 26.92 36.46
525 1.34 2.86 4.68 5.25 8.73 9.36 13.41 19.65 27.30 36.98
558 1.36 2.90 4.74 5.32 8.85 9.48 13.59 19.91 27.67 37.48
591 1.37 2.94 4.80 5.39 8.96 9.60 13.76 20.16 28.02 37.96
412 82640 2021-04-22

623 1.39 2.97 4.86 5.45 9.07 9.72 13.93 20.41 28.36 38.41
656 1.41 3.01 4.91 5.52 9.17 9.83 14.09 20.64 28.68 38.86

1 light ⊽ = 22.6 [mph] => for z = 32.8 [ft] => q (z) = 2.61 [lbF/ft2]
2 normal ⊽ = 32.0 [mph] => for z = 32.8 [ft] => q (z) = 5.22 [lbF/ft2]
Table 11: Dynamic pressure in relation to height above ground in mph
⊽ [mph]: wind speed, averaged over 10 min at a height of 32.8 m (top limit of the Beaufort level)
z [ft]: Height over level ground
v(z) [mph]: speed of a 3-second wind gust, effective at height z, decisive for calculation
q(z) [lbF/ft2]: Quasi-static dynamic pressure, effective at height z, calculated from v(z)
9.2.5 Permitted Maximum Wind Speed Values

Assembling / dismantling / erecting the boom system
Wind speed, configuration of the crane and positioning of the boom /
boom system have an important effect on the stability of the crane
during assembly / dismantling.
For all crane configurations, the boom system may only be assem-
bled / dismantled or erected (raised off the ground) if the current and
anticipated wind speeds (weather forecast) are permitted for crane
operation as well.
82640 2021-04-22 413

Measures to be taken in accordance with the wind speed
DANGER
Risk of accidents due to failing to observe the wind
conditions to be anticipated!
It is part of operational planning to enquire at the re-
sponsible meteorological office about the wind condi-
tions to be expected for the duration of operations.
Adhere to the permitted wind speed for hoist opera-
tion (see 9.2.4 Determining the Permitted Wind
Speed for Crane Operation, side 387).
Observe the valid national regulations.
Operating sta-
Wind speed What you have to do....
tus
up to the permitted wind speed
for crane operation (see 9.2.4
Crane operation does not need to be restric-
Crane operation Determining the Permitted Wind
ted.
Speed for Crane Operation,
side 387)
Stop crane operation; place the main boom in
Crane out of op- above the permitted wind speed the high position and telescope in completely;
eration: for crane operation up to 15 m/s main boom extension can remain in operating
configured (54 km/h; 33.6 mph) position; if possible, set boom system into the
wind.
Telescope the main boom in and set it down in
Crane out of op-
above 15 m/s (54 km/h; the transport position
eration:
33.6 mph) When the fly jib is fitted: telescope the main
set down
boom in, set the fly jib down on the ground
Table 12: Procedure for wind speeds
In this regard, also observe the information in the "Instructions on

crane operation" which are with the capacity tables.
414 82640 2021-04-22

Setting down at the right time when the wind speed is too high
DANGER
Risk of accidents!
If wind speeds over 15 m/s (33.6 mph) are anticipa-
ted, place the boom system in the transport position
and/or set the fly jib on the ground in good time.
Crane without supervision
DANGER
Risk of accidents!
If the crane is to be left parked and unattended for a
longer period of time, e.g. overnight, the main boom
must be telescoped in and any additional equipment
which is fitted must be set down on the ground.
9.2.6 Measuring the Wind Speed

To check the wind speed, the crane is equipped with a wind meter
(anemometer).
DANGER
If an anemometer rotor is not fitted to the top section
of the main boom / boom system, adherence to the
permitted wind speeds cannot be monitored in the
display of crane control. If required, adherence to the
permitted wind speeds must be monitored in another
way (e. g., external wind measuring equipment at the
height of the top section of the main boom/boom sys-
tem).
82640 2021-04-22 415

The wind meter consists of two elements:
Fig. 294: Rotor
- The rotor (see arrow), which must be fitted on the head of the main
boom or the fly jib. Detailed information on fitting can be found:
- concerning the main boom head – in section "Safety equip-
ment" under "Safety chain"
- concerning the fly jib – in the corresponding sections.
NOTE
If the rotor (see arrow) is fitted on the main boom in the operat-
ing position, the transport dimensions listed in the official crane
documents are exceeded.
- the display on the IC-1 screen with the corresponding symbol.

The rotational movement of the rotor caused by the wind is conver-
ted into an electrical signal which is displayed on the IC-1 display
in the crane operator's cab. The crane operator can read off the
wind speed here in m/s (mph).
NOTE
Before commencing work or erecting the equipment it must be
ensured that the anemometer is fully functional. This is the case
if the displayed value changes when the rotor is rotated. If there
is no wind, this must be simulated by manual rotation of the ro-
tor.
416 82640 2021-04-22

9.3 Cameras on the crane (option)
9.3.1 Camera system by the Motec company (optional)
9.3.1.1 Components of the camera system
Fig. 295: Components of the camera system (schematic diagram)
1 Camera surveillance monitor 2 Operating panel - load hook camera

3 Camera, right side of superstructure 4 Camera hoist 1
5 Camera hoist 2 6 Hook camera on the pendulum bracket
7 Pendant light
Item Explanation
1 Camera surveillance monitor
See 9.3.1.2 Monitor, camera monitoring (optional), side 418
2 Operating panel - load hook camera
See 9.3.1.3 Hook camera, side 421.
3 Camera, right side of superstructure
For monitoring the area to the right of the superstructure during slewing, see the section
"Slewing the superstructure".
4 Camera hoist 1
For monitoring the hoist rope's reeling behaviour, see 12 Hoist 1, side 517.
5 Camera hoist 2
- For monitoring the reeling behaviour of the hoist rope, see the section "Hoist 2" under
"Camera monitoring of the hoist (optional)";
- With hoist 2 dismantled: For monitoring the area behind it when slewing the superstruc-
ture, see the section "Slewing the superstructure".
6 Hook camera on the pendulum bracket

For observation of the load on the hook and of the immediate vicinity, see part 9.3.1.3
Hook camera, side 421.
7 Pendant light
(See "Pendant light on the main boom head")
The camera system is switched on as soon as the ignition and the

monitor in the crane operator’s cab are ready for operation.
82640 2021-04-22 417

9.3.1.2 Monitor, camera monitoring (optional)
9.3.1.2.1 General
Fig. 296: Camera surveillance monitor
Preset priorities of the individual cameras
Priority Display on the Camera

screen
1 upper left Hoist 1
2 upper right Hoist 2 (optional)
3 lower left Hook camera
Camera, right side of super-
4 lower right
structure
If a camera is not available/in operation, the next figure moves up in

accordance with the set priorities.
418 82640 2021-04-22

9.3.1.2.2 Operating elements and display elements
Fig. 297: Operating elements and display elements (schematic diagram)
Symbol Explanations
Mode key
- The mode switch is used to switch between different display modes (single frame,
split screen, display split into thirds and quarters and timer mode).
Single picture mode

- This button can be used to switch between the connected cameras in single picture
mode. The split picture mode can be used to switched between the camera dis-
plays 1/2, 2/3, 3/4, 4/1, 1/3 and the camera displays 2/4. The key has a Play/Pause
function in timer mode. This button has no function when the picture is split into
thirds or quarters.
Call up and changeover of the menu to the sequence:

Brightness Brightness - 0(MIN) ... 60(MAX)
Contrast Contrast - 0(MIN) ... 60(MAX)
Colour Colour saturation - 0(MIN) ... 60(MAX)
standard Reset to factory settings
Language – English, French, German, Spanish, Portuguese, Italian,
Language
Polish
Mirroring The camera picture is mirrored. You return to the main menu via the "In-
put" menu point. The "Finish" menu point quits the menu.
Video PAL, NTSC, Auto
Poc, Not assigned
Timer OFF/ON – timer mode is activated
Camera selection which is shown in timer mode and setting of the dis-
Timer setup
play duration (OFF/ON 5-30 sec.)
Finish End the menu
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Fig. 298: Operating elements and display elements (schematic diagram)
Symbol Explanations
"Minus"
"Plus" selection list
Day/night switch over
Monitor on/off
Indicator lights
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9.3.1.3 Hook camera
9.3.1.3.1 General
Fig. 299: Load hook camera (schematic diagram)
1 Monitor 2 Control unit

3 Video receiver 4 Video transmitter
5 Hook camera 6 Pendant light
The hook camera provides the crane operator with a view from above
of the load and the immediate surroundings. The pendant light (6) de-
scribed in "Pendant light on the main boom head" can be used to illu-
minate the load area better.
The video signal of the load hook camera (5) that is suspended on
the main boom head is transmitted by cable to the video transmitter
(4); from here via radio signal to the video receiver (3); from here via
cable to the control unit (2) and then onto the monitor (1) in the crane
operator’s cab.
The operating panel is described in 9.3.1.3.5 Operating panel - load
hook camera, side 424.
9.3.1.3.2 Important Information / Warning Information

For operation of the hook camera
DANGER
Risk of accidents!
Before each use of the camera system, check the
system for visible defects and make sure it functions
properly. Monitor the system for defects during the
entire operation period.
The camera system may not be operated without
drop protection (safety chain)!
82640 2021-04-22 421

There can be malfunctions in the video image for technical reasons

in the case of short extension lengths of the main boom for which
the distance between the video transmitter and video receiver is less
than 10 m (33 ft).
For driving of the crane
DANGER
Risk to life and limb when the view is obstructed!
Death or serious injuries can result if the crane is driven
despite the view being obstructed.
Remove the hook camera for driving the crane.
The crane operator's visibility is impaired if the crane is driven with

the main boom set down and the load hook camera fitted on the main
boom head at the same time (see arrow, schematic diagram).
If the crane is driven with the main boom set down and the hook block
reeved at the same time, the hook block can collide with the hook
camera.
NOTE
Risk of damage to the hook camera due to collision!
Remove the load hook camera for driving.
9.3.1.3.3 Operation of the hook camera
Fig. 300: Hook camera

1 Monitor
2 Control unit
422 82640 2021-04-22

Once the ignition, the control unit (2) and the monitor (1) in the crane
operator’s cab are switched on, the load hook camera system be-
comes active. The hook (hook block) can be monitored in the monitor
(1) after making an appropriate selection.
9.3.1.3.4 Assembling/dismantling of the hook camera at the main boom head
Fig. 301: Load hook camera on the main boom head (schematic diagram)
1 Bracket 2 Pendulum bracket

3 Locking spring 4 Safety chain
5 Hook camera 6 Connection
7 Carabiner
Assembling of the hook camera at the main boom head

1. Insert the hook camera (5) with the shaft of the pendulum brack-
et (2) in the bracket (1).
2. Secure the load hook camera using locking spring (3) fastened to
safety chain (4).
NOTE
Risk of damage!
Locking spring (3) must be inserted from below to prevent a col-
lision with the bracket of the hanging light (if the hanging light is
fitted).
3. Attach the carabiner (7) of the safety chain (4) in the bore at the
main boom head's holding plate.
82640 2021-04-22 423

4. Connect the hook camera to the electrical system. To do so, con-

nect the transmitter connecting cable connection with load hook
camera (5).
DANGER
Risk of accidents!
The load hook camera may not be operated without
fall protection (safety chain (4)).
Disassembly is performed analogously in the reverse direction.
When dismantled, the camera must be transported in such a way

that the camera cable connection cannot get wet.
9.3.1.3.5 Operating panel - load hook camera
NOTE
The operating panel may only be used in excellent condition in
accordance with the operating instructions. The user is person-
ally responsible for the correct use.
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The operation of the hook camera is done using the shown operating
panel (schematic diagram).
Element Display Function
Switching on or off
Brightness Switching the screen brightness on or off
Auto focus
Switching the auto focus on or off
AF OFF
Function button in combination with other buttons
Focus Manual focussing of the motor zoom camera in the "AF OFF" state
Focus Manual focussing of the motor zoom camera in the "AF OFF" state
Camera xx Switching between camera 1 and camera 2

No second camera is connected during installation in this
crane, therefore the screen is blue (no video signal present).
Zoom Zoom out (in normal mode)
Video channel xx
Manual switch-over to the next video channel (in service mode)
service mode
Zoom Zoom in (in normal mode)
Camera xx video
Manual switch-over to the previous video channel (in service mode)
channel xx
Green System switched on
red The hook camera is defective or the connection to the camera has
been interrupted
In this case, check the cabling.
The service mode is selected by simultaneously actuating the two

keys displayed on the left. Depending on the design of the operating
panel, the service mode is automatically exited after 20 seconds.
For the operating panel design in which the service mode is not exi-
ted automatically, the keys displayed on the left must be actuated si-
multaneously in order to exit.
82640 2021-04-22 425

9.3.2 Camera system by the Motec company (optional)
9.3.2.1 General Information / Important Instructions / Warning Information
Fig. 302: Load hook camera (schematic diagram)
1 Monitor 2 Zoom control unit of the load

hook camera
3 Video receiver 4 Video transmitter
5 Hook camera 6 Pendant light
The hook camera provides the crane operator with a view from above
of the load and the immediate surroundings. The pendant light (6) de-
scribed in "Pendant light on the main boom head" can be used to illu-
minate the load area better.
The video signal of the hook camera (5) that is suspended on the
main boom head is transmitted by cable to the video transmitter (4);
from here via radio signal to the video receiver (3). The camera can
be zoomed in and out using the zoom control unit (2). The camera im-
age is displayed on the monitor (1) in the crane operator's cab.
If the load hook camera from Orlaco and other cameras from Motec
are on the crane, there are two monitors in the crane operator's cab.
Observe section 9.3.1.3.2 Important Information / Warning Informa-

tion, side 421.
To assemble and dismantle the load hook camera on / from the main
boom head, see 9.3.1.3.4 Assembling/dismantling of the hook cam-
era at the main boom head, side 423.
426 82640 2021-04-22

9.3.2.2 Operating elements and display elements
9.3.2.2.1 Monitor
Element Function
Camera selection
Press this button to manually select the camera: camera LED flashes. Select the camera
using the minus and plus keys. Press the button again to deactivate the function.
Day/night settings (background lighting)
Press this button to switch over between the day and night settings for the automatic
background lighting.
Contrast
Press this button to set the desired contrast using the plus and minus button. Press the
button again to deactivate the function.
Brightness
Press this button to set the desired brightness using the plus and minus button. Press
the button again to deactivate the function.
Colour saturation
Press these two buttons at the same time to set the desired colour saturation using the
plus and minus button. Press the button again to deactivate the function.
Back (optional)
Back to the previous menu.
Minus
Move to the next menu point or to the left.
Plus
Move to the previous menu point or to the right.
Enter
Switch to Standby or activate the selected option in the menus.
9.3.2.2.2 Zooming in and out with the Load Hook Camera

It is possible to zoom in and out with the load hook camera using the
zoom control unit in the crane operator’s cab.
9.3.2.3 Operation of the hook camera

The load hook camera is active as soon as the ignition and the moni-
tor in the crane operator’s cab are switched on.
82640 2021-04-22 427

9.3.3 Hanging light on the main boom head.
Fig. 303: Hanging light on the main boom head (schematic diagram)
1 Bracket 2 Locking spring

3 Pendant light
Assembling/dismantling of the hanging light at the main boom

head
1. Plug in the hanging light (3) on the bracket (1).
2. Secure hanging light (3) with locking spring (2).
NOTE
Risk of damage!
Locking spring (2) must be inserted from below to prevent a col-
lision with the hanging light bracket.
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Fig. 304: Distribution box "X0550" (schematic diagram)
L Connection
3. Electrically connect the hanging light at connection (L) at the dis-

tribution box "X0550".
Disassembly is performed analogously in the reverse direction. The

connection of the hanging light must be closed using the sealing cap
provided.
When dismantled, the hanging light must be transported in such a

way that the electric cable connection cannot get wet.
Operation
The switch for switching on and off is in the crane operator’s cab.
For driving of the crane
If the crane is driven with the main boom set down and the hanging
light fitted to the main boom head at the same time, the crane opera-
tor's view will be obstructed.
DANGER
Risk to life and limb when the view is obstructed!
Death or serious injuries can result if the crane is driven
despite the view being obstructed.
Remove the hanging light for driving the crane.
If the crane is driven with the main boom set down and the hook block
reeved at the same time, the hook block and the hanging light can
collide.
NOTE
Risk of damage to the hanging light due to collision!
Remove the hanging light for driving the crane.
82640 2021-04-22 429

9.4 Conversion of units

Instructions:
Multiply the known value by the conversion factor to obtain the result
in the desired units.
Example: 2 kg in lbs (US) as follows:
- 2 x 2.2046 = 4.4092 lbs (US)
Convert from in Multiply by

kg lbs 2.2046
lbs kg 0.45359
lbs kip 0.001
kip lbs 1000
kg kip 0.002205
kip kg 453.6
t (metric) kip 2.2046
kip t (metric) 0.0004535924
t (metric) ton (US) 1.103
ton (US) t (metric) 0.907
kip ton (US) 0.5
ton (US) kip 2.0
mm inch (in) 0.039
inch (in) mm 25.4
cm inch (in) 0.394
inch (in) cm 2.54
m ft 3.281
ft m 0.3048
km mile 0.621
mile km 1.6093
cm2 inch2 0.155
inch2 cm2 6.4516
sq,ft. (ft2) m2 9.2903 x 10-2

m2 sq,ft. (ft2) 10.746
m/s ft/sec 3.281
ft/sec m/s 0.3048
m/s ft/min 196.86
ft/min m/s 0.00508
430 82640 2021-04-22

Convert from in Multiply by

m/s mph 2.236
mph m/s 0.447
km/h mph 0.621
mph km/h 1.6093
bar psi 14.513
psi bar 0.0689
psf lbs/ft2 1.0
lbs/ft2 psf 1.0
N/cm2 psi 1.478

psi N/cm2 0.677
N/m2 lbF/ft2 0.0208
lbF/ft2 N/m2 48.07

Nm lbf-ft 0.7376
lbf-ft Nm 1.3558
kW HP 1.3410
HP kW 0.7457
ltr gal (US) 0.264
gal (US) ltr 3.7854
ltr barrel 0.0063
barrel ltr 158.99
ml floz 0.0338
floz ml 29.6
°C °F t°F= 1.8 (t°C) + 32
°F °C t°C= (t°F-32) / 1.8
82640 2021-04-22 431

432 82640 2021-04-22

10 Telescoping
10 Telescoping
10.1 General
Section content
- Telescoping procedure, including assembly and functioning princi-
ple of the main boom as required for comprehension of the tele-
scoping procedure.
- Capacities with the main boom in the unpinned state, telescoping
under load: Explanation of the correlation between the state of the
main boom (pinned, unpinned, in the intermediate position) and
permitted or achievable loads (see "Capacities in the unpinned
state")
- Main boom state for driving the crane in the transport position (see
"Placing the main boom in the transport condition").
Definition telescoping
"Telescoping" means retracting or extending the main boom.
Damage to paint in the area of the upper sliding guides of the tele-
scopic sections does not decrease the quality. This happens during
operation and does not cause any restriction in function.
Risk of crushing at bearing points
WARNING
Risk of crushing during telescoping!
Death or serious injuries can result if someone is in the
area of telescopic section bearing points during telescop-
ing in or out (for example, for maintenance work).
Persons must not be within the hazardous area.
Noise development during telescoping

Depending on the system, it can cause noise and vibrations when tel-
escoping the main boom and when pinning the telescopic sections;
this noise and vibrations can also be perceived in the crane opera-
tor's cab.
If there are unwanted noises during operation, the sliding surfaces
should be relubricated with a lubricating agent, or the locking and pin-
ning unit should be lubricated and checked. If necessary, our service
department must be informed.
82640 2021-04-22 433

10 Telescoping
Cranes with the assembly jib fitted in the transport position on

the main boom head
CAUTION
Risk of accidents when hoisting loads with hoist
rope reeved on the main boom head!
Before telescoping out the main boom, fold or remove
the assembly jib in front of the main boom head in the
assembly position.
See the section "Assembly jib" to fold the assembly jib in the assem-
bly position.
10.2 Assembly, Function of the Main Boom
10.2.1 Components of the Main Boom
Fig. 305: Components of the Main Boom (schematic diagram)
T0 Basic case T telescopic sections
The main boom consists of a basic case (fixed outer case) and a
crane type dependent number of telescopic sections (mobile inner ca-
ses). The figure shows a main boom with 5 telescopic sections as an
example.
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10 Telescoping
10.2.2 Extension States of the Main Boom

All telescopic sections can be pinned at 0% / 45% / 90% and 100% of
their possible extension lengths. There are length codes ("LC") for all
extension states used in load capacity tables.
10.2.3 Telescoping System's Mode of Operation

The telescopic sections are telescoped in and out using the following
elements:
- A telescoping cylinder with its cylinder rod fastened to the rear of
the basic case.
- A Locking and Pinning Unit "LPU" which is attached to the cylinder
barrel of the telescoping cylinder and is actuated hydraulically. The
LPU is moved along in the lengthways direction of the main boom
as soon as the telescoping cylinder is driven.
82640 2021-04-22 435

10 Telescoping
10.2.4 Locking and Pinning Unit (LPU)
10.2.4.1 Function of the LPU
Fig. 306: Locking and Pinning Unit (LPU) (schematic diagram)
1 Next largest telescopic section 2 Bolts

3 Clamshell 4 Bolts
5 Telescopic section to be moved 6 Locking and Pinning Unit (LPU)
Item Explanation
1 Next largest telescopic section (is not moved)
2 Pins for locking between the telescopic sections
3 Gripper on LPU
4 Pins for locking between the telescopic section to be moved
and the locking and pinning unit (LPU)
5 Telescopic section to be moved
6 Locking and Pinning Unit (LPU)
The Locking and Pinning Unit (6) is fitted to the cylinder barrel of the
telescoping cylinder. This means that the LPU is moved in the length-
ways direction of the main boom as well as soon as the telescoping
cylinder is telescoped out.
A hydraulically moved shifting gate controls the pins for the locking
and pinning movement:
- Lock / unlock:
Two horizontally arranged pins (4) on the side of the LPU are for
mechanical locking between the Locking and Pinning Unit and the
individual telescopic section.
436 82640 2021-04-22

10 Telescoping
- Pin / unpin:
Two horizontally arranged pins (2) on the side of the LPU are for
locking between the respective telescopic section and the next
largest telescopic section.
States of the Locking and Pinning Unit (LPU)
Three states of the LPU are of importance to the functionality:
Fig. 307: States of the Locking and Pinning Unit (LPU) (schematic diagram)
"I" unlocked and pinned "II" locked and pinned

"III" locked and unpinned
The arrows in the pictures show the extension state (retract/extend)

of the affected pin.
Symbol Extension state

retracted
extended
82640 2021-04-22 437

10 Telescoping
Unlocked and pinned

If the individual telescopic sections are connected to each other with
pins, the locking and pinning unit is in the "Unsecured and pinned"
state. When this is done, the telescoping cylinder can be moved
"empty"; that is, without locked telescopic section.
Locked and pinned

The LPU is in the "Lock and pin" state when changing between the
two states "Unsecured and pinned" and "Secured and unpinned". In
this state, the telescopic section to be moved is locked to the LPU
and to the next largest telescopic section.
Locked and unpinned

When telescoping the main boom, the LPU is in the state "Locked
and unpinned". In this state, the largest telescopic section to be
moved is locked to the telescoping cylinder via the LPU.
The locking and pinning unit is designed in such a way that the state
"Unlocked and unpinned" can never occur.
10.2.4.2 Supply of the LPU with Hydraulic Oil
10.2.4.2.1 Automatic supply

A hydraulic accumulator is required for supplying the LPU with hy-
draulic oil.
If the pressure in the tank falls below the desired value, the loading
procedure is normally automatically started.
The automatic loading procedure is not carried out if:
- the pressure in the accumulator is higher than the desired pres-
sure.
- the telescoping cylinder is retracted.
- the LPU is in the state "locked / unpinned" and the telescoping cyl-
inder is not telescoped (unpinned loads).
- the LPU is in the state "unlocked / pinned", the telescoping cylinder
is not telescoped and the entire telescoping drive is telescoped out
less than 1.5 m (4.9 ft)
- The LPU is in the approach position, fine position or follow-up posi-
tion during the locking or pinning procedure.
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10 Telescoping
Malfunction of the pressure sensor

If there is a malfunction of the pressure sensor, a corresponding fault
message will appear.
In this case, the hydraulic accumulator pressure must be checked

(see 10.2.4.2.2 Hydraulic accumulator pressure display, side 439).
If the pressure is too low, the hydraulic accumulator can also be re-
charged manually (see 10.2.4.2.3 Manual loading of the hydraulic
accumulator, side 441).
10.2.4.2.2 Hydraulic accumulator pressure display

The pressure is displayed in the "Manual telescoping" screen at the
marked point.
Fig. 308: "Tele Display" Screen (schematic diagram)
1. Call up "Tele Display" Screen (see corresponding section).
The screen for a main boom with 5 telescopic sections is shown as

an example regardless of the actual quantity of telescopes.
2. Select the "Manual telescoping" screen in the "Tele display"

screen. Press the button shown to do so.
82640 2021-04-22 439

10 Telescoping
Fig. 309: "Manual telescoping" screen
The "Manual telescoping" screen appears (see "Manual tele-

scoping").
The hydraulic accumulator pressure is indicated at the point shown.
Meaning of the colours of the button:
Symbol Colour Meaning
Green Pressure in the target range
red Pressure outside the target range
yellow during the loading procedure (max. 15 s)
440 82640 2021-04-22

10 Telescoping
10.2.4.2.3 Manual loading of the hydraulic accumulator

If the automatic supply of the Locking and Pinning Unit (LPU) with hy-
draulic oil does not work, the "LPU hydraulic supply" button is shown
with a red background colour in the "Manually telescoping" screen.
The pressure of the hydraulic accumulator has to be manually applied
to the target range.
1. Call up the "Manual telescoping" screen (see "Manual telescop-

ing").
2. "Hydraulic supply of the LPU" button (red background) actuated.
An arrow is depicted in the hydraulic accumulator symbol dur-

ing loading.
If the pressure is higher than the desired pressure, the loading pro-
cedure cannot be started manually with the pressure sensor intact.
The button must have a green background again once the loading
procedure has been completed.
10.2.4.2.4 Exit screen

Activate the displayed key to quit the screen again.
82640 2021-04-22 441

10 Telescoping
10.2.5 Correlation of the Components

In order to achieve an extension state, the telescopic sections to be
moved must be telescoped one after the other.
There are arrow symbols in the schematic diagrams in the description
below. These have the following meaning:
Symbol Extension state

retracted
extended
Starting situation
Before each telescoping procedure, all telescopic sections must be
pinned and unlocked.
This means that the rear area of each telescopic section is locked to
the next largest telescopic section by two pins.
Telescoping out
When telescoping out, you start with the smallest telescopic section
to be telescoped.
The Locking and Pinning Unit (LPU) is moved to the rear end of the
telescopic section to be moved.
442 82640 2021-04-22

10 Telescoping
Fig. 311: LPU state "locked and pinned"
1 Pins 2 Pins
The horizontal pins (2) lock the Locking and Pinning Unit to the indi-
vidual telescopic section. This is called "Lock" (see the state of pins
(2)). After the "Lock" movement has been carried out, the LPU is in
the "locked and pinned" state.
The telescopic section to be moved is still pinned to the next largest
telescopic section.
The pins (1) must be relieved so that the unpinning procedure descri-
bed in the following can be carried out. To do so, the telescoping cyl-
inder telescoped out slightly.
Fig. 312: LPU state "locked and unpinned"
1 Pins 2 Clamshell
"Unpinning" follows. In this case, the grippers (2) draw both pins (1)
inwards to lock the corresponding telescopic section with the next
largest section. After the "Unpin" movement has been carried out, the
LPU is in the state "locked and unpinned".
82640 2021-04-22 443

10 Telescoping
The telescopic section to be moved is only locked to the LPU. The

telescopic section can be telescoped in this state.
Fig. 313: LPU state "locked and pinned"
1 Pins 2 Clamshell
The telescopic section must be pinned again to set down the tele-
scopic section locked to the LPU at the new pinning point. The clam-
shells (2) of both pins (1) now enable locking again between this and
the next largest telescopic section (= "Pin"). After the "Pin" movement
has been carried out, the LPU is in the "locked and pinned" state.
The telescopic section is locked to the LPU and pinned to the next
largest telescopic section.
Fig. 314: LPU state "unlocked and pinned"
1 Locking pins
Then both horizontal locking pins (1) are retracted so that there is no
longer a connection between the locking and pinning unit and the
telescopic section (“Unlocking“ ). After the "Unlock" movement has
been carried out, the LPU is in the state "unlocked and pinned".
444 82640 2021-04-22

10 Telescoping
In order to telescope out the next telescopic section, the telescoping

cylinder must be moved back with "empty" Locking and Pinning Unit.
If the main boom has been extended or retracted to its final operat-
ing length and pinned, the telescoping cylinder must be completely
retracted. The values of the capacity tables are enabled only once
the telescoping cylinder has been completely retracted.
Telescoping in
Telescoping in works inversely to telescoping out which means that
you start with the largest telescopic section to be telescoped.
10.3 Operating Elements / Auxiliary Equipment
10.3.1 Control Levers in the Crane Operator's Cab

The telescoping cylinder is retracted or extended during telescoping
by activating the corresponding control lever (see arrows in the figure)
(depending on the set control lever assignment). Further information
on the possible control lever assignments, on changing the control
lever assignment, etc. can be found in the section "Safety equipment"
under "Joystick modes" / "Control lever assignment" screen.
The telescoping cylinder with the firmly fitted locking and pinning unit
can be retracted and extended empty or with an attached telescopic
section (locked).
Movement direction of the corresponding control levers

Manual
Left-hand control Right-hand con- Automatic tele-
tele-
lever (modes 1, trol lever (mode scoping scoping
3, 4) 6)
activate after input
of the length code
Tele-
(LC); depending on
to the front to the right scoping
the current state,
out
telescoping in or out
is carried out
telescoping in with-
Tele-
out selection of a
to the rear to the left scoping
LC (LC 1 is auto-
in
matically selected)
Table 13: Telescoping direction depending on type of telescoping
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The crane is equipped with a release switch system to prevent acci-

dental activation of crane movements.
A crane movement can only be carried out if one of the release but-
tons of the release switch system is pressed. To do so, observe the
detailed specifications in the section "Safety equipment" under "Re-
lease switch system for crane movements".
10.3.2 Input and Monitoring Screens on Crane Control

There are input and monitoring screens for telescoping. Depending
on the procedure, different screens are used for telescoping ("Auto-
matic" or "Manual"). The screens are explained with the correspond-
ing descriptions of the procedures.
10.4 Telescoping the Main Boom
10.4.1 General
Introduction
This section describes telescoping the main boom without load from
one pinned state to another pinned state.
If loads are to be raised in the unpinned state, see "Capacities in the

unpinned state".
Telescoping with fitted additional equipment:

Any special characteristics which must be taken into consideration
are described in the section which deals with the corresponding ad-
ditional equipment.
Automatic telescoping
As long as there is no fault, telescoping must always be carried out in
automatic mode.
The description of automatic telescoping can be found in "Automatic
telescoping".
Manual telescoping
If there are mechanical or electrical faults, telescoping can be carried
out manually.
For the description of manual telescoping, see "Manual telescoping".
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10.4.2 Automatic telescoping
10.4.2.1 General
Introduction
As long as there is no fault, telescoping must always be carried out in
automatic mode. Automatic telescoping is carried out with the help of
the telescoping information system of crane control.
The telescoping information system is an aid to operation. It is not a
replacement in any way for the judgement and experience of the
crane operator as well as recognised safe operating procedures for
the operation of cranes!
When using the operating aid, the crane operator still remains fully re-
sponsible for the safe crane operation!
WARNING
Risk of accidents due to incorrect operation.
Death or serious injuries can result if the crane overturns
or is damaged due to incorrect inputs at crane control.
The crane operator must be aware of his responsibili-
ty for the safe operation of the crane.
The crane operator must ensure that all the issued
specifications and instructions at the crane control
and in the operation instructions are understood and
observed.
Telescoping the main boom a new final length
Fig. 315: Operating panel of crane con- Fig. 316: Control Levers in the Crane Op-
trol (schematic diagram) erator's Cab
The crane control Fig. 315, side 447 makes it possible for the tele-
scoping procedure to run automatically after entering the length code
"LK" of the desired final length in the operating panel of the crane
control and actuating the corresponding control lever Fig. 316,
side 447.
This is also the case if the new main boom length is smaller than the
current length.
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10 Telescoping
Telescoping the main boom in

The main boom can be telescoped in two ways by automatic tele-
scoping:
Fig. 317: Control Levers in the Crane Op- Fig. 318: Entry length code "LK1" (sche-
erator's Cab matic diagram)
- Move the control levers (see arrows in the left figure) in the direc-
tion of retraction: "LK1" is then automatically selected (all tele-
scopes 0%)
- On the operating panel of the crane control (see right figure), se-
lect "LK1" and create the corresponding extension state as descri-
bed in the section "Telescoping the main boom to new final
length".
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10 Telescoping
Telescoping Procedure
The current telescoping speed varies during the procedure. Just be-
fore the pinning position is reached, the telescoping speed is re-
duced, so that the telescopic sections can be pinned.
Fig. 319: "Telescoping display" screen

(schematic diagram)
The crane control prescribes the extension / retraction sequence of

the telescopic sections to achieve the selected length code. The ex-
tension states of the telescopic sections are displayed in colour as a
bar display in the "Telescoping display" screen (see 10.4.2.2.1 "Tel-
escoping display" screen, side 450). Furthermore, the current tele-
scoping speed (see marking in Fig. 319, side 449) is also displayed.
If there is a fault during telescoping, the depicted fault symbol ap-
pears on the operating panel of the crane control.
For detailed information on calling up fault messages (see

8.1.7.21 "Fault messages" screen, side 324).
After eliminating the error, work can only be continued, once the error
message has been acknowledged.
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10.4.2.2 Input and Monitoring Screens at Crane Control (Automatic Telescoping)
10.4.2.2.1 "Telescoping display" screen
10.4.2.2.1.1 Calling up the "Tele Display" Screen
1. Select the "Tele display" screen in the "Quick menu" screen.

Press the displayed button to do so.
Fig. 320: "Tele Display" screen (sche-

matic diagram)
The "Tele display" screen appears instead of the "Quick

menu" screen.
The screen for a main boom with 5 telescopic sections is shown as

an example regardless of the actual quantity of telescopes.
Submenus can be selected in this screen and information on the state

of the telescoping system can be obtained.
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10.4.2.2.1.2 Structure of the "Tele Display" Screen
Item Colour Explanation

1 Extension lengths of the telescopic section as a bar display and in percentages
blue The telescopic section has been extended for the selected length code
Grey The telescopic section has been retracted and must be extended
black The telescopic section must be retracted and possibly extended again, according to
the selected length code
yellow The telescopic section extends or retracts with the locking and pinning unit
white The telescopic section has been retracted.
The number of bars represents the number of telescopic sections of the main
boom. The screen for a main boom with 5 telescopic sections is shown as an
example in the figure.
If the main boom is in the state for driving the crane (see "Placing the main
boom in the transport condition") a crane symbol is displayed instead of the bar
display.
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10 Telescoping
1 Combined display 2 Calling up the "Manual telescoping" screen.

1 Combined display:
- Position display of the LPU as a bar display and in percentages
- Telescoping speed display of main boom / telescoping cylinder
Just before the pinning position is reached, the telescoping speed is reduced, so
that the telescopic sections can be pinned.
2 Calling up the "Manual telescoping" screen (see "Manual telescoping")
The "Manual telescoping" screen is not required for automatic telescoping. The
"Manual telescoping" screen can be called up during automatic telescoping to ob-
serve the procedures carried out at the telescoping cylinder and LPU.
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1 Current driving configurations of the telescoping cyl- 2 Call up the "Length code (LC) selection" screen
inder
Col-
our
1 Display of the current driving configuration of the telescoping cylinder
Forward at reduced speed
Reverse at reduced speed
Forward at high speed
Reverse at high speed
2 Call up the "Length code (LC) selection" screen
(see "Length code (LC) selection" screen)
Grey The selected length code has not been achieved.
Green The selected length code has been achieved.
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10.4.2.2.2 "Length code (LC) selection in accordance with main boom length" screen
10.4.2.2.2.1 Calling up the "Length code (LC) selection in accordance with main
boom length" screen
1. Actuate the depicted button in the "Telescoping display" screen.

(For further information on the "Telescoping display" screen, see
10.4.2.2.1 "Telescoping display" screen, side 450).
The digit shown on the button is the number of the current selected
length code (LC).
Fig. 324: "Length code (LC) selection" screen (schematic diagram)
The "Length code selection" screen appears instead of the

"Crane operation" screen.
All length codes (including corresponding main boom length, exten-

sion state of the individual telescopic sections and possible maximum
load capacities) which are permitted and can be activated for the se-
lected operating mode are displayed in the "Length code (LC) selec-
tion" screen.
The basic structure of the screen is the same for all main booms, in-
dependent of the number of telescopic sections. The screen for a
main boom with 5 telescopic sections is shown as an example in the
figure and in the further description.
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10.4.2.2.2.2 Structure of the "Length code (LC) selection in accordance with main
boom length" screen
1 Number of the length code 2 Main boom length

3 Max. lifting capacity in high position 4 Radius in high position
5 Max. lifting capacity in low position 6 Radius in low position
Item Explanation
1 Number of the length code (LC-N.)
2 Main boom length
Max. lifting capacity in high position
3
(is only displayed if symmetrical support bases are set)
Radius in high position
4
Max. lifting capacity in low position
5
Radius in low position
6
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1 Extension state of the telescopic sections (from left to right)
white 0% extended
blue 45% extended
Grey 90% extended
black 100% extended
The number of bars represents the number of telescopic sec-

tions of the main boom. The display for a main boom with 5 tele-
scopic sections is shown as an example in the figure.
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1 Selected length code 2 Scroll bar for scrolling through the length codes
3 Exit the screen with Save 4 Selection of the screen for selection of the length
code
Item Explanation
1 Selected length code
The desired length code is selected and receives a coloured background when pressed (the
entire line is touch-sensitive).
2 Can be scrolled for leafing through length code:
- line by line: Touch the triangular marking at the bottom and top at the end of the bar.
- through the entire table: Sliding over the progress bar
3 Leave the screen with save. the settings are saved.

The "Telescoping display" screen appears again. For further information on the "Telescoping
display" screen, see 10.4.2.2.1 "Telescoping display" screen, side 450.
4 Selection of the screen for length code selection for lubrication of the main boom (only possi-
ble for operating mode "HA")
Detailed information on this can be found in the lubrication and maintenance instructions, at
"Main boom, ropes, equipment".
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10 Telescoping
1 Length code selection for the position of the LPU 2 Selection of the "Length code (LC) selection in ac-
cordance with capacities" screen
3 Fault button 4 Exit the screen
Item Explanation
1 Length code selection for the position of the LPU for driving the crane (only for "HA" set
crane configuration). To do so, see "Placing the main boom in the transport condition".
2 Selection of the "Length code (LC) selection in accordance with capacities" screen See
10.4.2.2.3 "Length code (LC) selection in accordance with capacities (pinned-unpinned)"
screen, side 458.
3 Error button (appears in case an error is displayed. See section "Safety equipment")
4 Exit the screen without save. The settings are not saved.
The "Telescoping display" screen appears again. For further information on the "Telescoping
display" screen, see 10.4.2.2.1 "Telescoping display" screen, side 450.
10.4.2.2.3 "Length code (LC) selection in accordance with capacities (pinned-unpin-

ned)" screen
10.4.2.2.3.1 Calling up the "Length code (LC) selection in accordance with capacities
(pinned-unpinned)" screen
1. Press the button shown in the "Length code (LC) selection"

screen.
The "Length code (LC) selection in accordance with (pinned-

unpinned)" screen appears instead of the "Length code (LC)
selection" screen.
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10.4.2.2.3.2 Structure of the "Length code (LC) selection in accordance with capaci-
ties (pinned-unpinned)" screen
1 Selected length code 2 Exit the screen with Save

3 Change to the pinned load capacities 4 Change to the unpinned load capacities
5 Display of current angle step 6 Exit the screen without Save

Selected length code
1 The desired length code is selected and receives a colour background when you
press it (entire column is touch-sensitive).
Exit the screen with Save

2
the settings are saved.
Change to the pinned load capacities

3
only for operating mode "HA"
Change to the unpinned load capacities

4
only for operating mode "HA"
for luffing boom extensions (HAVHY), the current angle step (e. g. 40°) is dis-
played here.
5
Then the remaining angle steps can be called up one after the other by pressing
this button.
Exit the screen without Save

6
The settings are not saved.
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10.4.2.3 Procedure for Automatic Telescoping

Requirements:
- Crane assembled, supported on outriggers and aligned in accord-
ance with regulations.
- Crane engine is running.
- Crane control:
- Set the correct configuration in the "Selecting the operating
mode" screen.
- Control lever assignment selected for which telescoping is pos-
sible.
Fig. 330: Display of the control lever assignment
Current assignment of the control levers (in this case: 1) is displayed

by the corresponding symbol in the top line of the IC-1 display.
WARNING
Risk of accidents!
Death or serious injuries can result if unintended crane
movements are carried out.
Check which control lever assignment has been cur-
rently selected.
See section "Safety equipment" for detailed information on the con-

trol lever assignment and other settings on the crane control.
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1. Enter length code (LC):
1.1. Press the depicted button in the "Quick menu" partial

screen in the "Crane operation" screen. The "Telescoping
display" screen appears.
1.2. Actuate the button for selection of the "Length code (LC)
selection" screen in the "Telescoping display" screen. The
"Length code (LC) selection" screen appears.
Fig. 333: "Length code (LC) selection" screen
1.3. Press the desired length code (the whole line is touch-sen-
sitive) in the "Length code (LC) selection" screen. The se-
lected length code receives a coloured background.
Fig. 334: "Length code (LC) selection" screen
1.4. Leave the screen with "Save".
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10 Telescoping
Alternatively, you can switch to the "Length code (LC) selection in

accordance with load capacity (pinned-unpinned)" screen and select
a corresponding length code (LC) there.
For further information on selecting the length code (LC), see

10.4.2.2.2 "Length code (LC) selection in accordance with main
boom length" screen, side 454.
Pay attention to the following during the performance of the following

work step:
WARNING
Risk of accidents!
Death or serious injuries can result if unintended crane
movements are carried out.
Check which control lever assignment has been cur-
rently selected.
tions on the release switch system. See the section
"Safety equipment" under "Release switch system for
crane movements".
WARNING
Risk of crushing and collision!
Death or serious injuries can result if the load or the hook
block swings out when the respective crane movement is
switched off.
Only carry out crane movements with adapted accel-
eration or speed.

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Fig. 335: Control Levers in the Crane Op-

erator's Cab
2. Initiate the telescoping procedure by actuating one of the "Re-

lease switch system" buttons and carefully moving the corre-
sponding control lever (see arrows), which has been assigned
the telescoping movement, in the extension direction.
As soon as the desired final length is reached, the colour of
the "LC" button switches from grey to green.
The selected length code number (LC) is shown with a green

background under the configuration information in the "Crane
operation" screen.
The hook height changes when telescoping.

It must be ensured that the hoist limit switch is not triggered when
extending. For this reason, the hoist (the hook) must also be low-
ered when telescoping out.
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Telescoping in
Fig. 336: Control Levers in the Crane Op-

erator's Cab
1st option:
The main boom is automatically fully telescoped in by actuating one
of the "Release switch system" buttons and carefully pulling the corre-
sponding control lever (see arrows in Fig. 336, side 464) back the
direction of telescoping in. "LC 1" is then activated.
2nd option:
Procedure for telescoping as previously described in this section with
input of the length code "LC 1".
10.4.3 Manual telescoping
10.4.3.1 General
Manual telescoping must only be used in exceptional cases if there
are faults in the automatic telescoping system.
Mechanical faults
If there are mechanical faults, telescoping can be carried out manual-
ly. Crane control is fully functional in this case. The procedure for
manual telescoping is described at 10.4.3.4 Procedure for manual
telescoping with mechanical faults, semi-automatic, side 479.
Electrical faults
If there are electrical faults, the load limit device (LLD) must also be
overridden during manual telescoping. Observe the description, spec-
ifications and warning information under 10.4.3.6 Procedure for
manual telescoping in the case of electrical faults, side 493.
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10 Telescoping
Display on crane control
The information required (position and state of the LPU) and the oper-
ating elements for manual telescoping are in the "Manual telescoping"
screen. The description of the input and monitoring screens in crane
control for manual telescoping can be found at 10.4.3.3 Input and
Monitoring Screens at Crane Control (Manual Telescoping),
side 466.
10.4.3.2 Basic procedure for carrying out the functions lock / unlock or pin / unpin
10.4.3.2.1 Variant 1: Semi-automatic (with preselection)

Procedure for the following situations:
- in the case of mechanical fault
- in the case of electrical faults which do not prevent the semi-auto-
matic execution of the functions
1. Telescope just before the respective position to lock / unlock or
pin / unpin.
2. Activate preselection.
3. Activate the required function; it is not activated as yet.
4. Continue to telescope slowly; Once the corresponding fine posi-
tion has been reached, the selected function will be executed au-
tomatically.
5. After carrying it out, deactivate the selected function and prese-
lection manually.
10.4.3.2.2 Variant 2: Manually (without preselection)

Procedure in the case of electrical faults which prevents the semi-au-
tomatic execution of the function.
In principle, you should proceed as follows:
1. Telescope until the respective fine position has been achieved.
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10 Telescoping
NOTE
Risk of damage!
The function may only be activated during the procedure descri-
bed below once the corresponding fine position has been ach-
ieved (green display).
2. Activate the required function; it is executed immediately.
10.4.3.2.3 Note on the described example

The variant "Semi-automatic (with preselection)" is described in detail
in the example "Procedure for manual telescoping, in the case of me-
chanical faults, semi-automatic". For the "Manual (without preselec-
tion)" variant, proceed analogously, taking into account the basic se-
quence described above.
10.4.3.3 Input and Monitoring Screens at Crane Control (Manual Telescoping)
10.4.3.3.1 "Manual telescoping" screen
10.4.3.3.1.1 Purpose of the "Manual telescoping" screen
Status messages and buttons for manual operation of the locking and
pinning unit (LPU) are shown in the "Manual telescoping" screen.
The "Manual telescoping" screen can also be called up during auto-
matic telescoping to observe the procedures carried out on the tele-
scoping cylinder and LPU.
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10.4.3.3.1.2 Calling up the "Manual telescoping" screen.
1. Actuate the marked button in the "Crane operation" screen in the

"Quick menu" area.

(schematic diagram)
Instead of the "Quick menu", the "Telescoping display" screen

appears.
2. Actuate the depicted button in the "Telescoping display" screen.
The "Manual telescoping" screen appears instead of the "Tel-

escoping display" screen.
When the "Manual Telescoping" screen opens, the hand symbol is

crossed out. This means that the automatic mode is active. The
function buttons for operating the locking and pinning unit (LPU) are
displayed greyed out.
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10.4.3.3.1.3 Exiting the "Manual telescoping" screen

The "Manual telescoping" screen can be exited directly by pressing
the "Exit" button in two cases:
- No change has been made to the screen.

- Telescoping was carried out manually and there are no electrical
faults.
If there is an electrical fault, the "Teaching" procedure must be carried
out after manual telescoping to exit the "Manual telescoping" screen.
This means that the telescoping system must be informed concerning
the extension state of each telescopic section. See 10.4.3.5 Teach-
ing the Extension State of the Telescopic Sections, side 490
If the "Teaching" procedure must be carried out, the "Exit" button is
displayed "greyed out" in the area of the "Crane operation" screen
and cannot be actuated.
Fig. 341: Partial screen "Telescoping display"
After exiting, the "Crane operation" screen appears again with the
partial "Telescoping display" screen.
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10.4.3.3.1.4 Structure of the "Manual telescoping" screen
1 LPU position 2 LPU speed

3 Number of the telescopic section 4 Approach position "Locking position"
5 Follow-up position "Locking position"
Col-
Item Explanation
our
LPU position
1 Depending on the unit of measurement set in the "System" screen, the position
value is displayed in m ("metric") or in ft ("feet").
LPU speed
2 Depending on the unit of measurement set in the "System" screen, the speed
value is displayed in mm/s ("metric") or in ft/min ("feet").
Number of the telescopic section identified by crane control.
3 It means that crane control has not identified any telescopic section when "0" is dis-
played.
Approach position "Locking position" (symbol has a green background when the po-
4 Green
sition is reached)
Follow-up position "Locking position" (symbol has a green background when the po-
5 Green
sition is reached)
If the "Lock" approach and follow-up position have been reached

(symbols (4) and (5) have green backgrounds), the affected tele-
scopic section is in the "Lock" fine position.
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1 Display of the pinning state of 2 Display of the locking state of the

the LPU LPU
(1) - Display of the pinning state of the LPU
Symbol Meaning
"Pinning" basic symbol
pinned
unpinned
(2) - Display of the locking state of the LPU
Symbol Meaning
"Locking" basic symbol
locked
unlocked
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10 Telescoping
1 State Sensor System of the LPU
(1) - State Sensor System of the LPU
Status code Symbol State of the LPU
1 unlocked and pinned
12 State change lock and pinned
2 locked and pinned
23 locked and state change pinning
3 locked and unpinned
5 "Locking/pinning unknown" state
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1 Hydraulic supply of the LPU 2 Pinning

3 Unpinning 4 Preselection lock / unlock
5 Locking 6 Unlocking

Hydraulic supply of the LPU (see 10.2.4.2 Supply of the LPU with Hydraulic Oil,
1
side 438)
2 Pinning
3 Unpinning
4 Preselection lock / unlock
5 Locking
6 Unlocking
Notes on buttons (2) to (6): The button is displayed with a red back-
ground after it has been pressed.
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1 Telescoping Operation 2 "Teaching"

3 LPU states

1 Switch-over between automatic and manual telescoping operation:
Automatic telescoping operation active
Manual telescoping operation active.

The "Teach telescopic section" screen appears after this key has been se-
lected if "teaching" must first be carried out after manual telescoping (see
corresponding section). After "Teaching", "Automatic telescoping operation"
is "active".
2 Call up the "Teach telescope" screen (setting and saving the position of the tele-
scopic sections). To do this, see corresponding section.
3 Call up the visual depiction of the current LPU state (see 10.4.3.3.1.5 "Visual
depiction of the LPU states" screen, side 474)
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10.4.3.3.1.5 "Visual depiction of the LPU states" screen

By pressing the displayed key, visual depictions of the LPU states
currently shown in the "Manual telescoping" screen are called up.
Fig. 347: "Manual telescoping" screen Fig. 348: unlocked and pinned
Fig. 349: locked and pinned Fig. 350: locked and unpinned
State code in the screen (figure

Figure Meaning
Fig. 347, side 474)
1 unlocked and pinned
Fig. 348, side 474
12 State change lock and pinned
2 locked and pinned
Fig. 349, side 474
23 locked and state change pinning
3 locked and unpinned
Fig. 350, side 474
5 "Locking/pinning unknown" state
10.4.3.3.1.6 "Teach telescope" screen

The displayed button in the "Manual telescoping" screen must be acti-
vated for "teaching"; that is, to inform the telescoping system which
extension state each telescopic section is in.
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10 Telescoping
Structure of the "Teach telescope" screen:
Fig. 351: Calling up the "Teach telescope" screen (schematic diagram)
1 Telescopic section numbers with 2 Save extension state

input fields
3 Entering the length code
Item Explanation
1 Telescopic section numbers and corresponding input fields
The displayed value changes by activating the input field. All input fields assigned to the
individual telescopic sections are filled in with a star when the screen is selected. Subse-
quently, the current extension states for all telescopic sections must be selected manual-
ly. The following options are available for selection: "0", "45", "90" and "100" for pinned
states and "LPU" if the telescopic section is unpinned and locked to the LPU.
The number of bars represents the number of telescopic sections of the main boom. The
display for a main boom with 5 telescopic sections is shown as an example in the figure.
2 Saving the set extension state: the settings are saved.
3 Entering the length code
If the extension state corresponds with an existing length code (LC):
To call up the "Length code (LC) selection - teaching" screen, see 10.4.3.3.1.7 "Length code
(LC) selection - teaching" screen, side 476 for setting the length code (LC).
Select the corresponding length code (LC) in the "Length code (LC) selection - teaching"
screen and exit the screen with "Save".
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10.4.3.3.1.7 "Length code (LC) selection - teaching" screen

Activate the button displayed on the left in the "Teach telescope"
screen to select the length code (LC) for the desired main boom
length.
Fig. 352: "Length code (LC) selection - teaching" screen (schematic diagram)
The "Length code (LC) selection - teaching" screen appears.

All length codes, including the corresponding main boom length, ex-
tension state of the individual telescopic sections and possible maxi-
mum capacities, which are permitted and can be activated for the se-
lected operating mode are displayed in the "Length code (LC) selec-
tion - teaching" screen.
The basic structure of the screen is the same for all main booms, in-
dependent of the number of telescopic sections. The screen for a
main boom with 5 telescopic sections is shown as an example in the
figure and in the further description.
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1 Number of the length code 2 Main boom length

3 Extension state of the telescopic
sections

1 Number of the length code (LC-N.)
2 Main boom length
3
white 0% extended
blue 45% extended
Grey 90% extended
black 100% extended
The number of bars represents the number of telescopic sections of

the main boom. The display for a main boom with 5 telescopic sec-
tions is shown as an example in the figure.
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1 Max. lifting capacity in high posi- 2 Radius in high position

tion
3 Max. lifting capacity in low posi- 4 Radius in low position
tion
Item Explanation
1 Max. lifting capacity in high position
2 Radius in high position
3 Max. lifting capacity in low position
4 Radius in low position
These positions are only displayed if symmetrical support bases are

set.
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1 Selected length code 2 Scroll bar for scrolling through

the length code
3 Base Line
Item Explanation
1 Selected length code
The desired length code is selected and receives a coloured background when press-
ed (the entire line is touch-sensitive).
2 Can be scrolled for leafing through length code:
Touch the triangular marking at the bottom and top at the end of the
> line by line:
bar
through the en-
> Sliding over the progress bar
tire table:
3 Base line:
The keys in the base line are described in 8.1.7.2 Submenus - basic structure, side 263.
After exiting the screen, the "Teach telescope" screen appears

again (see the 10.4.3.3.1.6 "Teach telescope" screen, side 474)
10.4.3.4 Procedure for manual telescoping with mechanical faults, semi-automatic

Observe the description of the basic procedure to carry out the func-
tions lock / unlock or pin / unpin under 10.4.3.2 Basic procedure for
carrying out the functions lock / unlock or pin / unpin, side 465.
Requirements:
See the relevant description at the start of the section "Procedure for
automatic telescoping".
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Procedure:
The function keys for operating the locking and pinning unit (LPU)
are displayed greyed out.
1. Call up the "Manual telescoping" screen. See 10.4.3.3.1 "Man-

ual telescoping" screen, side 466.
2. Activate manual telescoping operation. To do so, actuate the

marked key in the "Manual telescoping" screen.
The function keys for operating the locking and pinning unit
(LPU) are no longer displayed greyed out. Crane control is
now in manual telescoping operation.
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Fig. 357: Principle sketch of the main boom (schematic diagram)
1 Telescoping cylinders T1 Telescopic section 1:

P1 0 % pinning hole P4 100 % pinning hole
For clarification, the further procedure is described using a main

boom with 5 telescopic sections as an example.
Telescopic section 1 (T1) is to be driven out of the 100% pinning hole
(P4) into the 0% pinning hole (P1) (telescoped in).
The telescoping cylinder (1) must be completely retracted at the start.
Telescoping of several telescopic sections:

If several telescopic sections are to be moved, you must always
start with the smallest telescopic section to be moved when extend-
ing the main boom.
When telescoping in, you must always start with the largest tele-
scopic section to be moved.
During the following procedure, telescoping the hydraulic cylinder –

in accordance with the prescribed steps – must be interrupted or re-
sumed using the corresponding control lever.
When telescoping, one of the release switch system buttons must
be pressed at the same time as the corresponding control lever is
moved.
If there is an electrical fault, the load limit device (LLD) must also be
bridged. To do so, see 10.4.3.6 Procedure for manual telescoping
in the case of electrical faults, side 493.
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Fig. 358: Pinning positions, telescopic sections (schematic diagram)
1 Telescoping cylinders 2 LPU
3. Check in the "Manual telescoping" screen using the displayed

symbols whether the LPU (2) is in the state "unlocked and pin-
ned"; the digit "1" must appear. For a description of the states of
the LPU, see 10.4.3.3.1 "Manual telescoping" screen,
side 466. The telescoping cylinder (1) can be moved in this state
using the control lever to which the telescoping movement is as-
signed without a telescopic section being moved.
This can be seen in the "Manual telescoping" screen at the

position shown in the figure: a speed value ("LPU v": ) > 0
mm/s (ft/min) must be displayed without a telescopic section
moving.
The following is assumed in the sequence below:

- Telescoping must be interrupted or resumed using the correspond-
ing control lever, depending on the specified action steps.
- At the start, telescoping cylinder (1) is telescoped in.
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3 Display "LC"
4. Telescope the telescoping cylinder (1) up to just before the lock-

ing position. Steer the respective control lever in order to extend
the LPU. Telescoping cylinder (1) is moved to the lock position
on telescopic section 1 (T1) with the LPU (2) mounted on it. As
soon as telescopic section 1 (T1) has been reached, display (3)
changes from "IK: 0" to "IK: 1".
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Fig. 360: Example - pinning position 100 % (schematic diagram)

T1 Telescopic section 1: 3 Table "LPU positions"
4 Telescopic section 1: 5 100% pinning hole
6 Relevant table value
5. Interrupt telescoping as soon as the LPU is just in front of the

lock position. The table of the LPU positions of the main boom in
the section "Locking and pinning positions of the telescopic
drive" shows to which extension length the telescoping cylinder
must be telescoped for "locking". In our example (telescopic sec-
tion 1: 100% telescoped out), the telescoping system must be
telescoped out to the table value (6) listed in the table "Locking
and pinning position" (3) under telescopic section 1 (4) and
100 % (5) to secure the LPU (2) to telescopic section 1 (T1).
The definitive extension length ("LPU s:") is displayed in the
"Manual telescoping" screen as shown.
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NOTE
Observe the correct sequence when pressing the keys.
First press "Preselect", then press "Lock".
6. Preselect the telescoping. To do so, press the "Preselection" key

(top symbol) and then the "Lock" key (bottom symbol) one after
the other.
The keys are displayed red after they are pressed.
7. Continue to telescope slowly.

When the fine position "Lock" has been reached, both corre-
sponding symbols are displayed accordingly with a green
background. The locking procedure is automatically triggered.
The locking procedure is completed as soon as the "locked and pin-

ned" state (the digit "2" must appear at the marked point in the "Man-
ual telescoping" screen) is displayed for the LPU.
Fig. 361: "Manual telescoping" screen (schematic diagram)
1 "Preselect" button 2 "Lock" key
Even though the locking procedure is completed, the "Preselect" (1)

and "Lock" (2) buttons are still displayed against a red background.
This means that the hydraulic valve is still activated for the locking
movement to be carried out.
8. Place the hydraulic valve in the neutral position to control the

locking movement. To do this, press the "Preselect" (1) and
"Lock" (2) buttons again.
The buttons are then displayed in grey once again.
9. The telescoping cylinder must be extended by approx. 10 mm

(0,4 in) to relieve the pins of the pinning between the telescopic
sections.
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10. Press the displayed "Unpin" key in the "Manual telescoping"

screen for unpinning.
The key is displayed red after it has been pressed.
The unpinning procedure is completed as soon as the "locked and

unpinned" state (the digit "3" must appear at the marked point in the
"Manual telescoping" screen) is displayed for the LPU.
In this state, telescopic section 1 is locked to the LPU and can be tel-
escoped in as follows.
Even though the unpinning procedure has been completed, the "Un-
pin" key marked in the figure is still displayed with a red background.
This means that the hydraulic valve is still activated for the unpin-
ning movement to be carried out.
11. Place the hydraulic valve in the neutral position to control the un-
pinning movement. To do so, press the displayed "Unpin" key
again.
The key is shown in grey again.
1 LPU T1 Telescopic section 1:
12. Telescope in the telescopic section 1 (T1) secured to the LPU (1)
by activating the control lever in the direction of telescoping in.
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T1 Telescopic section 1: P1 0% pinning hole
3 Table "LPU positions" 4 Telescopic section 1:
5 0% pinning hole 6 Relevant table value
In our example, telescopic section 1 (T1) is to be completely telesco-

ped in.
The table of the LPU positions of the main boom, section "Locking
and pinning positions of the telescopic drive" shows to which exten-
sion length the telescoping cylinder (1) must be telescoped in this
case. In our example (telescopic section 1: 0 % telescoped out), the
telescoping system must be telescoped in to the value (6) listed in the
table "Locking and pinning position" (3) under telescopic section 1 (4)
and 0% (5) to pin the telescopic section 1 (T1) locked to the LPU (2)
in (P1) in the "0 % pinning hole".
The current extension length "LPU s" is displayed in the "Manual tele-
scoping" screen as illustrated.
13. Shortly before reaching the pinning point: press the "Pin" button
shown.
The key is displayed red after it has been pressed.
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1 Telescoping cylinders T0 Telescopic section T0

T1 Telescopic section 1:
14. Continue to slowly telescope telescopic cylinder (1) until the

locked telescopic section (here: telescopic section T1 (1)) is pin-
ned to the next larger telescopic section (here: telescopic section
T0 (0)).
The pinning procedure is completed as soon as the "locked and pin-
ned" state (the digit "2" must appear at the marked point in the "Man-
ual telescoping" screen) is displayed for the LPU.
Even though the pinning procedure has been completed, the "Pin"
key marked in the figure is still displayed with a red background.
This means that the hydraulic valve is still activated for the pinning
movement to be carried out.
15. Place the hydraulic valve in the neutral position to control the pin-
ning movement. To do so, press the displayed "Pin" key again.
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NOTE
Observe the correct sequence when pressing the keys.
First press the "Preselect" button, then press the "Unlock" but-
ton.
16. Preselect the unlocking procedure. To do so, press the "Prese-

lection" key (top symbol) and the "Unlock" key (bottom symbol)
one after the other.
The keys are displayed red after they are pressed.
17. Continue to telescope slowly. When the fine position "Lock / un-
lock" has been reached, both corresponding symbols are dis-
played accordingly with a green background. The unlocking pro-
cedure is automatically triggered.
The unlocking procedure is completed as soon as the "unlocked and

pinned" state (the digit "1" must appear at the marked point in the
"Manual telescoping" screen) is displayed for the LPU.
1 "Preselect" button 2 "Unlock" button
Even though the unlocking procedure is completed, the "Preselect"

(1) and "Unlock" (2) buttons marked in the figure are still shown with
a red background. This means that the hydraulic valve is still activa-
ted for the unlocking movement to be carried out.
18. Place the hydraulic valve in the neutral position to control the un-
locking movement. To do so, press the "Preselect" button (top
symbol) and "Unlock" button (bottom symbol) again.
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1 Telescoping cylinders T0 Telescopic section T0

T1 Telescopic section 1:
This completes the actual sample manual telescoping procedure. The

LPU state is "unlocked and pinned". The telescoping cylinder can
therefore be moved "empty", i.e. without a locked telescopic section.
The procedure described in this section can now be repeated for the
next telescopic section to be moved.
See 10.4.3.3.1 "Manual telescoping" screen, side 466 and the
notes on the subject "Exiting the 'Manual telescoping' screen" to exit
the "Manual telescoping" screen.
10.4.3.5 Teaching the Extension State of the Telescopic Sections
10.4.3.5.1 General Instructions on Risks

Depending on the faults / malfunctions and the activities carried out
on the telescoping system during manual telescoping, it might not be
possible to exit the "Manual telescoping" screen directly. In this case,
the telescoping system must be informed with regard to the extension
state of each telescopic section.
This procedure is referred to as "teaching". During "teaching", the po-
sitions of the telescopic sections are "set" and saved.
DANGER
Risk of accidents!
During the "Teaching" process, only precisely the val-
ues which correspond to the actual state may be en-
tered in the control system. The crane operator is
solely responsible for this!
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10.4.3.5.2 Procedure for teaching
1. Actuate the depicted button in the "Manual telescoping" screen.
Fig. 369: "Teach telescope" screen (schematic diagram)
"Teach telescope" screen appears.
The number of fields represents the number of telescopic sections

of the main boom. The display for a main boom with 5 telescopic
sections is shown as an example in the figure. At first, all of the but-
tons assigned to individual telescopic sections are only filled in with
a star.
If the length code (LC) for the extension state to be taught is known,
see Entering the length code directly during teaching.
2. Enter the length code (LC) as described in 10.4.3.5.3 Entering
the length code directly during teaching, side 492.
Fig. 370: "Teach telescope" screen (schematic diagram)
3. If the length code (LC) is unknown, a telescopic section is se-

cured to the "LPU" and/or there is no LC for the current exten-
sion state, the extension state of each telescopic section must be
entered individually. The following options are available for selec-
tion: "0", "45", "90" and "100" for pinned states and "LPU" if the
telescopic section is unpinned and locked to the LPU. To do so:
Activate button next to T1 until the corresponding value appears.
In our example: "0", i.e. telescopic section 1 is extended 0%).
4. Repeat the procedure described for telescopic section 1 accord-
ingly for the remaining telescopic sections.
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Fig. 371: "Teach telescope" (schematic

diagram)
DANGER
If incorrect values have been "taught", there is a risk
of overturning.
Check the set values carefully.
5. Make sure the defined state corresponds to the actual extension

state for all telescopes. In our example, "0" has been entered for
all telescopic sections.
6. Exit the "Teach telescope" screen with "Save".
The "Manual telescoping" screen appears.
10.4.3.5.3 Entering the length code directly during teaching

Teaching for a main boom with 5 telescopic sections is described as
an example in this section. The description applies analogously for a
crane with a different number of telescopic sections.
Fig. 372: Extension state of the telescopic sections (schematic diagram)
1. Press the "LC" button in the "Teach telescope" screen.
The "Length code (LC) selection - teaching" screen appears.
2. Select the line of the length code which corresponds with the ac-
tual extension state of the telescopic sections (right-hand side of
the figure).
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3. Exit the "Length code (LC) selection - teaching" screen using the
depicted "Save" button.
The "Teach telescope" screen reappears and all sections on

the individual telescopic sections are filled in.
DANGER
If incorrect values have been "taught", there is a risk
of overturning.
Check the set values carefully.
4. Make sure the defined state corresponds to the actual extension

state for all telescopes. In our example, "0" has been entered for
all telescopic sections.
5. Exit the "Teach telescope" screen with "Save".
The "Manual telescoping" screen appears.
10.4.3.6 Procedure for manual telescoping in the case of electrical faults

If there is an electrical fault, the load limit device (LLD) must be over-
ridden during manual telescoping for telescoping the telescoping cyl-
inder in and out. Otherwise, the procedure is in principle identical to
the one for mechanical faults (see corresponding section).
When bridging the LLD, you must differentiate between the
"EN 13000" and "Non-EN 13000" designs. See the corresponding de-
scriptions in the section "Safety equipment" at "Bridging the load limit
device".
You must remember in particular that bridging continues for a certain
period of time in the "EN13000" version. For the "Non-EN 13000" ver-
sion, the bridging button must be pressed again every time each tele-
scoping movement is carried out.
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DANGER
Risk of accidents, overturning and damage!
When the load limit device (LLD) is bridged, all crane
movements are carried out without crane control monitor-
ing whether the executed movements can cause risks.
Bridging may only be carried out by authorised per-
sons who are fully acquainted with operation of the
crane.
The crane operator must be aware that they are re-
sponsible for the resulting damages and accidents.
Proceed with appropriate caution
You must "teach" after completing telescoping in the case of electrical

(see "Teaching the extension state of the telescopes"). The "Manual
telescoping" screen cannot be exited without "teaching".
Coming off the inner guide rails
1 LPU position
NOTE
Risk of damage!
When the load limit device (LLD) is bridged, the telescopic drive
can be extended so far that it comes off the inner guide rails.
For this reason, there is a table with the approximate locking
and pinning positions of the LPU under subpoint "Locking and
pinning positions of the telescopic drive".
The table values correspond with the LPU position (1) in the
"Manual telescoping" screen.
If the corresponding locking and pinning position is not found,
probably several electronic sensors are defective at once. In this
case or when the telescopic drive has come off the inner sliding
rails please contact our customer services department.
If the telescopic drive has come off the inner guiding slides, tele-
scoping is no longer possible. The telescopic drive can be extended
but will always stick at the same place when being retracted.
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10.4.3.7 Locking and Pinning Positions of the Telescopic Drive
NOTE
Risk of damage!
The indicated extension lengths may be exceeded at the most
by approx. 0.05 m (approx. 0.164 ft) during manual telescoping
so that the telescopic drive cannot come off the inner guide
rails.
1 LPU position 2 Display of the telescopic section

number
The locking and pinning positions are required during manual tele-
scoping.
Observe the tables below to detect beyond a doubt at which pinning
hole the LPU is located for each respective telescopic section (display
of the telescopic section under "2") using the specification (1, LPU po-
sition).
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10.4.3.7.1 LPU Position of the Main Boom of the AC 250-5

Locking and pinning position
Telescopic Pinning hole LPU position LPU position
section (%) (m) (ft)
0 0,035 0.115
45 4,750 15.584
1
90 8,565 28.100
100 9,725 31.906
0 0,215 0.705
45 4,480 14.698
2
90 8,745 28.691
100 9,905 32.497
0 0,395 1.296
45 4,660 15.289
3
90 8,925 29.281
100 10,085 33.087
0 0,575 1.886
45 4,840 15.879
4
90 9,105 29.872
100 10,235 33.579
0 0,755 2.477
45 5,020 16.470
5
90 9,285 30.463
100 10,255 33.645
0 0,935 3.068
45 5,200 17.060
6
90 9,465 31.053
100 10,210 33.497
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0 0,035 0.115
45 4,750 15.584
1
90 8,265 27.116
100 9,475 31.086
0 0,215 0.705
45 4,330 14.206
2
90 8,445 27.707
100 9,785 32.103
0 0,395 1.296
45 4,510 14.797
3
90 8,625 28.297
100 9,935 32.595
0 0,575 1.886
45 4,690 15.387
4
90 8,805 28.888
100 10,055 32.989
0 0,755 2.477
45 4,870 15.978
5
90 8,985 29.478
100 9,885 32.431
0 0,935 3.068
45 5,050 16.568
6
90 9,165 30.069
100 10,180 33.399
0 1,115 3.658
45 5,230 17.159
7
90 9,345 30.659
100 10,165 33.350
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Telescopic Pinning hole LPU position
LPU position (ft)
section (%) (m)
0 0,035 0.115
45 4,600 15.092
1
90 8,265 27.116
100 9,445 30.987
0 0,215 0.705
45 4,330 14.206
2
90 8,445 27.707
100 9,625 31.578
0 0,395 1.296
45 4,510 14.797
3
90 8,625 28.297
100 9,785 32.103
0 0,575 1.886
45 4,690 15.387
4
90 8,805 28.888
100 9,935 32.595
0 0,755 2.477
45 4,870 15.978
5
90 8,985 29.478
100 9,975 32.726
0 0,935 3.068
45 5,050 16.568
6
90 9,165 30.069
100 9,930 32.579
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0 0,035 0.115
45 4,600 15.092
1
90 8,265 27.116
100 9,670 31.726
0 0,215 0.705
45 4,330 14.206
2
90 8,445 27.707
100 9,830 32.251
0 0,395 1.296
45 4,510 14.797
3
90 8,625 28.297
100 9,980 32.743
0 0,575 1.886
45 4,690 15.387
4
90 8,805 28.888
100 10,020 32.874
0 0,755 2.477
45 4,870 15.978
5
90 8,985 29.478
100 9,975 32.726
10.5 Capacities in the Unpinned State
10.5.1 General
Requirement
The capacity tables supplied apply only to extension conditions where
all telescopic sections are pinned to each other.
There are also load bearing capacities for the main boom when un-
pinned.
- There is no length code (LK) for raising loads in intermediate posi-
tions of the main boom (see 10.5.4 Lifting loads in unpinned in-
termediate positions, side 506).
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- If the main boom is to be telescoped with the load attached (see

10.5.5 Telescoping with a suspended load, side 507).
The main boom is extended to an length for which there is no length
code (LC).
Unpinned capacities are only for main boom operation.
In this case, the lowest extended telescopic section is not pinned to
the next telescopic section, but is connected to the telescoping cylin-
der via the LPU.
Limit of the load which can be attached
When attaching loads to the unpinned main boom, the capacity of the
telescoping cylinder and the deflection of the main boom additionally
limit the loads which can be attached.
10.5.2 Display of the "Unpinned capacities" table in crane control's
operating unit, side 501 describes how the table of unpinned ca-
pacities can be displayed in the control panel of crane control.
Display of the permitted capacities in crane control
The load limit device automatically carries out a comparison between
the pinned and unpinned capacities. The lower of the two load bear-
ing capacities compared is the maximum permissible load. This maxi-
mum permissible load will be shown in the "Crane operation" screen.
A relevant example can be found in "Example: Permitted capacity /
display in the "Crane operation" screen.
Applying the capacity in the unpinned state of the main boom
- Unpinned capacities for which the main boom length remains un-
changed, so-called "Capacities in intermediate positions". See
10.5.4 Lifting loads in unpinned intermediate positions, side 506.
- Unpinned capacities, for which the main boom length is changed

under load, so-called "Capacities which can be telescoped". See
10.5.5 Telescoping with a suspended load, side 507.
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10.5.2 Display of the "Unpinned capacities" table in crane control's operating unit
Fig. 375: "Quick menu" screen (schematic diagram)
1. Actuate the displayed button in the quick menu (left-hand side).
The "Selecting the operating mode" screen appears (right-

hand side of the figure).
2. In the "Selection of the operating mode" screen, press the dis-

played button.
Fig. 376: "Table view" screen (schematic diagram)
The "Table view" screen appears. The pinned capacities

(marked area) for the set operating mode appear there.
The button shown to the left is shown in the screen's footer.
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3. Press the depicted button in the "Table view" screen.
Fig. 377: "Table view" screen (schematic diagram)
The unpinned capacities (marked area) for the set operating

mode appear. The main boom symbol is changed as shown
(without double arrow).
The symbols on the buttons are very similar. They only differ by the
presence or absence of the double arrow.
10.5.3 Example: Permitted capacity / display in the "Crane operation" screen

The capacity tables shown in this section are examples.
WARNING
There is a risk of accidents when using the capacity
tables incorrectly.
Only use the capacity tables supplied with the crane
for crane operation.
10.5.3.1 Example: Capacity comparison AC 250-5

Pinned capacity
Fig. 378: "Pinned capacities" screen
A Main boom length B Radius

C Pinned capacity
For a main boom length (A) of 21.2 m / 69.6 ft (with LC 12) and a ra-
dius (B) of 4 m (13.1 ft), the pinned capacity (C) is 68.8 t / 151.7 kip.
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Unpinned capacity
Fig. 379: "Unpinned capacities" screen

D Unpinned capacity
dius (B) of 4 m (13.1 ft), the corresponding unpinned capacity (D)
would be 39.2 t / 86.4 kip.
Permitted capacity / display in the "Crane operation" screen
As described, the load limit device automatically compares the pinned
and unpinned capacities.
The lower of the two load bearing capacities compared is the maxi-
mum permissible load. In the "Crane operation" screen, this value for
the load bearing capacity is shown as the maximum permissible load
(here: MAX (t) 39.2 t / 86.4 kip).

Pinned capacity

C Pinned capacity
For a main boom length (A) of 21.0 m / 68.9 ft (with LC 12) and a
radius (B) of 4 m (13.1 ft), the pinned capacity (C) is 90.8 t /
200.2 kip.
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Unpinned capacity

D Unpinned capacity
(here: MAX (t) 36.3 t / 80.0 kip).

Pinned capacity

C Pinned capacity
radius (B) of 4 m (13.1 ft), the pinned capacity (C) is 56.4 t /
124.3 kip.
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Unpinned capacity

D Unpinned capacity
For a main boom length (A) of 20.6 m / 67.6 ft (with LK 12) and a radi-
us (B) of 4 m (13.1 ft), the corresponding unpinned capacity (D) would
be 33.6 t / 74.1 kip.
(here: MAX (t) 33.6 t / 74.1 kip).

Pinned capacity

C Pinned capacity
radius (B) of 4 m (13.1 ft), the pinned capacity (C) is 32.8 t / 72.3 kip.
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Unpinned capacity

D Unpinned capacity
(here: MAX (t) 12.6 t / 27.8 kip).
10.5.4 Lifting loads in unpinned intermediate positions

The main boom is extended to the required length before attaching
the load.
The main boom length remains unchanged when the load is attached.
The capacity values "MAX (t)" permitted by crane control when unpin-
ned can be raised.
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10.5.5 Telescoping with a suspended load

The capacity values "MAX (t)" permitted by the crane control system
when unpinned will also be enabled by the crane control system dur-
ing a telescoping procedure.
However, the capacities that are actually achievable during telescop-

ing under load are only given as approximate values due to the large
number of variable external influences.
The capacities which can be telescoped (on request) are achieved
under the following conditions:
- Sliding surfaces well lubricated
- Normal ambient temperature
- During telescoping, the main boom angle may not be changed us-
ing the luffing cylinder.
10.6 Put the main boom into transport condition

To move the crane into the transport position, all telescopic sections
must be completely retracted and pinned and the Locking and Pin-
ning Unit (LPU) must be secured at the position specified for the
transport condition. If the procedure described in this section is ob-
served, then this is ensured.
The basic procedure is the same for all main booms, independent of
the number of telescopic sections. Wherever figures are used to clari-
fy the description, the figures show a main boom with 5 telescopic
sections as an example.
WARNING
Risk of collision!
If the telescopic sections of the main boom are not pin-
ned in the intended position, either the main boom will
protrude too far to the front over the crane contour or the
telescopic sections can slip out in an uncontrolled fash-
ion while driving.
Bring the main boom into the transport position using
the procedure described in this section.
If the telescopic sections are not the position intended for driving,
the specified axle loads will not be correct.
The transport condition of the main boom is also the starting condi-
tion when fitting the main boom extension (see the section "Main
boom extension (optional)").
82640 2021-04-22 507

10 Telescoping
Requirements:
The main boom is telescoped in and placed on the crane chassis in
transport position (current length code LC1).
Fig. 386: "Selecting the operating mode" screen: Crane configuration
1. Set the "HA" crane configuration in the crane control's control

panel in the "Selecting the operating mode" screen.
If a deviating setting is made for the crane configuration, then the

button for selection of the length code to establish the driving config-
uration will not be shown in the "Length code (LC) selection" screen
which is used in one of the following work steps.
The displays in the "Select operating mode" varies in details. This

does not affect the procedure described.
2. Leave the screen with "Save".
The "Crane operation" screen with partial "Quick menu"

screen appears.
3. Select the "Telescoping display" in the "Quick menu" screen.

Press the button shown to do so.
Fig. 387: "Telescoping display" screen (schematic diagram)
The "Telescoping display" screen appears.
508 82640 2021-04-22

10 Telescoping
4. Select the "Length code (LC) selection" screen in the "Telescop-

ing display" screen. Press the button shown to do so.
The "Length code (LC) selection" screen appears.
5. Select the length code to establish the driving configuration of

the main boom for driving the crane in the "Length code (LC) se-
lection" screen. Press the button shown to do so.
The "Telescoping display" screen with selected "LC0" appears

again. The "LC0" button is shown in grey.
6. Move the control lever to which the telescoping movement is as-

signed in the "Telescope out" direction.
The locking and pinning unit (LPU) will be corresponding
moved and secured.
82640 2021-04-22 509

10 Telescoping
Fig. 391: Main boom in the transport condition (schematic diagram)
The control lever must remain pressed until a symbolic crane is dis-
played in the top half of the "Telescoping display" screen. Only then is
the main boom, including the LPU, in transport condition for driving
the crane.
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11 Luffing
11 Luffing
11.1 Luffing Operation
11.1.1 General Safety Instructions
Fig. 392: Luffing the main boom (schematic diagram)
The main boom is raised or lowered (luffing) by retracting or extend-

ing the luffing cylinder (see Fig. 392, side 511).
If a prohibited overload condition has occurred, the load-moment-re-
ducing "Luff up" movement will also be shut down by the load limit de-
vice. The "Luff up" movement can be bridged to move a freely sus-
pended load back out of the overload range and into the normal oper-
ating range. Observe the description in section "Safety description".
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (hook) must
be lowered (see section "Hoist 1" under "Procedure for reeling in and
unreeling the hoist rope").
82640 2021-04-22 511

11 Luffing
11.1.2 Procedure for Luffing

Requirements:
and counterweight and supported on outriggers horizontally.
Fig. 393: Optional stop valve on the main boom (schematic diagram)
1 Ball valve
- Optional stop valve (see Fig. 393, side 512) for blocking the bot-
tom of the luffing cylinder is in the open position (position for crane
operation, see also 11.4 Dolly Preparation / Preparation for Dis-
mantling the Main Boom (Options), side 515).
Procedure:
WARNING
crane movements.
crane movement.

modes can be found under 8.1.7.11.4 Control Lever Assignments
(6 Modes), side 309 described.
512 82640 2021-04-22

11 Luffing
WARNING
out.
celerations.
WARNING
Risk of accidents!
movements".

NOTE
Risk of damage!
Control levers may must not be switched directly in an opposite
direction, but must first rest in the neutral position. A counter
movement may be initiated only after movement has ceased.
2. Initiate luffing movement by actuating one of the buttons of the

"Release switch system" and carefully steering the correspond-
ing control lever (see arrows) in the corresponding direction.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the hook)
must be lowered (see 12 Hoist 1, side 517).
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11 Luffing
11.2 Regulating the Luffing Speed
Fig. 394: Control levers - crane opera-

tor’s cab
The luffing gear is electrically pre-controlled. The luffing speed de-

pends on the engine speed and the movement of the corresponding
control lever (see Fig. 394, side 514).
11.2.1 High speed mode "Raise main boom"

A high-speed mode can be selected to raise the main boom (luffing
up) (see section "Safety equipment" under "High speed mode").
WARNING
Risk of accidents when using high speed!
The high speed mode may not be used for operation
with loads > 30% of the capacity, with the fly jib fitted
or for raising the fully or partially extended main
boom.
WARNING
Risk of overturning due to dynamics!
It is only permitted to activate the luffing gear in high
speed mode during main boom operation without
loads well before shutdown by the load limit device
(at latest up to the advanced warning).
11.2.2 Fine tuning "Lowering main boom"

In addition, speed fine tuning is possible for lowering the main boom
(luffing down) (see section "Safety equipment" under "Fine tuning of
the movement speed").
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11 Luffing
11.3 Setting down the Main Boom in the Support Device for the Boom
When setting down the main boom in the support device for the
boom, the alignment of the superstructure and the luffing angle of the
main boom must be selected so that no components of the chassis
(e.g. hydraulic tank of the chassis) are damaged.
For this crane type, this is supported by a movement limit. The slew
gear and luffing gear are shut down before anything can be damaged.
The superstructure position must then be corrected accordingly be-
fore the main boom can be lowered any further.
The setting down procedure is carried out at a superstructure angle of
180°.
Fig. 395: Slew display in the "Crane operation" screen
The slew display in the "Crane operation" screen indicates in which

direction slewing is possible if there is a shut-down (see section
"Slewing the superstructure" under "Slewing angle / slewing direc-
tion").
11.4 Dolly Preparation / Preparation for Dismantling the Main Boom (Options)
Fig. 396: Stop valve - luffing cylinder
If the crane is prepared for driving with dolly (optional) or for disman-
tling the main boom (optional), there is a stop valve (see arrow in the
figure) to block the bottom-side oil supply of the luffing cylinder. Stop
valve (see arrow in the figure) must be open for crane operation; that
is, the bottom-side oil supply of the luffing cylinder must be ensured.
If the stop valve is closed, the main boom cannot be luffed up or

down.
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11 Luffing
516 82640 2021-04-22

12 Hoist 1
12 Hoist 1
12.1 Hoist operation
12.1.1 General Safety Instructions

Loads are raised or lowered by reeling the hoist rope onto the rope
drum of the hoist or by unreeling the hoist rope from the rope drum of
the hoist.
Observe the reeling behaviour of the hoist (see "Camera monitoring

of the hoist (optional)" in this section).
12.1.2 Procedure for reeling the hoist rope in and out

Requirements:
and counterweight and supported on outriggers horizontally.
Procedure:
WARNING
crane movements.
crane movement.

modes are described in section "Safety equipment" under "Control
lever assignment (6 modes)".
82640 2021-04-22 517

12 Hoist 1
WARNING
out.
celerations.
WARNING
Risk of accidents!
movements".

NOTE
Risk of damage!
Control levers may must not be switched directly in an opposite
direction, but must first rest in the neutral position. A counter
movement may be initiated only after movement has ceased.
2. Initiate the hoist movement by actuating one the keys of the "Re-
lease switch system" and carefully steering the control levers in
the corresponding direction.
Fig. 397: Control lever, right
As soon as hoist 1 rotates, vibration is felt on the rotation indi-

cator of the right-hand control lever.
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12 Hoist 1
- The movement "raise load" is automatically shut down when :

- the load limit device has shut down.
- the hook block in the hoist limit switch is activated.
- Lowering load is possible.
- The movement "lower load" is automatically shut down, when the
lower limit switch for hoist 1 has tripped. It is possible to raise the
load.
- If the hook is fully raised, and if the hoist limit switch has trig-
gered, the main boom can no longer be lowered. First the hoist
(the hook) must be lowered.
- To prevent the high-running/low-running hoist rope from cutting
into the rope structure, observe section "Working instructions" un-
der "Picking up loads at great height or reeling onto the top rope
layers of the winches".
12.2 Regulating the hoist speed

The hoist is pilot controlled electrically. The hoist speed depends on
the engine speed and the movement of the corresponding control lev-
er.
12.2.1 High speed

A high speed mode can be actuated for the hoist (see section "Safety
equipment" under "High speed mode").
NOTE
Risk of damage when using the high speed mode.
The high speed mode may not be used for operation with loads
> 30% of the capacity or for single rope operation of the main
boom extension.
12.2.2 Fine tuning

In addition, speed fine tuning can take place for the hoist (see section
"Safety equipment" under "Fine tuning of the movement speed").
82640 2021-04-22 519

12 Hoist 1
12.3 Camera monitoring of the hoist (optional)
Fig. 398: Camera and display
1 Display 2 Camera
A camera (2) is attached to hoist 1 to monitor of the hoist rope's reel-

ing behaviour. The camera is permanently installed.
The display (1) is in the crane operator’s cab.
When the ignition is switched on, the camera pictures appear in dis-
play (1) if it is turned on.
Observe the detailed specifications on operating the camera and

display under 9.3 Cameras on the crane (option), side 417.
520 82640 2021-04-22

13 Hoist 2 (optional)
13.1 Transport Dimensions and Weights
Fig. 399: Hoist 2 (width / height) Fig. 400: Hoist 2 (depth)
Width Height Depth Weight

mm ft mm ft mm ft kg lbs
1066 3.5 779 2.6 1783 5.9 1600 3530
All specifications are approximate values.
13.2 Fitting and Removing Hoist 2
13.2.1 General
Hoist gear 2 can be fitted and removed in the following ways:
- using an auxiliary crane (see 13.2.2 When Fitting and Removing
Hoist 2 with the Auxiliary Crane, side 522)
- using a forklift truck (see 13.2.3 When Fitting and Removing
Hoist 2 with the Forklift Truck, side 531)
- with your own crane using special-purpose accessories (option)
(see 13.2.4 Fitting and removing hoist 2 with your own crane
(optional), side 532.
82640 2021-04-22 521

WARNING
fied.
Equipment may only be fitted and removed by trained
and qualified personnel!
WARNING
ary equipment.
Carry out all assembly work/work at height using suit-
able auxiliary equipment (ladders, hoist platforms,
scaffolding, auxiliary crane, personal protective
equipment).
Observe the detailed information on this subject in
the section "Structure of the mobile crane" under
"Getting on and down from the crane", in particular
"Getting on and off using mobile multi-purpose lad-
ders" and "Attachment eyelets for personal protective
equipment".
NOTE
Risk of damage due to interchanged crane components!
Only attach hoist 2 (including all auxiliary and assembly equip-
ment) delivered with the crane.
13.2.2 When Fitting and Removing Hoist 2 with the Auxiliary Crane
13.2.2.1 Before Fitting

1. Support the crane correctly on outriggers and align. Select the
outrigger support area in accordance with the subsequent crane
operation. Please observe the corresponding description in the
operating instructions of the crane chassis.
We recommend first fitting hoist 2 and then the counterweight. This

makes it easier to knock in the connecting pins for fastening hoist 2.
Generally, it is also possible to fit hoist 2 with the counterweight fit-
ted.
Exception: For the two largest counterweight combinations 51.6 t
(113.8 kip) and 70.2 t (154.8 kip), first the top counterweight plate
(5) must be removed to obtain sufficient space to retract hoist 2 from
below into the fitting position.
2. A trained assembly assistant must be on the crane in the assem-

bly area.
522 82640 2021-04-22

Fig. 401: Hoist 2 with rope shackle
1 Rope shackles
3. Release rope shackle (1) from the transport position on hoist 2

and fit (see section "Reevings" under "Reeving/unreeving the
hoist rope").
Fig. 402: Hoist 2 with pins
1 Pins
4. Check that the 4 pins (1) are fitted and secured in the fork heads
of hoist 2 as illustrated. They are used at a later point during the
fitting procedure to fix in place the assembly position of hoist 2.
82640 2021-04-22 523

13.2.2.2 Fitting
NOTE
Risk of damage to the hoist and the superstructure frame.
In the following, hoist 2 may neither swing out nor hang crook-
edly.
CAUTION
Risk of crushing between hoist 2 and the superstruc-
ture frame.
Maintain sufficient safety clearances.
DANGER
Risk of accidents under suspended loads or in areas
where loads/equipment could fall.
1. Attach hoist 2 to the two middle lifting lugs of the auxiliary crane
as illustrated.
Hoist 2 weighs approx. 1600 kg (3530 lbs).
524 82640 2021-04-22

Fig. 403: Hoist 2 on the superstructure frame
2. Raise and position hoist 2 so that the pins in the fork heads of
hoist 2 are aligned with the corresponding hook jaws on the su-
perstructure frame as illustrated.
Fig. 404: Hoist 2 on the superstructure frame
3. Using the auxiliary crane, raise hoist 2 until the pins in the fork
heads of hoist 2 are retracted into the hook jaws on the super-
structure frame - as illustrated.
82640 2021-04-22 525

WARNING
ary equipment.
Additional suitable auxiliary equipment (e. g. lifting
platform) must be used to safely carry out this work at
height.
Fig. 405: Hoist 2 on the superstructure Fig. 406: Hoist 2 on the superstructure
frame frame
1 Pins 1 Pins
4. Pin hoist 2 on both sides using pins (1) - as illustrated - and se-
cure each pin with forelocks.
5. Release the auxiliary crane.
13.2.2.3 Connecting
1. Position the superstructure to the crane chassis (see adjacent

schematic diagram) so that there is sufficient access on the
crane chassis to create the hydraulic and electric connections on
the superstructure.
2. Release the hydraulic hoses and electric cables from of the

transport position. To do so, release the protective tube on the
transport receptacle (above the hoist motor) , remove the hoses
and cables and reattach and secure the protective tubes.
526 82640 2021-04-22

It is only ever permitted to create and release hydraulic connections

in the depressurised state, that is, the engine may not be running.
NOTE
Risk of damage when the quick disconnect couplings are con-
nected incorrectly.
Closed or only partially open non-return valves of the quick release
couplings can cause damage to the hydraulic system.
Screw quick disconnect couplings in up to the stop.
3. Connect hoist 2 hydraulically and electrically. To do so, unscrew

the protective caps from the corresponding hydraulic couplings /
sockets and fully screw on the quick release couplings of the cor-
responding hydraulic hoses or plug in the connecting cable
plugs.
The coupling sleeves and plugs of the hydraulic quick release cou-
plings are marked with plates. Connect the connections with identi-
cal markings. For marking of the connections, observe Fig. 407,
side 527 and Fig. 408, side 528.
Fig. 407: Connection
1 Mobile control panel for driving the hydraulic cylin- 2 Distribution box hoist 2 (X8200)
ders of the configuration aid hoist 2 (XS560.1)
3 Camera hoist 2 (X7134) 4 Can bus hoist 2
82640 2021-04-22 527

Fig. 408: Connections (schematic diagram)
6 Control pressure for releasing the brake (DN 8, 7 Lower hoist 2 (DN 32, nominal diameter about
nominal diameter approx. 8 mm / 0.31 in) 32 mm / 1.25 in)
8 Raise hoist 2 (DN 32, nominal diameter about 9 Leak oil (DN 20, nominal diameter approx. 20 mm /
32 mm / 1.25 in) 0.8 in)
17 Retract hydraulic cylinders of the configuration aid 18 Extend hydraulic cylinders of the configuration aid
(DN 8, nominal diameter approx. 8 mm / 0.31 in) (DN 8, nominal diameter approx. 8 mm / 0.31 in)
Connections (17) and (18) are only available for the optional "Fitting
and dismantling using your own crane" for driving the erection cylin-
ders (see from 13.2.4 Fitting and removing hoist 2 with your own
crane (optional), side 532).
528 82640 2021-04-22

If the crane is equipped with the superstructure central lubricating

system, connect hoist 2. To do so, carry out the following work steps.
Fig. 409: Supply line
1 Protective cap 2 Coupling

3 Return line plug
4. Remove the return line plug (3) from the depicted collecting plate
of coupling (2) of the supply line and close it with protective cap
(1).
NOTE
Risk of damage due to contamination in the central lubricating
system.
The free plug of the return line may not remain unprotected so
that no contamination can get into the lubrication system.
In the same way, after dismantling hoist 2 and disconnecting the

lube line of hoist 2, it must be closed with a protective cap and the
return line must be reconnected to the supply line coupling.
82640 2021-04-22 529

Fig. 410: Supply line
1 Coupling 2 Lube line plug (optional)
5. Remove the protective cap and then fit lubricant line plug (2)
from hoist 2 to coupling (1) of the supply line as illustrated
DANGER
the endangered area!
After making the connections, the assembly assistant
must exit the crane and the endangered area.
NOTE
Risk of damage due to fitting the hoist rope incorrectly.
For fitting / reeving the hoist rope, you must observe the corre-
sponding specifications in the section "Reevings" under "Hoist
ropes".
13.2.2.4 Dismantling
The procedure for dismantling hoist 2 is the same as for fitting, but in
the reverse sequence.
DANGER
observed.
In particular, observe the safety instructions listed un-
der Fitting (see 13.2.2.2 Fitting, side 524).
530 82640 2021-04-22

13.2.3 When Fitting and Removing Hoist 2 with the Forklift Truck
Fig. 411: Hoist 2 (schematic diagram)
1 Forklift pockets
DANGER
Risk of accidents due the hoist falling down.
When raising/lowering hoist 2 with a forklift truck, en-
sure that hoist 2 is lying fully on the forks of the forklift
truck.
Only the four forklift pockets (1) may be used to pick
up hoist 2.
In principle, fitting and dismantling with a forklift truck is as described

from 13.2.2 When Fitting and Removing Hoist 2 with the Auxiliary
Crane, side 522 for using an auxiliary crane.
However, observe the following special features as well:
- Superstructure is rotated so that the forklift truck can safely reach
the assembly area.
- The ground at the assembly area must be suitable for the forklift
truck to be positioned safely.
- Forklift truck with sufficient capacity.
82640 2021-04-22 531

13.2.4 Fitting and removing hoist 2 with your own crane (optional)
13.2.4.1 General
Fig. 412: Hoist 2 on configuration frame (schematic diagram)
1 Hoist gear 2 2 Erection cylinder

3 Configuration frame
In order to fit and dismantle hoist 2 using your own crane, the basic
crane and hoist 2 (1) must be equipped accordingly in terms of hy-
draulics and configuration frame (3) is required. Among other things,
hoist 2 is then equipped with two erection cylinders (2) which are
used to place it in the fitting position.
13.2.4.2 Before Installation

1. Observe the specifications under 13.2.2.1 Before Fitting,
side 522.
Fig. 413: Counterweight support - crane chassis
2. Set counterweight combination 13.1 t (28.9 kip) down on the

counterweight support of the crane chassis (as for fitting the
counterweight). Observe the corresponding description in the
section "Counterweight".
NOTE
The attached load is oscillating or hanging crookedly.
Risk of damage for the attached load.
Attach the load correctly at the specified attachment points.
Raise, move or position the load evenly (not abruptly).
532 82640 2021-04-22

1 Hoist gear 2 2 Erection cylinder

3 Configuration frame
3. Using your own crane, attach hoist 2 (1) to the two middle lifting
lugs and set down on configuration frame (3) so that the piston
rods ends of the two erection cylinders (2) are aligned with the
corresponding receptacles on the configuration frame.
82640 2021-04-22 533

1 Bolts
4. On both sides, remove pins (1) from the transport position on the
configuration frame and pin and secure to the corresponding
shackles of the configuration frame as illustrated.
Hoist 2 and the configuration frame are connected with each
other. They form an assembly unit from this point.
534 82640 2021-04-22

13.2.4.3 Fitting
13.2.4.3.1 Fitting the assembly unit on the draw bars of the counterweight
Fig. 416: Attaching the assembly unit (schematic diagram)
1. Attach the assembly unit to the lifting lugs of the hoist on both
sides - however, not to the middle ones at this point, but to the
rear ones.
After raising, this results in a slightly tilted assembly unit posi-
tion, which makes the following fitting procedure easier.
The assembly unit weighs approx. 1770 kg (3902 lbs).
82640 2021-04-22 535

Fig. 417: Assembly of hoist 2 (schematic diagram)
1 Spigot 2 Shackles
3 Draw bars
2. Raise the assembly unit and position it in the area of the draw
bars of the counterweight combination which has been set down
- as illustrated.
3. Retract the assembly unit with spigots (1) and shackles (2) at the
corresponding counterparts on the draw bars (3).
536 82640 2021-04-22

Fig. 418: Assembly of hoist 2 (schematic Fig. 419: Assembly of hoist 2 (schematic
diagram) diagram)
1 Bolts 1 Bolts
2 Draw bars 2 Draw bars
4. Remove pins (1) from both sides of the transport position on

hoist 2 (see figure Fig. 418, side 537) and pin and secure them
as shown in ( Fig. 419, side 537).
The assembly unit is then pinned to the draw bars (2) on both
sides.
5. Release lifting tackle from the assembly unit.
82640 2021-04-22 537

13.2.4.3.2 Fitting hoist 2 on the superstructure frame
Fig. 420: Hoist 2 below superstructure

frame (schematic diagram)
1. Slew the superstructure so that the main boom is to the rear. The
pins in the fork heads of hoist 2 are aligned with the hook jaws
on the superstructure frame (see arrows).
Fig. 421: Connections erection cylinder hoist 2 (schematic diagram)
17 Connection erection cylinder 18 Connection erection cylinder

hoist 2 hoist 2
2. At first, only create the hydraulic connection for both erection cyl-
inders on hoist 2 (connections "17" and "18"). Observe the corre-
sponding description in 13.2.2.3 Connecting, side 526 to create
the hydraulic connections.
538 82640 2021-04-22

Fig. 422: Collecting plate (schematic diagram)
1 Mobile control panel 2 Socket
3. Plug mobile control panel (1) into socket (2) on the collecting
plate.
Fig. 423: Hoist 2 on superstructure frame

Fig. 424: Mobile control panel
(schematic diagram)
1 Selector switch
2 Rocker switch
4. Extend erection cylinder (see arrow) until the 4 pins in the fork
heads of hoist 2 are all retracted up to the stop into the corre-
sponding hook jaws on the superstructure frame. To do so,
switch selector switch (1) in the mobile control panel to position
"1" while the engine is running and press rocker switch (2) up un-
til this state has been reached.
82640 2021-04-22 539

DANGER
Risk to life and limb due to the hoist falling down if
pins are pinned incorrectly!
For a detailed description of pinning and securing
these pins, you must observe the corresponding de-
scription in 13.2.2.2 Fitting, side 524.
WARNING
ary equipment.
Additional suitable auxiliary equipment (e.g. lifting
height.
Fig. 425: Hoist 2 on superstructure frame Fig. 426: Hoist 2 on superstructure frame
(schematic diagram) (schematic diagram)
1 Bolts 1 Bolts
5. Pin hoist 2 to the superstructure frame on both sides. To do so,

remove pins (1) from the shackles - connection between hoist 2
and the configuration frame is released - and pin and secure as
illustrated.
540 82640 2021-04-22

Fig. 427: Hoist 2: Erection cylinder re-

tracted (schematic diagram)
1 Selector switch
2 Rocker switch
6. Fully retract both erection cylinders (see arrow for left side). To
do so, switch selector switch (1) in the mobile control panel to
position "1" and press rocker switch (2) down until this state has
been reached.
7. Remove the mobile control panel from the socket on the collect-
ing plate.
8. Connect all the hydraulic and electric lines of hoist 2. Observe
the corresponding description in 13.2.2.3 Connecting,
side 526.
9. If the crane is equipped with the superstructure central lubricat-
ing system (optional), connect hoist 2. Observe the correspond-
ing description in 13.2.2.3 Connecting, side 526.
82640 2021-04-22 541

13.2.4.3.3 Removing the configuration frame
DANGER
Risk of crushing in the slewing range of the super-
structure.
The assembly assistant must leave the area at risk
before the superstructure is slewed in the following
procedure (e.g. by getting down from the crane).
If the assembly assistant remains on the crane out-
side of the slewing range, he must remain in constant
contact with the crane operator.
Fig. 429: Configuration frame (schematic diagram)
1. Once the crane operator has ensured that there is no longer any-
one in the area at risk, slew the superstructure to dismantle the
configuration frame (see arrow) using your own crane. To do so,
attach the configuration frame to the crane using suitable lifting
slings.
The configuration frame weighs approx. 227 kg (500 lbs).
2. Slightly tension the lifting tackle so that the crane takes the
weight of the attached configuration frame.
542 82640 2021-04-22

Fig. 430: Configuration frame (schematic diagram)
1 Bolts
3. Once the configuration frame is securely attached (lifting tackle

not depicted), unlock and pull out pins (1) and pin in the top
shackles (transport position) and secure.
4. Raise the configuration frame and set it down.
5. Either dismantle the remaining counterweight combination as
well or fit to the superstructure frame, possibly after adapting the
fitted counterweight combination.
DANGER
Risk of the crane overturning due to incorrect coun-
terweight.
Only operate the crane if the fitted counterweight cor-
responds with the one set on the crane control and
the corresponding capacity table.
13.2.4.4 Dismantling
Hoist 2 is removed in the same way as it is fitted, only in the reverse
order.
DANGER
observed!
In particular, observe the safety instructions listed un-
der Fitting (see 13.2.4.3 Fitting, side 535).
13.3 Hoist operation

For detailed specifications on raising or lowering loads with hoist 2,
see the corresponding point in the section "Hoist 1" analogously.
82640 2021-04-22 543

Fig. 431: Rotary transmitter H2 on the left control lever
The following differences must be observed:

- Select a mode for the control lever assignment which enables op-
eration of hoist 2.
- Slewing of is displayed by a vibration on the hoist rotation indicator
(see arrow) of the left-hand control lever.
13.4 Regulating the hoist speed

For more detailed information on regulating the hoist speed see sec-
tion "Hoist 1" under "Regulating the hoist speed".
13.5 Camera surveillance of the hoist (optional)
Fig. 432: Hoist camera (schematic diagram)
1 Hoist camera 2 Star knob screw
A hoist camera (1) can be fitted to hoist 2 to monitor the hoist rope's
reeling behaviour. This camera is simply fitted by screwing it in place
with star knob screw (2) - as illustrated.
544 82640 2021-04-22

Fig. 433: Connection - hoist camera (schematic diagram)
Plug the hoist camera plug on the collecting plate into the corre-
sponding socket (see arrow) to connect the camera electrically.
Fig. 434: Crane operator’s cab display
As soon as the ignition and the display are switched on, the images
from the camera are displayed (see arrow) in the crane operator's
cab.
For detailed information on operating the camera and display, ob-

serve the specifications in 9 Working Instructions, side 373 and
the corresponding manufacturer's documents in the part "Various"
Fig. 435: Camera hoist gear 2 (schematic diagram)
1 Camera 2 Hoist gear 2
As long as hoist 2 is not fitted, the camera of hoist 2 (2) can be fitted
at the back on the superstructure frame - next to camera (1) for
hoist 1 - as illustrated. This makes it possible to monitor the rearward
crane surroundings.
82640 2021-04-22 545

546 82640 2021-04-22

14 Heating and Ventilation
14.1 Cab heater arrangement, engine-independent (optional auxiliary heating)
14.1.1 General
The crane operator's cab can be heated using the cab heater ar-
rangement. The heating system has its own water circuit.
14.1.2 Operating / Safety Instructions
WARNING
Risk of poisoning and asphyxiation.
Operating the heater assembly in enclosed spaces, e. g.
garages or car parks, causes poisoning and asphyxiation
of persons.
Never operate the heater assembly in enclosed
spaces, e.g. garages or car parks.
WARNING
Risk of fire and explosion!
Operating the heater assembly can cause flammable va-
pours and dust to ignite and explode. This can cause se-
rious injuries, burns or death.
Do not use the heating device if combustible vapour
or dust may build up (e.g. at filling stations or near
fuel, coal dust, wood dust, grain storage and similar).
WARNING
Risk of burning on the heater assembly.
Working on the heater assembly can cause burns.
Switch off the heating device and let all hot compo-
nents cool down when working on the heating device
or in its vicinity.
WARNING
Risk of injury by electric shock.
Components of the heater assembly can conduct high
electrical currents, which can cause serious injuries
when touched.
The electric fuse must be removed before any work
on the heater assembly is carried out.
82640 2021-04-22 547

NOTE
Only a contractual partner authorised by the manufacturer may
repair the heater assembly. Repairs by unauthorised third par-
ties and / or using non-original spare parts are dangerous and
hence not allowed.
The original installation condition of the heating device and the
corresponding components should not be changed. This is es-
pecially applicable for electric wiring, fuel supply, combustion
and flue gas evacuation.
Defective fuses must be replaced with the ones having the pre-
scribed rating.
Before the heating period a test run must be carried out using
the heater assembly. If thick smoke develops, remaining for an
extended period of time, or if there are unusual noises from the
burner or a definite stench of burning, the heating must be
switched off and put out of operation by removing the fuse. The
equipment should only be restarted once it has been tested by
authorised service personnel.
During electric welding work on the vehicle, the + pole must be
disconnected from the battery and connected to ground to pro-
tect the control unit.
If the crane is equipped with an optional battery isolating switch, the

heater assembly must be switched off and the after-run time should
elapse before disconnecting the battery.
548 82640 2021-04-22

NOTE
Risk of damage!
If the battery is disconnected while the heater assembly is running,
or if the after-run time is not allowed to elapse, the heater assembly
can overheat and become damaged.
Only disconnect batteries after switching off the heater assem-
bly and expiration of the after-run time.
Switch on the heater assembly for approximately 10 minutes about

once a month, even outside of regular heating periods. This prevents
the water pump and burner motor from seizing up.
Fuel: The heater assembly is connected to a separate fuel tank (on
the superstructure) (for fitting location see chapter "Structure of the
mobile crane" under "Main elements" or "Overview of the superstruc-
ture").
NOTE
Risk of damage due to unsuitable fuel.
Only operate the heating system using fuel in accordance with
DIN EN 590.
From an ambient temperature of 0°C, use winter diesel.
No biodiesel may be used.
- Before switching on and during later operation, the filling level of

the diesel tank must be checked regularly by visual inspection on
the inspection glass/sight window (for details, see the "Lubrica-
tion and maintenance instructions" in the "Heating system" sec-
tion at "Cab heater arrangement, engine-independent").
- Do not allow the tank to run dry. Air can get into the lines. The
heating system goes to "Fault".
- After filling the tank, clear the fault memory (see 14.1.7.5 Read-
ing/deleting fault code (workshop menu), side 565). The heat-
ing system can only be restarted afterwards.
After a long operational break, check the fuel system for leak tight-
ness; have leaks repaired immediately.
82640 2021-04-22 549

14.1.3 Heating system operating elements
14.1.3.1 Control Elements in the Crane Operator's Cab
Fig. 436: Crane operator's cab operating elements (schematic diagram)
1 Rotary switch - fan 2 Rotary switch - temperature

3 Rotary switch - fan air distribu- 4 Switch - fresh air / recirculated
tion air operation
5 Heating system operating ele-
ments
The temperature in the crane operator's cab can be regulated via a

rotary switch (2). A fan can also be installed via the rotary switch (1).
The air exchange in the cab can be accelerated accordingly by using
the fan.
The fan's air distribution in the cab is monitored using a rotary switch
(3).
In the cab there are several vent nozzles. The air vents can be
opened and closed individually as required.
To achieve a maximum effect of the defroster nozzles at the front
window, the other air vents should be closed.
Air distribution only at the defroster nozzles of the front

-
window.
- Air distribution only at the vent nozzles in the foot area.
You can select between fresh air and recirculated air operation using
switch (4). To do this, actuate the switch (4) according to the symbols:
- Fresh air operation
- Recirculated air operation
550 82640 2021-04-22

14.1.3.2 Overview of the display and the buttons
Fig. 437: Operating element of the heater timer
1 Display 2 Control button

3 LED ring 4 BACK key
14.1.3.3 Display
Fig. 438: Display
1 Menu bar 2 Input/status area
The display shows the following parameters:

- Current operating condition
- Operating mode
- Timer slots
- Settings
- Error Codes
In the menu bar (1), the selected menu is shown in the centre of the
display. The corresponding setting value flashes in the input range
(2). It can be changed and confirmed with the control button.
Display
The display shows the overview screen at startup and then goes into
sleep mode. A set and active heating program is still carried out.
The display must be reactivated before a new entry can be made
(see 14.1.3.4 Activating the display, side 552).
82640 2021-04-22 551

Menu bar
Sym- Sym-
Meaning Meaning
bol bol
Heating Ventilation
Residual heat Settings
Timer
Input/status area
When the menu is activated (heater, fan, settings, timer or residual
heat), the respective selected information is displayed in the status
area.
14.1.3.4 Activating the display

As long as the ignition of the crane operator's cabin is on, the display
is permanently illuminated.
If the ignition is not "on", the display can be activated as follows:
- Press or turn the control knob.
- Press the BACK button.
The display goes into sleep mode after 30 seconds if no setting is se-
lected. The display must be reactivated before a new entry can be
made.
14.1.3.5 Function control button, LED ring and BACK key

Control button
The control button is used to select and program all menus and val-
ues of the heater timer.
Turning selects a menu, value or function.
- Turning to the right increases a value or selects the menu point on
the right.
- Turning to the right decreases a value or selects the menu point on
the left.
Pressing confirms the respective flashing menu point or the value in
the display.
Observe the activation time for the control button .

"SHORTPRESS": press <2 sec.
"LONGPRESS": long press >2 sec.
552 82640 2021-04-22

LED ring
The LED ring indicates the current operating mode using different col-
ours.
Colour Meaning Colour Meaning

Red ring Heating Operation Blue ring Fan operation
Orange Residual heat opera-
White ring System configuration
ring tion
Error in the heater as-
Red flash-
sembly or the heater
ing ring
timer.
BACK key
The BACK key returns to the next higher level in the menu or to
the previous value.
14.1.4 Switching the heating on
14.1.4.1 General
The filling level of the fuel tank must be checked regularly before
switching the system on and during subsequent operation.
NOTE
If a start attempt has been unsuccessful, another start may only
be attempted after five minutes.
14.1.4.2 Immediate heating without settings
1. Press the control button for longer than 2 seconds.

Heating is switched on.
The setting values are adopted from the previous heating op-
eration. The remaining time is displayed. The LED ring lights
up red.
2. Set the heating level using the middle rotary switch.
14.1.4.3 Heating with settings

Requirements:
- The display is activated (see 14.1.3.4 Activating the display,
side 552).
82640 2021-04-22 553

The functions described in the following can be

-
Selected by turning the control button ,
-
Confirmed by pressing the control button .
Cancel the settings by pressing the BACK key .
1. Press the control button .
2. Set the operating duration.
Heating is switched on.
The setting values are adopted from the previous heating op-
eration. The remaining time is displayed. The LED ring lights
up red.
The setting range for the operating duration is between a minimum

of 10 and maximum of 720 minutes. The changed operating dura-
tion is offered again at the next start.
3. Set the heating level using the middle rotary switch.
14.1.4.4 Changing the operating duration during heating operation

Requirements:
side 552).

-
-
554 82640 2021-04-22

2. Select the flashing "Heater" menu.
3. Select the "Settings" menu.

Heating is continued with the set operating duration.
The remaining time is displayed. The LED ring lights up red.
14.1.4.5 Switching off the heating system

Requirements:
side 552).

-
-
2. Select the flashing "Heater" menu.
3. Press the control button again when "OFF" is flashing.

The heating system is switched off.
Press control button >2 seconds (LONGPRESS). The heating

operation ends immediately.
There is some after-run time after switching off the heater assembly.
82640 2021-04-22 555

NOTE
Risk of damage!
If the battery is disconnected while the heater assembly is running,
or if the after-run time is not allowed to elapse, the heater assembly
can overheat and become damaged.
Only disconnect batteries after switching off the heater assem-
bly and expiration of the after-run time.
If the crane is equipped with an optional battery isolating switch,

switch off the heater assembly and wait for the after-run time to
elapse before disconnecting the battery.
14.1.5 Preselection times
The "Timer" menu controls three programmable timer slots. The

timer slots can either be distributed over one or more weekdays or
weekday ranges that can be combined as desired.
Weekday ranges
Weekday ranges are defined days within a week, e.g.
Mon-Fri 5 x heatings
Mon-Sun 7 x heatings
If a weekday range is activated, all weekdays are processed one after

the other. After a weekday range has been processed, the timer slot
must be reactivated for the following week.
If the weekday range Mon-Fri is activated on Wednesday, the heater
assembly heats on Wednesday, Thursday and Friday. Operation con-
tinues on Monday and Tuesday (5 x heatings) of the following week.
14.1.5.1 Selecting timer slot

Requirements:
side 552).

-
-
556 82640 2021-04-22

1. Select the "Timer" menu.
Activated program memories are marked with a tick .
2. Select timer slot 1, 2 or 3 (here 1).
14.1.5.2 Programming the timer

Requirements:
side 552).
- A timer slot is selected (see 14.1.5.1 Selecting timer slot,
side 556).
The preselection time is the time by which the cab should be warm.
This corresponds to the finish time in the standard settings (see
14.1.6.1 First Operation, side 559).

-
-
1. Select the "Settings" menu in the selected timer slot.
2. Select an individual weekday Mon-Sun or group of weekdays

Mon-Fri, Sat-Sun, Mon-Sun.
3. Preselected time: Set hours.
82640 2021-04-22 557

4. Preselected time: Set minutes.
5. Confirm "heating" function.
Settings are completed.
7. Confirm timer.
Selected timer position is activated.
Heating starts on the next selected day with the set parame-
ters.
The same procedure is required to program the preselection times

in the timer 2 or 3.
14.1.5.3 Deactivating the timer

Requirements:
side 552).
- A timer slot is selected.

-
-
1. Select timer slot.
2. Press the control button when "OFF" is flashing.

The timer is deactivated. All timer settings are retained.
558 82640 2021-04-22

14.1.6 Basic settings
14.1.6.1 First Operation

Requirements:
side 552).

-
-
Depending on the application, the system can be reconfigured. The

procedure is the same as for initial commissioning.
1. Reset user settings (see 14.1.6.5 Resetting user settings,
side 562).
3. Press the BACK button for more than 2 seconds.

The workshop menu is displayed.
4. To set the basic settings, proceed as described in the following

chapters.
82640 2021-04-22 559

Special specifications apply for some additional functions:
Menu point Description

Select "None".
Display sensor
No external temperature sensor is installed.
Select "Finish time".
Finish time: Time at which the cab should be warm.
Start time: Time at which the heating system starts
Start/finish time to heat.
If the finish time is set, the cubic capacity and max-
imum operating time of the heater assembly must
still be set
Displacement Select "4000 ccm".
Max. Operating
Select "60 min".
time
Select 5000 h.
If the maintenance interval is active, EasyStart Pro
reminds the user with a display note to switch on
Maintenance in- the "HEAT" function for 10 minutes in the summer
terval months after four months of non-use. The short op-
eration removes any residues and deposits in the
burning chamber and ensures proper operation
during the heating period.
14.1.6.2 Set the time

Requirements:
side 552).

-
-
The "Time" symbol is displayed.
2. Select the "Time" menu .

3. Set hours.
560 82640 2021-04-22

4. Set minutes.
5. Select the "Time format" menu.

6. Set time format (24 hrs here).
7. Tap on BACK key to return to menu selection.
14.1.6.3 Setting the day of the week

Requirements:
side 552).

-
-
2. Select the "Weekday" menu.

3. Set the day of the week.
14.1.6.4 Setting temperature format

Requirements:
side 552).

-
-
82640 2021-04-22 561

2. Select the "Temperature format" menu.

3. Set the temperature format to "degrees Celsius" or "degrees
Fahrenheit".
14.1.6.5 Resetting user settings

Requirements:
side 552).

-
-
2. Select the "Reset" function.

3. Select "YES".
The user settings are reset to the factory settings. All pro-
grammed settings, e.g. timer, date and time settings, are de-
leted.
"NO" cancels the process and retains the existing user settings.
562 82640 2021-04-22

14.1.7 Fault finding and troubleshooting
14.1.7.1 Error display operating panel

The heating operating panel indicates malfunctions and faults during
operation through the "Fault" symbol in the display and the red
flashing LED ring on the control button.
- The display shows a fault message. After pressing the control but-
ton , the fault message disappears and the LED ring stops
flashing.
- If there are several faults or errors, they are displayed one after the
other by pressing the control button .
Calling up all stored fault messages via the "Fault memory" menu:
see 14.1.7.4 Read out faults, side 565
14.1.7.2 Possible faults in operating panel

The following displays are possible in case of an operating panel
fault:
Display Description Remedy

- Check the wiring of the external temperature
sensor for short circuit and damage and en-
- The external temperature sure it is running freely; replace temperature
sensor is faulty. sensor if necessary.
- If the fault cannot be rectified, contact Serv-
ice.
- The internal temperature sen-

- The operating element must be replaced.
sor is faulty.
- Make the control button movable again by

hand.
- The control button is locked.
ice.
- Make the key movable again by hand.

- The button is locked. - If the fault cannot be rectified, contact Serv-
ice.
- The timer mode is not per- - End ADR operation and retest timer mode.
missible during ADR opera- - If the fault cannot be rectified, contact Serv-
tion. ice.
82640 2021-04-22 563


- The heater assembly is in
auxiliary heating mode via
the switch and cannot be op- - End auxiliary heating mode via the switch.
erated via the operating ele-
ment for a long time.
- Check wiring for cable breakages/short cir-

- Communication error of the cuits.
CAN bus connection. - If the fault cannot be rectified, contact Serv-
ice.
14.1.7.3 Possible faults in the heater assembly
After several unsuccessful start attempts, the control unit is locked.

First check the fill level of the fuel tank. For other faults, see
14.1.7.6 Overview of heater assembly fault code, side 566.
The lock is only unlocked after rectifying the fault and deleting the
fault memory (see 14.1.7.5 Reading/deleting fault code (workshop
menu), side 565).
The following displays are possible in case of a heater assembly fault:

- Fault in the heater assembly
which can only be rectified by - Inform the service team.
Service.
- Undervoltage is present at the - Check battery for voltage drop.

control unit of the heater as- - Charge the battery.
sembly for at least 20 sec- - If the fault cannot be rectified, contact Serv-
onds without interruption. ice.
- Overvoltage is present at the - Check the battery.

control unit of the heater as-
sembly for at least 20 sec- - If the fault cannot be rectified, contact Serv-
onds without interruption. ice.
- Check the fuel line to the heater assembly

for short circuiting and damage and to en-
sure there is a free flow.
- Fault in fuel supply or fuel - Disconnect the plug from the metering
pump. pump and check for damage.
- Check filling level of the fuel tank
ice.
564 82640 2021-04-22


- Check the water pump to ensure it func-
tions faultlessly.
- Water temperature detected - Check water circulation in the water circuit.
in the heater assembly that is
too high. - The heater assembly can be reset to the
delivery state by pulling the heater fuse.
- Inform the service team.
- Overheating of the heater as- - The heater assembly can be reset to the
sembly detected. The heater delivery state by pulling the heater fuse.
assembly is locked for safety
reasons. - Inform the service team.
- There is a fault in the heater assembly.

- Emergency mode of the heat- Limited operation is however possible.
er assembly.
- Inform the service team.
14.1.7.4 Read out faults

Requirements:
side 552).

-
-
To read out the faults:
2. Select the "Fault memory" function.

3. Select operating element or heater assembly.
Fault messages are displayed one after the other.
Deleting fault message

To delete fault messages, see 14.1.7.5 Reading/deleting fault code
(workshop menu), side 565.
14.1.7.5 Reading/deleting fault code (workshop menu)

Requirements:
side 552).
82640 2021-04-22 565

Only the menu points which are relevant for the installed heating
system are described below.

-
-
To read out the fault codes
The "Time" symbol is displayed flashing.
2. Press the BACK button for more than 2 seconds.

The workshop menu is displayed.
3. Select the "Fault memory" function.

4. Select operating element or heater assembly.
Fault codes are displayed one by one.
Reading out the fault codes

5. Select fault code.
6. Select the function.
The fault is read out.
Deleting fault code

7. After correcting the fault, select the "Delete" function.
8. Delete the entire fault list by pressing the control button .
14.1.7.6 Overview of heater assembly fault code

Fault code Error Comments/remedy
Water outlet sensor - interrup-
P000100
tion
Check the line and key for continuity, short circuiting
Water outlet sensor - short-cir-
P000101 and damage.
cuit
Inform the service team.
Water outlet sensor - short-cir-
P000102
cuit to Ub+
The burning chamber has not cooled down sufficiently
for a restart.
P00010A Cold blowing - time exceeded
Check whether hot combustion air is sucked in.
566 82640 2021-04-22


Water inlet sensor - interrup-
P000110
tion
Water inlet sensor - short-cir-
P000111 and damage.
cuit
Water inlet sensor - short-cir-
P000112
cuit to Ub+
Temperature difference between water inlet sensor and
water outlet sensor too great
Potential risk of overheating
- Check the water circuit for leak-tightness (heating
(Only displayed if the heater
controller in warm position).
assembly is in operation and
P000114 - Vent the water circuit.
the water temperature at the
overheating sensor has - In case of a non-return valve/thermostat in the water
reached at least 80 °C) circuit, check the direction of flow.
Overheating - software thresh-
P000115 Temperature at water outlet sensor too high.
old is exceeded
For remedy, see fault code P000114.
Overheating - hardware Inform the service team.
P000116
threshold exceeded
Control unit locked due to too many overheating pro-
cesses in a row.
For remedy, see fault code P000114.
Operation disabled - too many
P00011A After rectifying the error, clear the fault memory (see
overheating processes
14.1.7.5 Reading/deleting fault code (workshop menu),
side 565 to unlock).
P000120 Flame probe -- interruption
P000121 Flame probe - short circuit
and damage.
Flame probe - short circuit to Inform the service team.
P000122
Ub+
P000125 Flame shut-off - at start-up
Flammabbruch - im Regelber-
P000126 - Check the exhaust and combustion air ducts.
eich 0% – 25%
- Check the fuel quantity and fuel supply (for details,
Flame interruption - in the see the lubrication and maintenance instructions in
P000127
control range 25% – 50% section "Heating system" under "Engine-independ-
Flame interruption - in the ent heating system").
P000128
control range 50% – 75% Inform the service team.
Flame interruption - in the
P000129
control range 75% – 100%
82640 2021-04-22 567


P00012A After several unsuccessful start attempts, the control
unit is locked.
- Check the exhaust and combustion air ducts.
- Check the fuel quantity and fuel supply (for details,
see the lubrication and maintenance instructions in
section "Heating system" under "Engine-independ-
Operation disabled - too many ent heating system").
P00012B safety time transgressions - Replacing fuel strainer
- Cleaning the fuel strainer in the support of the me-
tering pump
After rectifying the error, clear the fault memory (see
14.1.7.5 Reading/deleting fault code (workshop menu),
side 565 to unlock).
Heater assembly in emergency operation.
Air pressure sensor - implausi- Air pressure is outside the characteristic curve for
P000143
ble signal height adjustment.
Delete the fault. If the error persists, notify Service.
P000200 Metering pump -- interruption
Check the lines for continuity, short circuiting and dam-
P000201 Metering pump - short circuit
age.
Metering pump - short circuit Inform the service team.
P000202
to +Ub or transistor fault
P000210 Glow plug interruption
P000211 Glow plug - short circuit
Glow plug - short circuit to age.
P000212
+Ub or transistor fault Inform the service team.
Glow plug - ignition power is
P000213
too low
P000220 Electric motor - interruption Inform the service team.
P000221 Electric motor - short circuit Inform the service team.
Electric motor - short circuit to
P000222 Inform the service team.
+Ub or transistor fault
P000223 Electric motor - locking Fan wheel is locked (frozen, contaminated, stiff, …):
- Remove the blockage and check the burner motor
for free movement by manually rotating the fan
Electric motor - current con-
P000224 wheel.
sumption too low
P000250 Water pump -- interruption Check the lines for continuity, short circuiting and dam-
age.
P000251 Water pump - short circuit Inform the service team.
568 82640 2021-04-22


Water pump - short circuit to
P000252 Inform the service team.
+Ub or transistor fault
Check that there are no twists in the water hoses.
P000253 Water pump - locking
Water pump - overflow shut-
P000254
down Check water pump/water circuit for contamination.
Water pump - minimum speed Inform the service team.
P000255
not reached
Check the coolant level in the water circuit.
P000256 Water pump - dry running Bleed the water pump/water circuit.
Ambient temperature of water pump too high.
P000257 Water pump - overheating
ADR water pump - undervolt-
P000258 age.
age/overvoltage
Water pump/ADR vehicle fan - age.
P000259
short circuit Check coolant circuit.
P000260 Universal output - interruption age.
Check cover of electric motor for damage and correct
P000261 Vehicle fan - short circuit fit.
Universal output - short circuit
P000262 age.
to +Ub or transistor fault
Overheating detection in hard- Check the lines for continuity, short circuiting and dam-
P000300 ware or shutdown path age.
Metering pump faulty Inform the service team.
P000301-
Control unit defective Inform the service team.
P000306
CAN communication fault in
P000307
operating element Delete fault, notify Service if it occurs more than once.
P00030A CAN communication fault
82640 2021-04-22 569


Control unit shut-down due to
P000310 overvoltage (heater assembly
without function) Overvoltage is present at the control unit for at least
20 seconds without interruption.
Heater assembly shut-down Inform the service team.
P000311 due to overvoltage (heater as-
sembly without function)
Control unit shut-down due to
P000312 undervoltage (heater assem-
bly without function) Undervoltage is present at the control unit for at least
20 seconds without interruption.
Heater assembly shut-down Inform the service team.
P000313 due to undervoltage (heater
assembly without function)
Loss of communication between the control unit and air
Implausible air pressure infor-
P000315 pressure sensor
mation
Too many short heating operations in a row.
Insufficient heat dissipation via
P000316 Check coolant circuit.
the coolant
P000330-
Control unit defective Inform the service team.
P000332
P000342 Prohibited configuration Inform the service team.
P000394 ADR button - short circuit and damage.
Fault memory entry Error-
P000500 State_GSC (heating operation Reset faults by cancelling the active request (fault re-
is continued) mains active as long as heating or diagnostic request is
Communication is terminated still present).
by the heater assembly. Easy- Delete the fault memory.
P000A00 Inform the service team.
Fan does not respond to the
coded number of messages.
Coded run time end reached.
P000E01 Running time limit exceeded
14.1.7.7 Diagnostics interface

The X3300 diagnostic interface is located in the central electrical unit
of the superstructure. It is used to connect a diagnostic tool for en-
gine-independent heating.
570 82640 2021-04-22

14.2 Air conditioning (optional)
14.2.1 Operating the air conditioning

The air conditioning system only works when the engine is running
and the fan is switched on. Proceed as follows to operate the air con-
ditioning:
Fig. 439: Operating elements - crane operator’s cab
1 Rotary switch - fan 2 Rotary switch - temperature

3 Rotary switch - fan air distribu- 4 Air conditioning ON/OFF (option-
tion al)
5 Switch - fresh air / recirculated
air operation
1. Switch (4) on the switch (gearshift position I).

2. Put the rotary switch (1) onto the desired blower level.
3. Set fan air distribution by turning rotary switch (3).
4. Set rotary switch (2) to the desired cooling temperature.
The actual cooling power of the air conditioning is determined by the

blower level.
CAUTION
Risk to health.
Cold air directed straight at your body can cause colds
and conjunctivitis.
Do not direct cold air coming out of the air vents di-
rectly onto unprotected parts of your body.
5. Open air vents.

6. Set switch (5) to ventilation.
When operating the air conditioning, windows and doors of the

crane operator's cab should be closed to achieve better cooling
power.
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14.2.2 Notes on operating the air conditioning equipment

It is possible that the evaporator has iced over if the cooling power of
the air conditioning has decreased noticeably with the temperature
and fan settings unchanged.
1. In this case, switch off the air conditioning – with the cab ventila-
tion running – for approx. 3 minutes.
The ice on the vaporiser will now thaw.
On damp, wet days, the air conditioning equipment can dehumidify

the air in the cab. With the vehicle heating the cooling effect is com-
pensated for. This then achieves a pleasant cab climate and prevents
windows fogging up.
14.2.3 Switching on the Air-Conditioning (Damage Prevention)

1. Switch the air conditioning on at least once a month for ap-
prox. 10 minutes.
This prevents the shaft seal in the air conditioning compressor
becoming dry and brittle. Otherwise there is a risk of cooling
agent leaking.
The components of the air conditioning compressor are lubri-

cated regularly.
14.3 Auxiliary AC System (Optional)
14.3.1 Operating additional air conditioning

The air conditioning is installed in the crane operator’s cab (see ar-
row).
Just like the standard air conditioning system, the auxiliary air condi-
tioning system only works when the engine is running and the fan is
switched on and it constantly operates at maximum output.
Proceed as follows to operate the air conditioning:
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Fig. 440: Air conditioning (schematic diagram)
1 Rotary switch
1. Put the rotary switch (1) onto the desired blower level.
The switch position of the fan switch determines whether and to

what extent the auxiliary air conditioning system cools.
Fig. 441: Air conditioning (schematic diagram)
CAUTION
Health hazard!
Cold air directed straight at your body can cause colds
and conjunctivitis.
Cold air coming out of the ventilation nozzles must
not be allowed to flow directly over unprotected skin.
2. Open the air vents of the auxiliary air conditioning system (see
arrow) completely.
3. Close the windows and doors of the crane operator's cab.
82640 2021-04-22 573

- The specifications for the air conditioning under 14.2.2 Notes

on operating the air conditioning equipment, side 572 and
14.2.3 Switching on the Air-Conditioning (Damage Prevention),
side 572 apply accordingly.
- For maintenance of the air conditioning equipment, see "Lubrica-
tion and maintenance instructions" in "Heating system" or "Air
conditioning".
To achieve the maximum cooling output, the auxiliary air condition-

ing in the driver's cab must be switched off.
14.4 Petrol gas heating (optional)
14.4.1 Safety instructions (petrol gas heating)
WARNING
Danger!
The petrol gas heating must be switched off while
driving.
The cylinder valve of the gas cylinder must be closed
while driving.
WARNING
Risk of explosions!
When filling up, switch off the heater assembly.
Proceed as follows if there are leaks in the gas feeder
arrangement and/or if there is a smell of gas:
- Close the gas cylinder immediately.
- Extinguish all naked flames.
- Do not smoke.
- Switch off the auxiliary heating.
- Open windows.
- Do not actuate any electrical switches.
- Have the entire system checked by qualified per-
sonnel in a suitable workshop.
Do not expose spray cans and gas cartridges to the

flow of hot air.
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WARNING
Risk of asphyxiation!
Switch the heater assembly off when in enclosed
spaces, e.g. garages.
NOTE
Risk of damage, risk of malfunctions.
Every time before starting operation, check that the wall flue of
the flue gas evacuation system is free of contamination (slush,
leaves, etc.). The cover cap (if it exists) on the wall flue must be
removed or opened.
The cover cap for the wall flue must always be fitted and/or
closed when the heating system is not in operation. This is par-
ticularly the case when the crane is being washed.
Have the exhaust gas ventilation checked by a specialist after
each deflagration (backfire) .
During electric welding work on the chassis and/or on the super-
structure, the positive terminal must be disconnected from the
battery and connected to ground to protect the heating system
control units.
In addition, the "Trumatic E 2400" operating instructions from the

heating unit's manufacturer must be observed when operating and
servicing the heating system.
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14.4.2 Operating element
14.4.2.1 Operating element with combination rotary switch
Fig. 442: Operating element with combination gas heating rotary switch
1 Rotary switch – thermostat 2 Rotary switch - heating setting /

ventilation
3 Indicator lights under rotary A Heating setting
switch
B OFF setting C Ventilation setting
Green indicator light:

- is illuminated during heating or ventilation operation
- is illuminated after heating operation has been switched off
as long as the fan is still running to use the residual heat.
The ignition-starter switch may therefore only be switched
off once the fan comes to a standstill.
- if the indicator light does not light up, the fuse in the elec-
tronic control unit must be replaced (see 'Lubrication and
maintenance instructions').
Red indicator light:

- is illuminated in case of a fault due to a lack of gas, air in
the gas line, a severely contaminated fan impeller or a de-
fect in a fuse link, etc. The fault is unlocked/deactivated by
switching the heating system off and then on again.
- flashes if the operating voltage is too low.
Heating setting
high setting
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low setting
Ventilation setting
high setting
low setting
14.4.2.2 Operating element with sliding switch
Fig. 443: Operating element with gas heating sliding switch
1 Red indicator light 2 Sliding switch - output control

3 Sliding switch - heating setting / 4 Green indicator light
ventilation
5 Rotary switch – thermostat A Heating setting
B OFF setting C Ventilation setting
Green indicator light:

- is illuminated during heating or ventilation operation
- is illuminated after heating operation has been switched off
as long as the fan is still running to use the residual heat.
The ignition-starter switch may therefore only be switched
off once the fan comes to a standstill.
- if the indicator light does not light up, the fuse in the elec-
tronic control unit must be replaced (see 'Lubrication and
maintenance instructions').
Red indicator light:

- is illuminated in case of a fault due to a lack of gas, air in
the gas line, a severely contaminated fan impeller or a de-
fect in a fuse link, etc. The fault is unlocked/deactivated by
switching the heating system off and then on again.
- flashes if the operating voltage is too low.
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Sliding switch - output control:
high setting
low setting
14.4.3 Switching on the heating setting
14.4.3.1 Operating element with combination rotary switch

1. Remove the wall flue cover if there is one.
2. Open gas cylinder valve and quick-closing valve in the gas sup-
ply line.
3. Switch the gas heating to the desired heating setting.

3.1. To do so, set the rotary switch (arrow in figure) to the de-
sired heating setting. If ambient temperatures are low,
switch the heating system to the high setting.
high setting
low setting
4. Set the desired room temperature on the rotary switch (arrow in

figure).

1. Remove the wall flue cover if there is one.
2. Open gas cylinder valve and quick-closing valve in the gas sup-
ply line.
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Fig. 444: Operating element with sliding switch
2 Sliding switch - output control 3 Sliding switch - heating setting /

ventilation
A Heating setting
3. Switch the gas heating to the desired heating setting.

3.1. Set sliding switch (3) to heating (position A).
3.2. Set sliding switch (2) to the desired heating setting. If am-
bient temperatures are low, switch the heating system to
the high setting.
high setting
low setting
4. Set desired room temperature using the rotary switch.
14.4.4 Switching on the ventilation setting
14.4.4.1 Control element with combination rotary switch
1. Set the rotary switch to the desired ventilation setting.
82640 2021-04-22 579

high setting
low setting
Fig. 445: Operating element with sliding switch
2 Sliding switch - output control 3 Sliding switch - heating setting /

ventilation
C Ventilation setting
1. Set the gas heating to the desired ventilation setting.

1.1. Set sliding switch (3) to ventilation (position C).
1.2. Set sliding switch (2) to the desired ventilation setting.
high setting
low setting
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14.4.5 Switching off the petrol gas heating
Fig. 446: Operating element - gas heat- Fig. 447: Operating element - gas heat-
ing ing
1. Place the rotary switch or sliding switch (see arrow) in the middle
position.
Switch position:
Heating / ventilation switched off
If the heating system is switched off following a heating phase, the

light on the green indicator light means that the fan is still running to
use up the residual warmth.
NOTE
Risk of damage and overheating!
Only switch off the ignition switch of the crane engine once the
fan has come to a standstill.
2. Close the gas cylinder valve and quick-closing valve in the gas
line.
3. For longer operational breaks, fit the cover cap onto the wall flue
(if existing).
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15 Reevings
15 Reevings
15.1 General information/instructions on risks

The safety of the crane is at risk due to incorrect reeving.
A minimum reeving number has been assigned to each configuration.
This can be found in the corresponding capacity tables.
DANGER
Risk of accidents due to incorrect reeving number.
Only work with the reeving numbers listed in the ca-
pacity tables.
Set the corresponding reeving number in the load lim-
it device.
Specifications on the maximum permitted cable pull per rope line

and on "Minimum reeving" can be found in "Specifications on crane
operation" supplied with the capacity tables.
Fig. 448: Rope guard pin
NOTE
Risk of damage to the rope guard pin/hoist rope!
An even number of falls must be reeved for boom angles below
10°.
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15 Reevings
With this crane type, two different rope shackles are used on the top
of the main boom at the 2nd telescopic section depending on whether
hoist 1 or optional hoist 2 is reeved in.
Fig. 449: Small and large rope shackle
1 Small shackle if only hoist 1 is 2 Large shackle if hoist 1 and/or

reeved in hoist 2 is reeved in
NOTE
Risk of damage when permitted vehicle height is exceeded
with the large shackle installed (2)!
Should national regulations require compliance with a vehicle
height of 4 m (13.1 ft), the large rope shackle (2) will have to be
dismantled when driving on public roads.
For assembly/dismantling or for replacing the rope shackle, see

15.7 Reconfiguration of rope shackle for hoist 2, side 632.
Fig. 450: Spin Stabilizer
Twisting problems can occur when fitting a new hoist rope which
has never been placed under load. For this reason, we recommend
that a spin stabilizer is used at the rope attachment point (see ar-
row) in this case.
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15 Reevings
DANGER
Risk of accidents in the case of delayed shut-down
of the hoist movement by the hoist limit switch.
The chain of the hoist limit switch must be long enough
so that the hoist movement is shut down at a sufficient
distance to the boom head. Otherwise, the load could
collide with the boom head and could fall down.
Observe and adhere to specified minimum chain
lengths.
Fig. 451: Chain shift weight
If a spin stabilizer is fitted at the rope attachment point of the main

boom head, the length of the chain of the hoist limit switch shift
weight (to the bottom edge of the hoist limit switch) must be AT
LEAST approx.1500 mm (4.9 ft) (see Fig. 451, side 585). Only then
is it ensured that "Raise hoist" is shut down by the hoist limit switch
within a sufficient distance of the lowest point of the main boom head.
Fig. 452: Chain shift weight
If no spin stabilizer is fitted in the rope attachment point of the main

boom head, the length of the chain of the hoist limit switch shift
weight (to the bottom edge of the hoist limit switch) must be AT
LEAST approx. 1250 mm (4.1 ft) (see Fig. 452, side 585). In order
to achieve maximum hoist heights, a longer chain could be used once
it is shortened. However, the measurement of about 1250 mm (4.1 ft)
may never be undercut.
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15 Reevings
15.2 Load-handling Equipment
15.2.1 General
If a load is to be raised with the crane, so-called load-handling
equipment is required to raise the said load. These are:
Fig. 453: Carrying equipment (schematic diagram)
1 Hoist rope 2 Hook block
- Carrying equipment
Carrying equipment is permanently connected to the crane. This
includes:
- Hoist ropes (1); in this section, see "hoist ropes".
- Hook blocks (2); in this section, see "hook blocks".
- Load-handling devices
Load-handling devices are devices which do not belong to the
crane, such as crossbars. They are connected to the carrying
equipment and take up the load. Their selection and safe operation
lies within the responsibility of the crane operator.
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15 Reevings
- Lifting tackle
Lifting tackle is equipment such as slinging ropes, which do not be-
long to the crane. They connect the carrying equipment with the
load or the carrying equipment with the load handling devices.
Their selection and safe operation lies within the responsibility of
the crane operator.
DANGER
Risk of accidents due to improper selection or use of
load-handling equipment.
Observe the respective national regulations such as
e.g. the accident prevention regulation "Load-han-
dling equipment in lifting operation (GUV-V 9a)".
15.2.2 Hoist Ropes
15.2.2.1 General
Information on how to handle ropes safely and correctly is described
in the section "Equipment" in the lubrication and maintenance instruc-
tions.
DANGER
Danger by being dragged in at the rope sheaves.
When reeving, there is a risk of becoming caught and en-
tangled in the head sheaves and deflection sheaves as
well as in the hook blocks.
Make sure that safety guards, such as e. g. infeed
guards are fitted.
If a rope must be replaced, the new rope must satisfy the technical
parameters of the original rope, e. g. with regard to rope diameter,
nominal tensile strength, calculated breakage force, minimum break-
age force, type of lay etc. in accordance with the rope certificate in
the crane log book.
DANGER
Risk of overloading and accidents when using un-
suitable hoist ropes.
The operating safety of the crane within the normal per-
mitted capacity range is no longer ensured. The hoist
rope could tear and the load could fall down.
Only use suitable hoist ropes in accordance with the
parameters of the original rope.
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15 Reevings
15.2.2.2 Rope End Connections
DANGER
Risk of accidents due to falling parts!
If the rope end connection is not made correctly as de-
scribed below, the hook block / load could fall.
You must observe the following description.
Rope end connection with press fitting (rope pocket)

The hoist rope is equipped with press fitting on hoist 1 and on hoist 2
(optional).
Fig. 454: Rope end connection with press fitting (schematic diagram)
1 Rope pouch 2 Press fitting

3 Forelock 4 Locking pin
Proceed as follows to make the rope end connection as described be-

low:
1. Remove forelock (3), thereby unlocking locking bolt (4).
2. Pull locking bolt (4) out of rope pocket (1).
3. Fit hoist rope with press fitting (2) in rope pocket (1).
4. Fit locking bolt (4) back in rope pocket (2) and secure with fore-
lock (3).
Locking pin (4) prevents press fitting (2) from becoming detached
from rope pocket (1) when the hoist rope is not carrying a load (e.g.
when the hook block lands abruptly on the ground).
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15 Reevings
Fig. 455: Rope end connection with press fitting (schematic diagram)
1 Rope pouch 2 Press fitting

3 Forelock 4 Locking pin
DANGER
Risk of accidents due to press fitting not being se-
cured.
The hoist rope may be loaded subsequently only
when the press fitting (2) is locked with locking pin (4)
and forelock (3). In the design that is described and
shown, the rope pocket (1) may only be used for low-
twisting / non-twisting ropes.
NOTE
Risk of damage!
If this is not done, the hoist rope cannot be drawn through with the
press fitting or can cause damage.
Before reeving a hoist rope with press fitting, all rope protection
devices such as support rollers, pins or rods on the deflection
sheaves or rope idlers to be reeved must be removed or
opened.
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15 Reevings
Rope end connection with rope socket
Fig. 456: Rope socket (schematic diagram)
1 Rope socket 2 Wedge

3 Rope clamp 4 Wire thread
5 "Dead" rope end
The diagrams of rope socket (1) and rope clamp (3) are schematic
diagrams and do not correspond exactly with the components sup-
plied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.
The rope end is secured by clamping it in a tapered rope socket (1)

with the help of a wedge (2).
To attach the rope socket (1) the rope end is first pulled through the
tapered rope pocket, turned in a loop and fed out of the rope pocket
again. The rope wedge is then laid inside the loop. The rope ends
protruding from the rope pocket are then pulled out further, pulling the
wedge far into the tapered pocket.
The "dead" rope end (5) must be protruding from the rope pocket by
about 8 times the rope diameter. It must be secured with a suitably
sized rope clamp (3) at a distance of about 3 times the rope diameter
behind where it comes out of the rope socket, to prevent the wedge
loosening and possibly falling out if the end connection is suddenly
relieved of load. From rope clamp (3), wire thread (4), ø 1.5 mm
(0.06 in) must be wound around the free rope end to prevent the rope
being drawn through.
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15 Reevings
Fig. 457: Rope socket (schematic diagram)
1 Rope clamp 2 "Live" rope end

3 "Dead" rope end
WARNING
Risk of accidents if the rope end connection is made
incorrectly.
The rope clamp (1) must be fitted in a way that does
not connect the "live" (2) and "dead" rope line (3) with
each other.
When assembling the rope socket, make sure that the "live" rope line
(see arrow) runs into the pocket so that, when the end connection is
placed under load, the active line of the tensile force runs precisely
through the centre of the fixing pin without a kink developing in the
cable.
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15 Reevings
Fig. 458: Assembling the rope socket
WARNING
Risk of accidents due to incorrect assembly of the
rope end connection.
If assembled incorrectly, the end connection will position
itself when placed under load so that the active line of
the tensile force runs through the fixing pin, each time
developing a kink in the heavily loaded "live" line of the
cable at the outlet of the rope pocket. On one hand, this
reduces the maximum transmittable tension force of the
end connection, on the other hand the pressure coupled
with the frequent bending within a very small radius cre-
ates a premature wear of the rope cables in this area, so
that the end connection can fail prematurely even when
there are only small tension forces.
Carry out the assembly in accordance with the speci-
fications.
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15 Reevings
15.2.2.3 Reeving / unreeving the hoist rope
1 Small shackle if only hoist 1 is 2 Large rope shackle when hoist 1

reeved in and / or hoist 2 is / are reeved
NOTE
Risk of damage for the small rope shackle (1) during operation
with the reeved hoist 2!
When reeving the hoist rope of hoist 2, the large rope shackle
(2) must be fitted.
For assembly/dismantling or for replacing the rope shackle, see

15.7 Reconfiguration of rope shackle for hoist 2, side 632.
WARNING
Risk of accidents when using components that are
not in a proper condition!
Before reeving and before starting crane work, check
the status of all accessible ropes (including the end
connections), winches and rope sheaves.
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15 Reevings
Fig. 460: Main boom head (schematic diagram)
E1 Run-in sheave (hoist 1) E2 2nd run-in sheave (for optional

hoist 2)
K3 Additional head sheave (HD at- 1 Load hook camera (optional)
tachment, optional)
The main boom head with the optional equipment, additional head
sheave, load hook camera and 2nd run-in sheave is shown in
Fig. 460, side 594 and other figures.
Reeving
As an example, the description is of reeving the rope of hoist 1 over
run-in sheave (E1).
1. Position the hook block under the main boom head in such a way
that it is stable.
WARNING
Risk of the hook block which has been set down
overturning!
Only work on the hook block (reeved or unreeved)
when it is stably positioned on hard ground.
The Vario hook block (see 15.2.3.4 Vario Hook
Block, side 608) may only be set on the ground with
the pinned ballast weight. The hook block is too un-
stable without the ballast weight.
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15 Reevings
Fig. 461: Hook block (schematic diagram)
1 Rope guard pin 2 Rope guard plate
2. Remove the rope guard pin (1) from the hook block and fold out
the metal rope protection plates (2).
Fig. 462: Main boom head
1 Rope guard pin (run-in sheave) 2 Rope guard pin (head sheaves)
3. Remove rope guard pin (1) and both rope guard pins (2) from the
main boom head.
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15 Reevings
DANGER
Risk of accidents due to slipping / falling.
The hoist rope must be pulled forward from the
ground. There is a risk of accidents due to slipping
and stumbling when stepping onto the main boom. It
is therefore prohibited to step onto the main boom.
NOTE
Risk of damage to the hoist rope.
While the crane operator is using the hoist, the hoist rope must
be guided by a helper to prevent slack rope from forming.
4. Guide the hoist rope from the hoist drum to the ground and there,
pull it forwards up to in front of the main boom head.
5. Move the auxiliary rod (see arrow) from the transport position
and fit the hoist rope on the main boom.
6. Set up and attach the mobile multi-purpose ladder supplied on

the main boom head in accordance with regulations. Detailed in-
formation on this can be found in the section "Structure of the
mobile crane" under "Getting on and off using mobile multi-pur-
pose ladders". After getting on, secure yourself against falling us-
ing the corresponding attachment eyelets.
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15 Reevings
Using the rope shackles
Fig. 464: Rope shackles
1 Rope shackle if only hoist 1 is 2 Rope shackle if hoist 1 and / or

reeved in hoist 2 is / are reeved
7. Feed hoist rope 1 and, if available, hoist rope 2, through the cor-
responding rope shackle.
Fitting the large rope shackle for operation with hoist 2, see 15.7
Reconfiguration of rope shackle for hoist 2, side 632.
WARNING
ary equipment.
Additional suitable auxiliary equipment (for example,
lifting platform) must be used to safely carry out this
work at height.
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15 Reevings
Fig. 465: Main boom head and hook block
1 Main boom head 2 Rope guard pin

3 Rope guard pin 4 Hook block
5 Rope guard pin 6 Rope guard plate
E1 Run-in sheave (hoist 1) E2 Run-in sheave (hoist 2)
K Head sheaves
8. Guide the hoist rope over run-in sheave (E1) to the sheaves (K)
in the main boom head (1) and reeve in accordance with the cor-
responding reeving diagram (see from 15.3 Reeving the hoist
rope on the main boom head with 4 head sheaves, side 619).
9. Fit rope guard pins (5) on hook block (4) and rope guard pins (3),
(2) on the main boom head (1) again and secure. To do so, first
the rope protection plates (6) must be folded in on hook block
(4).
10. Fit the rope end with press fitting in the rope pocket. To do so,
observe 15.2.2.2 Rope End Connections, side 588.
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15 Reevings
Fig. 466: Hook block Fig. 467: Main boom head

FU Fixed point - hook block 1 Spin Stabilizer
FK Fixed point - main boom head
11. Pin the rope pocket to the corresponding fixed point:

- with uneven number of falls fixed point (FU) on the hook block.
- with even number of falls fixed point (FK) on the main boom
head. In the corresponding figure, the rope pocket is not
shown at the fixed point (FK) but the spin stabilizer (1). Use a
ladder if the fixed point on the main boom head cannot be
reached from the ground. To do so, the supplied multi-pur-
pose ladder can be used as a sliding ladder.
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15 Reevings
Fig. 469: Shift weight with spring cotter

Fig. 468: Shift weight
pin
1 Shift weight 1 Shift weight
2 Spring cotter pin
12. Release shift weight (1) of the hoist limit switch out of the trans-
port position, remove both spring cotter pins (2) and pull the two
shift weight (1) halves apart.
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15 Reevings
Fig. 470: Shift weight with spring cotter

Fig. 471: Rope with shift weight
pin
1 Shift weight
2 Spring cotter pin
13. Rejoin the separated halves of the shift weight around the hoist
rope (1) and secure them again with the spring cotter pins (2).
The state shown in Fig. 471, side 601 must be achieved.
DANGER
Risk of accidents due to non-functioning hoist limit
switch.
If the shift weight of the hoist limit switch is not – as de-
scribed – fitted on the hoist rope, the hoist stroke limita-
tion does not work. The hook block could be pulled into
the head of the main boom. There is a risk of the hoist
rope breaking, so that the hook block / load fall.
Observe the listed specifications.
Make sure that the shift weight is hanging freely. Only
then is it guaranteed to function properly.
Attach the shift weight to the "resting" rope (rope line
to the fixed point). This avoids wear to the hoist rope
and shift weight.
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15 Reevings
Unreeving
In principle, the procedure for unreeving corresponds to the proce-
dure for reeving, but it is carried out in the reverse order. In particular
the following points must be observed:
WARNING
Risk of the hook block which has been set down
overturning!
Only work on the hook block (reeving or unreeving) if
it is set down on the ground in a stable manner.
The Vario hook block (optional, see 15.2.3.4 Vario
Hook Block, side 608) may only be set down with
the pinned ballast weight.
WARNING
Risk of accidents due to the hoist rope end knocking
out of the hook block abruptly!
When unreeving, the hoist must be operated with
great care and the hoist rope unwound gradually.
No-one may be in the dangerous area around the
hook block.
NOTE
Risk of damage to the hoist rope.
Pay attention to how the hoist rope winds on. There must be no
slack rope.
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15 Reevings
15.2.3 Hook blocks
15.2.3.1 Definition
In DIN 15002, the hook block is defined as a "multi-stranded suspen-
sion of the carrying equipment with hook".
A single-line suspension is referred to as hook suspension gear. As

this differentiation is not relevant for the following general contexts,
only the description "Hook block" is used.
DANGER
Risk of accidents due to using unsuitable hook
blocks!
Only use hook blocks obtained from the crane manu-
facturer. To do so, observe the Tab. 14, side 604
"Definition of the hook blocks". The use of other hook
blocks is only permitted following consultation with
the crane manufacturer.
Under no circumstances exceed the indicated max.
permitted capacity of the hook blocks.
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15 Reevings
Capacity Hook type Weight

Description Item number (a) (b)
t kip (d) (E) kg lbs
57461312 1670 3682
160-7/21-D 160 352.7 7
61784012 1660 3660
X - 32
57461112
125-5/21-D 125 275.6 5 1130 2492
61783812
57460712
80-3/21-E - X 850 1874
61783412
80 176.4 3 20
57460912 830 1830
80-3/21-D X -
61783612 850 1874
57460312
32-1/21-E - X 630 1389
61783012
10
57460512 32 70.5 1 620 1367
32-1/21-D
61783212 X - 630 1389
32-1/21-D Vario (*) 57474812 8 580 1279
57460112
12.5-0/21-E 12.5 27.6 0 - X 5 340 750
61784512
Table 14: Definition of the hook blocks
(a) - Quantity of sheaves
(b) - Hook size in accordance with DIN 15401 (single hook) or

DIN 15402 (twin hook)
(d) - Double hook
(E) - Single hook
(*) - Explanations on Vario hook blocks, from 15.2.3.4 Vario

Hook Block, side 608
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15 Reevings
15.2.3.2 Markings
The following specifications must be permanently attached to the
hook blocks and must be easily recognisable:
- Warning marking
- Manufacturer or supplier
- Year of construction
- Type, if type designation exists
- Make or serial number
- Permitted load
- Rope diameter
- Drive group
- Dead weight.
Furthermore, observe the respective specifications concerning the

permitted hook blocks in the "Instructions on operation of the crane",
which are supplied together with the capacity tables.
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15 Reevings
15.2.3.3 Operation
WARNING
When handled incorrectly, there is a risk of becom-
ing entangled, pulled in and a risk of crushing at ro-
tating and mobile parts of the hook blocks.
Ensure safety guards are fitted, e.g. intake guards.
Any other safety instructions listed below must be ob-
served.
- The fitter (person attaching/detaching the load) must be qualified

and conversant with the handling of hook blocks and must be
wearing suitable protective clothing.
- When attaching and disconnecting the load, particular care must
be taken due to hazards resulting from swinging loads or hook
blocks. The fitter must leave the slewing or hazardous area imme-
diately after the procedure has been completed.
- The fitter must be easily recognisable to the crane operator. The
person handling the load must wear one or more means of identifi-
cation, for example, jacket, helmet, special collars, armbands, sig-
nalling discs. These means of identification should be in a distinc-
tive colour and where possible of an identical design and must be
exclusive to the fitter.
- Before starting movements of the winches (raising or lowering), all
persons must leave the hazardous areas in the proximity of the
rope drums and sheaves.
- The crane operator must have visual contact with the operating
personnel and must give a warning signal before starting the crane
movements.
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15 Reevings
Fig. 472: Handling the hook blocks (schematic diagram)
- The hook block should only be handled using the existing hand-
rails. Hands must be KEPT CLEAR of the following areas:
- between the sheaves, side plates and covers.
- in the area of the fixing points (sometimes of a folding design),
the hook, the hook nut, the lifting beam or the protecting bars.
- Make sure that items of clothing do not get caught in rotating parts.
- Work on the hook block may only be carried out (reeving), when it
is set down in a stable position on firm ground. Proceed carefully,
since the hook block may still fall over.
- Only use the hook block for lifting in the vertical direction. Oblique
pull is not permitted.
- Place the hook block under load gradually and evenly. No sudden
loads! No one-sided loading!
- Always fit the load / load-handling device in the middle of the hook
(hook jaw), never at the tip.
- Never load only one side of the double hook.
- No welding may be carried out on the hook block.
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15 Reevings
15.2.3.4 Vario Hook Block
15.2.3.4.1 Components
The Vario hook block is a 1-sheave hook block which consists of 2
main elements which can be separated:
- actual hook block; Weight: 197 kg (434 lbs)
- Weight frame (depiction together with hook block); Weight: 390 kg

(860 lbs)
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15.2.3.4.2 Placing the Vario hook block in the operating state (assembly)
The Vario hook block must be used as an assembled unit in order to
be used during crane operation. The actual hook block on its own
would be too light.
The assembled unit weighs approx. 590 kg (1300 lbs).
Starting situation:
Weight frame (see arrow) set down in the support on the rear of the
crane chassis (see 15.2.3.4.3 Placing the Vario hook block in the
transport condition (dismantling), side 612); Vario hook block fas-
tened to the front coupling ring of the crane chassis.
1. Release the Vario hook block from the transport position at the
front coupling ring of the crane chassis.
Fig. 473: Rear - crane chassis
1 Vario Hook Block 2 Weight frame
2. Position the Vario hook block (1) over the weight frame (2) on the
rear of the crane chassis.
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15 Reevings
The crane operator must be supported by an assembly assistant in

order to align the unit precisely when lowering it into the weight
frame.
CAUTION
Risk of crushing when lowering the hook block.
There is a risk of crushing for the assembly assistant be-
tween the hook block and the weight frame when retract-
ing the hook block.
Proceed with caution when handling the hook block.
There must be constant contact between the crane
operator and the assembly assistant.
Fig. 474: Rear - crane chassis
1 Vario Hook Block 2 Weight frame
3. Lower the Vario hook block (1) into the weight frame (2).
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15 Reevings
Fig. 475: Hook block with weight frame
1 unpinned 2 pinned
4. Remove the two connecting pins (left- and right-hand sides) and
the corresponding locking elements from configuration (1, unpin-
ned) and place them in configuration (2, pinned).
This pins the hook block to the weight frame and at the same
time, the weight frame is disconnected from the support.
5. Lift the assembled unit out of the support and use it for crane op-
eration.
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15 Reevings
15.2.3.4.3 Placing the Vario hook block in the transport condition (dismantling)
1 unpinned 2 pinned
To separate the hook block and the weight frame, the pins and lock-
ing elements must be placed in configuration (1, unpinned).
Fig. 477: Hook blocks support
1 Support
The actual hook block can be fastened to the front coupling ring of the
crane chassis and the weight frame can be stored in the support (1)
on the rear of the crane chassis when transporting them when discon-
nected.
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15 Reevings
Proceed as described below to set the weight frame down in the sup-
port on the rear of the crane chassis:
Fig. 478: Weight frame above rear
1. Position the assembled unit over the support at the rear.
The crane operator must be supported by an assembly assistant in

order to align the unit precisely when lowering it into the weight
frame.
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15 Reevings
CAUTION
Risk of crushing when lowering the hook block.
There is a risk of crushing for the assembly assistant be-
tween the hook block and the weight frame when retract-
ing the hook block.
Proceed with caution when handling the hook block.
There must be constant contact between the crane
operator and the assembly assistant.
Fig. 479: Transport position on the rear
2. Lower the unit into the support.
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15 Reevings
1 unpinned 2 pinned
3. Move the connecting pins on both sides from configuration (2,

pinned) and place them in configuration (1, unpinned).
This means that the weight frame is pinned to the support on
one side at the same time (see Fig. 481, side 616).
4. Lift the hook block out of the weight frame and fasten it to the
front coupling ring of the crane chassis.
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15 Reevings
Fig. 481: Support
5. Ensure that the weight frame has been pinned to the support.
15.2.3.5 Transport dimensions of the hook blocks
Fig. 482: Standard hook blocks, ID no. 574.... Fig. 483: Standard hook blocks, ID no. 617....
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Standard hook blocks

Height "H" Width "B" Depth "T"
Description ID number
mm in mm in mm in
57461312 1813 71.5 680 27 682 27
160-7/21-D
61784012 1750 69 625 25 622 24.5
57461112 1863 73.5 680 27 482 19
125-5/21-D
61783812 1680 66.5 625 25 442 17.5
57460712 1717 68 680 27 363
80-3/21-E
61783412 1650 65 625 25 362
14.5
57460912 1633 64.5 680 27 363
80-3/21-D
61783612 1540 61 625 25 362
57460312 1513 60 680 27 420 16.5
32-1/21-E
61783012 1500 59.5 625 25 255 10
57460512 1441 57 680 27 420 16.5
32-1/21-D
61783212 1430 56.5 625 25 255 10
57460112 914 36
12.5-0/21-E 350 mm / 13.8 in
61784512 730 29
Table 15: Standard hook blocks
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15 Reevings
Fig. 484: Vario hook blocks
Vario - hook block (only AC250-5 (Explorer 5800))

Height "H" Width "B" Depth "T"
Description
mm in mm in mm in
only hook
165 6.5
block
32-1/21-E Vario Hook block 1389 55 750 29.5
+ weight 495 19.5
frame
only hook
165 6.5
block
32-1/21-D Vario Hook block 1348 53 750 29.5
+ weight 495 19.5
frame
Table 16: Vario hook blocks
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15.3 Reeving the hoist rope on the main boom head with 4 head sheaves
15.3.1 General
DANGER
Risk of accidents due to incorrect reeving.
Only reeve the hoist rope in accordance with the de-
picted reeving diagram. Other reevings would disrupt
the function of the load limit device.
15.3.2 Reeving 8-, 7-fold

Hook block type 125, 5-sheave
Fig. 485: Reeving 8-, 7-fold
E Run-in sheave(n) K Head sheaves

U Hook block pulleys FK Outer fixed point on the sheave head
FU Fixing point on the hook block
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15 Reevings
15.3.3 Reeving 7-, 6-, 5-, 4-, 3-fold

Fig. 486: Reeving 7-, 6-, 5-, 4-, 3-fold

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15 Reevings
15.3.4 Reeving 3-, 2-, 1-fold

Hook suspension gear, type 12.5
Fig. 487: Reeving 3-, 2-, 1-fold

FU Fixing point on the hook block FH Fixed point on the hook suspension gear
82640 2021-04-22 621

15 Reevings
15.4 Reeving the hoist rope on the main boom head with 4 head sheaves and addi-
tional head sheave (HD attachment, optional)
15.4.1 General
DANGER


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15 Reevings
15.5 Reeving the Hoist Rope on the Main Boom Head with Two Auxiliary Sheaves
(HD Attachment, Optional)
15.5.1 Fitting and Removing the HD Attachment
WARNING
Risk of accidents due to using unsuitable additional
equipment.
Only use the original HD attachment of the crane
manufacturer for this crane type. The crane operator
carries sole responsibility for using other additional
equipment.
WARNING
ary equipment.
equipment).
Observe the detailed information on this in the sec-
tion "Structure of the mobile crane" under the corre-
sponding points.
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15 Reevings
1 Attachment shackle 2 Bolts

3 Main boom axle 4 Auxiliary sheaves (HD attach-
ment)
5 Park position
There are 5 rope sheaves on the main boom axle (3) of the main
boom. For reevings that have over 10 rope lines, there is the possibili-
ty of fitting additional sheaves (4). Both of these additional sheaves
(4) are called HD attachment.
The weight of each additional sheave (4) is approx. 105 kg

(230 lbs).
1. Stand the main boom axle (3) on its end.

2. Then attach one additional sheave (4) to the attachment shackle
(1), raise it into the assembly position and slide onto the main
boom axle (3).
3. Remove bolt (2) from park position (5) and pin as illustrated.
4. Remove the lifting tackle.
5. Repeat operating steps 2 to 4 for the second additional sheave.
6. Reeve the hoist rope. Possible reevings can be found under
15.5.2 Reeving 14-, 12-fold, side 629.
The figure Fig. 489, side 624 does not show the hoist rope.
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15 Reevings
Fig. 490: HD attachment
To reeve the hoist rope on the HD attachment, the three rope locking
pins (see arrows) can be removed. Immediately after fitting the hoist
rope, all 3 rope locking pins (see arrows) must be fitted again and
locked.
7. Fit the hoist limit switch weight (see arrow) of the main boom
head hoist limit switch on the bracket attached to the right-hand
side of the main boom head and secure it against falling out with
locking springs as illustrated.
If the hoist limit switch weight of the hoist limit switch on the
main boom head is placed in the transport position, this hoist
limit switch must be bridged (see 8.6.3.3.3 Bridging the
hoist limit switch (putting it out of operation), side 369).
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15 Reevings
Fig. 491: Hoist Limit Switches
1 Hoist Limit Switches 2 Restrainer
DANGER
Risk of accidents if the hoist limit switch is not func-
tioning.
Ensure that the hoist limit switch is in a functioning
state.
Under no circumstances may it be bridged with the
restrainer.
8. Put the hoist limit switch of the HD attachment in the functional

configuration (see 8.6.3.3.2 Placing the hoist limit switch in
the functional state, side 368). This means that restrainer (2) of
hoist limit switch (1) may not be fitted, but hangs freely or is in
the transport position.
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15 Reevings
1 HD attachment 2 Hoist Limit Switches
9. Fit the hoist limit switch (2) with corresponding shift weight to the
HD attachment (1) on the left-hand side of the main boom head.
To do so, fit the hoist limit switch (2) onto the corresponding bolt
on the HD attachment - as illustrated - and secure with forelock.
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15 Reevings
Fig. 493: Connection - hoist limit switch (schematic diagram)
1 Hoist Limit Switches A Connection - air speed indicator/

hazard light
10. Connect the hoist limit switch (1) electrically. To do so, use the
supplied adapter cable (length is about 1 m / 3.3 ft) to create a
connection between the hoist limit switch and distribution box
X0550 on the main boom head, connection (A).
The HD attachment is incorporated in crane control (electrical
safety chain). However, the wind speed indicator and the haz-
ard light can no longer be connected. Adherence to the per-
mitted wind speeds can no longer be monitored in the crane
control screen.
DANGER
Risk of accidents if the permitted wind speeds are
not observed.
Suitable alternative measures must be taken to re-
cord the current wind speed. Observe the specifica-
tions in 9.2.6 Measuring the Wind Speed, side 415.
11. Correctly fit the shift weight of the hoist limit switch to the hoist
rope.
To do so, observe the detailed description in this chapter under

"Reeving/unreeving the hoist rope".
The HD attachment is removed in the same way, in the reverse order.
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15 Reevings
DANGER
These two reevings are performed in "US-/Texan-style reeving". This

means that the rope sheaves are not reeved continuously from one
side to the other, but are partially skipped and subsequently reeved.
DANGER
There is an increased risk of accidents and a risk of dam-
age to the hoist rope if the reeving is incorrect.
Rope line (4) - from U1 to K2 - must be guided cor-
rectly to in relation to rope line (2) - from U2 to Z1.
The two rope lines may not come into contact!
The figures below illustrate how the hoist rope is not to be guided and
how it must be guided correctly:
incorrect rope guidance of rope line 4
Fig. 494: incorrect rope guidance of rope line 4
2 Rope line "2" 4 Rope line "4"
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15 Reevings
correct rope guidance of rope line 4
Fig. 495: correct rope guidance of rope line 4
correct complete reeving
Fig. 496: correct complete reeving
The corresponding reeving plan can be found in the appendix.
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15 Reevings

Observe the following representation of the rope guidance. A solid
line indicates that the rope runs to the front side of the next sheave, a
dashed line that it runs to the rear one.
E Run-in sheaves K Head sheaves

Z Auxiliary sheaves on the sheave head (HD attach- U Hook block pulleys
ment)
FZ Fixed point on the auxiliary sheave (HD attachment) FU Fixing point on the hook block
Number of falls Guiding rope over the sheaves

E1-K1(v)-U2(v)-Z1(h)-U1(v)-K2(v)-U3(v)-K3(h)-U4(v)-K4(h)-U5(v)-K5(h)-U6(v)-
14
Z2(h)-U7(v)-Fz
12 E1-K1(v)-U2(v)-Z1(h)-U1(v)-K2(v)-U3(h)-K3(h)-U5(v)-K5(h)-U6(v)-Z2(h)-U7(v)-Fz
(v) - Front of the rope sheave
(h) - Back of the rope sheave
82640 2021-04-22 631

15 Reevings
DANGER
There is an increased risk of accidents and a risk of dam-
age to the hoist rope if the reeving is incorrect.
Rope line (4) - from U1 to K2 - must be guided in front
of rope line 2 - U2 to Z1 - in the depicted view of the
reeving diagram. The preceding detailed information
in reference to this must be observed.
15.6 Reeving the Hoist Rope on Additional Equipment

The relevant specifications can be found directly in the section of the
corresponding additional equipment (e.g. section "Assembly jib").
15.7 Reconfiguration of rope shackle for hoist 2

The rope shackles must be changed to reeve the hoist rope of hoist
2.
WARNING
ary equipment.
Additional suitable auxiliary equipment (e.g. lifting
height.
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15 Reevings
Fig. 498: Rope shackles
1 Small rope shackle (for opera- 2 Large rope shackle (for operation
tion with hoist 1) with hoist 2)
Item Dimensions Weight

625 x 840 mm 15 kg
1
(25 x 33 in) (33 lbs)
1450 x 840 mm 25 kg
2
(57 x 33 in) (55 lbs)
Fig. 500: Large rope shackle in the trans-

port position on hoist 2
1 Small rope shackle (for opera-
tion with hoist 1) to the front
2 Large rope shackle (for opera-
tion with hoist 2) to the rear
1. On both sides of rope shackle (1), remove the forelocks and pull
out the pins.
2. Lift rope shackle (1).
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15 Reevings
3. Release the four lashing straps on hoist 2 and raise the rope
shackle (2) out of the transport position (see arrow in Fig. 500,
side 633).
4. Fit rope shackle (2) to the rear - in the opposite direction as the
previously fitted rope shackle (1).
5. Using the two previously removed pins, pin rope shackle (2) to
the 2nd telescopic section and secure each one with forelocks.
The reconfiguration procedure for using rope shackle (1) is analo-

gous, but in the reverse sequence.
634 82640 2021-04-22

16 Central lubricating system (optional)
16.1 Structure and lubrication chart
You must follow the operating instructions of the manufacturer.

These can be found in the part "Various". The following points are
primarily limited to information which specifically affects the crane.
Fig. 501: Central lubricating system AC 250-5, AC 220-5
A Lubricant pump with control board and safety valve B Main distributor
C Sub-distributor D Distributor, ball bearing slewing rim
"X" Quick coupling connection, hoist 2 1.0 Roller-bearing slewing ring
2.1 Main boom foot bearing 2.2 Main boom foot bearing
3.1 Luffing cylinder foot bearing 3.2 Luffing cylinder foot bearing
4.1 Luffing cylinder head bearing 5.0 Winch, hoist 1
6.0 Winch, hoist 2 (optional)
82640 2021-04-22 635

Fig. 502: Central lubricating system AC 160-5, AC 130-5
A Lubricant pump with control board and safety valve B Main distributor
C Distributor, ball bearing slewing rim "X" Quick coupling connection, hoist 2
1.0 Roller-bearing slewing ring 2.1 Main boom foot bearing
2.2 Main boom foot bearing 3.1 Luffing cylinder foot bearing
3.2 Luffing cylinder foot bearing 4.1 Luffing cylinder head bearing
5.0 Winch, hoist 1 6.0 Winch, hoist 2 (optional)
The central lubricating system, consisting of a lubricant pump (A) with

integrated control board, a main distributor (B) as well as a subdistri-
butor (C), enables automatic lubrication of all connected lubricating
points.
If hoist 2 is not fitted, lubricating line from main distributor (B) must
be connected with return line (R) of the lubricant pump using the
quick coupling connection ("X").
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Fig. 503: Fitting location - lubricant pump (schematic diagram)
The lubricant pump is located on the right side of the crane.
16.2 Settings Ex Works
16.2.1 General
The length of a lubrication cycle is dependent on the lubricant require-
ments of the lubricating points.
The pause and operating times are controlled electronically via the
control circuit board. As soon as the ignition is switched on, the inter-
val time begins. When the pause time has expired, the operating time
starts, which is the actual lubrication cycle.
The pause time determines the time period in which there is no lubri-
cation cycle.
The operating time determines the time period in which there is a lu-
brication cycle.
If the set pause time or operating time is interrupted by the ignition

unit being switched off, the time passed up to that point is stored.
Once the ignition unit is switched back on, the time period resumes
its sequence at the point that it was switched off.
16.2.2 Set time values
NOTE
Risk of insufficient supply of the connected lubricating points.
The set times must not be changed to ensure sufficient lubrica-
tion of the connected lubricating points.
82640 2021-04-22 637

Fig. 504: Rotary switch, blue, "Pause time" and red, "Operating time"
The pause and operating times are determined at the factory and are
set as follows:
Pause time: 4 hours
- Switch position, rotary switch, blue = 4
Operating time: 4 minutes
- Switch position, rotary switch, red = 2
This means that there is a lubrication procedure lasting 4 minutes

every 4 hours.
16.3 Activating the additional lubrication impulse

When you are not within an automatic lubrication cycle, it is possible
to end the interval time prematurely and to introduce additional lubri-
cation procedures.
Fig. 505: Control board
1 LED on the left "Battery voltage 2 LED on the right "Display lubri-
applied and engine running" cating procedure is running"
3 Button for additional lubrication
impulse
638 82640 2021-04-22

1. Switch on the ignition and start the engine.

Left light-emitting diode (1) is illuminated.
2. Press button (3) and hold down (> 2 seconds) until the right light-
emitting diode (2) is illuminated.
The length of the lubrication impulse depends on the set operating

time.
16.4 Manual Lubrication in the Case of an Emergency
Fig. 506: Lubricating nipple - lube pump
If the lube pump fails, the lubricating points can also be lubricated
manually using grease. To do so, grease is fed into the system via
the depicted lubricating nipple using a grease gun.
16.5 Malfunction
Error Cause Remedy
Bearing point, lines or distributor
Remove blockage in the central
blocked. Grease leaking from
Blockage in the installation con- lubricating system, see the man-
the safety valve. The check
nected in series ufacturer's documents in the
bolts (if present) fitted to the dis-
"Various" part.
tributor piston are not moving.
When a distributor is blocked, Clean distributor, see the manu-
no lubricant emerges at any out- facturer's documents in the "Var-
let). ious" part.
Check power supply/fuses. Rec-
tify fault/if required replace
Pump engine is not running Power supply interrupted
fuses. Inspect the line to the plug
of the pump/to the control board.
82640 2021-04-22 639

Error Cause Remedy

Fill up container with clean
grease, allow pump to run (trig-
gering additional lubrication) until
lubricant emerges at all lubricat-
ing points. NOTE: Depending on
Pump is not pumping Container is empty
the ambient temperature and / or
the lubricant, the pump elements
can require up to 10 minutes
running time in order to achieve
the full pumping capacity.
Activate additional lubrication im-
pulse. Remove outlet screw from
Air trapped in the lubricant the safety valve. The lubricant
must emerge without any bub-
bles.
Replace lubricant, see lubricants
Unsuitable lubricant used table (lubrication and mainte-
nance instructions).
Remove pump element and ex-
Intake hole of the pump element
amine intake bore for foreign
is clogged
bodies and remove if necessary.
Pump piston worn Replace pump element.
Non-return valve in the pump el-
Replace pump element.
ement defective or clogged
Remove valve body and check if
Different quantities of lubricant Corresponding valve body was
there is a clamping ring. If not, fit
at the lubrication points fitted without a clamping ring.
a clamping ring.
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17 Head Sheave (Optional)
Fig. 507: Head sheave (length / height) Fig. 508: Head sheave (width)
Length Width Height Weight

1500 4.9 700 2.3 600 2 155 342
Table 17: Transport Dimensions and Weights
82640 2021-04-22 641

17.2 General
Fig. 509: Head sheave
1 Head sheave 1.1 Frame

1.2 Rocker arm
The head sheave (1) is for raising small loads with single strand reev-
ing. If the crane is equipped with hoist gear 2, the hook block can re-
main reeved on the main boom head.
Head sheave (1) consists of frame (1.1) and a hinged rocker arm
(1.2) which is pinned in place .
The head sheave can be folded to the side on the main boom for
transport.
The depiction shows the head sheave in the operating position (rock-
er arm "1.2" folded down).
The head sheave is marked with the construction number of the

crane. It may only be fitted on the crane with this construction num-
ber. Exceptions are only permitted if this is expressly stated in the
crane papers (e. g. crane log book).
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17.3 Fitting (assembly position)
WARNING
fied.
WARNING
Risk of crushing between the main boom head and
head sheave.
In particular, observe the instructions on risks in
1.13 Assembling and dismantling crane components,
side 59 and the procedure described below.
WARNING
Risk of falling when working at heights!
Use suitable auxiliary equipment.
It is prohibited to walk on the boom.
All assembly work/work at height must be carried out using suitable

auxiliary equipment (ladders, hoist platforms, scaffolding, auxiliary
crane, personal protective equipment). Observe the detailed informa-
tion on this in the section "Structure of the mobile crane" under the
corresponding points.
82640 2021-04-22 643

Fig. 510: Head sheave in the assembly position
1 Head sheave 1.2 Rocker arm

2 Coupling pins
Prior to installation, the head sheave (1) is in mounting position on the

ground. This means that hinged rocker arm (1.2) is pinned to coupling
pin (2) in the straight position, as illustrated. Secure the coupling pin
with forelock.
1. Support the crane on outriggers, align it and fit the counterweight
-in accordance with the regulations of the capacity table.
2. Attach head sheave (1) to the auxiliary crane with three falls
(see Fig. 510, side 644).
644 82640 2021-04-22

Fig. 511: Head sheave (schematic diagram)
1 Holes (frame) 2 Mounting plates
DANGER
Risk of accidents due to falling parts.
No-one may be in the area where loads/equipment
could fall as long as the head sheave is attached to
the auxiliary crane or has not yet been completely
pinned.
3. Move the head sheave on the main boom head to the fitting posi-
tion. To do so, the respective holes (1) on both sides of the head
sheave frame must be flush with the holes of the mounting plates
(2) at the front side of the main boom head.
In the following procedure, the head sheave may not swing out or
dangle at an angle when it is raised.
82640 2021-04-22 645

1 Hole (pinning) 2 Holes (pivot point)
The pivot point is pinned at holes (2) at a later point. After folding it
to the rear in the transport position, the head sheave is secured me-
chanically by pinning at hole (1) at a later point.
4. Knock in one biconical pin (see arrow) each at the two pinning
points so that the head sheave is pinned to the main boom head
in these two points. Secure each biconical pin with 2 locking
springs.
646 82640 2021-04-22

5. Knock in pin (see arrow) and secure with forelocks at the top and
bottom. The head sheave can be folded to the rear in the trans-
port position around this point at a later point.
This means that the head sheave is connected to the main
boom head in 3 points.

The head sheave is then fitted in the assembly position (see
Fig. 514, side 647). The assembly position is only for fitting and dis-
mantling and for folding the head sheave to the rear in the transport
position.
DANGER
This assembly position is expressly NOT permitted to
be used for the raising of loads. To do so, the head
sheave must first be put in the operating position. To
do so, observe 17.4.1 Folding the head sheave
down in the operating position, side 648.
82640 2021-04-22 647

17.4 Preparing the head sheave for operation
17.4.1 Folding the head sheave down in the operating position

To fold down the head sheave from the assembly position into the op-
erating position, proceed as follows:
1 Coupling pins 2 Rocker arm
1. Raise the hinged rocker arm (2) slightly to relieve coupling pin (1)
of load and unlock and pull out coupling pin (1).
The gas-operated positioner holds the rocker arm in the hori-
zontal position.
648 82640 2021-04-22

WARNING
Risk of crushing between the rocker arm and the
frame.
There is a risk of crushing between the rocker arm and
the frame of the head sheave as soon as the rocker arm
moves itself or is moved.
2. Press the rocker arm (see arrow) down against the pressure of
the gas-operated positioners until the corresponding hole of the
rocker arm is flush with the rear one on the head sheave frame.
82640 2021-04-22 649

3. Pin using the pin (see arrow) and secure as illustrated.

This locks the rocker arm in the folded-down position.
Only after this has happened is the head sheave in head
sheave in operating position.
DANGER
Operation with the head sheave in assembly position
is not permitted under any circumstances!
The head sheave is folded up into the assembly position in the analo-
gously reverse order.
17.4.2 Reeving the head sheave

1. Feed the hoist rope from the hoist drum to the run-in sheaves on
the main boom head. To do so, observe the detailed specifica-
tions in the section "Reevings" under "Reeving/unreeving the
hoist rope".
650 82640 2021-04-22

Fig. 518: Hoist rope
1 Hook suspension gear E1 Run-in sheave (standard)

E2 Run-in sheave for head sheave R Rope sheave of head sheave
WARNING
The head sheave may only be operated with single-
strand lines.
The rope may not be fed via run-in roller (E1) as this
would make the deflection angle of the hoist rope too
large - risk of damaging the rope.
During reeving, there is a risk that all involved
sheaves become entangled and wound up. Proceed
with appropriate caution.
2. Guide the hoist cable over the run-in roller (E2) on the main
boom head to the rope sheave (R) of the head sheave and pin to
hook suspension gear (1), model 12.5.
82640 2021-04-22 651

3. Attach the hoist limit switch (1) with the corresponding shift
weight (2) to the head sheave. To do so, peg the hoist limit
switch to the respective mandrel at the tip section of the head
sheave on the left-hand side - as shown - and secure with a linch
pin.
652 82640 2021-04-22

DANGER
tioning.
state.
restrainer.
4. Place the hoist limit switch of the head sheave in the functional
This hoist limit switch and the corresponding shift weight can be
used in all additional equipment. That is the reason that there is only
one of them for all additional equipment. It may therefore be neces-
sary to remove them from a different additional device so that they
can then be used on the head sheave.
82640 2021-04-22 653

DANGER
tioning.
5. Fit shift weight (2) of hoist limit switch (1) to the hoist rope of the
head sheave.
654 82640 2021-04-22

17.4.3 Connecting the head sheave electrically (closing the safety chain)
17.4.3.1 Distribution box "X0550" on the main boom head
Fig. 522: Distribution box "X0550" on the main boom head (schematic diagram)
A Connection - air speed indicator/

hazard light/additional equip-
ment
1. Connection (A): Connect the cable plug of the head sheave dis-
tribution box. The other connection is assigned as for main boom
operation (see the section "Safety equipment" at "Electrical safe-
ty chain").
17.4.3.2 Distribution box "X0560.1" on the head sheave
Fig. 523: Distribution box "X0560.1" on the head sheave (schematic diagram)
A Connection - air speed indicator/ A1 Bridging plug

hazard light
H Connection - hoist limit switch
1. Connection "H": Remove the protective cap and connect the

hoist limit switch plug.
82640 2021-04-22 655

2. Connection "A": Remove the protective cap and connect the plug
of air speed indicator/hazard light.
During operation without the air speed indicator/hazard light, assign
bridging plug "A1" to connection "A".
DANGER
Risk of breaking and overturning if the crane is oper-
ated without an air speed indicator.
During crane operation without an air speed indicator,
adherence to the permitted wind speeds can no longer
be monitored in the crane control screen. Prohibited high
wind speeds could remain unnoticed. Crane operation
with prohibited high wind speeds is PROHIBITED.
Take suitable alternative measures to determine wind
speeds.
Observe the corresponding specifications in 9.2.6
Measuring the Wind Speed, side 415.
The hazard light (optional equipment) and the rotor of the anemome-
ter remain mounted on the main boom head.
17.5 Operation
1. Attach the head sheave, fold downwards into operating position,
attach hoist cable and pin on hoist suspension gear, attach hoist
limit switch and associated shift weight and then connect the
head sheave electrically. This is described in detail on the pre-
ceding pages (from 17.3 Fitting (assembly position), side 643).
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2. Enter the operating mode. The head sheave is operated in one

main boom operating mode. For this reason, select accordingly
(here: "HA").
WARNING
The head sheave may only be operated with single-
strand lines!
3. Set "Number of reeved rope lines" parameter to "1".
4. Select all other parameters in accordance with the actual crane

configuration, which must correspond to the relevant capacity ta-
ble.
Detailed specifications on selecting the operating mode can be

found in the section "Safety equipment".
82640 2021-04-22 657

17.6 Fold backwards into transport position

If the head sheave is not required, it can be folded laterally back-
wards to the main boom head.
WARNING
head sheave.
When folding the head sheave there is a risk of crushing
between the main boom head and head sheave.
During the folding procedure, no-one is permitted in
the area where loads/equipment could fall.
1. Unreeve the hoist rope and reel onto the rope drum.
2. Place the electrical safety chain on the main boom head back in
the configuration for main boom operation (see the section
"Safety equipment" at "Electrical safety chain").
Fig. 525: Shift weight on the head sheave (schematic diagram)
3. Dismantle the hoist limit switch and corresponding shift weight

(see arrow). Alternatively, pin the shift weight on the right-hand
side of the head sheave's top section in the transport position
and secure.
4. First, fold the head sheave up out of the operating position into
the assembly position. To do so, proceed as described for folding
down in 17.4.1 Folding the head sheave down in the operating
position, side 648, in the reverse sequence.
658 82640 2021-04-22

5. Check that the depicted pin (see arrow) is pinned correctly and is
secured at the top and bottom, which means that the head
sheave is connected to the main boom head in the pivot point.
82640 2021-04-22 659

DANGER
Risk of accidents due to the head sheave falling
down.
The following step may only be carried out if the head
sheave is correctly connected with the main boom
head in the pivot point (as described in the previous
point). The head sheave is then held by one pin only
(see arrow in Fig. 526, side 659).
6. Unlock and remove both biconical pins between the head sheave
and the main boom head. Pin the biconical pins to the corre-
sponding plates on the head sheave in the park position (see ar-
row) and secure.
7. Unlock coupling pin (see arrow) and remove from the park posi-
tion. Otherwise, it would bump into the transport lock plate on the
main boom head during the following folding procedure.
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8. Fold the head sheave around and over pin (1, pivot point) to the
rear until the hole of the head sheave's mounting plate is flush
with the corresponding plate hole (2) on the main boom head.
9. Pin the head sheave in this position using coupling pin (see ar-
row) and secure it.
This secures the head sheave against folding away from the
main boom head.
The folding back of the head sheave to the front in assembly position
and/or the further folding down into operating position is carried out in
the analogously reverse order.
17.7 Dismantling
To do so, proceed as described in 17.3 Fitting (assembly position),
side 643 but in the reverse sequence. The head sheave must be dis-
mantled in the assembly position. To do so, observe 17.4.1 Folding
the head sheave down in the operating position, side 648, in the re-
verse sequence.
82640 2021-04-22 661

662 82640 2021-04-22

18 Assembly Jib (Optional)
Fig. 531: Assembly jib
Length Width Height Weight

1810 5.9 1040 3.4 1322 4.3 450 990
Table 18: Transport Dimensions and Weights
NOTE
Risk of damage to the plastic rope sheaves if they touch the
ground.
The plastic rope sheaves are not adequate for taking the weight of
the assembly jib.
Always underpin the assembly jib so that the plastic rope
sheaves have no contact with the ground.
82640 2021-04-22 663

18.2 General
Fig. 532: Assembly jib (schematic diagram)
1 Assembly jib 1.1 Frame

1.2 bracing rods 1.3 Adapter
The assembly jib (1) is for raising loads with up to 4-fall reeving. If the
crane is equipped with hoist 2, the hook block can remain reeved on
the main boom head.
Assembly jib (1) consists of frame (1.1), bracing rods (1.2) and adapt-
er (1.3).
The assembly jib can be folded and it may be folded on the side of
the main boom when the permitted axle loads for transport are taken
into consideration.
The above figure shows the assembly jib in the operating position.
If the crane is to be telescoped out with the assembly jib folded in the
transport position, it must be located in the "folded position" in front of
the main boom head.
Operating the main boom with the assembly jib fitted leads to a re-
duced capacity of the crane.
- On the left-hand side of the main boom head, the optional "Head
sheave" can also be folded in the transport position to the side on
the main boom head.
- However, only the assembly jib or the head sheave can be folded
to the left of the main boom head.
664 82640 2021-04-22

If the crane with main boom extension is equipped with hydraulically

variable operating angle adjustment "HAVHY", a bracket is located
on the left-hand side of the main boom head for attaching the hy-
draulic hoses. The bracket must be removed in order to fit the as-
sembly jib laterally in transport position.
The assembly jib is marked with the construction number of the

crane. It may only be fitted on the crane with this construction num-
ber. Exceptions are only permitted if this is expressly stated in the
crane papers (e.g. crane log book).
18.3 Fitting and Removal
WARNING
fied.
WARNING
the assembly jib.
In particular, observe the instructions on risks in
1.13 Assembling and dismantling crane components,
side 59 and the procedure described below.
WARNING
Risk of falling when working at heights!
Use suitable auxiliary equipment.
All assembly work/work at height must be carried out using suitable

auxiliary equipment (ladders, hoist platforms, scaffolding, auxiliary
crane, personal protective equipment). Detailed information on this
subject can be found in the section "Structure of the mobile crane" at
"Getting on and down from the crane", in particular "Getting on and
off using mobile multi-purpose ladders" and "Attachment eyelets for
personal protective equipment".
To attach the ladder securely, there are ladder brackets on the main
boom head and the assembly jib itself.
82640 2021-04-22 665

1. Support the crane on outriggers, align it and fit the counterweight

-in accordance with the regulations of the capacity table.
NOTE
Risk of collision when fitting the assembly jib.
If the bracket remains fitted on the main boom head, there is a
risk of collision when fitting the assembly jib in the procedure
described below.
2. Remove bracket with anemometer and hazard light (optional)

from the main boom head.
1 Assembly jib 1.1 Frame

1.3 Adapter 2 Bolts
E2 Run-in sheave
3. Guide the hoist rope on the main boom head over run-in sheave
(E2) and reel off a few metres - over the prepared assembly jib
(1).
The assembly jib must be in the depicted "folded" position for fitting.
In this position, adapter (1.3) and frame (1.1) are pinned on both
sides with pins (3) (and secured). The rope in the auxiliary winch fit-
ted in the assembly jib may not be under tension. This would cause
a risk of damage to the rope.
In the following procedure, the assembly jib may not swing out or
dangle at an angle when it is raised.
666 82640 2021-04-22

Fig. 534: Attachment Points
There are two variants for the front attachment points. The illustra-
tions in this section show always the left variant. In the right variant,
the attachment points are only slightly offset.
1.3 Adapter 2 Biconical bolt
DANGER
No-one may be in the area at risk of falling equip-
ment, etc. as long as the assembly jib is attached to
the auxiliary crane or has not yet been completely
pinned!
4. Attach the assembly jib to the auxiliary crane in the 4 attachment

points - as illustrated - and position on the main boom head in
the fitting position and pin. To do so:
4.1. First retract the bottom fork heads of adapter (1.3) of the
assembly jib at the bottom head axis of the main boom.
4.2. On both sides, remove the biconical pins (2) from the
transport position, knock in place and secure.
4.3. Proceed in the same manner for the two top pinning
points.
82640 2021-04-22 667

The assembly jib is then fitted in the "folded" position, i.e. at the four
points on the head axes of the main boom. This "folded" position is
only for fitting and removing or folding the assembly jib over to the
rear in the transport position.
This "folded" position may NEVER be used for raising loads. To do
so, the assembly jib must first be brought in the operating position. To
do so, observe 18.4.1 Lowering the assembly jib into the operating
position, side 668.
DANGER
Risk of accidents when raising loads in the "folded"
position!
If loads are raised in this position, the assembly jib will be
overloaded and the load could fall down.
To raise loads, first bring the assembly jib into the op-
erating position.
The assembly jib must also be removed in the "folded" position. To do

so, proceed in the same manner just in the opposite sequence.
18.4 Preparing assembly jib for operation
18.4.1 Lowering the assembly jib into the operating position

Proceed as described below to lower the assembly jib from the folded
position into the operating position:
Fig. 536: Transport position - crank (schematic diagram)
1. Release crank (see arrow) from the transport position on the

crane chassis frame.
668 82640 2021-04-22

1.1 Assembly jib frame 1.2 Bracing rods

2 Rope 3 Auxiliary winch
5 Attachment eyelet 6 Crank
6.1 Hook 8 Bolts
2. Check that rope (2) of auxiliary winch (3) has been fitted properly
and is taut (as illustrated). It must hold the assembly jib in the fol-
ded position after the pins (8) are removed (as described in the
next work step).
3. Unlock and release pins (8) on both sides.
At a later point after lowering the assembly jib, pins (8) can be peg-
ged and secured without function at this point (park position).
4. Lower the frame (1.1) of the assembly jib. To do so, fit hook (6.1)
of crank (6) to attachment eyelet (5) of auxiliary winch (3) and
unreel the auxiliary winch rope until bracing rods (1.2) of the
frame are fully stretched on both sides.
NOTE
Risk of damage due to loading the rope of the auxiliary winch.
In the operating position of the assembly jib (bracing rods
stretched), loosen the auxiliary winch rope somewhat by unree-
ling it lightly so that it is never placed under load during assem-
bly jib operation.
The crank hook is best attached to the attachment eyelet of the aux-
iliary winch from the front left.
82640 2021-04-22 669

Only after complete lowering is the assembly jib in the operating po-
sition as shown.
5. Release crank (see arrow) and refit it in the transport position on

the crane chassis frame and secure it (holding fixture).
The assembly jib is raised in the folded position in the same way in
the opposite sequence.
670 82640 2021-04-22

18.4.2 Reeving the assembly jib
Fig. 538: Head of the assembly jib
1 Rope guard pin 2 Fixed point
1. Pull out both rope guard pins (1) on the head of the assembly jib,
let fixed point (2) fold down in the operating position and reeve
the hoist rope. After reeving, the two rope guard pins (1) must be
fitted again and secured.
82640 2021-04-22 671

E1 Run-in sheave (standard) E2 Run-in sheave for assembly jib

R1 Rope sheave of assembly jib
WARNING
The rope may not be fed via run-in roller (E1) as this
would make the deflection angle of the hoist rope too
large - risk of damaging the rope.
During reeving, there is a risk that all involved
sheaves become entangled and wound up. Proceed
with appropriate caution.
2. Feed hoist rope to the rope sheave (R1) of the assembly jib via
intake sheave (E2).
672 82640 2021-04-22

Example: Hook block type 80, 3-sheave
Fig. 540: Reeving diagrams (schematic diagram)
"A" Reeving plan direction of sight E Intake sheaves on the main boom head
R Rope sheaves on the assembly jib U Hook block pulleys
FR Fixing point on the assembly jib FU Fixing point on the hook block
DANGER
3. Reeve the hoist rope to the hook block (4-ropes, 3-ropes or 2-

ropes).
Number of falls Rope guidance over sheaves

4 E2-R1-U1-R2-U3-FR
3 E2-R1-U2-R2-FU
2 E2-R1-U2-FR
Table 19: Hook block type 80, 3-sheave
82640 2021-04-22 673

4. Fit hoist limit switch(1) with the corresponding shift weight (2) to
the assembly jib. To do so, peg the hoist limit switch to the re-
spective mandrel on the top section of the assembly jib on the
right-hand side - as shown - and secure with a forelock.
674 82640 2021-04-22

DANGER
tioning.
state.
restrainer.
5. Place the hoist limit switch of the assembly jib in the functional
This hoist limit switch and the corresponding shift weight can be
used in all additional equipment. That is the reason that there is only
one of them for all additional equipment. It may therefore be re-
quired that they be dismantled from a different auxiliary device in or-
der to be able to be used on the assembly jib.
82640 2021-04-22 675

DANGER
tioning.
6. Attach shift weight (2) of hoist limit switch (1) to the hoist rope of
the assembly jib.
676 82640 2021-04-22

8. Fit the bracket with anemometer and hazard light (optional) on

the left-hand side on the corresponding thread bolts of the as-
sembly jib adapter. The bracket can be either fixed or adjustable.
To do so, and for fitting, observe the corresponding description
relating to the main boom head (see 8.6 Electric Safety Chain,
side 361).
18.4.3 Connecting the assembly jib electrically (closing the safety chain)
18.4.3.1 Distribution box "X0550" on the main boom head
A Connection - air speed indicator,

hazard light, additional equip-
ment
1. Connection "A": Connect the cable plug of the assembly jib distri-
bution box. The assignment of the other connection is as for
main boom operation (see 8.6 Electric Safety Chain, side 361).
82640 2021-04-22 677

18.4.3.2 Distribution box on the assembly jib
Fig. 545: Distribution box (schematic diagram)
H Connection - hoist limit switch
1. Connection "H": Remove the protective cap and connect the

hoist limit switch plug.
Fig. 546: Distribution box (schematic diagram)
A Connection - air speed indicator/ A1 Bridging plug

hazard light
2. Connection "A": Remove the protective cap and connect the plug
of air speed indicator/hazard light.
During operation without the air speed indicator/hazard light, assign
bridging plug "A1" to connection "A".
678 82640 2021-04-22

DANGER
Risk of breaking and overturning if the crane is oper-
ated without an air speed indicator.
During crane operation without an air speed indicator,
adherence to the permitted wind speeds can no longer
be monitored in the crane control screen. Prohibited high
wind speeds could remain unnoticed. Crane operation
with prohibited high wind speeds is PROHIBITED.
Take suitable alternative measures to determine wind
speeds.
Observe the corresponding specifications in 9.2.6
Measuring the Wind Speed, side 415.
18.5 Operation
1. Fit the assembly jib, lower it in the operating position, fit the hoist
rope and reeve the hook block, fit the hoist limit switch and corre-
sponding shift weight and then connect electrically. This is de-
scribed in detail on the preceding pages (from 18.3 Fitting and
Removal, side 665).
Fig. 547: "Operating mode" screen
2. Select the operating mode (here "MS" for assembly jib).

3. Select all other parameters in accordance with the actual crane
configuration, which must correspond to the relevant capacity ta-
ble.
Detailed specifications on selecting the operating mode can be

found in the section "Safety equipment".
82640 2021-04-22 679

18.6 Fold backwards into transport position

If the assembly jib is not required, it can be folded back to the side on
the main boom head.
It is normally folded onto the left side. The components required for
pinning the assembly jib in the laterally folded position are then only
located on one side of the main boom head and assembly jib. This
case is also described in the following.
The required components are located on both sides of the main boom
head and assembly jib in some machine designs. In this case, the as-
sembly jib can also alternatively be folded onto the right side. The
procedure is the same for folding onto the left side, but mirror-inver-
ted.
The assembly jib can only be folded onto the right side if no main
boom extension is installed here.
CAUTION
Driving configuration does not comply with national
regulations - Risk of accidents due to excess width!
Especially in the case of the AC130-5 (Explorer 5500)
and AC160-5 (Explorer 5600), driving with a laterally fol-
ded assembly jib can result in excess width.
Choose the folding direction accordingly.
Do not drive on public roads with the assembly jib fol-
ded alongside.
WARNING
the assembly jib.
There is a risk of crushing between the main boom head
and the assembly jib when folding the assembly jib.
During the folding procedure, no-one is permitted in
the area where loads/equipment could fall.
680 82640 2021-04-22

Fig. 548: Hydraulics bracket (schematic diagram)
NOTE
Risk of collision!
If the crane is also equipped with a main boom extension with hy-
draulically smooth angle adjustment, a bracket for hydraulic ele-
ments on the main boom head prevents folding to the rear.
Remove the bracket. To do so, observe the corresponding regu-
lations (see the section "Main boom extension" under "Equip-
ment on the basic unit (MBE with hydraulically smooth angle ad-
justment)".
1. Unreeve the hoist rope and reel onto the rope drum.
2. Bring the electric safety chain on the main boom head back into
the state required for main boom operation. (See "Safety equip-
ment" under "electric safety chain").
Fig. 549: Shift weight on the assembly jib (schematic diagram)
3. Dismantle the hoist limit switch and corresponding shift weight

(see arrow).
82640 2021-04-22 681

Fig. 550: Shift weight on the assembly jib
Alternatively, pin the shift weight on the assembly jib in the transport
position (see arrow) and secure.
4. Remove bracket with anemometer and hazard light (optional).
5. First, raise the assembly jib out of the operating position in the
"folded" position. To do so, proceed as described for lowering
from 18.4.1 Lowering the assembly jib into the operating posi-
tion, side 668, in the reverse sequence. In the folded position,
both elements of the assembly jib are connected with each other
on both sides by pins (see arrow).
682 82640 2021-04-22

1 Biconical bolt
6. Release both biconical pins (1) on the right-hand side and peg in
the park position and secure. This releases the connection on
the right-hand side between the assembly jib and the main boom
head. In the following step, the assembly jib is folded back round
the pin connection which is still in place (2 biconical pins) on the
left-hand side.
1 Shackles 2 Coupling pins

3 Mounting plate
7. On the left-hand side, unlock coupling pin (2) and remove from
the park position on the assembly jib. Otherwise, it would bump
into the transport lock plate on the main boom head during the
following folding procedure. After the folding procedure, the holes
of plates (1) on the assembly jib and of mounting plate (3) on the
main boom head are flush. The assembly jib can then be locked
in the transport position by pinning it with coupling pins (2).
82640 2021-04-22 683

8. Fasten the auxiliary reeving rope (provided by the customer) at a

suitable point on the left-hand side of the assembly jib. The as-
sembly jib can be folded from the ground using this auxiliary
reeving rope.
9. Fold the assembly jib back round the pivot point (2 biconical pins,
left-hand side) until the holes of the mounting plates of the as-
sembly jib are flush with the corresponding hole of the plate on
the main boom head.
For detailed depictions of these shackles, see Fig. 553, side 683.
10. Pin the assembly jib in this position using coupling pin (see ar-
row) and secure it.
This secures the assembly jib against folding away from the
main boom head.
11. Remove the auxiliary reeving rope.
18.7 Folding back the assembly jib

The assembly jib is folded back to the front in the assembly position
and / or lowered further in the operating position in the same way in
the opposite sequence.
684 82640 2021-04-22

19 Main Boom Extension (Optional)
19.1 General / Versions of the Main Boom Extension

There are two alternative designs for the main boom extension (MBE)
for this type of crane:
Main boom extension with fixed operating angles to the longitu-
dinal main boom direction (0° / 20° / 40°)
Fig. 555: Main boom extension with fixed operating angles
Crane type
MBE length
AC 250-5 AC 220-5 AC 160-5 AC 130-5
11.4 m (37.4 ft) x x x x
21.0 m (68.9 ft) x x x x
23.4 m / 76.8 ft x x x
33.0 m (108.3 ft) x x x
82640 2021-04-22 685

Main boom extension with hydraulically smooth operating angle

adjustment from 0° - 40° to the longitudinal main boom direction
(hydraulically luffing MBE: "HAVHY")
Fig. 556: HAVHY (hydraulically infinitely adjustable)
Crane type
MBE length
AC 250-5 AC 220-5 AC 160-5 AC 130-5
11.4 m (37.4 ft) x x x x
21.0 m (68.9 ft) x x x x
23.4 m / 76.8 ft x x x
33.0 m (108.3 ft) x x x
35.4 m (116.1 ft) x
45.0 m (147.6 ft) x
686 82640 2021-04-22

Similarities between the two versions

Both versions are angled directly at the main boom head or at the in-
termediate section.
The assembly procedures for both versions are virtually identical. The
differences are described in the corresponding procedure.
19.2 Important Notes
WARNING
Risk of accidents!
The main boom extension is marked with the con-
struction number of the crane. It may only be fitted on
the crane with this construction number.
Exceptions are only permitted if this is clearly indica-
ted in the crane documents (e.g. crane log book).
The main boom extension may only be installed and
removed by qualified personnel who have been in-
structed accordingly.
WARNING
Risk of accidents!
Check that there is no damage to the pipes on the lat-
tice mast components of the main boom extension.
If damaged tubes or defective weld seams are dis-
covered during a visual check, then continuing to
work with the main boom extension is prohibited.
82640 2021-04-22 687

WARNING
Risk of breakage!
The components of the main boom extension must
be checked at least once a year by an expert (in ac-
cordance with the accident prevention regulations
"Load handling equipment in hoist operation (GUV-
V 9a)"). In addition they must be checked by a techni-
cal expert between these intervals as and when re-
quired by the operating and site conditions. The test
intervals are generally determined by the operating
and site conditions. This means that the more the
equipment is used, the shorter the inspection inter-
vals should be.
It must be documented that this inspection has been
carried out (e.g. in the crane log book).
The following checks should be carried out:
- Checking for cracks
- Checking the Length
- Check for wear
- Check of paint
- Check for plastic deformation
Instructions on how to carry out the inspection are de-

scribed in the "Lubrication and maintenance instruc-
tions".
WARNING
Risk of overturning! Risk of uncontrolled movement!
Before fitting the main boom extension, support the
crane on outriggers in relation to the planned configu-
ration (MBE, CWT etc.) and fit the counterweight (see
capacity table).
Align the crane horizontally (level). To do so, see the
operating instructions of the crane chassis under
"Outriggers".
CAUTION
Risk of uncontrolled movement of the MBE.
Align the main boom horizontally when fitting or fold-
ing the main boom extension.
Any exceptions to this rule are clearly listed.
688 82640 2021-04-22

Working at height
Depending on the height of the technician, some of the assembly
work steps can be carried out from the ground.
Assembly work that can not be carried out from the ground must be
carried out with the help of appropriate auxiliary equipment (such as a
multi-purpose-ladder (included in the delivery), a lifting platform or
similar).
WARNING
Risk of falling!
It is not permitted to walk on the main boom or on any
auxiliary equipment.
Supplied multi-purpose ladder
Transporting the multi-purpose ladder

The transport position of the multi-purpose ladder is described in sec-
tion "Assembling the mobile crane".
82640 2021-04-22 689

Bracket for attaching the ladder

There are plates on the entire crane for safely attaching the ladder
during the corresponding working procedures.
Fig. 558: Bracket for attaching the ladder (schematic diagram)
WARNING
Risk of falling!
When working with ladders, always make sure they
are positioned firmly and safely!
If there are brackets for attaching the ladder, attach
the ladder correctly in the appropriate brackets (see
figure above).
It can occur that the plates for attaching the multi-purpose ladder to
the main boom head and to the main boom extension can only be
used in a limited capacity when the main boom is tilted.
CAUTION
Risk of falling if the multi-purpose ladder is attached
in a way that is unsuitable for the specific operation!
Ensure the ladder is held securely before getting onto
the multi-purpose ladder.
Handling the hoist rope

When fitting the main boom extension, the hoist rope is fitted and re-
eved.
WARNING
There is a risk of injury when handling the hoist
rope.
Observe the section "Hoist ropes" from the section
"Reeving".
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Auxiliary rod
Fig. 559: Auxiliary rod (schematic diagram)
The depicted auxiliary rod is required for fitting the hoist rope and to
carry out individual work steps when fitting the main boom extension
in the transport position. Further information, e.g. the transport posi-
tion of the auxiliary rod, is described in section "Reevings".
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Attachment eyelets
Fig. 560: Attachment eyelets (schematic diagram)
There are attachment eyelets on the crane and the additional equip-
ment for attaching suitable personal protective equipment. Fig. 560,
side 692 shows an example of an attachment eyelet design. It might
be required to adhere to country-specific regulations on personal pro-
tective equipment.
Fig. 561: Hook with corresponding size Fig. 562: Hook with incorrect size
The diameter of the attachment eyelets is 35 mm (1.4 in). Hooks

which are too large ( Fig. 562, side 692) may not be used, as they
could break during a fall despite sufficient dimensioning.
WARNING
Risk of accidents! Risk of overloading! Risk of break-
age!
Use an appropriately sized suitable hook for attach-
ment ( Fig. 561, side 692).
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Fig. 563: Attachment eyelets (schematic diagram)
All attachment eyelets (see arrow in Fig. 563, side 693) are marked
with corresponding adhesive labels.
WARNING
Risk of accidents!
Only use the marked attachment eyelets for attaching
the hook of personal protective equipment.
Do not use attachment eyelets for attaching crane
components to a crane.
WARNING
Risk of falling!
When working at heights, the ladders must be attach-
ed and you must be secured against falling using per-
sonal protective equipment during the entire assem-
bly procedure.
Fig. 564: Attachment points / Attachment eyelets (schematic diagram)
There are also plates which combine the function of attachment eye-
lets for personal protective equipment (PPE) and attachment points
for raising the corresponding component group. It must be ensured in
particular that the attachment eyelets for PPE are not accidentally
used as attachment points.
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The main components of the main boom extension can be combined

in different lengths.
The combination of the main components of the main boom exten-

sion is described in 19.3.2 Combination of the Main Components,
side 699.
The main components are connected to each other and/or to the

main boom head using pins.
Fig. 565: Fastening of the MBE (schematic diagram)
1 pin Ø 50 mm / 2.0 in 2 Locking spring

3 Pins Ø 40 mm / 1.6 in 4 Locking spring
5 Pins Ø 45 mm / 1.8 in
Pins (1) must each be secured against falling out with a functioning
locking spring (2). Pins (3) and (5) must be secured against falling out
with two functioning locking springs (4).
If intermediate sections are component parts of the main boom ex-

tension assembly, they are fastened using pins Ø 45 (5) and these
pins are secured against falling out with locking springs (4).
WARNING
Risk of breakage due to interchanged or lost pins!
Only the corresponding original pins are to be used
for assembly.
Secure the pins against falling out using functional
locking springs.
For easier fitting of the pins, the grease application of the pins must
be checked before every pinning procedure and grease must be re-
applied if necessary.
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The force is transmitted at the top via the tension plates (design with
fixed operating angles) or via the adjusting cylinders (hydraulic luff-
ing MBE (HAVHY)). Detailed specifications can be found in the cor-
responding section.
Fig. 566: Main boom extension in the transport position (schematic diagram)
1 Basic Boom MBE 2 Box top piece
CAUTION
Risk of accidents!
When moving the crane, the permitted axle loads
must be observed (see the section entitled "Driving"
in the operating instructions of the crane chassis).
When moving the crane or during crane operation on the main boom,
the basic boom MBE (1) or the basic boom MBE (1) and the box top
piece (2) can be folded to the side on the main boom basic case
(transport position).
If only the box top piece (2) (without basic boom MBE (1)) is fitted at
the side on the main boom basic case in the transport position, then
the crane may only be driven at a walking pace.
If, when raising loads with the main boom extension, the box top
piece (2) on the side of the main boom basic case is in the transport
position, the weight of the box top piece (2) reduces the load that can
be lifted.
82640 2021-04-22 695

Fig. 567: Raising loads with the box top piece folded down is prohibited (schemat-
ic diagram)
When raising loads with the main boom extension, the box top piece
(2) must never be located at the side of the basic boom MBE (1).
WARNING
Risk of accidents due to impermissible twisting and
deflection of the main boom.
Do not raise loads when the box top piece (2) is at
the side of the basic boom MBE (1).
The main boom extension can only be fitted and removed using the
auxiliary crane.
If the crane is equipped with an HD attachment (auxiliary sheaves at
the side), this must be removed before the main boom extension is fit-
ted (see section "Reeving").
696 82640 2021-04-22

Wind speed indicator (1) with hazard light (2; option)
Fig. 568: Wind speed indicator / hazard

light on the main boom head (schematic
diagram)
1 Wind speed indicator
2 Hazard light
3 Bracket
4 Wing nut
Before fitting the MBE on the main boom head, wind speed indicator
(1) and / or hazard light (2; option) including bracket (3) must be com-
pletely removed from the main boom head.
NOTE
Risk of the fitted MBE colliding with the brackets of the wind
speed indicator / hazard light.
If the MBE is fitted, there is a risk of it colliding with the brackets
of the wind speed indicator / hazard light if they are still on the
main boom head.
Loosen wing nuts (4) on the main boom head and remove the entire
bracket (3). Screw wing nuts (4) back in firmly.
At a later point when the MBE is fitted, the bracket is fitted at the front
on the respectively fitted MBE with the rotor of the wind speed indica-
tor and the hazard light (optional).
WARNING
Risk of overturning during crane operation without a
wind speed indicator or with a defective one!
Without knowing the current wind speed, the observance
of the permitted wind speed can not be monitored.
Loads must only be raised with a fitted, faultlessly
functioning wind speed indicator.
82640 2021-04-22 697

Observe the information concerning the air speed indicator and the
hazard light under 8.6 Electric Safety Chain, side 361.
- The folding procedure of the main boom extension from the

transport into the operating position (and vice versa) is described
under 19.5.4 Folding over the 11,4 m MBE (37.4 ft), side 721
or 19.5.5 Folding over the 21 m MBE (68.9 ft), side 827.
- Fitting the main boom extension for separate transportation is de-
scribed at 19.6.3 Fitting and dismantling for separate transpor-
tation, side 867.
- The guidance of the hoist rope is described at 19.7 Position-
ing / Reeving the Hoist Rope, side 976.
- The procedure for adjusting the operating angle with the MBE fit-
ted is described under 19.8 Adjustment of the operating angle
for fitted MBE, side 984.
19.3 Construction of the Main Boom Extension
19.3.1 Main Components of the Main Boom Extension
Fig. 569: Main Components of the Main Boom Extension
1 Intermediate section with fasten- 2 Intermediate section without fas-

ing eyes, top front tening eyes, top front
3 Basic Boom MBE 1) 4 Box top piece
1) = Depending on whether the MBE has fixed operating angles (0°,

20°, 40°) or hydraulically smooth operating angle adjustment (0°
- 40° HAVHY), there are two design variants for the MBE basic
boom (2).
698 82640 2021-04-22

19.3.2 Combination of the Main Components
Fig. 570: Combination of the Main Components
1 Intermediate section with fastening eyes, top front 2 Intermediate section without fastening eyes, top
front
The main boom extension can be assembled to the following lengths:
MBE Components Fig. 570,

side 699
Inter- Inter-
medi- medi- Box
Basic
ate ate top
boom
sec- sec- piece
MBE (3)
tion tion (4)
(1) (2)
11.4 m / 37.4 ft x "a"
21 m / 68.9 ft x x "b"
23.4 m / 76.8 ft x x "c"
33 m / 108.3 ft x x x "d"
35.4 m / 116.1 ft 1) x x x "E"
45 m / 147.6 ft 1) x x x x "F"
1) = only as hydraulically luffing MBE (HAVHY)
WARNING
Risk of accidents!
Only MBE lengths may be fitted to the crane which
can be selected at crane control.
82640 2021-04-22 699

19.3.3 Equipment on the basic machine (MBE with fixed operating angles)
There is a hydraulic auxiliary cylinder on the main boom extension for
setting the tension plates during fitting of the main boom extension so
that the desired operating angle is in place during crane operation at
a later date. There are hydraulic connections on the main boom to
supply this auxiliary cylinder hydraulically.
Cross beam for angling at the main boom

To be able to angle the main boom extension with the help of the aux-
iliary cylinder, the cross beam shown must be fitted on the main
boom.
19.3.4 Equipment on the basic unit (MBE with hydraulically smooth operating angle
adjustment)
The figures in this section are schematic diagrams.
700 82640 2021-04-22

Fig. 571: Main boom extension (HAVHY) (schematic diagram)
1 Basic boom 2 Hydraulic cylinder

3 Hose drum
There are two hydraulic cylinders (2) in the rear area of the basic
boom (1) of the MBE for setting the operating angle of the main boom
extension with hydraulic continuous operating angle adjustment.
There is a hose drum (3) on the side on the main boom to supply the
two hydraulic cylinders (2) with hydraulic oil for setting the operating
angle.
Position of the hydraulic hoses for MBE operation
Fig. 572: Hydraulic hoses during MBE operation (schematic diagram)
1 Bracket 2 Bracket
3 Safety linch pin
The ends of the hydraulic hoses are mounted on bracket (1). When
working with the main boom extension (MBE), bracket (1) is pinned to
bracket (2) on the side of the main boom along with the hydraulic ho-
ses. A safety pin (3) is used to secure the bracket (1).
The bracket (2) fitted on the side of the head must be removed in or-
der to fit the assembly jib on the side of the main boom in the trans-
port position. Depending on the design of the crane, bracket (2) is
fastened or inserted with screws and secured with a safety pin for this
purpose.
It is always assumed during the operating procedures described be-
low that the holding device is pinned with the ends of the hydraulic
hoses on the main boom head and that it is secured against falling
out with a safety pin.
82640 2021-04-22 701

Resting position of the hydraulic hoses
Fig. 573: Hydraulic hoses during MBE operation (schematic diagram)
1 Safety linch pin Y Pinning position
If the hydraulic adjustment of the main boom extension is not used,

the bracket with the hydraulic hose ends is fastened to the basic case
so that the hoses are not unreeled when telescoping out the main
boom.
The bracket with the hydraulic hose ends is then pinned in point "Y"
on the basic case and secured against falling out using safety pin (1).
Reconfiguring from the MBE operation position to the resting
position
The spring preload tension of the spring-loaded drum must be taken
into consideration when reconfiguring the hydraulic hoses from the
MBE operation position to the resting position (and vice versa).
WARNING
Risk of falling due to the spring preload tension in
the hydraulic hoses.
Carry out the reconfiguring procedure with two people
(one person monitors the turning of the spring-loaded
drum).
Only carry out the reconfiguring procedure from a
fixed scaffolding or operating platform.
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Procedure for reconfiguration
Fig. 574: Roller adapters (schematic diagram)
1 Roller adapters
The roller mouthpieces which guide the hydraulic hoses must first be
opened before the bracket can be pegged again with the ends of the
hydraulic hoses.
To open the roller adapters (1) on the flanges of the telescopic sec-
tions, the respective nut must be loosened and the roller element fol-
ded downward.
The safety linch pin must be fitted again for mounting purposes once
the bracket has been repegged with the ends of the hydraulic hoses.
Crane with assembly jib in transport position
If the crane is equipped with a hydraulically luffing main boom exten-
sion and the assembly jib is to be erected into the transport position
at the same time, then the hose holder on the main boom head must
be removed. The hose holder is pinned with a locking spring on the
main boom head. The locking springs must be removed to release
the hose holder.
Relief connections for hydraulic cylinders

If the hydraulically adjustable main boom extension is fitted in the
transport position, the two connections of the hydraulic cylinders for
pressure relief must be connected to the right-hand side of the main
boom at the marked connections.
82640 2021-04-22 703

Dismantling / assembling the hose drum secured with bolts (for

example, in case of repair)
No assembly work is carried out on the hose pieces on the main
boom or on the hose drum. The hose drum is not equipped for rapid
assembly/disassembly for that reason.
If the hose drum is dismantled, e.g. for repair work on the main boom,
this must be done carefully using the appropriate tools.
NOTE
Risk of damage!
Hose drums may only be dismantled and assembled by special-
ly trained personnel.
WARNING
Risk of accidents!
The hose drum is subject to prestressing!
If the hose drum is removed, it must be slowly and
carefully relieved of the pressure it is under. The
number of turns must be counted while doing so.
The hose drum must be pretensioned with the same number of

turns when it is remounted at a later date.
Always turn the drum only in the direction of the arrow.
704 82640 2021-04-22

Dismantling the bolted hose drum (design for rapid assembly

using the auxiliary crane)
The hose drum has been designed for quick assembly with an auxili-
ary crane in order to achieve certain axle load states.
Fig. 576: Hose drum transport dimen-

Fig. 575: Hose drum
sions
1 Hose drum
2 Mounting bracket
3 Clevis
4 Eyebolt
5 Transport frame
The mounting bracket (2) and the hose drum (1) fastened to it form
one assembly unit. The assembly unit is attached to clevis (3) at the
top of the assembly bracket (2). The assembly unit is set down on a
supplied transport frame (5) for transportation. The transport frame
(5) (incl. assembly unit) (together: 300 kg (661 lbs)) can either be at-
tached to ring bolt (4) or raised using fork pockets. During driving, the
transport frame (5) must be positioned in the upright position as illus-
trated and secured against falling over.
82640 2021-04-22 705

Fig. 577: Hose drum (schematic diagram)
Place the hydraulic hoses in the resting position as described further

in this section.
Fig. 578: Hose drum
Roll up the hose end.
Fig. 579: Hose drum
1 Push rod clamping device 2 Hose drum
Lock the hose drum (2) with the push rod clamping device (1).
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Fig. 580: Hose drum
1 Bracket
Release the hose quick disconnect couplings at the hub of the hose
drum and fasten hose ends to corresponding bracket (1).
Fig. 581: Attaching the assembly unit
Attach the assembly unit to the clevis on the auxiliary crane.
Fig. 582: Hose drum
1 Mounting bracket 2 Locking spring

3 Bolts
On the fastening of the mounting bracket (1), remove the locking

spring (2) and pull out pin (3).
82640 2021-04-22 707

Fig. 583: Hose drum
1 Assembly unit 2 Transport frame
Raise assembly unit (1) and fit in supplied transport frame (2).
Fig. 584: Hose drum
1 Holder 2 Bolts
3 Bolts
Fold down both holders (1). Fit corresponding pin (2) and secure
against falling out. Fit pins (3) and secure against falling out.
Wrap up hydraulic hose ends so they are dustproof to prevent sub-

sequent malfunctions.
708 82640 2021-04-22

Fig. 585: Hose drum
1 Assembly unit 2 Lashing strap / textile loop

3 Transport frame
To prevent the assembly bracket (1) from twisting during transport,

the transport frame (3) and assembly bracket (1) can be lashed in
place using a lashing strap (2), a textile loop (2) or something similar.
NOTE
Risk of damage!
When lashing the assembly bracket (1) in place, it must be ensured
that the hose drum or assembly bracket (1) do not become dam-
aged.
Do not tighten the lashing strap or textile loop too firmly.
Detach the assembly unit.
Fig. 586: Hose drum
1 Transport frame 2 Eyebolt
Either the fork pockets or eyebolt (2) on the transport frame (1) can
be used to lift off the transport frame (1).
Assembling the hose drum in the AC 220-5 / AC 300-6
The assembly procedure is the same as the dismantling procedure,
but in the opposite sequence.
82640 2021-04-22 709

19.4 Operation of the Crane with Main Boom Extension
19.4.1 Procedure for crane operation

Requirements:
- Crane supported on outriggers in accordance with the subsequent
configuration in which loads are to be raised; crane chassis hori-
zontally aligned, axles raised
- Counterweight fitted in accordance with the subsequent configura-
tion in which loads are to be raised
- 19.2 Important Notes, side 687 read and understood.
1. Position the hook block at a suitable point so that it can be sub-
sequently reeved on the main boom extension (MBE).
Fig. 587: Position of the superstructure (schematic diagram)
2. Slew the superstructure in the 0° or 270° position for fitting the

main boom extension.
3. Place the main boom in the horizontal position.
4. Fit the MBE on the main boom head at the front in the operating
position. To do so, if the main boom extension is fitted to the side
of the main boom in the transport position: fold the main boom
extension from the transport into the operating position as descri-
bed in 19.5.4 Folding over the 11,4 m MBE (37.4 ft), side 721
or 19.5.5 Folding over the 21 m MBE (68.9 ft), side 827.
Or
If the MBE components are to be transported separately: fit the
main boom extension for separate transportation with the auxili-
ary crane as described in 19.6.3 Fitting and dismantling for
separate transportation, side 867.
In the MBE version with fixed operating angles (0°, 20°, 40°), the op-
erating angle is set during fitting.
In addition to the specifications in the corresponding section on fit-

ting, rope guidance / reeving of the hoist rope information on control
and troubleshooting is described in 19.7 Positioning / Reeving the
Hoist Rope, side 976.
710 82640 2021-04-22

If required:
5. Install the optional load hook camera and the optional hanging
light. See 19.10 Main Boom Extension with Load Hook Cam-
era / Hanging Light (Optional), side 1010.
WARNING
There is a risk of accidents when assembly work is
not completed and due to falling parts.
Carry out the inspection step described in the next
work step carefully.
6. Before carrying out the next work steps, check that all required
pins have been fitted and that there are no loose objects (e.g.
hammers) on the main boom or the MBE.
WARNING
Risk of overturning due to crane parameters being
set incorrectly at crane control.
Carry out the inspection and setting steps described
in the next work step carefully.
7. Set the operating mode suitable for the assembly state at crane
control in the "Operating mode selection" screen (see 19.4.3
Setting the operating mode at crane control in the "Operating
mode selection" screen, side 714).
8. Luff up the main boom in the high position.
9. Telescope out the main boom.
The hydraulic luffing MBE (HAVHY) can only be telescoped out at

an operating angle of 0° between the main boom and MBE (HAV-
HY) until the end length code is reached.
The capacity values in the capacity table are not enabled and dis-
played in the LLD until the final length code has been reached.
Under no circumstances may any additional load be attached when

configuring during the telescoping process of the main boom.
For the hydraulic luffing MBE (HAVHY):

10. Set the operating angle of the MBE.
The crane is now prepared for raising loads.
82640 2021-04-22 711

19.4.2 Procedure for deconfiguring the main boom extension

Requirements:
- Crane supported on outriggers in the operating position (with MBE)
with luffed up main boom which is telescoped out
- 19.2 Important Notes, side 687 read and understood.
For the hydraulic luffing MBE (HAVHY):
1. Set the MBE operating angle to 0°.
2. Luff up the main boom in the high position.
3. Completely telescope the main boom in.
4. Slew the superstructure in the 0° or 270° position for dismantling

the main boom extension.
5. Place the main boom in the horizontal position.
If fitted:
6. Uninstall the optional load hook camera and optional hanging
light. See 19.10 Main Boom Extension with Load Hook Cam-
era / Hanging Light (Optional), side 1010.
7. Fit the MBE to the main boom on the side in the transport posi-
tion. To do so, fold over the main boom extension from the oper-
ating position into the transport position as described in 19.5.4
Folding over the 11,4 m MBE (37.4 ft), side 721 or 19.5.5
Folding over the 21 m MBE (68.9 ft), side 827.
Or
If the MBE components are to be transported separately: dis-
mantle the main boom extension for separate transportation with
the auxiliary crane as described in 19.6.3 Fitting and disman-
tling for separate transportation, side 867.
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8. Set the operating mode "HA" in the "Operating mode selection"

screen in crane control.
9. Before continuing work, check that all pins are in the suitable
park position and that there are no loose objects (e.g. hammers)
on the main boom or MBE.
82640 2021-04-22 713

19.4.3 Setting the operating mode at crane control in the "Operating mode selec-
tion" screen
Fig. 590: MBE operating modes
When setting the operating mode, the design of the MBE (fixed oper-
ating angle or hydraulic luffing) must be taken into consideration.
1. Set the abbreviation of the crane configuration in accordance
with the following table:
Abbreviation of the crane con-

figuration
Main boom ex- Fig. 590,
tension side 714 Design with
hydraulic luffing
fixed operating
MBE
angles
11.4 m (37.4 ft) "a" HAV HAVHY
21 m (68.9 ft) "b" HAV HAVHY
23.4 m / 76.8 ft "c" HAV-VA HAVHY-VA
33 m (108.3 ft) "d" HAV-VA HAVHY-VA
35.4 m (116.1
"E" not possible HAVHY-VA
ft)
45 m (147.6 ft) "F" not possible HAVHY-VA
2. Select the fly jib length (here: main boom extension length).
Length Fig. 590, side 714

11.4 m (37.4 ft) "a"
21 m (68.9 ft) "b"
23.4 m / 76.8 ft "c"
33 m (108.3 ft) "d"
35.4 m (116.1
"E"
ft)
45 m (147.6 ft) "F"
714 82640 2021-04-22

3. Select angling of the fly jib (only for the version with fixed operat-
ing angles).
Angling Fig. 590, side 714

0°
20° "a", "b", "c", "d"
40°
The 35.4 m (116.1 ft) MBE "e" and the 45 m (147.6 ft) MBE "f" in
Fig. 590, side 714 are only available as hydraulically luffing main
boom extensions.
4. Select all other parameters in accordance with the actual assem-

bly state of the crane, which must correspond to the specifica-
tions in the respective capacity table.
Detailed specifications on selection of the operating mode can be

found in the section "Safety equipment" under the "Operating mode
selection" screen.
19.4.4 Raising loads with the main boom extension folded in the transport position
The capacity values in the capacity table are not reached when rais-
ing loads with the main boom extension folded in at the side. See the
'instructions for operating the crane', contained in the supplied load
capacity table set.
19.5 Main Boom Extension Fitted to the Main Boom
19.5.1 General
As long as the 11.4 m (37.4 ft) / 21 m (68.9 ft) MBE is not required,
the main boom extension can be carried alongside the main boom -
folded in the transport position and pinned.
As previously described, the main boom extension is available in a
design with fixed operating angles and with hydraulically smooth op-
erating angle adjustment. This makes no difference to the explana-
tions in this section. The figures in this section show the main boom
extension with fixed operating angles as an example.
82640 2021-04-22 715

19.5.2 Transport Instructions for the MBE in the Transport Position

To move the crane with the main boom extension folded in the trans-
port position, the following applies:
- When driving, observe the permitted axle loads.
Fig. 591: Fastening the basic boom MBE / box top piece (schematic diagram)
1 Bolts 2 Locking spring

3 Box top piece 4 Basic Boom MBE
- For the 21 m (68.9 ft) MBE: Bolts (1; x 2) between the basic boom
MBE (4) and box top piece (3) must be pinned and secured
against falling out with two locking springs (2).
Fig. 592: Folding cylinder MBE (schematic diagram)
1 Folding cylinder 2 Basic Boom MBE
- The folding cylinder (1) must have "gripped" the basic boom MBE
(2).
716 82640 2021-04-22

Fig. 593: Basic boom MBE with fixed operating angles (schematic diagram)
1 Bolts 2 Basic Boom MBE
- For the main boom extension with fixed operating angles (0°, 20°,
40°): The bolts (1) of the basic boom MBE (2) for fastening the ten-
sion plates must be fitted as shown and secured against falling
out. The bolts are on the right- and left-hand draw shackle.
Fig. 594: Fastening the MBE on the main boom basic case (schematic diagram)
1 Bolts 2 Bracket
3 Box top piece
- If the 21 m (68.9 ft) MBE is fitted in the transport position, box top
piece (3) must be pinned to bracket (2). The bolt (1) protrudes out
of the top end of the holding device.
Bracket (2) is only there if the crane has been prepared for the
transport position of the 21 m (68.9 ft) main boom extension.
82640 2021-04-22 717

Fig. 595: MBE with rollway (schematic diagram)
1 Locking plate 2 Basic Boom MBE

3 Mobile part of the rollway 4 Bolts
- The mobile part (3) of the rollway must be folded in and pinned
with bolts (4).
This means that locking plate (1) of basic boom MBE (2) is clamped
between the mobile part (3) of the rollway and the fixed part of the
rollway. This prevents the main boom extension (MBE) from folding
away during transport.
718 82640 2021-04-22

Fig. 596: Pivot point MBE (schematic diagram)
1 pivot point 2 Basic boom MBE
- The basic boom MBE (2) must be pinned at the side on the brack-
et of pivot point (1).
Bolts
All bolts must be in a transport position which is secured against fall-
ing out.
Hoist Limit Switches
The entire hoist limit switch must be removed from the main boom ex-
tension and stored safely.
19.5.3 General instructions and instructions on risks for folding over the equipment
Observe the "Important specifications" listed at the beginning of the
section.
The conditions listed below must be observed both when folding the
equipment from the transport into the operating position, and vice ver-
sa.
- Depending on the planned configuration (MBE, counterweight,
etc.), support the crane and the MBE and fit the counterweight (for
more information, see the capacity table).
- Slew gear brake applied.
82640 2021-04-22 719

Fig. 597: Telescoping display (schematic diagram)
- Main boom in the transport position (travel position: fully telesco-

ped in, pinned and horizontal) (see section "Telescoping" under
"Placing the main boom in the transport condition"). View on dis-
play (see Fig. 597, side 720).
In order for the folding procedure to be carried out without any prob-
lems, the main boom must be completely retracted. The stops be-
tween the telescopic sections must be flush. Some of the stops have
been fitted so that they are covered. It is not always possible at a
casual glance to recognise whether the stops are fitted correctly. For
this reason, the transport position of the main boom (display: see
Fig. 597, side 720) must be restored every time the MBE is folded
from the transport into the operating position and vice versa. The
tele drive secured to the last telescopic section might have to be re-
tracted additionally by hand (see section "Telescoping" under "Man-
ual telescoping") until it is no longer possible to retract the telescopic
sections any further.
- The catches must be fitted (top and bottom of the main boom).
WARNING
When folding the MBE from the transport into the op-
erating position or vice versa, there are risks of
crushing, shearing or falling objects (e.g. forgotten
tools).
There must therefore be no-one in the endangered
area during the folding procedure. It is prohibited to
walk between the MBE and the main boom.
Do not stand directly under the MBE to carry out this
work step.
720 82640 2021-04-22

NOTE
Risk of damage!
When the MBE is folded from the transport into the operating
position or vice versa the folding procedure must not be obstruc-
ted in any way.
Fig. 598: Folding cylinder (schematic diagram)
1 Hook 2 Folding cylinder

3 Auxiliary rod
- A folding cylinder (2) fitted to the side of the main boom is used for
one part of the folding over procedure. This folding cylinder can
tension the steel components mechanically. It could become more
difficult to move pins which must be loosened or fitted. For this rea-
son, it can be useful to retract or extend the folding cylinder mini-
mally in these cases. Before assembly or when telescoping the
folding cylinder (2) "freely", the hook (1) can become twisted. De-
pending on the design of the supplied auxiliary rod (3), the front
end of the auxiliary rod (3) can be moved over the hook (1) for
aligning or guiding in order to prevent twisting.
NOTE
Risk of damage!
Damage to the piston rod can cause leaks.
When aligning and moving the folding cylinder e.g. with the aux-
iliary rod: do not touch the piston rod.
The engine speed is automatically increased when sliding the fold-

ing cylinder in and out.
19.5.4 Folding over the 11,4 m MBE (37.4 ft)
WARNING
Risk of accidents!
When folding and during pinning and unpinning there
must be no-one in the slewing range or beneath the
MBE or in areas where loads/equipment could fall,
etc.
82640 2021-04-22 721

Fig. 599: 11.4 m (37.4 ft) MBE in the transport position (schematic diagram)
1 Basic Boom MBE
When 19.5.4.1.1 Folding over the MBE 11.4 m (37.4 ft) from the
Transport into the Operating Position, side 722, only the MBE 11,4
m (37.4 ft) (basic boom MBE (1)) is fitted in transport position at the
main boom.
Fig. 600: 21 m (68.9 ft) MBE in the transport position (schematic diagram)
When 19.5.4.2.1 Folding over the MBE 11.4 m (37,4 ft) from the
Transport into the Operating Position, side 817 the MBE 21 m
(68.9 ft) (main boom extension (1) and box top piece (2)) are fitted in
the transport position. However, only the 11.4 m (37.4 ft) MBE should
be folded into the operating position. The tip section (2) remains fitted
on the basic case of the main boom in the transport position.
19.5.4.1 MBE (11,4 m (37.4 ft)) Fitted in the Transport Position
19.5.4.1.1 Folding over the MBE 11.4 m (37.4 ft) from the Transport into the Operat-
ing Position
19.5.4.1.1.1 Procedure
The procedure described below is analogously the same for the de-
sign with fixed operating angles as well as for the design with hydraul-
ic continuous operating angle adjustment ("HAVHY"). As a rule, the il-
lustrations generally show the design with fixed operating angles. If
differences exist, explicit reference is made to the specific design.
To provide a better structure of the steps for folding over the main
boom extension, the steps are grouped below by assemblies or by
topics. Reference is made to the segment in which the steps are de-
scribed in detail. The hazard risks in these combined steps are de-
scribed in the corresponding sub-section.
722 82640 2021-04-22

WARNING
Risk of accidents!
Observe the procedure-related instructions on risks to
be found in the detailed description of the individual
steps.
Requirements:
- 19.5.3 General instructions and instructions on risks for folding
over the equipment, side 719 read and understood.
Fig. 601: Preparations on the MBE (schematic diagram)
1. Carry out preparations for folding over on the main boom exten-
sion (see 19.5.4.1.1.2 Carrying out preparations on the main
boom extension, side 728).
82640 2021-04-22 723

Fig. 602: Preparations on the basic crane unit (schematic diagram)
2. Carry out preparations on the basic crane unit for folding over
(see 19.5.4.1.1.3 Making Preparations on the Basic Crane
Unit, side 731).
Fig. 603: Fold the main boom extension off the rollway (schematic diagram)
3. Fold the main boom extension at the side of the rollway (see
19.5.4.1.1.4 Folding the Main Boom Extension at the Side of the
Rollway, side 736).
724 82640 2021-04-22

Fig. 604: Fold the MBE to the front (schematic diagram)
4. Fold the main boom extension to the front (see 19.5.4.1.1.5

Folding the Main Boom Extension to the Front, side 742).
Fig. 605: Electrically connect the MBE (schematic diagram)
5. Electrically connect the main boom extension to the main boom

head (see 19.5.4.1.1.6 Connecting the Electric Cables of the
Main Boom Extension to the Main Boom Head, side 747).
Fig. 606: Tension plates in the 0°position (schematic diagram)
For the main boom extension (MBE) variant with fixed operating an-
gles:
6. For 0° crane operation to the longitudinal main boom direction:
Place the tension plates in the 0° position. To do so, see
19.5.4.1.1.7 Fitting the tension plates in the 0° position,
side 750.
Or
82640 2021-04-22 725

For crane operation 20°/40° to the longitudinal main boom direc-

tion: Place the tension plates in the 20°/40° position. To do so,
see 19.5.4.1.1.8 Fitting the tension plates in the 20°/40° posi-
tion, side 759.
Fig. 607: Adjusting cylinder
For the main boom extension variant with hydraulic continuous oper-
ating angle adjustment (HAVHY):
7. Fit the adjusting cylinders. To do so, see 19.5.4.1.1.9 Fitting
the adjusting cylinders (main boom extension with hydraulic con-
tinuous operating angle adjustment), side 769.
Fig. 608: Fitting the hoist rope, reeving the hook block (schematic diagram)
8. Fit the hoist rope and reeve the hook block (see 19.5.4.1.1.10
Fitting the hoist rope and reeving the hook block, side 774).
726 82640 2021-04-22

Fig. 609: Remaining work on the basic boom MBE
9. Carry out remaining work on the basic boom of the main boom
extension (see 19.5.4.1.1.11 Carrying out Remaining Work on
the Basic Boom of the Main Boom Extension, side 777.
Fig. 610: Remaining work on the basic crane unit (schematic diagram)
10. Carry out the remaining work on the basic crane unit (see
19.5.4.1.1.12 Carrying out Remaining Work on the Basic Crane
Unit, side 779).
82640 2021-04-22 727

19.5.4.1.1.2 Carrying out preparations on the main boom extension
Fig. 611: Main boom extension (schematic diagram)
The procedure described in the following is identical, regardless of

whether the box top piece (2) is fitted on the basic boom MBE (1) or
not.
Fig. 612: Basic boom MBE with auxiliary reeving rope
1 Basic Boom MBE 2 Auxiliary reeving rope
1. Fasten the auxiliary reeving rope (2) to the head of the basic
boom MBE (1).
- The MBE can be pulled and braked using the auxiliary reeving
rope (2).
- The auxiliary rod can be used to assemble and dismantle the
auxiliary reeving rope (2).
728 82640 2021-04-22

WARNING
There is a risk of accidents due to the main boom ex-
tension falling down and folding over in an uncon-
trolled manner and there are additional risks during
the fitting procedure.
Carry out the checks described in the following or
place the components in the configuration described.
2. Carry out the following checks:
2.1. The main boom extension must be pinned at the lateral

pivot point (see arrow).
2.2. The folding cylinder must have "gripped" the basic

boom MBE.
2.3. For the MBE with fixed operating angles, the marked
measurement on the auxiliary cylinder of the basic
boom MBE may be max. 100 mm (3.9 in).
2.4. For the MBE with hydraulically smooth operating angle

adjustment, the hydraulic cylinders must be retracted.
If the measurement on the auxiliary cylinder is more than 100 mm

(3.9 in) for the MBE with fixed operating angles or the hydraulic cyl-
inders are not retracted for the MBE with hydraulically smooth oper-
ating angle adjustment, there is a risk of collision with the head of
the main boom when folding forward in front of the head of the main
boom. For this reason, the hydraulic cylinders affected must be re-
tracted before folding over in the operating position. This is descri-
bed at the relevant point in the further sequence.
82640 2021-04-22 729

Fig. 613: Preparing the hydraulic hoses for assembly (schematic diagram)
1 Holding device 2 Hydraulic hose
3. If the hydraulic cylinders have to be retracted before folding over

into the operating position: Prepare the hydraulic hoses of the
basic boom MBE for assembly. To do so, release the quick-re-
lease couplings of the hydraulic hoses (2; x 2) from holding de-
vice (1) and pull the hoses out of the steel construction from the
side to the rear and let them hang down.
For simplification purposes, only the steel construction of the basic

boom is shown in the figure.
730 82640 2021-04-22

Fig. 614: Electric connections - basic

boom MBE
NOTE
There is a risk of damage to the cable ends.
Ensure that the cable ends do not touch the ground or another
obstacle.
4. If the hydraulic cylinders of the main boom extension with hy-

draulically smooth operating angle adjustment must be retracted
before folding over into the operating position: Prepare the elec-
tric connections of the basic boom MBE for assembly. To do so,
pull the electric connections out of the steel construction from the
side to the rear and attach or mount them to the side of the basic
boom so that the cable ends do not touch the ground.
19.5.4.1.1.3 Making Preparations on the Basic Crane Unit
WARNING
1. Check whether the head axle is turned as shown.
82640 2021-04-22 731

Fig. 616: Electric connection on the basic

Fig. 615: Mobile control panel case of the main boom (schematic dia-
gram)
1 Electric connection
2 Fastening rope
2. Fit the mobile control panel (see Fig. 615, side 732) on the ba-
sic case of the main boom:
2.1. Connect the mobile control panel with the electric connec-
tion (1) at the front left on the basic case of the main boom
2.2. Attach fastening rope (2) for the mobile control panel to
the bracket using the carabiner hook. There is also a cara-
biner hook on the free end of fastening rope (2) which is
attached to the mobile control panel.
Fig. 617: Course of rope, main boom head (schematic diagram)
1 Hoist rope
3. Fit hoist rope (1) on run-in sheave (E2) on the main boom head.
See 19.5.4.1.1.3.1 Fitting the hoist rope on the run-in sheave
on the main boom head, side 735.
4. Unreel hoist rope approx. 3 m (10 ft) longer than the length of the
main boom extension when it is fitted at a later point.
732 82640 2021-04-22

1 Hoist rope
5. Lead the hoist rope (1) laterally along the left side of the main
boom head, as illustrated.
Fig. 619: Hydraulic valve
6. For the variant of the main boom extension (MBE) with fixed op-
erating angles to the longitudinal direction of the main boom: set
the hydraulic valve on the right-hand side of the main boom for
operation of the lateral folding cylinder.
82640 2021-04-22 733

Fig. 620: Fold out the rollway (schematic diagram)
1 Mobile part of the rollway 2 Pin
7. Fold out the moving part (1) of the guide rail. To do so:
7.1. Remove the pin (2) (left-hand side of the figure).
7.2. Fold over the mobile part (1) of the rollway.
7.3. Assemble the pin (2) (right-hand side of the figure).
After the mobile part of the rollway has been folded out, only the
folding cylinder prevents the main boom extension from folding over
(see arrow in Fig. 621, side 734).
734 82640 2021-04-22

19.5.4.1.1.3.1 Fitting the hoist rope on the run-in sheave on the main boom head
1 Bolt with rope slip-off protection 2 Rope guard

sheave
3 Forelock 4 Hoist rope
E2 Run-in sheave
1. Remove forelock (3) on the rope slip-off protection (2).

2. Pull out the bolt with the rope slip-off protection sheave (1) from
the side.
3. Guide hoist rope (4) over run-in sheave (E2).
4. Slide the bolt with rope slip-off protection sheave (1) back in
place and secure against falling out with forelock (3).
82640 2021-04-22 735

19.5.4.1.1.4 Folding the Main Boom Extension at the Side of the Rollway
The operation described is identical regardless of whether the box

top piece is fitted or not.
It must be ensured during the procedure described in this section that

the bottom head axle is turned as illustrated.
The following figure shows the initial state for the next steps.
Fig. 623: MBE folding procedure (schematic diagram)
736 82640 2021-04-22

WARNING
If the hydraulic cylinders have become damaged due
to incorrect use, it can cause death or serious inju-
ries when raising loads.
Always firmly connect both hydraulic hoses of the ba-
sic boom (MBE).
NOTE
There is a risk of damage to the two adjusting cylinders of the
HAVHY if the temperature is increased e.g. due to sun radia-
tion.
Always firmly connect both hydraulic hoses of the basic boom
(MBE).
1. For the MBE with hydraulic continuous operating angle adjust-

ment (HAVHY): Remove the hydraulic connection between the
basic boom (MBE) and the main boom. To do so:
1.1. Remove the two hydraulic hoses of the basic boom

(MBE) on the right-hand side of the main boom.
1.2. Close the connections on the main boom with protective

caps.
1.3. Connect the two hydraulic hoses firmly to the load relief
connection of the basic boom (MBE).
If not already occurred:

2. Start the drive motor.
82640 2021-04-22 737

1 Folding cylinder 2 Stop screws

3 Selector switch 4 Rocker switch
B pivot point F Pinning point, upper head axle
G Pinning point, lower head axle
WARNING
When folding the lattice mast top section from the
transport into the operating position in the following
procedure, there are risks of crushing, shearing or
falling objects (e.g. forgotten tools).
During the folding procedure, unauthorised persons
are not allowed within the working range of crane. In
particular, do not enter the area between the lattice
mast top section and the main boom.
work step.
3. Extend folding cylinder (1) sensitively until stop screws (2) are up
to the side of the main boom head. In this condition, the holes in
the fork heads are aligned with the corresponding holes in the
head axle (F, G). To do so, press rocker switch (4) in the mobile
control panel until the position is reached (selector switch (3) in
position "1").
The MBE then rotates around the slewing point "B".
738 82640 2021-04-22

1 Folding cylinder
4. To prevent mechanical tension on the basic boom MBE, retract

folding cylinder (1) slightly so that there is space on both sides
between the tube and the grip.
Fig. 626: MBE attachment points (schematic diagram)

F Attachment point G Attachment point
5. Lock the MBE at the boom head axes at fixing points (F) and (G)
with bolts (1) and secure the bolt with locking springs (2).
82640 2021-04-22 739

6. Place the rear locking bar on the basic boom MBE in the lock po-
sition.
In the lock position, the locking bar lever is the bottom posi-
tion.
740 82640 2021-04-22

Fig. 627: MBE connecting parts (schematic diagram)
1 Lever 2 Auxiliary rod

3 Bolts B Pinning point
F Pinning point, upper head axle G Pinning point, lower head axle
WARNING
Risk of accidents!
During the subsequent unpinning procedure persons
must stay clear of the area beneath the main boom
extension and in areas where loads/equipment could
fall.
Only remove bolt (3) in point (B) when the MBE is
pinned at the front on the main boom head at (F) and
(G).
7. Remove bolt (3) of the main boom extension to the basic case of
the main boom by pressing up lever (1) with the auxiliary rod (2).
Lever (1) is locked in the upper position by sliding it to the side.
82640 2021-04-22 741

1 Rollway 2 Folding cylinder

8. Extend the folding cylinder (2) carefully until the main boom ex-
tension has moved down from the rollway (1). To do so, press
rocker switch (4) in the mobile control panel until the final posi-
tion has been reached (selector switch (3) in position "1").
The MBE then rotates around the pivot point (B).
19.5.4.1.1.5 Folding the Main Boom Extension to the Front
The operation described is identical regardless of whether the box

top piece is fitted or not.
742 82640 2021-04-22

1 Lever 2 Auxiliary rod
1. Disable locking of lever (1). To do so, lift lever (1) to the side us-
ing auxiliary rod (2).
1 Bolts 2 Lever
Due to a mechanical lock, bolt (1) remains open and lever (2)
remains in the upper position.
82640 2021-04-22 743

1 Folding cylinder 2 Retaining piece

3 Auxiliary rod
WARNING
Risk of accidents due to the main boom extension
moving unchecked!
When detaching the folding cylinder in the next work
step, hold the main boom extension with the auxiliary
reeving rope.
2. Detach folding cylinder (1). To do so, lift retaining piece (2) with
auxiliary rod (3) and pull the main boom extension slightly for-
ward with the auxiliary reeving rope.
Folding cylinder (1) can be slightly retracted as an alternative to pull-

ing the MBE forward with the auxiliary reeving rope.
744 82640 2021-04-22

Fig. 632: Folding the MBE
3. If the preceding check has shown that the auxiliary cylinder

(MBE version with fixed operating angles) or hydraulic cylinders
(MBE version with hydraulically smooth operating angle adjust-
ment) has / have been extended too far: Fold the MBE at the
auxiliary reeving rope in front of the main boom until the hydraul-
ic hoses of the basic boom of the MBE can be connected to the
main boom. Retract the auxiliary cylinder or hydraulic cylinders
(see 19.9.2 Retracting the hydraulic cylinders on the basic
boom of the MBE, side 1007).
If required, an assistant must hold the main boom extension in this

position at the auxiliary reeving rope.
82640 2021-04-22 745

WARNING
Risk of injury!
When swinging the MBE in the following and during
pinning and unpinning, there must be no-one in the
swinging range or beneath the MBE or in areas
where loads/equipment could fall, etc.
4. Fold the MBE at the auxiliary reeving rope in front of the main
boom until the locking bar engages in place at the cross axle on
the left.
Fig. 634: Locking bar (schematic diagram)
When engaged, the locking bar is positioned up against the

back of the cross axle (see arrow in Fig. 634, side 746).
746 82640 2021-04-22

Fig. 635: Pinning point I bottom head axle (schematic diagram)
1 Locking spring 2 Bolts

I Pinning point, lower head axle
WARNING
Risk of accidents due to unsafe ladder position if it is
attached to the basic boom MBE for this procedure.
Attach the multi-purpose ladder to the corresponding
brackets on the main boom.
5. Knock in bolt (2) in point (I) and secure against falling out with 2
locking springs (1).
19.5.4.1.1.6 Connecting the Electric Cables of the Main Boom Extension to the Main
Boom Head
A Connection - air speed indicator
1. Connect plug of the basic boom MBE cable harness with con-
nection (A) on distribution box "X0550" on the left-hand side of
the main boom head.
82640 2021-04-22 747

C CAN connection C1 CANBUS terminating plug
Before the CAN lead is connected in the MBE with hydraulic contin-
uous operating angle adjustment (HAVHY) in the next work step, the
engine ignition must be switched off (if this has not already been
done). Otherwise, there will be fault messages in crane control. If
the CAN lead was accidentally connected with the ignition switched
on, the corresponding fault message can be deleted by switching off
the ignition.

ment (HAVHY): Connect the plug of the basic boom MBE CAN
line to connection (C) on distribution box "X0550" on the left-
hand side of the main boom head.
Note on MBE with fixed operating angles (design with tension

plates): Connection (C) remains fitted with the CAN BUS terminating
plug (C1).
748 82640 2021-04-22

Fig. 638: Optional load hook camera connection (schematic diagram)
1 Transmitter 2 Connection
NOTE
Risk of damage due to excessive strain on the connecting
socket of transmitter (1).
In the next work step, use connection (2) on the connecting ca-
ble of the transmitter to connect the electrical cable of the load
hook camera.
3. If the optional load hook camera is fitted on the fly jib head: Con-
nect the camera cable from the MBE with connection (2) of the
transmitter (1) connecting cable.
The camera cable coming from the MBE should not be connected
directly with the connecting socket of transmitter (1), as the connect-
ing socket on transmitter (1) is not suitable for daily alternating oper-
ation.
82640 2021-04-22 749

Fig. 639: Hoist limit switch weight
4. Fit the hoist limit switch shift weight (2) of the main boom head
hoist limit switch to the bracket attached to the right-hand side of
the main boom head and secure it against falling out with locking
spring (1).
5. Bridge the hoist limit switch of the main boom head (put it out of
operation). See 8.6.3.3.3 Bridging the hoist limit switch (putting
it out of operation), side 369.
19.5.4.1.1.7 Fitting the tension plates in the 0° position
Fig. 640: Bolts support and control panel (schematic diagram)
During this operating procedure and for transport, the bolts which are
removed can be attached to a transport support on the basic boom or
to transportation plates on the tension plates. Depending on the de-
sign of the transport support on the basic boom, the mobile control
panel can be temporarily fitted with its handle side in the transport
storage device during the corresponding operating procedures.
750 82640 2021-04-22

Fig. 641: Carrying out fitting of the tension plates (schematic diagram)
1. Carrying out preparations for fitting the tension plates. See

19.5.4.1.1.7.1 Preparations for fitting / dismantling the tension
plates, side 754.
Fig. 642: Fitting the tension plates (schematic diagram)
2. Fit both tension plates and pin auxiliary cylinder. See

19.5.4.1.1.7.2 Fitting the tension plates and pinning the auxiliary
cylinders, side 754.
Fig. 643: Relieving the bolts (schematic diagram)
1 Bolts 2 Auxiliary cylinder

3. Retract the auxiliary cylinder (2) sensitively until the upper bolt
(1) on the right-hand side of the main boom head is relieved of
load and can be removed. To do so, press rocker switch (4) in
the mobile control panel until the position is reached (selector
switch (3) in position "1").
82640 2021-04-22 751

Fig. 644: Top bolt - main boom head (schematic diagram)
1 Bolts
4. Remove the upper bolt (1) on the right-hand side of the main
boom head.
Fig. 645: Tension plate, 0° position (schematic diagram)
5. Pin the tension plates for 0° crane operation / retract the auxiliary
cylinders. See 19.5.4.1.1.7.3 Pinning the tension plates for 0°-
crane operation / relieving the auxiliary cylinders of load,
side 757.
752 82640 2021-04-22

Fig. 646: Hydraulic connections from the basic boom of the MBE (schematic dia-
gram)
WARNING
sic boom (MBE).
NOTE
There is a risk of damage to the auxiliary cylinder if the tem-
perature is increased e.g. due to sun radiation.
Always connect both hydraulic hoses of the basic boom (MBE)
firmly to the load relief connection.
NOTE
Risk of damage!
The hydraulic hoses are destroyed when telescoping out the main
boom in one of the next work steps if the hydraulics of the auxiliary
cylinder on the basic case are connected with the main boom.
Before continuing work after the next work step, check that the
hydraulic hoses have been dismantled.
6. Remove the hydraulic hoses of the basic boom of the MBE from
the front on the main boom and firmly connect them to the basic
boom in the quick-release couplings of the load relief connection.
82640 2021-04-22 753

19.5.4.1.1.7.1 Preparations for fitting / dismantling the tension plates
Fig. 647: Hydraulic valve
1. Set the hydraulic valve on the right-hand side of the main boom
for operation of the auxiliary cylinder for setting the tension
plates.
Fig. 648: Hydraulic connections from the basic boom of the MBE
2. Connect the hydraulic connections from the basic boom of the

MBE firmly to the flange of the basic case.
19.5.4.1.1.7.2 Fitting the tension plates and pinning the auxiliary cylinders
The tension plates can be fitted and the auxiliary cylinder can be
pinned from the left- as well as the right-hand side of the main boom
extension. However, we do recommend carrying out the work from
the right-hand side as the ladder required for dismantling the top cap
bolt in one of the next work steps does not then have to be reposi-
tioned.
754 82640 2021-04-22

Fig. 649: Tension plate
1. At both tension plates, remove bolt (1) (incl. washer and forelock)
and bolt (2) and place in the designated storage position.
2. At both tension plates, pull out the interior components until they
can be pinned to the main boom head.
1 Interior component 2 Locking spring

3 Bolts
3. At both tension plates, fit bolts (3) between interior component

(1) and the main boom head and secure against falling out with
locking spring (2).
82640 2021-04-22 755

Fig. 652: Auxiliary cylinder and cross beam
1 Auxiliary cylinder 2 Lifting beam
4. Extend auxiliary cylinder (1) until the bore holes of the cylinder
rod fork head align with the elongated hole in the cross beam (2)
for pinning the connecting pin in a later step.

sheave
5. Remove bolt with rope slip-off protection sheave (1) on rope slip-
off protection (2). Raise cross beam (4) and fit bolt with rope slip-
off protection sheave (1) between the fork head of auxiliary cylin-
der (3) and cross beam (4) and secure against falling out.
756 82640 2021-04-22

19.5.4.1.1.7.3 Pinning the tension plates for 0°- crane operation / relieving the auxili-
ary cylinders of load

"A" Pinning position
1. Retract auxiliary cylinder until the bolt can be pinned in point "A".
To do so, press rocker switch (2) in the mobile control panel until
the position is reached (selector switch (1) in position "1").
1 Bolts 2 Washers
3 Forelock "A" Pegging position 0°
2. At both tension plates, mount the bolts (1) at point "A" including
washer (2) and secure against falling out with the appropriate
forelock (3).
82640 2021-04-22 757

1 Screw 2 Support plate

3 Auxiliary cylinder 4 Bolts
NOTE
There is a risk of damage for the support plate (2) if the auxili-
ary cylinder (3) is extended too far.
Do not extend the auxiliary cylinder (3) too far.
3. Extend the auxiliary cylinder (3) until the bolt with rope slip-off
protection sheave (4) can be removed. To do so, auxiliary cylin-
der (3) must be extended a further approx. 5 mm (0.2 in) once
screw (1) is on support plate (2).

sheave
4. Remove pin with the rope slip-off protection sheave (1) between
auxiliary cylinder (5) and cross beam (6) and fit on rope slip-off
protection (2) so that the hoist rope (4) is under the rope slip-off
protection sheave of the pin (1) again. Secure bolt with rope slip-
off protection sheave (1) against falling out using forelock (3).
758 82640 2021-04-22

Fig. 658: Auxiliary cylinder (schematic diagram)
1 Auxiliary cylinder 2 Selector switch

3 Rocker switch
5. First, fully retract auxiliary cylinder (1) and then extend it again
approx. 10 mm (0.4 in) to relieve the pressure. To do so, press
rocker switch (3) in the mobile control panel until the position is
reached (selector switch (2) in position "1").
19.5.4.1.1.8 Fitting the tension plates in the 20°/40° position
The bolts which are removed can be attached to a transport storage

device for this operating procedure and for transportation. Depending
on the design of the transport storage device, the mobile control pan-
el can be temporarily fitted with its handle side in the transport stor-
age device during the corresponding operating procedures.
Fig. 660: Carrying out fitting of the tension plates
1. Carrying out preparations for fitting the tension plates. See

plates, side 754.
82640 2021-04-22 759

Fig. 661: Fitting the tension plates
2. Fit both tension plates and pin auxiliary cylinder. See

19.5.4.1.1.8.1 Fitting the tension plates for 20° /40° crane opera-
tion and pinning the auxiliary cylinders, side 763.
Fig. 662: Relieving the bolts

3. Retract the auxiliary cylinder (2) sensitively until the upper bolt
(1) on the right-hand side of the main boom head is relieved of
load and can be removed. To do so, press rocker switch (4) in
the mobile control panel until the position is reached (selector
Fig. 663: Top bolt - main boom head
1 Bolts
boom head.
760 82640 2021-04-22

Fig. 664: Basic boom MBE with box top piece
1 Box top piece 2 Basic boom
5. Place two wooden blocks next to each other under the sliding
tube of the basic boom (2) and for MBE variants with box top
piece (1), place them under the sliding tube on the head of the
box top piece. The wooden blocks must have a cross section of
10 cm x 10 cm (4 in x 4 in) and a minimum length of 180 cm
(71 in).
Fig. 665: Setting the MBE down on the ground
When setting down the main boom extension and when luffing the
main boom up and down, the main boom extension is lying on the
wooden blocks or slides over them.
6. Lower the main boom extension onto the ground. See

19.5.4.1.1.8.2 Lowering the main boom extension onto the
ground, side 766.
82640 2021-04-22 761

gram)
WARNING
sic boom (MBE).
NOTE
NOTE
Risk of damage!
cylinder of the basic boom MBE are connected with the main boom.
762 82640 2021-04-22

19.5.4.1.1.8.1 Fitting the tension plates for 20° /40° crane operation and pinning the
auxiliary cylinders
pinned from the left- as well as from the right-hand side of the main
boom extension. However, we do recommend carrying out the work
from the right-hand side as the ladder required for dismantling the
top cap bolt in one of the next work steps does not then have to be
repositioned.
1 Bolts 2 Bolts
3 Bolts
1. Repinning bolts (1) and (3) to both tension plates:

1.1. remove bolt (1) (incl. washer and forelock) from the 0° pin-
ning hole.
1.2. For 20° pinning: Remove bolts (1; incl. washer and fore-
lock) in the 20° pinning hole.
lock) in the transport position hole.
1.4. Remove bolt (3) and place in the designated transport po-
sition.
For the 40° angle, the force between the interior and exterior parts
of the tension plates is transferred at a later point via the permanent-
ly fitted bolt (2).
82640 2021-04-22 763

2. Pull out the two interior components of the tension plates until
they can be pinned to the main boom head.

3 Bolts

(1) and the main boom head and secure each one against falling
out with locking spring (2).
764 82640 2021-04-22


sheave
82640 2021-04-22 765

19.5.4.1.1.8.2 Lowering the main boom extension onto the ground

The operating procedure described below is analogous for all variants
of the main boom extension.
Fig. 672: Tension plates on the main boom head (schematic diagram)
1 Auxiliary cylinder 2 Bolt with rope slip-off protection

sheave
3 Lifting beam 4 Bolts
5 Bolts
Requirements:
- Main boom extension fitted on the main boom head or on the inter-
mediate section
- Bolt with rope slip-off protection sheave (2) fitted between auxiliary
cylinder (1) and cross beam (3)
- Both tension plates are fitted to the head of the main boom or in-
termediate section with bolts (4) and secured against falling out.
- The two bottom fork heads are pinned to the head of the main
boom or to the intermediate section with bolts (5) and secured
against falling out.
- Two wooden blocks placed next to each other under the sliding
tube of the basic boom and, for MBE variants, with box top piece,
placed under the sliding tube on the head of the box top piece.
766 82640 2021-04-22

Fig. 673: Angling the MBE
1 Bolts 2 Selector switch

3 Rocker switch
1. Extend auxiliary cylinder until the main boom extension is on the

ground and the bolt (1) is relieved of load so that the bolt (1) can
be removed in the next work step. To do so, press rocker switch
(3) in the mobile control panel until the position is reached (selec-
tor switch (2) in position "1").
82640 2021-04-22 767

Fig. 674: Angling the MBE (schematic diagram)

sheave
protection sheave of the pin (1) again. Secure bolt (1) against
falling out using forelock (3).
Fig. 675: Auxiliary cylinder (schematic diagram)

3 Rocker switch
768 82640 2021-04-22

19.5.4.1.1.9 Fitting the adjusting cylinders (main boom extension with hydraulic con-
tinuous operating angle adjustment)

Fig. 677: Adjusting cylinder on the main boom head (schematic diagram)
1 Pins (adjusting cylinder) 2 Pins (main boom head)
Pins (1) between the adjusting cylinder and the intermediate part
must never be removed.
Pins (1) and (2) have the same diameter. If pins (1) have been re-
moved after all, ensure that they are not confused with pins (2).
CAUTION
Risk of accidents due to mixing up the pins.
Ensure pins (1) and (2) are fitted in the correct instal-
lation location, as pins do not fulfil their function after
they have been interchanged, nor can they be se-
cured correctly.
82640 2021-04-22 769

1 Adjusting cylinder 2 Selector switch

3 Rocker switch 4 Rocker switch
During the work procedure, the adjusting cylinders (1) must be actu-
ated several times. To do so, use rocker switch (3) (selector switch
(2) in position "2") on the mobile control panel.
As the assembly point cannot be seen from the crane operator’s

cab, it is not advisable to actuate the adjusting cylinders (1) with
rocker switch (4) from the crane operator’s cab.
CAUTION
Risk of crushing when retracting/extending the ad-
justing cylinders!
Keep well clear of the hazardous areas when moving
the adjusting cylinders.
770 82640 2021-04-22

Requirements:
- Hydraulic connections of the laterally fitted hose drum are fitted at
the front on the left-hand side of the main boom head (see
operating angle adjustment), side 700).
Fig. 679: Hydraulic hoses of the main boom extension (schematic diagram)
1 Hydraulic hoses 2 Hydraulic connections
NOTE
Risk of damage for hydraulic hoses if the removed hoist rope
is in the assembly area!
Place hydraulic hoses between hoist rope and main boom ex-
tension.
Do not place hydraulic hoses around the hoist rope.
NOTE
Risk of damage to the hydraulic hoses when setting the angle
at a later point.
Ensure the hose can run freely.
1. Dismantle hydraulic hoses (1; x 2) to the hydraulic connections

(2) on the left-hand side of the main boom head.
If the motor is not running:
82640 2021-04-22 771

Fig. 680: Bolts, intermediate elements (schematic diagram)
1 Bolts 2 Bolts
3. Pull bolts (1; 2x) and bolts (2; 2x) from the intermediate ele-
ments.
1 Adjusting cylinder 2 Intermediate part

A Pinning point
4. Extend the adjusting cylinders (1) until the intermediate elements

(2) are aligned on both sides of the crane and can be pinned on
the head of the main boom on both sides in point (A).
Fig. 682: Adjusting cylinder on the main boom head
1 Intermediate part 2 Bolts

3 Locking spring 4 Main boom
5. Fit bolts (2) between intermediate elements (1) and the head of
the main boom (4) on both adjusting cylinders and secure
against falling out with locking spring (3). If required, readjust the
extension state of the adjusting cylinders.
772 82640 2021-04-22

1 Adjusting cylinder 2 Rod end

3 Intermediate part
6. Tension the adjusting cylinders (1) slightly so that the rod ends
(2) of the adjusting cylinders (1) and the intermediate elements
(3) are aligned.

3 Bolts 4 Intermediate part
7. Fit bolts (3) between rod ends (2) of the two adjusting cylinders
(1) and intermediate elements (4) and secure against falling out.
1 Bolts 2 Adjusting cylinder

A Pinning point
8. Retract the adjusting cylinders (2) sensitively until the top bolt (1)
on the right-hand side of the main boom head is relieved of load
in point (A) and can be removed.
82640 2021-04-22 773

1 Bolts
boom head.
19.5.4.1.1.10 Fitting the hoist rope and reeving the hook block
sign of the main boom extension with fixed operating angles as well
as for the design with hydraulic continuous operating angle adjust-
ment.
The main boom can be luffed down to carry out the work. Work that
cannot be carried out from the ground may only be carried out using
suitable auxiliary equipment (for example, the supplied multi-purpose
ladder, hoist platform).
WARNING
Risk of falling due to unsuitable auxiliary equipment!
Only use suitable auxiliary equipment to carry out
work at height.
WARNING
774 82640 2021-04-22

Fig. 687: Rope guidance - MBE (schematic diagram)
1 Hoist rope 2 Auxiliary rod

3 Basic Boom MBE
CAUTION
There is a risk of accidents if the hoist rope falls
down when carrying out the next work step.
Ensure the work step is carried out carefully.
1. Lay hoist rope (1) over the main boom extension using the auxili-
ary rod (2). This is done by laying hoist rope (1) section for sec-
tion, starting from the main boom head, so that the welded brack-
ets (see arrows) welded onto the upper chord or side of the basic
boom prevent the fitted sections from falling down. In the area of
the rear basic boom MBE (3), the hoist rope (1) fitted on the side
bracket must be guided by hand over the left draw bar or left ad-
justing cylinder on the top of the basic boom.
Fig. 688: Rope guidance, basic boom MBE (schematic diagram)
1 Hoist rope 2 Guide roller

3 Basic Boom MBE
2. Guide hoist rope (1) over guide roller (2) at the back of the basic
boom MBE (3).
82640 2021-04-22 775

Fig. 689: Reeving the basic boom MBE
1 Rope guard pin 2 Rope guard pin
3. Guide the hoist rope over the two front rope sheaves of the basic
boom MBE, fit rope guard pins (1) and (2).
4. Reeve hook block (see section "Reevings" at "Hook blocks").
S2 Hoist rope fixed point
With twofold reeving, the rope socket of the hoist rope end must be
secured at point (S2) on the basic boom MBE.
776 82640 2021-04-22

19.5.4.1.1.11 Carrying out Remaining Work on the Basic Boom of the Main Boom Ex-
tension
Fig. 691: Reeving the basic boom MBE Fig. 692: Distribution box "X0560"
1 Hoist rope H Connection - hoist limit switch
2 Shift weight
3 Hoist limit switch
1. Fit hoist limit switch (3) together with shift weight (2) in the func-
tional configuration and connect electrically:
1.1. On the right-hand side of the basic boom MBE, slide the
hoist limit switch (3) over the pins that have been welded
on and secure it against falling out using safety forelocks.
1.2. Guide the hoist rope (1) through the opening on the shift
weight (2) (see section "Reevings").
1.3. Connect the plug of the hoist limit switch (3) to the connec-
tion socket (H)
82640 2021-04-22 777

configuration. 8.6.3.3.2 Placing the hoist limit switch in the func-
tional state, side 368 describes how the hoist limit switch is moved
into the functional configuration.
Fig. 694: Hazard light / anemometer, basic boom MBE
A Electric connection X1 Pinning, transport position

X2 Pinning, non-angled MBE X3 Pinning, angled MBE
2. Fit the bracket with the rotor of the air speed indicator and haz-
ard light to the head of the basic boom MBE or place it in the op-
erating position (pinning of the bracket depends on the subse-
quent operating angle of the MBE) and connect the plug with
electric connection (A).
Observe the specifications on assembly, setting the operating angle

and handling the hazard light and anemometer in 8.6 Electric
Safety Chain, side 361.
778 82640 2021-04-22

WARNING
If the rotor of the wind speed indicator is not fitted to the
top section of the main boom / boom system, it is not
possible to monitor compliance with permitted wind
speeds in the crane control display.
If the crane's assembly situation does not permit fit-
ting the wind speed indicator rotor (e.g. due to the up-
per edge of the top section of the main boom / boom
system approaching a protruding edge), compliance
with the permitted wind speeds must be monitored in
a different way (e.g. external wind speed indicator at
the height of the top section of the main boom / boom
system).
Fig. 695: Distribution box "X0560"
A Electric connection A1 Bridging plug
If the bracket with the rotor of the air speed indicator and hazard light
is not fitted, bridging plug (A1) must be connected to electric connec-
tion (A).
19.5.4.1.1.12 Carrying out Remaining Work on the Basic Crane Unit
1. Remove the mobile control panel on the side on the main boom
together with the fastening rope which is dependent on the crane
design.
There is a risk of damage when working with the crane equipment at

a later point if the control panel and fastening rope remain on the
basic case of the main boom.
82640 2021-04-22 779

Fig. 696: Folding cylinder (schematic dia-

gram)
1 Folding cylinder
2 Locking bar
2. Fold in folding cylinder (1) on the main boom and lock with lock-
ing bar (2).
19.5.4.1.2 Folding from the Operating into the Transport Position
19.5.4.1.2.1 Procedure
WARNING
Risk of accidents!
steps.
For the main boom extension angled at 20° or 40° with fixed operat-
ing angles, you must remember - in contrast to the description in
19.5.3 General instructions and instructions on risks for folding over
the equipment, side 719 and as described below – that the main
boom can only be aligned horizontally if the hook block has been un-
reeved and the hoist limit switch and hoist limit switch weight have
been removed.
Requirements:
780 82640 2021-04-22

Fig. 697: Preparations on the crane and MBE
1. Carry out preparations on the basic crane unit and the main
boom extension (see 19.5.4.1.2.2 Carrying out preparations on
the basic crane unit and the main boom extension, side 783 ).
Fig. 698: MBE in 0° position
gles:
2. Move the tension plates from the 0° position into the transport
position. To do so, see 19.5.4.1.2.3 Moving the tension plates
from the 0° position into the transport position, side 787.
Or
Move the tension plates from the 20°/40° position and place in
transport position. To do so, see 19.5.4.1.2.4 Moving the ten-
sion plates from the 20°/40° position and placing them in the
transport position, side 795.
82640 2021-04-22 781

Fig. 699: Preparations on the basic boom MBE
3. For the main boom extension variant with hydraulic continuous

operating angle adjustment (HAVHY): move adjusting cylinders
to the transport position. To do so, see 19.5.4.1.2.5 Placing the
adjusting cylinders in the transport position, side 800.
4. Carry out preparations on the basic boom of the main boom ex-
tension for folding at the side (see 19.5.4.1.2.6 Carrying out
preparations for folding up to the side of the basic unit of the
main boom extension, side 805).
Fig. 701: Preparations on the main boom
5. Carry out preparations on the main boom for folding at the side
(see 19.5.4.1.2.7 Carrying out preparations for folding up to the
side of the main boom, side 806).
782 82640 2021-04-22

Fig. 702: Folding the MBE at the side on the main boom
6. Fold the main boom extension at the side of the main boom (see
19.5.4.1.2.8 Folding the Main Boom Extension at the Side on
the Main Boom, side 810).
Fig. 703: Carrying out Remaining Work
7. Carry out remaining work (see 19.5.4.1.2.9 Carrying out Re-

maining Work, side 817).
19.5.4.1.2.2 Carrying out preparations on the basic crane unit and the main boom ex-
tension
1. Luff the main boom down far enough so that if at all possible, the
hook block can be unreeved from the ground. However, the front
end of the main boom extension may not touch the ground.
2. Set the hook block down and unreeve (see the section "Reev-
ings" at "Hook blocks").
82640 2021-04-22 783

Fig. 704: Basic Boom MBE
WARNING
There is a risk of injury if one of the wing nuts falls
down during later MBE operation without the wind
speed indicator.
Tighten the wing nuts carefully even if the bracket
with the wind speed indicator and hazard light is not
fitted.
3. Dismantle the bracket with the rotor of the air speed indicator
and hazard light. To do so, loosen wing nuts (2x), remove the
bracket and then screw the wing nuts fully onto the correspond-
ing thread bolts until the wing nuts are up against the side plate.
Observe the information on the transport position of the bracket with

the rotor of the air speed indicator and hazard light in 8.6 Electric
4. Remove hoist limit switch (1) together with shift weight (2).
784 82640 2021-04-22

Fig. 706: Basic Boom MBE
1 Basic Boom MBE
5. For the main boom extension angled at 20°/40° with fixed operat-
ing angles: Place 2 wooden blocks under the sliding tube of the
basic boom MBE (1). The wooden blocks must have a cross sec-
tion of 10 cm x 10 cm (4 in x 4 in) and a minimum length of
180 cm (71 in).
For the main boom extension with hydraulic continuous operating an-
gle adjustment:
6. Align the main boom extension horizontally.
7. Align the main boom horizontally.
82640 2021-04-22 785

8. Remove the hoist rope on the basic boom of the main boom ex-
tension:
8.1. Remove the hoist rope from the rope sheaves on the head
of the basic boom MBE: To do so, remove rope guard pins
(1) and (2) from the head of the basic boom MBE. Pull the
hoist rope down from the rope sheaves. Refit rope guard
pins (1) and (2) and secure them against falling out.
8.2. Pull hoist rope (see arrow) back to the main boom head
so that it hangs down at the side.
786 82640 2021-04-22


gram)
2 Fastening rope
tion (1) on the front left on the basic case of the main
boom (see Fig. 709, side 787).
the bracket using the snap hook. There is also a snap
hook on the free end of fastening rope (2) which is attach-
ed to the mobile control panel.
19.5.4.1.2.3 Moving the tension plates from the 0° position into the transport posi-
tion

82640 2021-04-22 787

Fig. 711: Carrying out fitting of the tension plates
1. Carry out preparations for dismantling the tension plates. See

plates, side 754.
Fig. 712: Engaging the auxiliary cylinder
2. Engage the auxiliary cylinder (0°). See 19.5.4.1.2.3.1 Engaging

the auxiliary cylinder (0°), side 791.
Fig. 713: Positioning the auxiliary cylinders

"A" Pinning point
3. Position the auxiliary cylinder (2) so that the upper bolt (1) can be
fitted in point "A" on the right-hand side of the main boom head.
788 82640 2021-04-22

1 Bolts
4. Fit the upper bolt (1) on the right-hand side of the main boom
head and secure against falling out using two locking springs.
5. Slide in tension plates. See 19.5.4.1.2.3.2 Sliding in tension

plates, side 793.
82640 2021-04-22 789

Fig. 716: Hydraulic connections of the basic boom MBE (schematic diagram)
WARNING
sic boom (MBE).
NOTE
NOTE
Risk of damage!
The hydraulic hoses are damaged when swinging over the main
boom extension in one of the next work steps if the hydraulics of
the auxiliary cylinder of the basic boom MBE are connected with the
main boom.
the main boom and firmly connect them to the basic boom in the
quick-release couplings of the load relief connection.
790 82640 2021-04-22

19.5.4.1.2.3.1 Engaging the auxiliary cylinder (0°)

sheave
82640 2021-04-22 791

Fig. 719: Retracting the auxiliary cylinder

"A" Pinning point
3. Retract auxiliary cylinder until the bolt can be released in point

"A" and removed. To do so, press rocker switch (2) in the mobile
position "1").
1 Bolts
4. Remove bolts (1; incl. washer and forelock) from both tension
plates and peg in the respective transport position hole.
792 82640 2021-04-22

19.5.4.1.2.3.2 Sliding in tension plates
Fig. 721: Tension plate (schematic diagram)
1 Screw 2 Support plate

3 Auxiliary cylinder 4 Bolt with rope slip-off protection
sheave
NOTE
There is a risk of damage for the support plate (2) if the auxili-
ary cylinder (3) is extended too far.
Do not extend the auxiliary cylinder (3) too far.
1. Extend the auxiliary cylinder (3) until the bolt with rope slip-off
protection sheave (4) can be removed. To do so, press rocker
switch (6) (selector switch (5) in position "1") in the mobile control
panel. If screw (1) is on support plate (2), auxiliary cylinder (3)
must be extended a further approx. 5 mm (0.2 in).

sheave
protection sheave of the pin (1) again. Secure bolt with rope slip-
off protection sheave (1) against falling out using forelock (3).
82640 2021-04-22 793

Fig. 723: Auxiliary cylinder

3 Rocker switch
1 Tension plate 2 Locking spring

3 Bolts
4. At both tension plates, remove bolt (3) between the interior com-
ponent (1) of the tension plate and the main boom head. To do
so, remove locking spring (2) and pull out bolt (3).
1 Tension plate
5. At both tension plates, push the interior component (1) into the
exterior component.
794 82640 2021-04-22

6. At both tension plates, fit the depicted bolt and secure it against
falling out.
19.5.4.1.2.4 Moving the tension plates from the 20°/40° position and placing them in
the transport position
Requirements:
- The main boom extension is lying on the ground

Fig. 728: Preparations for dismantling the tension plates

plates, side 754.
82640 2021-04-22 795

2. Engage the auxiliary cylinder (20° / 40°). See 19.5.4.1.2.4.1

Engaging the auxiliary cylinder (20° / 40°)., side 799.
Fig. 730: Assuming the pinning position

"A" Pinning point
3. Position the auxiliary cylinder (2) so that the upper bolt (1) can be
fitted in point "A" on the right-hand side of the main boom head.
1 Bolts
796 82640 2021-04-22

5. Slide in tension plates. See 19.5.4.1.2.3.2 Sliding in tension

plates, side 793.
82640 2021-04-22 797

Fig. 733: Hydraulic connections of the basic boom MBE (schematic diagram)
WARNING
sic boom (MBE).
NOTE
NOTE
Risk of damage!
The hydraulic hoses are damaged when swinging over the main
boom extension in one of the next work steps if the hydraulics of
the auxiliary cylinder of the basic boom MBE are connected with the
main boom.
the main boom and firmly connect them to the basic boom in the
quick-release couplings of the load relief connection.
798 82640 2021-04-22

19.5.4.1.2.4.1 Engaging the auxiliary cylinder (20° / 40°).
Fig. 734: Auxiliary cylinder of the tension plates

1. Extend the auxiliary cylinder (1)until the bore holes in the cylinder
rod align with the elongated hole in the cross beam (2) for the in-
sertion of the connecting pin in the next operating step. To do so,
press rocker switch (4) in the mobile control panel until the posi-
tion is reached (selector switch (3) in position "1").

sheave
82640 2021-04-22 799

19.5.4.1.2.5 Placing the adjusting cylinders in the transport position
The bolts can be removed and attached to a transport storage device

for this operating procedure and for transportation. Depending on the
design of the transport storage device, the mobile control panel can
be temporarily fitted with its handle side in the transport storage de-
vice during the corresponding operating procedures.


CAUTION
Risk of crushing when retracting and extending the
adjusting cylinders.

800 82640 2021-04-22

1 Bolts 2 Adjusting cylinder

"A" Pinning point
2. Telescope in the adjusting cylinders (2) (in the 0° position) and

position them so that the upper bolt (1) can be fitted in point "A"
on the right-hand side of the main boom head.
1 Bolts

3 Intermediate part
(3) are aligned.
82640 2021-04-22 801

Fig. 741: Rod end

5. At both adjusting cylinders (1), remove the bolts (3) between the
rod end (2) and the intermediate part (4).
1 Adjusting cylinder 2 Bolts
6. Telescope out the adjusting cylinders (1) to relieve the bolts (2)
on the head of the main boom of load.
1 Adjusting cylinder 2 Bolts
7. At both adjusting cylinders (1), remove the bolts (2) from the
head of the main boom.
802 82640 2021-04-22

Fig. 744: Bolts in intermediate elements
8. Pull bolts (1; 2x) and bolts (2; 2x) for transport to the intermediate
elements and secure against falling out.
82640 2021-04-22 803

Fig. 745: Removing the hydraulic hoses (schematic diagram)

3 Quick disconnect couplings
WARNING
sic boom (MBE).
NOTE
tion.
(MBE).
9. Dismantle the hydraulic hoses of the main boom extension on

the main boom. To do so:
9.1. Dismantle hydraulic hoses (1; x 2) from the hydraulic con-
nections (2) on the left-hand side of the main boom head.
9.2. Slide hydraulic hoses (1; x 2) into the steel construction of
the basic boom.
9.3. Connect hydraulic hoses (1; x 2) firmly to the quick-release
couplings (3) of the load relief connection.
804 82640 2021-04-22

19.5.4.1.2.6 Carrying out preparations for folding up to the side of the basic unit of
the main boom extension
Fig. 746: Rope guidance, basic boom MBE
boom MBE (1).
rope (2).
Fig. 747: MBE connecting parts
1 Connecting pin 2 Lever

3 Auxiliary rod
2. If connecting bolt (1) is not yet prepared for engagement: Pre-

pare connecting bolt (1) for engagement. To do so, lever (2)
must be lifted to the side with auxiliary rod (3) to disable the lock
of lever (2).
82640 2021-04-22 805

1 Bolts 2 Lever
Due to a mechanical lock, bolt (1) remains open and lever (2)
remains in the upper position.
19.5.4.1.2.7 Carrying out preparations for folding up to the side of the main boom
Fig. 749: Hydraulic valve (schematic diagram)
1. For the variant of the main boom extension (MBE) with fixed op-
erating angles to the longitudinal direction of the main boom: set
the hydraulic valve on the right-hand side of the main boom for
operation of the lateral folding cylinder.
806 82640 2021-04-22

Fig. 750: Fold out the rollway (schematic diagram)
2. If you have not done so already, fold out the moving part (1) of
the guide rail. To do so:
2.1. Remove the pin (2) (left-hand side of the figure).
2.2. Fold over the mobile part (1) of the rollway.
2.3. Assemble the pin (2) (right-hand side of the figure).
82640 2021-04-22 807

1 Retaining piece 2 Folding cylinder
3. Place the folding cylinder (2) in the operating state:

3.1. If not already done: fold folding cylinder (2) into the operat-
ing position (as illustrated).
3.2. Align safety lug (1) of the folding cylinder (2) vertically if it
has twisted.
Fig. 752: Folding cylinder with auxiliary

rod
If the folding cylinder must be telescoped out a longer distance, we

recommend guiding the safety lug of the folding cylinder with the ac-
tuating rod during the telescoping out procedure to prevent the safe-
ty lug from twisting (see figure).
NOTE
Risk of damage to the hydraulic cylinder.
do not touch the piston rod.
808 82640 2021-04-22

Fig. 754: Optional load hook camera con-

Fig. 753: Terminal box
nection
A Connection 1 Transmitter
C Connection 2 Connection
C1 CAN BUS terminating plug
4. Remove the electric connections on the main boom head and fit
protective caps:
4.1. Remove the plug of the MBE cable harness from connec-
tion (A).
4.2. For the hydraulic luffing MBE (MBEHY): Remove the MBE
CAN plug from connection (C) and fit the CAN BUS termi-
nating plug (C1).
4.3. When using the optional load hook camera: Remove the
camera cable coming from the MBE from connection (2) of
the transmitter (1) connecting cable.
4.4. Fit the protective caps.
82640 2021-04-22 809

Fig. 755: Hoist limit switch in functional

configuration
configuration.
5. Bring the hoist limit switch on the main boom head into the func-
tional configuration (See 8.6.3.3.2 Placing the hoist limit switch
in the functional state, side 368)
19.5.4.1.2.8 Folding the Main Boom Extension at the Side on the Main Boom
Fig. 756: Pinning MBE (schematic diagram)
1 Bolts I Attachment point
WARNING
For the following unpinning procedure at point (I) (see
Fig. 756, side 810), ensure that the locking bar (see
arrow in Fig. 757, side 811) on the main boom on
the bottom left is locked.
1. Remove bolt (1) from point (I).
810 82640 2021-04-22

Fig. 757: Locking bar (schematic diagram)
WARNING
Risk of falling!
For the following locking bar unlocking procedure
(see arrow in Fig. 757, side 811) do not lean the
ladder against the main boom extension.
WARNING
Risk of accidents due to the main boom extension
moving unchecked!
The main boom extension must be held with the aux-
iliary reeving rope when unlocking the locking bar
(see arrow in Fig. 757, side 811) in the next work
step.
2. Unlock the locking bar (see arrow in Fig. 757, side 811) by
turning it 180°.
82640 2021-04-22 811

Fig. 758: MBE folding procedure
1 Folding cylinder 2 Connecting piece
WARNING
Risk of accidents due to crushing, shearing or falling
objects (such as forgotten tools) during the folding
procedure!
No one may be in the swivel area of the main boom
extension.
No one may be between the main boom extension
and the main boom.
WARNING
Risk of accidents due to uncontrolled flapping back
of the MBE if the connecting piece (2) does not en-
gage!
Carry out the folding over movement of the MBE with
sufficient momentum.
3. Fold over the MBE at the auxiliary rope until the connecting piece
(2) of the folding cylinder (1) engages.
If the joint piece (2) does not engage:
- Check the position of the MBE with the auxiliary rope
- Correct the angle of folding cylinder (1)
- If folding cylinder (1) was not completely telescoped out:
Extend the folding cylinder fully (as described in one of the
next work steps)

812 82640 2021-04-22

1 Folding cylinder 2 Connecting piece

WARNING
Risk of accidents!
work step.
5. If the joint piece (2) does not engage: Telescope folding cylinder
(1) out until connecting piece (2) has 'gripped' the basic boom
MBE. For this, on the mobile control panel, press rocker switch
(4) until the position is reached (selector switch (3) in position
"1").
1 Folding cylinder 2 Bolts

6. Using folding cylinder (1), pull the main boom extension carefully
alongside the main boom until the bolt (2) is engaged. For this,
on the mobile control panel, press rocker switch (4) until the posi-
tion is reached (selector switch (3) in position "1").
82640 2021-04-22 813

1 Bolts 2 Lever
3 Auxiliary rod
As soon as the holes of the shackles of the basic boom MBE

are aligned with the corresponding holes of the brackets, bolt
(1) is pressed in with spring force. Lever (2) moves down with
a jerk when this is done. If the pinning procedure malfunc-
tions, bolt (1) must be put in the pinning position by pressing
lever (2) up with auxiliary rod (3) before attempting pinning
again.
B Connection point
WARNING
Risk of accidents!
Before continuing the fitting procedure, you must
check visually whether the bolt (see arrow in
Fig. 762, side 814) has actually engaged at the lat-
eral pivot point (B).
814 82640 2021-04-22

1 Bolts 2 Bolts
3 Folding cylinder F Attachment point
G Attachment point
If necessary: Telescope the folding cylinder (3) out minimally so that

the biconical fixing bolts (1) / (2) are relieved of load in points (F/G).
7. Remove the bolts (1) / (2) from the fastening points (F/G) in the
boom head axles and insert them in the transport receptacle (on
the inside of the basic boom MBE) and secure them.
Fig. 764: Transport position - MBE
1 Folding cylinder 2 Selector switch

3 Rocker switch
8. Using the folding cylinder (1), pull the MBE fully into the transport
position on the main boom. For this, on the mobile control panel,
press rocker switch (3) until the position is reached (selector
82640 2021-04-22 815

WARNING
sic boom (MBE).
NOTE
tion.
(MBE).

ment (HAVHY): Establish a hydraulic connection between the
basic boom (MBE) and the main boom. To do so:
9.1. Remove the protective caps on the hydraulic connec-

tions on the right side of the main boom.
9.2. Remove the two hydraulic hoses from the load relief
connection of the basic boom (MBE).
9.3. Connect the two hydraulic hoses of the basic boom

(MBE) on the right-hand side of the main boom firmly
with the load relief connections there.
816 82640 2021-04-22

19.5.4.1.2.9 Carrying out Remaining Work
Fig. 765: Fold in rollway (schematic diagram)

3 Basic Boom MBE 4 Locking plate
1. Fold back the mobile part (1) of the rollway. To do so, release pin
(2), fold over the mobile part of the rollway (1) and repin pin (2).
This means that the locking plate (4) of the basic boom MBE
(3) is clamped between the mobile part (1) of the rollway and
the fixed part of the rollway. This prevents the main boom ex-
tension (MBE) from folding away during transport.
2. Remove the mobile control panel on the side on the main boom
together with the fastening rope.
19.5.4.2 MBE (21 m (68.9 ft)) Fitted in the Transport Position
19.5.4.2.1 Folding over the MBE 11.4 m (37,4 ft) from the Transport into the Operat-
ing Position
82640 2021-04-22 817

WARNING
Risk of accidents!
steps.
Requirements:
Fig. 766: Preparations on the MBE
1. Carry out preparations for folding over on the main boom exten-
sion (see 19.5.4.1.1.2 Carrying out preparations on the main
boom extension, side 728).
Fig. 767: Fastening the Box Top Piece to the Main Boom
2. Fasten the box top piece to the main boom (see 19.5.4.2.1.1
Fastening the Box Top Piece to the Main Boom, side 823).
818 82640 2021-04-22

3. Carry out preparations on the basic crane unit for folding over
(see 19.5.4.1.1.3 Making Preparations on the Basic Crane
Unit, side 731).
Rollway, side 736). The operation is identical regardless of
whether the box top piece is fitted or not.
82640 2021-04-22 819

Fig. 770: Fold the MBE to the front (schematic diagram)

Folding the Main Boom Extension to the Front, side 742). The
operation is identical regardless of whether the box top piece is
fitted or not.

Fig. 772: Tension plates in the 0°position (schematic diagram)
gles:
19.5.4.1.1.7 Fitting the tension plates in the 0° position, side 750.
Or
820 82640 2021-04-22


tion, side 759.

operating angle adjustment (HAVHY): Fit the adjusting cylinders.
To do so, see 19.5.4.1.1.9 Fitting the adjusting cylinders (main
boom extension with hydraulic continuous operating angle ad-
justment), side 769.
Fig. 774: Put on the hoist rope, reeve the hook block
82640 2021-04-22 821

Fig. 776: Fastening the box top piece to

Fig. 777: Auxiliary rod (schematic dia-
the basic boom MBE (schematic dia-
gram)
gram)
1 Bolts
2 Eyebolt
3 Box top piece
11. Lock bolts (1) on the box top piece (3). To do so, use the auxili-
ary rod (see Fig. 781, side 824) to turn the eyebolt (2) back
by 90°. Bolt (1) jumps independently to the lock position due to
spring resistance.
This work step prepares the folding over procedure from the operat-
ing into the transport position.
822 82640 2021-04-22

Unit, side 779).
19.5.4.2.1.1 Fastening the Box Top Piece to the Main Boom
Fig. 779: Fastening the box top piece to the main boom basic case (schematic di-
agram)
1 Bolts 2 Actuating lever
Fig. 779, side 823 is shown without the main boom extension for
clarification.
1. Fasten the box top piece to the basic case of the main boom (if
not already done). To do so, slide bolts (1) into the correspond-
ing bracket on the box top piece by moving actuating lever (2).
82640 2021-04-22 823


gram)
gram)
1 Basic Boom MBE
2 Bolts
3 Eyebolt
4 Box top piece
2. Pull out bolt (2) between the basic boom main boom extension
(1) and box top piece (4) and place in the locked position. To do
so, pull on eyebolt (3) from below using the auxiliary rod
( Fig. 781, side 824) and when pulled, place it in the locked po-
sition with a 90° turn.
Fig. 782: Connection between box top piece and basic boom MBE
1 Box top piece 2 Fixing bolt

3 Basic Boom MBE
3. Remove fixing bolts (2; 2x) between the basic boom MBE (3) and
the box top piece (1).
824 82640 2021-04-22

19.5.4.2.2 Folding from the Operating into the Transport Position

WARNING
Risk of accidents!
steps.
Fig. 783: MBE in transport position
1. Carry out all steps under 19.5.4.1.2 Folding from the Operating
into the Transport Position, side 780.
Fig. 784: Pinning - box top piece / basic boom MBE (schematic diagram)

2. Fit bolts (3; 2x) between basic boom MBE (2) and box top piece
(1) and secure against falling out with two locking springs (4)
each.
82640 2021-04-22 825

Fig. 785: Bolt in locked position (schematic diagram)

3 Bolts
If the bolt (3) on the box top piece (2) was placed in the locked posi-
tion before folding over, it locks into place on the basic boom (1) of
the MBE.
Fig. 786: Fastening the box top piece to the basic case of the main boom
Fig. 786, side 826 is shown without the main boom extension for
clarification.
3. Fasten the box top piece to the basic case of the main boom (if
not already done). To do so, slide bolts (1) into the correspond-
ing bracket on the box top piece by moving actuating lever (2).
826 82640 2021-04-22

19.5.5 Folding over the 21 m MBE (68.9 ft)
WARNING
Risk of accidents when the main boom extension is
folded over!
When folding and during pinning and unpinning there
must be no-one in the slewing range or beneath the
MBE or in areas where loads/equipment could fall,
etc.
The sequence of the operating steps must be ad-
hered to during the folding procedure.
19.5.5.1 Folding over the MBE 21 m (68.9 ft) from the Transport into the Operating
Position
WARNING
Risk of accidents!
steps.
Requirements:
82640 2021-04-22 827

Fig. 787: Preparations on the MBE
1. Carry out preparations for folding over at the main boom exten-
sion (see 19.5.5.1.1 Making Preparations for Folding over at
the Main Boom Extension, side 833).
2. Carry out preparations on the basic crane unit (see

19.5.4.1.1.3 Making Preparations on the Basic Crane Unit,
side 731).
828 82640 2021-04-22

Rollway, side 736). The operation is identical regardless of
whether the box top piece is fitted or not.
Fig. 790: Fold the MBE to the front

Folding the Main Boom Extension to the Front, side 742). The
operation is identical regardless of whether the box top piece is
fitted or not.
82640 2021-04-22 829


Main Boom Extension to the Main Boom Head, side 747). The
procedure is identical, regardless of whether the box top piece is
fitted or not.
Fig. 792: Folding the Box Top Piece to the Front
6. Fold the box top piece to the front (see 19.5.5.1.2 Folding the
Box Top Piece to the Front, side 837).
Fig. 793: Electrically connect the box top piece
7. Electrically connect the box top piece and the basic boom head
(see 19.5.5.1.3 Connecting the Box Top Piece at the Front to
the Basic Boom MBE Electrically, side 841).
830 82640 2021-04-22

Fig. 794: Tension plates in the 0° position
gles:
19.5.4.1.1.7 Fitting the tension plates in the 0° position, side 750.
Or
tion, side 759.

operating angle adjustment (HAVHY): Fit the adjusting cylinders.
To do so, see 19.5.4.1.1.9 Fitting the adjusting cylinders (main
boom extension with hydraulic continuous operating angle ad-
justment), side 769.
10. Fit the hoist rope and reeve the hook block (see 19.5.5.1.4 Fit-
ting the hoist rope and reeving the hook block, side 841).
82640 2021-04-22 831

Fig. 797: Remaining work on the box top piece
11. Carry out remaining work on the box top piece (see 19.5.5.1.5
Carrying out Remaining Work on the Box Top Piece, side 846).
Unit, side 779).
832 82640 2021-04-22

19.5.5.1.1 Making Preparations for Folding over at the Main Boom Extension
Fig. 799: Basic boom MBE with auxiliary reeving rope
boom MBE (1).
rope (2).
WARNING
82640 2021-04-22 833

2. Carry out the following checks:
2.1. The main boom extension must be pinned at the pivot

point on the side (see arrow).
2.2. The folding cylinder must have "gripped" the basic

boom MBE.
2.3. Bolts (see arrow; 2x) between the basic boom MBE and
the box top piece must be pinned. The bolts must be
secured against falling out with two locking springs.
2.4. The bolt (see arrow) on the box top piece must be en-
gaged on the basic boom MBE.
2.5. For the MBE with fixed operating angles, the marked
measurement on the auxiliary cylinder of the basic
boom MBE may be max. 100 mm (3.9 in).
2.6. For the MBE with hydraulically smooth operating angle

adjustment, the hydraulic cylinders must be retracted.
834 82640 2021-04-22

If the measurement on the auxiliary cylinder is more than 100 mm

(3.9 in) for the MBE with fixed operating angles or the hydraulic cyl-
inders are not retracted for the MBE with hydraulically smooth oper-
ating angle adjustment, there is a risk of collision with the head of
the main boom when folding forward in front of the head of the main
boom. For this reason, the hydraulic cylinders affected must be re-
tracted before folding over in the operating position. This is descri-
bed at the relevant point in the further sequence.
1 Holding device 2 Hydraulic hose
3. Preparing the hydraulic hoses of the basic boom MBE for assem-
bly: to do, release the quick release couplings of the hydraulic
hoses (2; x 2) from holding device (1) and pull the hoses out of
the steel construction from the side to the rear.

4. Prepare the electric connections of the basic boom MBE for as-
sembly. To do so, proceed as described in the previous step for
the hydraulic connections, and pull the electric connections out of
the steel construction of the basic boom MBE from the side to
the rear (main boom extension with fixed operating angles: one
electric connection; main boom extension with hydraulically
smooth operating angle adjustment: two electric connections).
82640 2021-04-22 835

Fig. 801, side 836 is a schematic diagram. This is shown without

the main boom extension for clarification.
5. Release the box top piece on the basic case of the main boom.
To do so, pull bolt (1) using actuating lever (2), releasing the pin-
ning between the box top piece and the basic case of the main
boom.
836 82640 2021-04-22


gram)
gram)
1 Bolts
2 Eyebolt
3 Box top piece
To make things clearer, the Fig. 802, side 837 for the next work
step is shown without the basic boom MBE.
6. Lock bolts (1) on the box top piece (3). To do so, use the auxili-
ary rod (see Fig. 803, side 837) to turn the eyebolt (2) back by
90°. Bolt (1) jumps independently to the lock position due to
spring resistance.
19.5.5.1.2 Folding the Box Top Piece to the Front
For risk-free operation, the locking bar must be in the lock position
at the front on the basic boom MBE during one of the following work
steps.
82640 2021-04-22 837

1. Move the locking bar at the front on the basic boom MBE into the
lock position.
tion.
Fig. 804: Box top piece with auxiliary reeving rope
1 Box top piece 2 Auxiliary reeving rope
2. Fasten the auxiliary reeving rope (2) to the head of the box top
piece (1).
rope (2).
838 82640 2021-04-22

Fig. 805: Connection between box top piece / basic boom MBE (schematic dia-
gram)
1 Basic Boom MBE 2 Bolts

3 Eyebolt 4 Box top piece
WARNING
Risk of accidents if the box top piece folds over in an
uncontrolled manner!
If bolt (2) has been released, the box top piece can fold
over in an uncontrolled manner.
The box top piece must be gripped and possibly held
at the auxiliary reeving rope to prevent this.
3. Pull out bolt (2) between the basic boom MBE (1) and the box
top piece (4). To do so, pull ring bolt (3) from below, releasing
box top piece (4).
82640 2021-04-22 839

Fig. 806: Folding the box top piece / ba- Fig. 807: Locking bar on the basic boom
sic boom MBE MBE
1 Bolts
2 Box top piece
4. Fold box top piece (2) around the two bolts (1, right side) until the
locking bar (see arrow in Fig. 807, side 840) engages at the
front on the basic boom MBE.
When engaged, the locking bar is positioned up against the
back of a dip in the box top piece.
Fig. 808: Pinning the box top piece / basic boom MBE

K Attachment point L Attachment point
5. Peg the tip section in points (K) and (L) using bolts (1) and se-
cure.
Both pins are driven in further (alternately if required) until the lock-
ing springs (2) for securing the pins can be inserted.
840 82640 2021-04-22

19.5.5.1.3 Connecting the Box Top Piece at the Front to the Basic Boom MBE Electri-
cally
A Connection
1. Connect the cable harness of the box top piece with distribution
box "X0560" of the basic boom MBE in connection (A).
H Connection H1 Bridging plug
2. Connect bridging plug (H1) with distribution box "X0560" of the

basic boom MBE in connection (H).
3. If the optional load hook camera on the fly jib head is to be used:
connect the camera cable from the box top piece with the corre-
sponding connection on the basic boom MBE.
19.5.5.1.4 Fitting the hoist rope and reeving the hook block
The procedure described below is the same for the design of the
main boom extension with fixed operating angles as well as for the
design with hydraulically smooth operating angle adjustment.
82640 2021-04-22 841

WARNING
work at height.
WARNING
842 82640 2021-04-22

1 Hoist rope 2 Basic Boom MBE

3 Auxiliary rod
Fig. 812: Rope guidance - box top piece (schematic diagram)
1 Hoist rope 2 Basic Boom MBE

3 Auxiliary rod 4 Box top piece
WARNING
down when carrying out the next step.
1. Lay hoist rope (1) over the main boom extension using the auxili-
ary rod (3). This is done by laying hoist rope (1) section for sec-
tion, starting from the main boom head, over the basic boom
MBE (2) and box top piece (4) so that the brackets (see arrows)
welded on the top or the side prevent the fitted sections of hoist
rope (1) from falling down. In the area of the rear basic boom
MBE (3), the hoist rope (1) fitted on the side bracket must be gui-
ded by hand over the left draw bar or left adjusting cylinder on
the top of the basic boom.
82640 2021-04-22 843


3 Basic Boom MBE
boom MBE (3).
1 Hoist rope 2 Rope guard pin

3 Basic Boom MBE
3. Guide hoist rope (1) over the top front rope sheave of the basic
boom MBE (3). To do so, first remove rope guard pin (2), fit hoist
rope (1) on the rope sheave and refit rope guard pin (2).
844 82640 2021-04-22

Fig. 815: Reeving the box top piece

3 Box top piece
4. Guide the hoist rope (1) over the rope sheave of the box top
piece (3), fit rope guard pins (2; 2x).
1 Hoist rope 2 Box top piece

S4 Fixed point
5. Reeve hook block (see section "Reevings" under "Hook blocks")
In the case of two-fold reeving, the rope lock at the end of hoist rope
(1) must be fastened at point ("S4") on box top piece (2). Observe
the fitting position of the rope socket.
82640 2021-04-22 845

19.5.5.1.5 Carrying out Remaining Work on the Box Top Piece
Fig. 817: Hoist limit switch on box top Fig. 818: Hoist limit switch in functional
piece configuration
1 Hoist limit switch
2 Shift weight
H Connection
1. Fit hoist limit switch (1) together with shift weight (2) in functional
configuration and connect electrically:
1.1. On the right-hand side of the box top piece, slide the hoist
limit switch (1) over the pins that have been welded on and
secure it against falling out using safety forelocks.
1.2. Guide the hoist rope through the opening on the shift
1.3. Connect the plug of the hoist limit switch (1) to the con-
necting port (H).
The figure (see Fig. 818, side 846) shows the hoist limit switch in
the functional configuration. 8.6.3.3.2 Placing the hoist limit switch
in the functional state, side 368 describes how the hoist limit switch
is moved into the functional configuration.
846 82640 2021-04-22

Fig. 819: Hazard light / anemometer, box top piece
1 Hazard light 2 Rotor

3 Box top piece A Connection
X1 Pinning, transport position X2 Pinning, non-angled MBE
X3 Pinning, angled MBE
2. Fit the bracket with rotor (2) of the wind speed indicator and haz-
ard light (1) to the head of the box top piece (3) or place in the
operating position (pinning of the bracket depends on the subse-
quent operating angle of the MBE) and connect electrically with
the distribution box "X0561" in connection (A).

and handling the hazard light and anemometer in 8.6 Electric
WARNING
If the rotor of the wind speed indicator is not fitted to the
top section of the main boom / boom system, it is not
possible to monitor compliance with permitted wind
speeds in the crane control display.
If the crane's assembly situation does not permit fit-
ting the wind speed indicator rotor (e.g. due to the up-
per edge of the top section of the main boom / boom
system approaching a protruding edge), compliance
with the permitted wind speeds must be monitored in
a different way (e.g. external wind speed indicator at
the height of the top section of the main boom / boom
system).
82640 2021-04-22 847

A Electric connection A1 Bridging plug
If the rotor of the wind measuring device is not fitted, bridging plug
(A1) must be connected to electric connection (A).
19.5.5.2 Folding the 21 m MBE (68.9 ft) from the Operating into the Transport Posi-
tion
WARNING
Risk of accidents!
steps.
Requirements:
848 82640 2021-04-22

Fig. 821: Preparations on the basic crane unit and MBE
1. Remove the hazard light, air speed indicator, hoist limit switch
and hoist rope from the main boom extension, fit the mobile con-
trol panel (see 19.5.5.2.1 Carrying out preparations on the ba-
sic crane unit and the main boom extension, side 853).
Fig. 822: Tension plates
gles:
2. Move the tension plates from the 0° position into the transport
position. To do so, see 19.5.4.1.2.3 Moving the tension plates
from the 0° position into the transport position, side 787.
Or
Move the tension plates from the 20°/40° position and place in
transport position. To do so, see 19.5.4.1.2.4 Moving the ten-
sion plates from the 20°/40° position and placing them in the
transport position, side 795.
82640 2021-04-22 849


operating angle adjustment (HAVHY): move adjusting cylinders
to the transport position. To do so, see 19.5.4.1.2.5 Placing the
adjusting cylinders in the transport position, side 800.
Fig. 824: Preparations on the box top piece
4. Carry out preparations on the box top piece (see 19.5.5.2.2

Making Preparations at the Box Top Piece, side 857).
Fig. 825: Folding the Box Top Piece at the Side on the Basic Boom MBE
5. Fold the box top piece at the side on the basic boom of the MBE
(see 19.5.5.2.3 Folding the Box Top Piece at the Side on the
Basic Boom MBE, side 859).
850 82640 2021-04-22

6. Carry out preparations on the basic boom of the main boom ex-
tension (see 19.5.4.1.2.6 Carrying out preparations for folding
up to the side of the basic unit of the main boom extension,
side 805). The operation is identical regardless of whether the
box top piece is fitted or not.
Fig. 827: Preparations on the main boom
7. Carry out preparations on the main boom (see 19.5.4.1.2.7

Carrying out preparations for folding up to the side of the main
boom, side 806).
82640 2021-04-22 851

Fig. 828: Folding the Main Boom Extension at the Side on the Main Boom
8. Fold the main boom extension at the side of the main boom (see
19.5.4.1.2.8 Folding the Main Boom Extension at the Side on
the Main Boom, side 810).
The figure below is shown without the main boom extension for clar-
ification.
9. Fasten the box top piece to the basic case of the main boom. Pin
actuating lever (2) with bolt (1) on the box top piece.
852 82640 2021-04-22

Fig. 830: Carrying out Remaining Work
10. Carry out remaining work (see 19.5.4.1.2.9 Carrying out Re-
maining Work, side 817).
After the described steps have been carried out, the 21 m (68.9 ft)
main boom extension is in the transport position on the side of the
main boom.
19.5.5.2.1 Carrying out preparations on the basic crane unit and the main boom ex-
tension
2. Set the hook block down and unreeve (see the section "Reev-
ings" at "Hook blocks").
82640 2021-04-22 853

Fig. 832: Box top piece
1 Hazard light 2 Wind speed indicator

3 Wing nut
Observe the information on the transport position of hazard light (1)

and rotor (2) of the wind speed indicator in 8.6 Electric Safety
Chain, side 361.
3. Dismantle the bracket with the rotor of the wind speed indicator
(2) and hazard light (1). To do so, loosen wing nuts (3; 2x), re-
move the bracket and then screw the wing nuts fully onto the cor-
responding thread bolts until the wing nuts are up against the
side plate.
WARNING
There is a risk of injury if one of the wing nuts falls
down during later MBE operation without the wind
speed indicator.
Tighten the wing nuts carefully even if the bracket
with the wind speed indicator and hazard light is not
fitted.
4. Remove hoist limit switch (1) together with shift weight (2).
854 82640 2021-04-22

Fig. 834: Main boom extension
5. For the main boom extension angled at 20°/40° with fixed operat-
ing angles: Place two wooden blocks next to each other under
the sliding tube of the basic boom MBE (2) or for MBE variants
with box top piece (1), place them under the sliding tube on the
head of the box top piece. The wooden blocks must have a cross
section of 10 cm x 10 cm (4 in x 4 in) and a minimum length of
180 cm (71 in).
For the main boom extension with hydraulic continuous operating an-
gle adjustment:
6. Align the main boom extension horizontally.
82640 2021-04-22 855

8. Remove the hoist rope on the main boom extension:

3 Box top piece
8.1. Remove hoist rope (1) from the rope sheave on the head
of box top piece (3): To do so, remove rope guard pins (2,
2x) from the head of box top piece (3). Pull hoist rope (1)
down from the rope sheave. Refit rope guard pins (2, 2x)
and secure against them falling out.
8.2. Remove rope guard pins (see arrow) from the front up-
per rope sheave on the basic boom MBE, pin in the
transport position and secure against falling out.
8.3. Pull hoist rope (see arrow) back to the main boom head
so that it hangs down at the side.
856 82640 2021-04-22


case of the main boom
2 Fastening rope
tion (1) on the front left on the basic case of the main
boom (see Fig. 837, side 857).
19.5.5.2.2 Making Preparations at the Box Top Piece
Fig. 838: Auxiliary reeving rope - box top piece
1 Box top piece 2 Auxiliary reeving rope
1. Fasten the auxiliary reeving rope (2) to the head of the box top
piece (1).
rope (2).
82640 2021-04-22 857

2. Remove the plug of the cable harness of the box top piece from
the head of the basic boom MBE.
H Connection H1 Bridging plug
3. Remove bridging plug (H1) from distribution box "X0560" of the

basic boom MBE in connection (H).
When using the optional load hook camera:
4. Remove the camera cable coming from the box top piece at the
corresponding connection on the basic boom MBE.
Fig. 840: Fastening the box top piece / Fig. 841: Auxiliary rod (schematic dia-
basic boom MBE gram)
1 Box top piece
2 Bolts
3 Eyebolt
5. Place bolt (2) on box top piece (1) in the lock position. To do so,
use the auxiliary rod (see Fig. 841, side 858) to turn the eye-
bolt (3) by 90°.
The bolt (2) returns independently to the lock position by
spring force. The upper end of the bolt (2) can be seen.
858 82640 2021-04-22

19.5.5.2.3 Folding the Box Top Piece at the Side on the Basic Boom MBE
For risk-free operation, the locking bar must be in the lock position
at the front on the basic boom MBE during one of the following work
steps.
1. Place the locking bar (2) at the front on the basic boom MBE (1)
in the lock position.
tion.
Fig. 842: Fastening the box top piece / Fig. 843: Auxiliary rod (schematic dia-
basic boom MBE gram)
1 Box top piece
2 Bolts
3 Eyebolt
2. If not already occurred: Lock bolts (2) on the box top piece (1).
To do so, use the auxiliary rod (see Fig. 843, side 859) to turn
the eyebolt (3) by 90°.
Bolt (2) jumps independently to the lock position due to spring
resistance. The upper end of the bolt (2) can be seen.
82640 2021-04-22 859

Fig. 844: Pinning the box top piece / basic boom MBE
1 Box top piece 2 Bolts

3 Basic Boom MBE K Pinning point
L Pinning point
3. Remove bolts (2, 2x) from the connection between the basic
boom MBE (3) and the box top piece (1) in points (K) and (L)
(left-hand side of the main boom extension).
4. Turn locking bar at the front on the basic boom of the main boom
extension by 180° in the release position.
In the release position, the locking bar lever is locked in the

upper position.
860 82640 2021-04-22

Fig. 845: Pinning the box top piece / ba- Fig. 846: Pinning the box top piece / ba-
sic boom MBE sic boom MBE
1 Box top piece
2 Bolts
K Pinning point
L Pinning point
WARNING
Risk of accidents if the box top piece folds back in
an uncontrolled manner!
Box top piece (1) could fold back in an uncontrolled man-
ner if the bolt marked in Fig. 846, side 861 does not
engage when carrying out the next work step.
Check that the bolt marked in Fig. 846, side 861 is
engaged.
5. Using the auxiliary reeving rope, fold box top piece (1) around
the right-hand bolts (2, 2x) until the bolt marked in Fig. 846,
side 861 engages on the basic boom MBE due to the folding
movement.
Fig. 847, side 861 shows the main boom extension when the last
work step has been carried out.
82640 2021-04-22 861

19.6 Transporting the Main Boom Extension Separately
19.6.1 Transport Instructions for Separate Transport

Transportation of the Main Components
Fig. 848: MBE components

The transport dimensions, transport weights and attachment points of

the main components (1), (2), (3) and (4) are described under
19.6.2 Transport Dimensions / Weights, Attachment Points,
side 864.
Pins
All pins must be in a fail-safe transport position.
862 82640 2021-04-22

Measures to be taken at the basic unit
Fig. 849: Rollway on the main boom (schematic diagram)
1 Pin 2 Mobile part of the rollway
If the parts of the transport position are on the main boom, the mobile
part (2) of the rollway must be folded in and pinned with pins (1).
82640 2021-04-22 863

19.6.2 Transport Dimensions / Weights, Attachment Points
19.6.2.1 Transport Dimensions / Weights
Fig. 850: MBE components

Part no. Transport dimensions Approx. weight

(kg / lbs)
Length mm Width mm Height mm
(in) (in) (in)
1 12315 mm 880 mm 1600 mm 1170 kg /
(485 in) (34.7 in) (63 in) 2580 lbs
2 12315 mm 880 mm 1600 mm 1160 kg /
(485 in) (34.7 in) (63 in) 2557 lbs
3 1350 kg / 2)
12040 mm 990 mm 1550 mm 2976 lbs
(474 in) (39.0 in) (61.0 in) 1500 kg / 3)
3307 lbs
4 9590 mm 770 mm 915 mm 720 kg /
(377.6 in) (30.3 in) (36.0 in) 1587 lbs
3+4 1) 2070 kg / 2)
12040 mm 1000 mm 1550 mm 4563 lbs
(474 in) (39.4 in) (61.0 in) 2220 kg / 3)
4894 lbs
1) folded together
2)Basic boom MBE for MBE with fixed operating angles (version
with tension plates)
3)Basic boom MBE for MBE with hydraulically smooth operating an-
gle adjustment (HAVHY)
864 82640 2021-04-22

19.6.2.2 Attachment points

The main boom extension is comprised of various partial compo-
nents. To attach the parts, observe the depictions in Fig. 852,
side 866. They show which attachment points must be used so that
the parts are attached symmetrically to the centre of gravity.
WARNING
Risk of accidents!
The parts must not swing out or dangle at an angle
when they are raised. If necessary, a suspension
tackle fitted with shortening claws must be used.
The lifting tackle must be supplied by the customer.
Fig. 851: Attachment points / attachment eyelets
The attachment point plates are designed so that it is possible to se-

cure yourself to them with your personal protective equipment. There
are marked attachment eyelets on the plates for this purpose. These
attachment eyelets (for PPE) are not suitable for use as attachment
points. It must be ensured that the attachment eyelets for PPE are not
accidentally used as attachment points.
WARNING
Risk of accidents!
Do not use attachment eyelets for attaching crane
components to a crane.
82640 2021-04-22 865

Fig. 852: MBE attachment points
(attachment points a - d) front (attachment points a - d)
3 Basic boom MBE (attachment points 1 - 6) 4 Box top piece (attachment points m + n)
Attachment points
Part no. Description
"a / b" "c / d" 6 5 4 3 2 1 "m" "n"
1 Intermediate section x x
2 Intermediate section x x
Basic boom MBE (HAV) 1) x x x x
3
Basic boom MBE (HAVHY) 2) x x x x
4 Box top piece x x
Basic boom MBE + box top 1)
3+4 x x x x
piece (folded together) 2)
1)
Basic boom MBE for MBE with fixed operating angles (version with tension plates)
2)
Basic boom MBE for MBE with hydraulically smooth operating angle adjustment (HAVHY)
Signs are fixed to the attachments points of the basic boom MBE
(3). The numbers on the signs match the descriptions in the figure or
table.
866 82640 2021-04-22

There are other plates on the main boom extension which are similar
to the plates for attachment. However, only the attachment points lis-
ted in the table may be used for attachment.
WARNING
Risk of accidents!
Only the attachment points listed in the table may be
used for attachment.
19.6.3 Fitting and dismantling for separate transportation

The components of the main boom extension can be transported sep-
arately. The components for the individual desired MBE length can be
fitted using an auxiliary crane. The parts must be attached at the at-
tachment points provided.
For a description of the attachment points, see 19.6.2.2 Attach-

ment points, side 865.
19.6.3.1 General instructions and instructions on risks for fitting

Observe the "Important specifications" listed at the beginning of the
section as far as these are important for fitting with the auxiliary
crane.
Slew the superstructure to the rear while supported (check the level)
and luff the main boom in the horizontal (0°). For the planned configu-
ration, the counterweight with the corresponding support base as
specified in the capacity table must be fitted.
WARNING
Risk of accidents! Walking or standing beneath sus-
pended loads or in areas where equipment could fall
is prohibited.
The auxiliary crane must hold the parts to be fitted
until all pinning points have been pinned and locked
correctly.
WARNING
When stretched and pinned together, there is a risk
of accidents when fitting the main boom extension!
The basic boom MBE, intermediate section and box
top piece may not be fitted on the main boom head
outstretched and pinned together.
The basic boom MBE and box top piece can be fitted
individually or folded together on the main boom
head.
82640 2021-04-22 867

When relieving the auxiliary crane of load after the intermediate sec-
tion, basic boom or box top piece have been pinned to the crane, the
main boom drops slightly due to the added load. If the multi-purpose
ladder is used as a leaning ladder, the attachment hooks can slide
out of the corresponding ladder bracket. The ladder could fall over.
WARNING
There is a risk of accidents and of falling due to the
attachment hooks possibly sliding out of the ladder
bracket when the main boom drops because of the
added load.
Get off the ladder before relieving the auxiliary crane
of load.
Before relieving the auxiliary crane of load, remove
the ladder from the main boom or the fly jib.
19.6.3.2 Fitting the 11.4 m MBE (37.4 ft)

To provide a better structure of the steps for fitting the main boom ex-
tension, the steps are grouped below by assemblies or by topics. Ref-
erence is made to the segment in which the steps are described in
detail. The hazard risks in these combined steps are described in the
corresponding sub-section.
WARNING
Risk of accidents!
steps.
Requirements:
- 19.6.3.1 General instructions and instructions on risks for fitting,
side 867 read and understood.
1. Carry out preparations on the main boom extension (see
19.6.3.2.1 Carrying out preparations on the main boom exten-
sion, side 872).
868 82640 2021-04-22

2. Carry out preparations on the basic crane unit (see 19.6.3.2.2

Making Preparations on the Basic Crane Unit, side 872).
Fig. 854: Main boom extension (MBE) with fixed operating Fig. 855: Main boom extension (MBE) with fixed operating
angles angles
gles:
3. Fit the basic boom of the main boom extension at the main boom
head in the in 0°position (see Fig. 854, side 869). See
19.6.3.2.3 Fitting the basic boom of the main boom extension on
the main boom head in the 0°-position, side 874).
Or
Fit the basic boom of the main boom extension at the main boom
head in the in the 20°/40° position (see Fig. 855, side 869).
See 19.6.3.2.4 Fitting the basic boom of the main boom exten-
sion on the main boom head in the 20°/40°-position, side 879.
Fig. 856: Main boom extension with hydraulic continuous operating angle adjust-
ment (HAVHY)

operating angle adjustment (HAVHY): Fit the basic boom of the
main boom extension (HAVHY) (see 19.6.3.2.5 Fitting the ba-
sic boom of the hydraulically adjustable main boom extension on
the main boom head, side 884).
82640 2021-04-22 869

870 82640 2021-04-22

The main boom extension is dismantled in the same way, in the re-
verse sequence.
Hydraulic hoses during separate transportation of the basic

boom of the main boom extension
Fig. 859: Load relief connection on the basic boom MBE (schematic diagram)
NOTE
Connect the hydraulic hoses of the basic boom of the MBE firmly to
the quick-release couplings of the load relief connection.
82640 2021-04-22 871

19.6.3.2.1 Carrying out preparations on the main boom extension
1 Load relief connection 2 Hydraulic hose

operating angle adjustment (HAVHY): Prepare the hydraulic ho-
ses of the basic boom MBE for assembly. To do so: Release the
quick-release couplings of the hydraulic hoses (2; x 2 ) at load
relief connection (1) and pull the hydraulic hoses out from the
side to the rear out of the steel construction.

2. Prepare the electric connections of the basic boom MBE for as-
sembly. To do so, proceed as described in the previous step for
the hydraulic connections, and pull the electric connections out of
the steel construction of the basic boom MBE from the side to
the rear (main boom extension with fixed operating angles: one
electric connection; main boom extension with hydraulically
smooth operating angle adjustment: two electric connections).
19.6.3.2.2 Making Preparations on the Basic Crane Unit
WARNING
872 82640 2021-04-22

Fig. 861: Course of rope on the main boom head (schematic diagram)
1 Hoist rope E2 Run-in sheave
2. Fit hoist rope (1) onto run-in sheave (E2) on the main boom
head. See 19.5.4.1.1.3.1 Fitting the hoist rope on the run-in
sheave on the main boom head, side 735.
main boom extension when it is fitted at a later point. Place the
hoist rope in the longitudinal main boom direction in front of the
head of the main boom.
Fig. 862: Course of rope on the main boom head
1 Hoist rope
82640 2021-04-22 873

19.6.3.2.3 Fitting the basic boom of the main boom extension on the main boom
head in the 0°-position
Fig. 863: Fitting the basic boom MBE
1 Basic Boom MBE G(I) Pinning point, lower head axle
1. Using the auxiliary crane, attach the basic boom MBE (1) at the
designated attachment points in front of the main boom head so
that the basic boom MBE (1) can be pinned in points (G, I) in the
next work step.
1 Pin 2 Locking spring

G(I) Pinning point, lower head axle
2. Fit pins (1, x 2) in points (G, I) in the bottom fork heads and se-
cure against falling out with 2 locking springs (2) each.
3. Fit the tension plates on the head of the main boom in the 0°po-
sition and pin. See 19.6.3.2.3.1 Fitting the tension plates on the
head of the main boom in the 0°position and pinning them,
side 875.
4. Get down from the ladder attached or fitted in a ladder bracket
on the main boom or fly jib. Remove the ladder from the crane.
874 82640 2021-04-22

WARNING
There is a risk of accidents due to the ladder falling
over.
Get down from the ladder and remove the ladder from
the crane as described in the previous work step.
5. Detach the basic boom MBE from the auxiliary crane.

19.6.3.2.3.1 Fitting the tension plates on the head of the main boom in the 0°position
and pinning them
Assembly can be carried out from the left as well as from the right
side of the main boom extension.
1 Bolts 2 Bolts
82640 2021-04-22 875

can be pinned to the main boom head.

3 Bolts

(1) and the main boom head and secure against falling out with
locking spring (2).
"A" Pinning point
4. Using the auxiliary crane, raise or lower the main boom exten-
sion until the bolts on both tension plates can be pinned in point
"A".
876 82640 2021-04-22

"A" Pinning point 1 Bolts

2 Washer 3 Forelock
5. On both tension plates, fit bolt (1) (incl. washer (2) and forelock
(3) and place bolt (4) in the transport position.
19.6.3.2.3.2 Connecting the Electric Cables of the Main Boom Extension to the Main
Boom Head
A Connection - air speed indicator
1. Connect plug of the basic boom MBE cable harness with con-
the main boom head.
82640 2021-04-22 877

Fig. 873: Optional load hook camera connection (schematic diagram)
NOTE
In the next work step, use connection (2) on the connecting ca-
ble of the transmitter to connect the electrical cable of the load
hook camera.
2. If the optional load hook camera is fitted on the fly jib head: Con-
nect the camera cable from the MBE with connection (2) of the
transmitter (1) connecting cable.
The camera cable coming from the MBE should not be connected
directly with the connecting socket of transmitter (1), as the connect-
ing socket on transmitter (1) is not suitable for daily alternating oper-
ation.
878 82640 2021-04-22

3. Fit the hoist limit switch shift weight (2) of the main boom head
hoist limit switch to the bracket attached to the right-hand side of
the main boom head and secure it against falling out with locking
spring (1).
19.6.3.2.4 Fitting the basic boom of the main boom extension on the main boom
head in the 20°/40°-position
next work step.
82640 2021-04-22 879


3. Fit the tension plates on the head of the main boom and pin for
20°/40° crane operation. See 19.6.3.2.4.1 Fitting the tension
plates on the head of the main boom and pinning for 20°/40°
crane operation., side 881.
Fig. 878: MBE lowered onto the ground
4. Lower the main boom extension onto the ground (see

19.6.3.2.4.2 Lowering the main boom extension onto the ground,
side 883).
880 82640 2021-04-22


19.6.3.2.4.1 Fitting the tension plates on the head of the main boom and pinning for
20°/40° crane operation.
The tension plates can be assembled from the left as well as from
the right side of the main boom extension. However, we do recom-
mend carrying out the work from the right-hand side as the ladder
required for dismantling the top cap bolt in one of the next work
steps does not then have to be repositioned.
82640 2021-04-22 881

1 Bolts 2 Bolts
3 Bolts
1. At both tension plates, repin bolts (1) and (3):

ning hole.
1.2. For 20° pinning: Pull bolts (1; incl. washer and forelock) in
the 20° pinning hole.
the transport position hole.
sition.
For the 40° angle, the force between the interior and exterior com-
ponents of the tension plates is transferred at a later point via the
permanently fitted bolts (2).
2. Pull out the interior components of the two tension plates until
they can be pinned to the main boom head.
882 82640 2021-04-22


3 Bolts
3. At both tension plates, fit bolt (3) between interior component (1)
and the main boom head and secure against falling out with lock-
ing spring (2).
19.6.3.2.4.2 Lowering the main boom extension onto the ground

tube of the basic boom MBE (2) or for MBE variants with box top
(71 in).
82640 2021-04-22 883

WARNING
over.
the crane as described in the previous step.
3. Lower the main boom extension onto the wooden blocks.
In the case of an MBE variant with box top piece (1), it lies on the
square timber. In the case of an MBE variant in which the basic
boom (2) forms the foremost part of the MBE, it lies on the square
timber.
19.6.3.2.5 Fitting the basic boom of the hydraulically adjustable main boom exten-
sion on the main boom head
next work step.
884 82640 2021-04-22


Fig. 887: Connect the MBE electric cables.

Fig. 888: Adjusting cylinder (schematic diagram)
4. Fit the adjusting cylinder. To do so, see 19.6.3.2.5.1 Fitting the

adjusting cylinders (main boom extension with hydraulic continu-
ous operating angle adjustment), side 886.
82640 2021-04-22 885

WARNING
over.

CAUTION
cured correctly.
886 82640 2021-04-22



CAUTION
justing cylinders!
82640 2021-04-22 887

Requirements:
- Hydraulic connections of the laterally fitted hose drum are fitted at
the front on the left-hand side of the main boom head (see
operating angle adjustment), side 700).
NOTE
tension.
NOTE
at a later point.
1. Dismantle hydraulic hoses (1; x 2) to the hydraulic connections

(2) on the left-hand side of the main boom head.
888 82640 2021-04-22


gram)
2 Fastening rope
2.1. Connect the mobile control panel to the electric connection
(1) at the front left on the basic case of the main boom
1 Bolts 2 Bolts
4. Pull bolts (1; 2x) and bolts (2; 2x) from the intermediate ele-
ments.
82640 2021-04-22 889


A Pinning point

the head of the main boom on both sides in point (A).
1 Intermediate part 2 Bolts

3 Locking spring 4 Main boom
6. Fit bolts (2) between intermediate elements (1) and the head of
the main boom (4) on both adjusting cylinders and secure
against falling out with locking spring (3). If required, readjust the
extension state of the adjusting cylinder.

3 Intermediate part
(3) are aligned.
890 82640 2021-04-22

1 Adjusting cylinder 2 Rods

8. On both sides, fit bolts (3) between rods (2) of the two adjusting
cylinders (1) and intermediate elements (4) and secure against
falling out.
9. Remove the mobile control panel together with the fastening

rope.

19.6.3.3 Fitting the 21 m MBE (68.9 ft)

To provide a better structure of the steps for fitting the main boom ex-
tension, the steps are grouped below by assemblies or by topics. Ref-
erence is made to the segment in which the steps are described in
detail. The hazard risks in these combined steps are described in the
corresponding sub-section.
WARNING
Risk of accidents!
steps.
82640 2021-04-22 891

Requirements:
sion, side 872).
Fig. 900: Preparations on the basic crane unit

angles angles
gles:
3. Fit the basic boom and box top piece on the main boom head in
the 0° position (see Fig. 901, side 892). See 19.6.3.3.1 Fit-
ting the basic boom of the main boom extension and box top
piece on the main boom head in the 0°-position, side 894).
Or
Fit the basic boom and box top piece on the main boom head in
the 20°/40° position (see Fig. 902, side 892). See 19.6.3.3.2
Fitting the basic boom of the main boom extension and box top
piece on the main boom head in the 20°/40° position,
side 898).
892 82640 2021-04-22

Fig. 903: Main boom extension with hydraulic continuous operating angle adjust-
ment (HAVHY)

operating angle adjustment (HAVHY): Fit the basic boom and the
box top piece (see 19.6.3.3.3 Fitting the basic boom of the hy-
draulically adjustable main boom extension and box top piece on
the main boom head, side 901).
82640 2021-04-22 893

verse sequence.

NOTE
19.6.3.3.1 Fitting the basic boom of the main boom extension and box top piece on
the main boom head in the 0°-position
next work step.
894 82640 2021-04-22


3. Fit the tension plates on the head of the main boom in the 0°po-
sition and pin. See 19.6.3.2.3.1 Fitting the tension plates on the
head of the main boom in the 0°position and pinning them,
side 875.
WARNING
over.
82640 2021-04-22 895


Fig. 911: Fitting the box top piece to the basic boom MBE
7. Fit the box top piece at the front on the basic boom of the main
boom extension (see 19.6.3.3.1.1 Fitting the Box Top Piece at
the Front on the Basic Boom of the Main Boom Extension,
side 897).
8. Electrically connect the box top piece to the basic boom head at
the front (see 19.5.5.1.3 Connecting the Box Top Piece at the
Front to the Basic Boom MBE Electrically, side 841).
896 82640 2021-04-22

19.6.3.3.1.1 Fitting the Box Top Piece at the Front on the Basic Boom of the Main
Boom Extension
Fig. 913: Fitting the box top piece

1. Using the auxiliary crane, attach the box top piece (1) to the des-
ignated attachment points in front of the basic boom MBE (2) so
that the box top piece (1) can be pinned in the next work step.
2. Knock in pins (3, x 4) in the pinning point and secure them
against falling out with two locking springs (4) each.
WARNING
over.
4. Detach the box top piece from the auxiliary crane.
82640 2021-04-22 897

19.6.3.3.2 Fitting the basic boom of the main boom extension and box top piece on
the main boom head in the 20°/40° position

H Pinning point, upper head axle
1. Fit the basic boom MBE (1) (see 19.6.3.3.2.1 Fitting the basic
boom of the main boom extension, side 900).
2. Fit the tension plates on the head of the main boom and pin them
for 20°/40° crane operation. See 19.6.3.2.4.1 Fitting the ten-
sion plates on the head of the main boom and pinning for 20°/40°
crane operation., side 881.

898 82640 2021-04-22

side 897).
6. Remove top bolt at the back on the basic boom of the MBE. See
19.6.3.3.2.2 Removing the top bolt at the back on the basic
boom of the MBE, side 901.

side 883).
8. Detach the main boom extension from the auxiliary crane.
82640 2021-04-22 899

19.6.3.3.2.1 Fitting the basic boom of the main boom extension

H Pinning point, upper head axle
that the basic boom MBE (1) can be pinned in points (G), (H) and
(I) in the next work step.

G(I) Pinning point, lower head axle H Pinning point, upper head axle
2. Fit pins (1, x 3) in points (G), (H) and (I) in the fork heads and
secure them against falling out using 2 locking springs (2) each.
WARNING
over.
900 82640 2021-04-22

19.6.3.3.2.2 Removing the top bolt at the back on the basic boom of the MBE
1. Attach the main boom extension with loop to the auxiliary crane
in the front area of the basic boom.
Fig. 923: Main boom extension, right-hand side
1 Bolts
2. Using the auxiliary crane, raise the main boom extension careful-
ly until the top bolt (1) on the right-hand side of the main boom
head is relieved of load and can be removed.
1 Bolts
boom head.
19.6.3.3.3 Fitting the basic boom of the hydraulically adjustable main boom exten-
sion and box top piece on the main boom head
next work step.
82640 2021-04-22 901


Fig. 927: Connect the MBE electric cables.

Fig. 928: Adjusting cylinder (schematic diagram)
4. Fit the adjusting cylinder. To do so, see 19.6.3.2.5.1 Fitting the

adjusting cylinders (main boom extension with hydraulic continu-
ous operating angle adjustment), side 886.
902 82640 2021-04-22

WARNING
over.
Fig. 929: Fitting the box top piece
side 897).
19.6.3.4 Fitting the 23.4 m MBE (76.8 ft)

To provide a better structure of the work steps for fitting the main
boom extension, the work steps are grouped below by assemblies or
by topics. Reference is made to the segment in which the work steps
are described in detail. The hazard risks in these combined work
steps are described in the corresponding sub-section.
WARNING
Risk of accidents!
work steps.
82640 2021-04-22 903

Fig. 931: Design variants of the intermediate section

An intermediate section is a component part of the 23.4 m (76.8 ft)

MBE. Depending on the crane delivery, there are two design variants
of the intermediate section:
- Intermediate section (1) with fastening eyes at the front in the top
area for pinning further fly jib components.
- Intermediate section (2) without fastening eyes, front, in the top
area.
It is irrelevant which intermediate section is fitted for the 23.4 m (76.8
ft) MBE. If the intermediate section with fastening eyes (1) is used, it
must be remembered that the intermediate section (1) in the top area
may not be pinned to the basic boom MBE at the fastening eyes,
even though this is mechanically possible.
DANGER
There is a risk of accidents if the intermediate sec-
tion is pinned to the basic boom MBE in the top area
when fitting the 23.4 m (76.8 ft) MBE.
Do not pin the basic boom MBE and the intermediate
section in the top area even if it is mechanically possi-
ble.
Fig. 932: Main boom extension 23.4 m (76.8 ft)
1 Basic Boom MBE 2 Intermediate section
904 82640 2021-04-22

Requirements:
sion, side 872).
2. Carry out preparations on the basic crane unit. See 19.6.3.4.1

Making Preparations on the Basic Crane Unit, side 907.
angles angles
gles:
3. Fit the intermediate section and basic boom on the main boom
head in the 0°-position (see Fig. 934, side 905). See
19.6.3.4.2 Fitting the intermediate section and the basic boom on
the main boom head in the 0°-position, side 909.
Or
Fit the intermediate section and the basic boom on the main
boom head in the 20°/40°-position (see Fig. 935, side 905).
See 19.6.3.4.3 Fitting the intermediate section and the basic
boom MBE to the main boom head in the 20°/40° position,
side 918.
82640 2021-04-22 905

Fig. 936: Main boom extension with hydraulically smooth operating angle adjust-
ment (HAVHY)
4. For the variant of the main boom extension with hydraulic infinite-
ly variable working angle adjustment (MBEHY): Attach the inter-
mediate section and basic boom (see 19.6.3.4.4 Fitting the in-
termediate section and basic boom of the hydraulic MBE on the
main boom head, side 922).
the Basic Boom of the Main Boom Extension, side 777).
906 82640 2021-04-22

verse sequence.

NOTE
19.6.3.4.1 Making Preparations on the Basic Crane Unit
82640 2021-04-22 907

1 Hoist rope
2. Fit hoist rope (1) on run-in sheave (E2) on the main boom head.
See 19.5.4.1.1.3.1 Fitting the hoist rope on the run-in sheave
on the main boom head, side 735.
main boom extension when it is fitted at a later point.
Fig. 941: Course of rope - main boom head
1 Hoist rope
908 82640 2021-04-22

19.6.3.4.2 Fitting the intermediate section and the basic boom on the main boom
head in the 0°-position
Fig. 942: Fitting the intermediate section
1. Fit the intermediate section on the head of the main boom. See
19.6.3.4.2.1 Fitting the Intermediate Section on the Main Boom
Head, side 912.
Fig. 943: Connect the intermediate section electric cables (schematic diagram)
2. Connect the intermediate section electrically with the main boom

head. See 19.6.3.4.2.2 Connecting the Intermediate Section to
the Main Boom Head Electrically, side 914.
Fig. 944: Basic boom MBE fitting (schematic diagram)
1 Basic Boom MBE
3. Using the auxiliary crane, attach the basic boom MBE (1) to the
designated attachment points in front of the intermediate section
so that the basic boom MBE (1) can be pinned at the marked
point in the next work step.
82640 2021-04-22 909

4. Fit pins (1, x 2) in the bottom fork heads and secure against fall-
ing out with 2 locking springs (2) each.
Depending on the design of the intermediate section, there are also

eyelets on the intermediate section at the front on the top for attach-
ing the fork heads. They are not used during the procedure descri-
bed here for fitting the basic boom on the intermediate section.
5. Fit the tension plates on the head of the intermediate section in

the 0°position and pin. See 19.6.3.4.2.3 Fit the tension plates
at the front on the intermediate section in the 0° position and pin,
side 916.
WARNING
over.
910 82640 2021-04-22

Fig. 947: Connecting the basic boom MBE electrically (schematic diagram)
8. Electrically connect the basic boom of the main boom extension

with the intermediate section (see 19.6.3.4.2.4 Connecting the
Main Boom Extension on the Intermediate Section Electrically,
side 918).
Fig. 948: Hydraulic hoses on the main boom extension
1 Basic Boom MBE 2 Hydraulic hoses

3 Intermediate section 4 Hydraulic connections
9. If the MBE angle is to be changed at a later point using your own

hydraulic equipment with the MBE fitted: fit hydraulic hoses (2) of
the basic boom (1) to the hydraulic connections (4) on the inter-
mediate section (3).
82640 2021-04-22 911

19.6.3.4.2.1 Fitting the Intermediate Section on the Main Boom Head

Depending on the crane delivery, there are two design variants of the
intermediate section:

The fitting procedure is the same for both variants of the intermedi-
ate section.
Fig. 950: Intermediate section fitting (schematic diagram)
1. Using the auxiliary crane, attach the intermediate section in front

of the main boom head at the designated attachment points so
that intermediate section can be pinned in the next work step.
912 82640 2021-04-22

Fig. 951: Intermediate section fitting (schematic diagram)
1 Intermediate section 2 Pin

3 Locking spring
2. Knock in pins (2, x 4) in the pinning point in the sequence descri-

bed below and secure them against falling out using 2 locking
springs (3) each.
2.1. Fit pins (2, x 2) on the right-hand side of intermediate sec-
tion (1).
2.2. Fit bottom pin (2) on the left-hand side of intermediate sec-
tion (1).
2.3. Fit top pin (2) on the left-hand side of intermediate section
(1).
WARNING
over.
the crane as described in the previous step.
4. Detach intermediate section from the auxiliary crane.
82640 2021-04-22 913

19.6.3.4.2.2 Connecting the Intermediate Section to the Main Boom Head Electrically
A Connection
1. Connect plug of the intermediate section cable harness with con-

the main boom head.
Fig. 953: Optional load hook camera (schematic diagram)
NOTE
Use connection (2) on the transmitter (1) connecting cable to
connect the electrical cable of the load hook camera.
connect the camera cable from the MBE with connection (2) of
the transmitter (1) connecting cable. The camera cable coming
from the MBE should not be connected directly with the connect-
ing socket of transmitter (1), as the connecting socket on trans-
mitter (1) is not suitable for daily alternating operation.
914 82640 2021-04-22

3. Fit the hoist limit switch weight (2) of the main boom head hoist
limit switch to the bracket attached to the right-hand side of the
main boom head and secure it against falling out with locking
spring (1).
82640 2021-04-22 915

19.6.3.4.2.3 Fit the tension plates at the front on the intermediate section in the 0°
position and pin
Assembly can be carried out from the left as well as from the right
side of the main boom extension.
1 Bolts 2 Bolts
can be pinned to the head of the intermediate section.

3 Bolts
3. On both tension plates, fit bolts (3) between interior component

(1) of the tension plate and the intermediate section and secure
against falling out with forelock (2).
916 82640 2021-04-22

"A" Pinning point
4. Using the auxiliary crane, raise or lower the main boom exten-
sion until the bolts on both tension plates can be pinned in point
"A".
"A" Pinning point 1 Bolts

2 Washer 3 Forelock
5. At both tension plates, mount the bolts (1) at point "A" including
washer (2) and secure against falling out with the appropriate
forelock (3).
82640 2021-04-22 917

19.6.3.4.2.4 Connecting the Main Boom Extension on the Intermediate Section Elec-
trically
Fig. 960: Basic boom MBE and intermediate section
1 Basic Boom MBE 2 Connection

3 Intermediate section
1. Plug cable harness plug of the basic boom MBE (1) into the cor-
responding connection (2) at the front on intermediate section
(3).
If the optional load hook camera on the fly jib head is to be used:
2. Connect the camera cable coming from the basic boom main
boom extension and connect it with the corresponding connec-
tion of the intermediate section.
19.6.3.4.3 Fitting the intermediate section and the basic boom MBE to the main
boom head in the 20°/40° position
Head, side 912.

918 82640 2021-04-22

1 Basic Boom MBE

Fig. 965: Tension bar
5. Fit the tension plates at the front on the intermediate section and
pin in place for 20° /40° crane operation. See 19.6.3.4.3.1 Fit-
ting the tension plates at the front on the intermediate section
and pinning in place for 20° /40° crane operation, side 921.
82640 2021-04-22 919


side 883).

side 918).


920 82640 2021-04-22

19.6.3.4.3.1 Fitting the tension plates at the front on the intermediate section and
pinning in place for 20° /40° crane operation
pinned from the left- as well as the right-hand side of the main boom
extension. However, we do recommend carrying out the work from
the right-hand side as the ladder required for dismantling the top cap
bolt in one of the next work steps does not then have to be reposi-
tioned.
1 Bolts 2 Bolts
3 Bolts
1. Relocate bolts (1) and (3) on both tension plates.

ning hole.
sition.
82640 2021-04-22 921

can be pinned to the head of the intermediate section.
1 Interior component 2 Forelock

3 Bolts
3. On both tension plates, fit bolts (3) between interior component

(1) and the intermediate section and secure against falling out
with forelock (2).
19.6.3.4.4 Fitting the intermediate section and basic boom of the hydraulic MBE on
the main boom head
Head, side 912.
922 82640 2021-04-22

Fig. 973: Connecting the intermediate section electrically and hydraulically (sche-
matic diagram)
2. Electrically and hydraulically connect the intermediate section

with the main boom head. See 19.6.3.4.4.1 Connecting the
electric and hydraulic cables of the intermediate section to the
main boom head, side 925.
1 Basic Boom MBE
4. Fit bolts (1, x 2) in the marked points on the bottom fork heads
and secure against falling out with 2 locking springs (2) each.

82640 2021-04-22 923


Main Boom Extension (HAVHY) on the Intermediate Section
Electrically, side 929).
6. Fit the adjusting cylinder on the intermediate section. To do so,

see 19.6.3.4.4.3 Fitting the adjusting cylinders (main boom ex-
tension with hydraulic continuous operating angle adjustment),
side 930.
WARNING
over.
924 82640 2021-04-22

Fig. 978: Remove connecting line (schematic diagram)
1 Intermediate section 2 Connecting lead

9. At the rear of the intermediate section (1): Remove the connect-

ing line (2) of the mobile control panel from the electric connec-
tion (3) on the front left of the basic case of the main boom.
NOTE
Risk of damage!
When continuing with telescoping out the main boom, the connect-
ing line (2) will be damaged if it remains connected.
Remove the connecting line (2) as described.
19.6.3.4.4.1 Connecting the electric and hydraulic cables of the intermediate section
to the main boom head
A Connection
1. Connect the intermediate section cable harness with connection

(A) on distribution box "X0550" on the left-hand side of the main
boom head.
82640 2021-04-22 925

C Connection C1 CAN BUS terminating plug
Notes on CAN lead connection:

- The engine ignition must be switched off (if this has not already
been done) before the CAN lead is connected. Otherwise, there
will be fault messages in crane control. If the CAN lead was acci-
dentally connected with the ignition switched on, the correspond-
ing fault message can be deleted by switching off the ignition.
- The engine and the ignition must remain switched off until the
CAN lead is connected with the basic boom of the main boom ex-
tension.
2. Connect the plug of the intermediate section CAN line with con-
nection (C) on distribution box "X0550" on the left-hand side of
the main boom head.
For the MBE with fixed operating angles (version with tension
plates): the connection (C) remains occupied by the CAN BUS ter-
minating plug (C1).
Fig. 981: Connect the mobile control panel cable (schematic diagram)
1 Intermediate section 2 Mobile control panel cable

3. Connect the cable (2) of the mobile control panel of the rear in-
termediate section (1) with the front left electric connection (3) on
the basic case of the main boom.
926 82640 2021-04-22

Fig. 982: Optional load hook camera (schematic diagram)
NOTE
Use connection (2) on the transmitter (1) connecting cable to
connect the electrical cable of the load hook camera.
connect the camera cable from the MBE with connection (2) of
the transmitter (1) connecting cable. The camera cable coming
from the MBE should not be connected directly with the connect-
ing socket of transmitter (1), as the connecting socket on trans-
mitter (1) is not suitable for daily alternating operation.
5. Fit the hoist limit switch weight (2) of the main boom head hoist
limit switch to the bracket attached to the right-hand side of the
main boom head and secure it against falling out with locking
spring (1).
82640 2021-04-22 927

Fig. 984: Hydraulic connections (schematic diagram)
7. Electrically and hydraulically connect the hydraulic hoses of the

intermediate section to the hydraulic connections marked in the
Fig. 984, side 928.
928 82640 2021-04-22

19.6.3.4.4.2 Connecting the Main Boom Extension (HAVHY) on the Intermediate Sec-
tion Electrically
Fig. 985: Basic boom MBE and intermediate section
1 Basic Boom MBE 2 Electric connection strip

1. Connect the cable harness of the basic boom MBE (1) on inter-
mediate section (3) to the corresponding connection on the elec-
tric connection strip (2).
Note on CAN lead connection:

- If the CAN lead is once again connected between the main boom
head and the basic boom of the main boom extension, the engine
can be restarted and the ignition switched on again.
- If the engine or the ignition was switched on while the CAN lead
connection was interrupted, there will be a fault message at
crane control. The fault message can be deleted by switching off
the ignition or the engine.
2. Connect the CAN lead of the basic boom MBE (1) on intermedi-
ate section (3) to the corresponding connection on the electric
connection strip (2).
If the optional load hook camera on the fly jib head is to be used:
3. Connect the camera cable coming from the basic boom main
boom extension and connect it with the corresponding connec-
tion of the intermediate section.
82640 2021-04-22 929


Fig. 987: Intermediate section fitted (schematic diagram)
CAUTION
cured correctly.
930 82640 2021-04-22



CAUTION
justing cylinders!
82640 2021-04-22 931

Requirements:
- The intermediate section is equipped with the front left hydraulic
connections.
Fig. 989: Fitting the hydraulic hoses (schematic diagram)

NOTE
tension.
NOTE
at a later point.
1. Fit hydraulic hoses (2) of the basic boom (1) to intermediate sec-
tion (3) on the hydraulic connections (4).
932 82640 2021-04-22

Fig. 991: Electric connection on the inter-

mediate section (schematic diagram)
2 Fastening rope
2. Fit the mobile control panel (see Fig. 990, side 933) on the in-
termediate section:
2.1. Connect the mobile control panel to the electric connection
(1) at the front left on the intermediate section (see
Fig. 991, side 933).
the intermediate section using the snap hook. There is al-
so a snap hook on the free end of fastening rope (2) which
is attached to the mobile control panel.
1 Bolts 2 Bolts
4. Remove bolts (1; 2x) and bolts (2; 2x) from the intermediate ele-
ments.
82640 2021-04-22 933


A Pinning point

the head of the intermediate section on both sides in point (A).
1 Intermediate part 2 Forelock

3 Bolts 4 Intermediate section
6. Fit bolt (3) between intermediate elements (1) and intermediate

section (4) on both adjusting cylinders and secure against falling
out with forelock (2). If required, readjust the extension state of

3 Intermediate part
(4) are aligned.
934 82640 2021-04-22


8. On both sides, fit bolts (3) between rod ends (2) of the two ad-
justing cylinders (1) and intermediate elements (4) and secure
against falling out.

rope.

ment.
WARNING
work at height.
82640 2021-04-22 935

WARNING
Fig. 997: Course of the rope, MBE (schematic diagram)
1 Hoist rope 2 Intermediate section

3 Basic Boom MBE 4 Auxiliary rod
CAUTION
1. Place hoist rope (1) over the main boom extension using the
auxiliary rod (4). This is done by laying hoist rope (1) section for
section, from the main boom head, over intermediate section (2)
and basic boom MBE (3) so that the brackets (see arrows) wel-
ded on the top or the side prevent the fitted sections of hoist rope
(1) from falling down. In the area of the rear basic boom MBE (3),
the hoist rope (1) fitted on the side bracket must be guided by
hand over the left draw bar or left adjusting cylinder on the top of
the basic boom.
936 82640 2021-04-22

Fig. 998: Rope path, MBE
1 Rope guard pin 2 Hoist rope

2. Guide hoist rope (2) over the front rope sheave on intermediate
section (3), fit rope guard pin (1) and secure against falling out.

3 Basic Boom MBE
boom MBE (3).
82640 2021-04-22 937

19.6.3.5 Fitting the 33 m (108.3 ft) MBE

WARNING
Risk of accidents!
work steps.
938 82640 2021-04-22


An intermediate section is a component part of the 33 m (108.3 ft)

MBE. Depending on the crane delivery, there are two design variants
of the intermediate section:
- Intermediate section (1) with fastening eyes at the front in the top
area for pinning further fly jib components.
- Intermediate section (2) without fastening eyes, front, in the top
area.
It is irrelevant which intermediate section is fitted for the 33 m (108.3
ft) MBE. If the intermediate section with fastening eyes (1) is used, it
must be remembered that the intermediate section (1) in the top area
may not be pinned to the basic boom MBE at the fastening eyes,
even though this is mechanically possible.
DANGER
There is a risk of accidents if the intermediate sec-
tion is pinned to the basic boom MBE in the top area
when fitting the 33 m (108.3 ft) MBE.
Do not pin the basic boom MBE and the intermediate
section in the top area even if it is mechanically possi-
ble.
82640 2021-04-22 939

Fig. 1003: main boom extension 33,0 m (108.3 ft)

Requirements:
sion, side 872).

940 82640 2021-04-22

angles angles
gles:
3. Fit the intermediate section, basic boom and box top piece on
the main boom head in the 0° position (see Fig. 1005,
side 941). See 19.6.3.5.1 Fitting the intermediate section, basic
boom and box top piece on the main boom head in the 0°-posi-
tion, side 943.
Or
Fit the intermediate section, basic boom and box top piece on
the main boom head in the 20°/40° position (see Fig. 1006,
side 941). See 19.6.3.5.2 Fitting the intermediate section, basic
boom and box top piece on the main boom head in the 20°/40°
position, side 946.
ment (HAVHY)
4. For the variant of the main boom extension with hydraulically

smooth operating angle adjustment (HAVHY): fit the intermediate
section, basic boom and box top piece (see 19.6.3.5.3 Fitting
the intermediate section, basic boom of the hydraulic MBE and
box top piece on the main boom head, side 948).
82640 2021-04-22 941

verse sequence.

NOTE
942 82640 2021-04-22

19.6.3.5.1 Fitting the intermediate section, basic boom and box top piece on the
main boom head in the 0°-position
Head, side 912.

1 Basic Boom MBE
82640 2021-04-22 943


5. Fit the tension plates on the head of the intermediate section in

the 0°position and pin. See 19.6.3.4.2.3 Fit the tension plates
at the front on the intermediate section in the 0° position and pin,
side 916.
WARNING
over.
944 82640 2021-04-22


side 918).


side 897).
82640 2021-04-22 945

19.6.3.5.2 Fitting the intermediate section, basic boom and box top piece on the
main boom head in the 20°/40° position
Fig. 1020: Fitting the intermediate section, basic boom and box top piece
1. Fit intermediate section, basic boom and box top piece on the
main boom head in the 0° position as described under
19.6.3.5.1 Fitting the intermediate section, basic boom and box
top piece on the main boom head in the 0°-position, side 943.
Fig. 1021: Preparation for angling
2. Attach the MBE with loop to the auxiliary crane in the front area
of the basic boom.
1 Bolts
3. Using the auxiliary crane, raise the main boom extension careful-
ly until bolts (1) on both tension plates are relieved of load and
can be removed.
946 82640 2021-04-22

1 Bolts 2 Bolts
4. Relocate bolts (1) on both tension plates.

ning hole.
lock) in the 20° pinning hole.
lock) in the transport position hole.

side 883).
82640 2021-04-22 947

19.6.3.5.3 Fitting the intermediate section, basic boom of the hydraulic MBE and box
top piece on the main boom head
Head, side 912.
Fig. 1026: Connecting the intermediate section electrically and hydraulically

(schematic diagram)
2. Electrically and hydraulically connect the intermediate section

with the main boom head. See 19.6.3.4.4.1 Connecting the
electric and hydraulic cables of the intermediate section to the
main boom head, side 925.
1 Basic Boom MBE
948 82640 2021-04-22

4. Fit bolts (1, x 2) in the marked points on the bottom fork heads
and secure against falling out with 2 locking springs (2) each.



side 930.
82640 2021-04-22 949

WARNING
over.
side 897).
950 82640 2021-04-22


NOTE
Risk of damage!
ment.
WARNING
work at height.
82640 2021-04-22 951

WARNING

5 Auxiliary rod
CAUTION
section, starting from the main boom head, over intermediate
section (2), basic boom MBE (3) and box top piece (4) so that
the brackets (see arrows) welded on the top or the side prevent
the fitted sections of hoist rope (1) from falling down. In the area
of the rear basic boom MBE (3), the hoist rope (1) fitted on the
side bracket must be guided by hand over the left draw bar or left
adjusting cylinder on the top of the basic boom.
952 82640 2021-04-22


2. Guide hoist rope (2) over the front rope sheave on intermediate

3 Basic Boom MBE
boom MBE (3).

3 Basic Boom MBE
82640 2021-04-22 953


3 Box top piece

S4 Fixed point
954 82640 2021-04-22

19.6.3.6 Fitting the 35.4 m (116.1 ft) MBE

WARNING
Risk of accidents!
work steps.
1 MBE basic boom - hydraulic (hy- 2 Intermediate section (without fas-

draulically adjustable) tening eyes)
3 Intermediate section (with fas-
tening eyes)
Risk of confusion!
Intermediate sections (2) and (3) are very similar. For the 35.4 m
(116.1 ft) MBE, intermediate section (3) with the fastening eyes on
the top must be fastened to the main boom head.
The 35.4 m (116.1 ft) MBE is only available with hydraulically

smooth operating angle adjustment.
Requirements:
sion, side 872).
82640 2021-04-22 955


ment (HAVHY)
3. Fit the intermediate sections and the basic boom MBE (see
19.6.3.6.1 Fitting the intermediate sections and the basic boom
MBE on the main boom head, side 957).
956 82640 2021-04-22

the Basic Boom of the Main Boom Extension, side 777).
verse sequence.
19.6.3.6.1 Fitting the intermediate sections and the basic boom MBE on the main
boom head

tening eyes)
1. Fit the intermediate section (1) (with fastening eyes) on the main
boom head (see 19.6.3.4.2.1 Fitting the Intermediate Sec-
tion on the Main Boom Head, side 912).
82640 2021-04-22 957

2. Connect the intermediate section to the main boom head electri-

cally and hydraulically (see 19.6.3.4.4.1 Connecting the electric
and hydraulic cables of the intermediate section to the main
boom head, side 925).
Fig. 1047: Fitting the Intermediate Sections
1 Intermediate section without fas- 2 Intermediate section with fasten-

tening eyes, top front ing eyes, top front
3. Using the auxiliary crane, hang intermediate section (without fas-

tening eyes) (1) in front of the intermediate section (with fasten-
ing eyes) (2) at the designated attachment points so that the in-
termediate section (1) can be pinned in the next work step.


958 82640 2021-04-22

Fig. 1049: Connect the intermediate sections
5. Connect the front intermediate section with the rear intermediate

section electrically and hydraulically (see 19.6.3.6.1.1 Connect-
ing the front intermediate section to the rear intermediate section
electrically and hydraulically, side 960).
1 Basic Boom MBE
6. Using the auxiliary crane, hang the basic boom MBE (1) in front
of the intermediate section so that the basic boom MBE (1) can
be pinned to the bottom fork heads in the next work step.
Fig. 1052: Electrically connect the basic boom-MBE

82640 2021-04-22 959


side 930.
WARNING
over.
19.6.3.6.1.1 Connecting the front intermediate section to the rear intermediate sec-
tion electrically and hydraulically
Fig. 1054: Intermediate sections
1 Front intermediate section 2 Hydraulic connection strip

3 Electric connection strip 4 Control panel cable connection
5 Rear intermediate section
1. Connect the cable harness of the front intermediate section (1) to

the corresponding connection of the electric connection strip (3)
of the rear intermediate section (5).
2. Connect the CAN lead of the front intermediate section (1) to the
corresponding connection of the electric connection strip (3) of
the rear intermediate section (5).
3. Connect the mobile control panel cable of the front intermediate
section (1) to the connection (4) of the rear intermediate section
(5).
960 82640 2021-04-22

connect the camera cable from the front intermediate section (1)
with the corresponding connection on the rear intermediate sec-
tion.
5. Connect the hydraulic hoses of the front intermediate section (1)
to the corresponding connection of the hydraulic connection strip
(2) at the front on the rear intermediate section (5).
ment.
WARNING
work at height.
82640 2021-04-22 961

WARNING

3 Intermediate section 4 Basic Boom MBE
5 Auxiliary rod
CAUTION
auxiliary rod (5). The hoist rope (1) is laid over intermediate sec-
tions (2) and (3) and the basic boom MBE (4) section for section,
starting from the main boom head, so that the fitted section of the
hoist rope (1) is prevented from falling down by the brackets (see
arrows) welded on the top and/or the side. In the area of the rear
basic boom MBE (4), the hoist rope (1) placed on the side brack-
et must be guided by hand over the left adjusting cylinder on the
top of the basic boom.
962 82640 2021-04-22

Fig. 1056: Course of rope – intermediate sections

2. Guide hoist rope (2) over the front rope sheave of the rear inter-
mediate section (3), fit rope guard pin (1) and secure against fall-
ing out.

3 Front intermediate section
3. Guide hoist rope (2) over the front rope sheave on the front inter-
mediate section (3). Fit rope guard pin (1) and secure against
falling out.

3 Basic Boom MBE
boom MBE (3).
82640 2021-04-22 963

19.6.3.7 Fitting the 45 m (147.6 ft) MBE

WARNING
Risk of accidents!
work steps.
964 82640 2021-04-22

1 Box top piece 2 MBE basic boom - hydraulic (hy-

draulically adjustable)
3 Intermediate section (without 4 Intermediate section (with fasten-
fastening eyes) ing eyes)
Risk of confusion!
Intermediate sections (3) and (4) are very similar. For the 45 m
(147.6 ft) MBE, intermediate section (4) with the fastening eyes on
the top must be fastened to the main boom head.
The 45 m (147.6 ft) MBE is only available with hydraulically smooth

operating angle adjustment.
Requirements:
sion, side 872).

82640 2021-04-22 965

ment (HAVHY)
3. Fit the intermediate sections, basic boom MBE and box top piece
(see 19.6.3.7.1 Fitting the intermediate sections, basic boom
MBE and box top piece on the main boom head, side 967).
verse sequence.
966 82640 2021-04-22

19.6.3.7.1 Fitting the intermediate sections, basic boom MBE and box top piece on
the main boom head

tening eyes)
1. Fit the intermediate section (1) (with fastening eyes) on the main
boom head (see 19.6.3.4.2.1 Fitting the Intermediate Sec-
tion on the Main Boom Head, side 912).
2. Connect the intermediate section to the main boom head electri-

cally and hydraulically (see 19.6.3.4.4.1 Connecting the electric
and hydraulic cables of the intermediate section to the main
boom head, side 925).

3. Using the auxiliary crane, hang intermediate section (without fas-

tening eyes) (1) in front of the intermediate section (with fasten-
ing eyes) (2) at the designated attachment points so that the in-
termediate section (1) can be pinned in the next work step.
82640 2021-04-22 967



Fig. 1070: Connecting the intermediate sections
5. Connect the front intermediate section with the rear intermediate

section electrically and hydraulically (see 19.6.3.6.1.1 Connect-
ing the front intermediate section to the rear intermediate section
electrically and hydraulically, side 960).
1 Basic Boom MBE
6. Using the auxiliary crane, hang the basic boom MBE (1) in front
of the intermediate section so that the basic boom MBE (1) can
be pinned to the bottom fork heads in the next work step.
968 82640 2021-04-22

Fig. 1073: Electrically connect the basic boom-MBE


side 930.
WARNING
over.
82640 2021-04-22 969

side 897).
1 Intermediate section 2 Mobile control panel cable

14. Remove the cable (2) of the mobile control panel of the rear in-
termediate section (1) from the front left electric connection (3)
on the basic case of the main boom.
NOTE
Risk of damage!
970 82640 2021-04-22

ment.
WARNING
work at height.
82640 2021-04-22 971

WARNING

3 Intermediate section 4 Basic Boom MBE
5 Box top piece 6 Auxiliary rod
CAUTION
section, starting from the main boom head, over intermediate
sections (2) and (3), basic boom MBE (4) and box top piece (5)
so that the brackets (see arrows) welded on the top or side pre-
vent the fitted sections of hoist rope (1) from falling down. In the
area of the rear basic boom MBE (4), the hoist rope (1) placed
on the side bracket must be guided by hand over the left adjust-
ing cylinder on the top of the basic boom.
972 82640 2021-04-22


ing out.

3 Front intermediate section
3. Guide hoist rope (2) over the front rope sheaves on the front in-
termediate section (3). Fit rope guard pin (1) and secure against
falling out.

3 Basic Boom MBE
boom MBE (3).
82640 2021-04-22 973


3 Basic Boom MBE

3 Box top piece
974 82640 2021-04-22


S4 Fixed point
19.6.3.8 Converting from One Length to Another

In order to convert the main boom extension from one length to an-
other, it might be necessary to first dismantle the MBE components of
the "original length" in accordance with the corresponding section; or
already assembled components can be fitted. Then the "desired
length" is created in accordance with the corresponding section.
82640 2021-04-22 975

19.7 Positioning / Reeving the Hoist Rope

The main boom can be luffed down to carry out the work described in
the following. Work that cannot be carried out from the ground may
only be carried out using suitable auxiliary equipment (e.g. supplied
multi-purpose ladder, hoist platform).
WARNING
work at height.
WARNING
Prerequisites:
- Main boom extension fitted to the main boom. Procedure for fitting
the main boom extension as described in the corresponding sec-
tion.
976 82640 2021-04-22

Fig. 1085: MBE lengths
front
5 Hoist rope
The rope guidance of the hoist rope (5) depends on the length of the
main boom extension fitted (MBE).
19.7.1 Fitting the Hoist Rope on the Main Boom Extension:

The procedure for fitting the hoist rope on the 33 m (108.3 ft) MBE is
described as an example below. The description applies analogously
for other MBE lengths.
1. Unreel hoist rope about 3 m (10 ft) longer than the length of the
main boom extension.
82640 2021-04-22 977


5 Auxiliary rod
CAUTION
section, depending on the length of the fitted main boom exten-
sion, starting from the main boom head, over intermediate sec-
tion (2), basic boom MBE (3) and box top piece (4) so that the
brackets (see arrows) welded onto the top or the side prevent the
fitted section of hoist rope (1) from falling down. In the area of the
rear basic boom MBE (3), the hoist rope (1) fitted on the side
bracket must be guided by hand over the left draw bar or left ad-
justing cylinder on the top of the basic boom.
19.7.2 Fitting the hoist rope on the main boom head
Fig. 1087: Course of rope on the main boom head
1 Sheave 2 Rope guard

E2 Intake sheave
1. Remove forelock (3).

2. Pull out rope sheave (1) sideways.
978 82640 2021-04-22

3. Guide hoist rope (4) over intake sheave (E2).

4. Slide rope sheave (1) back in and secure against falling out with
forelock (3).
5. Fold entire rope guard protection (2) upwards.
19.7.3 Fitting the front hoist rope on the rear intermediate section (35.4 m / 116.1 ft
and 45 m / 147.6 ft MBE)

ing out.
19.7.4 Fitting the hoist rope at the front on the intermediate section to which the ba-
sic boom MBE is attached (23.4 m / 76.8 ft MBE, 33 m / 108.3 ft MBE, 35.4 m /
116.1 ft MBE and 45 m / 147.6 ft MBE)
Fig. 1089: Course of rope on the intermediate section

1. Guide hoist rope (2) over the front rope sheave of intermediate
82640 2021-04-22 979

19.7.5 Fitting the hoist rope to the rear rope sheave of the basic boom MBE (all MBE
variants)
Fig. 1090: Course of rope, basic boom MBE (schematic diagram)

3 Basic Boom MBE
boom MBE (3).
980 82640 2021-04-22

19.7.6 Fitting the hoist rope at the front on the basic boom MBE (11.4 m / 37.4 ft
MBE, 23.4 m / 76.8 ft MBE and 35.4m / 116.1ft MBE)
Fig. 1091: Course of rope, basic boom MBE

S2 Fixed point

and handling the hazard light (1) and anemometer (2) in 8.6 Elec-
tric Safety Chain, side 361.
1. Guide the hoist rope (3) over the two front rope sheaves of the
basic boom MBE, fit rope guard pins (4), reeve the hook block
(see section "Reevings"), fit and electrically connect the hoist lim-
it switch with shift weight in the functioning condition, the hazard
light and rotor of the wind speed indicator.
82640 2021-04-22 981

19.7.7 Fitting the hoist rope at the front on the basic boom MBE (21 m / 68.9 ft MBE,
33 m / 108.3 ft MBE and 45 m / 147.6 ft MBE)
Fig. 1092: Course of rope, basic boom MBE

3 Basic boom
Guide hoist rope (1) over the top front rope sheave of the basic boom
(3). To do so, first remove rope guard pin (2), fit hoist rope (1) on the
rope sheave and refit rope guard pin (2).
982 82640 2021-04-22

19.7.8 Fitting the hoist rope to the box top piece (21 m / 68.9 ft MBE, 33 m / 108.3 ft
MBE and 45 m / 147.6 ft MBE)
Fig. 1093: Course of rope - box top piece

3 Rope guard pin 4 Box top piece
S4 Fixed point
With two-fold reeving, the rope socket of the hoist rope end must be
fastened at the point marked 'S4' on box top piece (4).

and handling the hazard light (1) and anemometer (2) in 8.6 Elec-
tric Safety Chain, side 361.
1. Guide the hoist rope via the rope sheave of the box top piece (4),
fit rope guard pins (3; 2x), reeve the hook block (see section
"Reevings"), fit the hoist limit switch with shift weight in operating
condition and fit the hazard light and rotor of the wind speed indi-
cator.
82640 2021-04-22 983

19.8 Adjustment of the operating angle for fitted MBE
19.8.1 Adjusting the operating angle - Instructions on risks and general instructions
Main boom extension with fixed operating angles
The crane can be operated with an MBE with fixed operating angles
at an angle of 0°, 20° or 40° to the main boom's longitudinal axis.
Fig. 1094: MBE 11.4 m (37.4 ft) Fig. 1095: MBE 21.0 m (68.9 ft)
For the 11.4 m / 37.4 ft MBE (see Fig. 1094, side 984) and the 21
m / 68.9 ft MBE (see Fig. 1095, side 984), the main boom extension
is angled on the head of the main boom.
Fig. 1096: 23.4 m / 76.8 ft MBE Fig. 1097: MBE 33 m / 108.3 ft
For the 23.4 m / 76.8 ft MBE (see Fig. 1096, side 984) and 33 m /
108.3 ft MBE (see Fig. 1097, side 984), the main boom extension is
angled at the front on the intermediate section.
984 82640 2021-04-22

Sliding of the main boom extension along the ground with MBE
with fixed operating angles (which are angled at the back on the
basic boom)
Fig. 1098: Basic Boom MBE Fig. 1099: Box top piece
When setting the operating angle, the basic boom MBE (see
Fig. 1098, side 985) or the box top piece (see Fig. 1099,
side 985) slides on the ground. Wooden blocks are put down for slid-
ing to prevent damage to the main boom extension or to prevent the
main boom extension from digging into the ground if the ground is
soft. The wooden blocks must have a cross section of 10 cm x 10 cm
(4 in x 4 in) and a minimum length of 180 cm (71 in). Two wooden
blocks are required which are placed next to each other. If the hoist
rope is lying on the main boom extension during the corresponding
operating step, it must be pulled to the side.
NOTE
Risk of damage for the hoist rope.
Te hoist rope must be placed to the side before the basic boom
MBE (see Fig. 1098, side 985) or box top piece touches the
ground. When sliding on the ground, it must be ensured that the
hoist rope does not get under the sliding surfaces.
hydraulic luffing main boom extension

In the case of the variants of the main boom extension which are an-
gled hydraulically and smoothly at the back of the basic boom MBE
(2) (HAVHY), the angle adjustment is done by means of the crane hy-
draulics (see 19.8.3 Setting the Operating Angle on the Hydraulical-
ly Luffing MBE ("HAVHY"), side 1003).
82640 2021-04-22 985

Pins support and control panel at the basic boom MBE (sche-
matic diagram)
Fig. 1100: Pins support and control panel (schematic diagram)
The pins can be removed and attached to a transport support for

these operating procedures and for transportation. Depending on the
design of the transport support, the mobile control panel can be tem-
porarily fitted with its handle side in the transport support during the
corresponding operating procedures.
19.8.2 On basic booms of the MBE with fixed operating angles: change from 0 - de-
gree to 20 -/ 40 - degree position (and vice versa)
In order to structure the work steps for switching from the 0° position
to the 20° - / 40° position (and vice versa), the work steps are grou-
ped below by component groups or topics. Reference is made to the
segment in which the work steps are described in detail. The hazard
risks in these combined work steps are described in the correspond-
ing subsection.
WARNING
Risk of accidents!
work steps.
986 82640 2021-04-22

Rear angling point at the basic boom MBE
Fig. 1101: Basic boom MBE 0° operating angle
1 Pin 2 Pin
F/H Pinning point, upper head axle G/I Pinning point, lower head axle
- two pins (1) on the tension plates in points (F) and (H)
- two pins (2) on the fork heads in points (G) and (I)
CAUTION
Risk of accidents!
After setting the operating angle, make sure that the
described pins are fitted and secured against falling
out.
The procedure for switching over from the 0° position into the 20 ° /
40° position (and vice versa) is the same for all main boom extension
(MBE) lengths in principle. However, in the figures in this section, only
assembly states without intermediate section are shown. For switch-
ing over the operating angle, 2 wooden blocks are required with a
cross section of 10 cm x 10 cm (4 in x 4 in) and a minimum length of
180 cm (71 in).
82640 2021-04-22 987

Prerequisites:
- Crane assembled in accordance with the subsequent configuration
(apart from the operating angle of the main boom extension) with
the main boom extension; parameters of operating mode set ac-
cordingly to crane control.
- MBE fitted in the 0° operating position on the main boom head (0°
operating position as described under 19.8.1 Adjusting the oper-
ating angle - Instructions on risks and general instructions,
side 984)
- Superstructure slewed in the 0°- , 90°- or 270° position

- The section "Instructions on risks and general instructions" (see
19.8.1 Adjusting the operating angle - Instructions on risks and
general instructions, side 984) has been read and understood.
Fig. 1103: Preparations for angling the MBE
1. Make preparations for angling the main boom extension (see

19.8.2.1 Making Preparations for Angling the Main Boom Exten-
sion, side 990).
988 82640 2021-04-22

Fig. 1104: Angling the MBE
Depending on the angling state:

2. move the tension plates from the 0° position and place them in
the 20° / 40° position. See 19.8.2.2 Moving the tension plates
from the 0° position into the 20° / 40° position, side 992.
Or
Move the tension plates from the 0° position and place them in
the 20° / 40° position. See 19.8.2.3 Moving the tension plates
from the 20° / 40° position into the 0° position, side 998.
Fig. 1105: Remaining work on the main boom and MBE
3. Carry out the remaining work on the main boom and MBE. See
19.8.2.4 Carrying out the remaining work on the main boom and
MBE, side 1000.
Fig. 1106: "Operating Mode Selection" Screen
4. Set the operating angle in the "Selection of the operating mode"

screen.
82640 2021-04-22 989

19.8.2.1 Making Preparations for Angling the Main Boom Extension

2. Set the hook block down on the ground and unreeve (see the
section "Reevings" at "Hook blocks").
NOTE
Risk of damage!
Lay the end of the hoist rope on the ground so that the hoist
rope does not get into the gap between the MBE and the ground
when sliding the MBE along the ground in the following proce-
dure.
3. Proceed as described below to place the hoist rope in a safe po-

sition:
3.1. For 11.4 m / 37.4 ft MBE and 23.4 m / 76.8 ft MBE: re-
move bottom rope guard pin and pull the hoist rope to
the front.
3.2. For 21 m / 68.9 ft MBE and 33 m / 108.3 ft MBE: re-

move bottom rope guard pin and pull the hoist rope to
the front.
990 82640 2021-04-22

Fig. 1107: Removing the hoist limit switch
1 Hoist limit switch 2 Shift weight
4. Remove hoist limit switch (1) together with shift weight (2) from
the basic boom or box top piece.
Fig. 1108: Basic boom MBE with box top piece
tube of the basic boom (2) and for MBE variants with box top
(71 in).
When the main boom extension is angled, the main boom extension
is set on the wooden blocks and slides over them during the following
horizontal alignment of the main boom.
NOTE
Before the main boom extension touches the ground, ensure
that the hoist rope is not crushed between the main boom ex-
tension and the ground.
82640 2021-04-22 991

For the 23.4m (76.8ft ) MBE and the 33m (108.3ft) MBE:
Fig. 1109: Electric connection on the intermediate section (schematic diagram)

7. At the rear of the intermediate section (1): connect the connect-

ing line (2) of the mobile control panel with the electric connec-
Fig. 1111: Electric connections for mobile

control panel (schematic diagram)
2 Fastening rope
8. Fit the mobile control panel (see Fig. 1110, side 992) on the
basic case of the main boom (11.4 m / 37.4 ft MBE and 21 m /
68.9 ft MBE) or at the front on the intermediate section (23.4 m /
76.8 ft MBE and 33 m / 108.3 ft MBE):
8.1. Connect the mobile control panel to electric connection (1)
(see Fig. 1111, side 992).
the bracket using the carabiner hook. There is also a cara-
biner hook on the free end of fastening rope (2) which is
attached to the mobile control panel.
19.8.2.2 Moving the tension plates from the 0° position into the 20° / 40° position
992 82640 2021-04-22

Fig. 1112: Carrying out fitting of the tension plates (schematic diagram)

plates, side 754.
Fig. 1113: Move the bolts from the 0° position into the 20°/40° position (schematic
diagram)
2. Move the bolts from the 0° position into the 20°/40° position (on
the main boom head). See 19.8.2.2.1 Moving the bolts from
the 0° position into the 20°/40° position (on the main boom
head), side 995.
Or
Move the bolts from the 0° position into the 20°/40° position (on
the head of the intermediate section). See 19.8.2.2.2 Moving
the bolts from the 0° position into the 20°/40° position (on the
head of the intermediate section), side 997.
Fig. 1114: Setting the MBE down on the ground
3. Lower the main boom extension onto the ground. See

19.5.4.1.1.8.2 Lowering the main boom extension onto the
ground, side 766.
82640 2021-04-22 993

Fig. 1115: Hydraulic hoses (schematic diagram)
NOTE
or of the intermediate section firmly to the load relief connection.
NOTE
Risk of damage!
cylinder of the basic boom MBE are connected with the main boom.
4. Remove the hydraulic hoses of the basic boom of the MBE or of

the intermediate section from the front on the main boom and
firmly connect them to the basic boom or the intermediate sec-
tion in the quick-release couplings of the load relief connection.
994 82640 2021-04-22

19.8.2.2.1 Moving the bolts from the 0° position into the 20°/40° position (on the main
boom head)

sheave
82640 2021-04-22 995

Fig. 1118: Retracting the auxiliary cylinder

"A" Pinning point
3. Retract auxiliary cylinder until the bolt can be released in point

"A" and removed. To do so, press rocker switch (2) in the mobile
position "1").
1 Bolts 2 Bolts
4. At both tension plates, repin bolts (1):

ning hole.
996 82640 2021-04-22

19.8.2.2.2 Moving the bolts from the 0° position into the 20°/40° position (on the head
of the intermediate section)
1 Auxiliary cylinder 2 Main boom

3 Lifting beam 4 Lifting beam
The procedure basically corresponds to that of section

19.5.4.1.2.3.1 Engaging the auxiliary cylinder (0°), side 791. The aux-
iliary cylinder (1) is fitted to the cross beam (4) at the intermediate
section (5) instead of at the cross beam (3) at the main boom (2).
Fig. 1121: Rope slip-off protection sheave of the intermediate section
1 Rope slip-off protection sheave

of the intermediate section
The rope guard pin (3) of the front rope sheave on the intermediate
section which is specifically suited for this procedure is used to con-
nect the auxiliary cylinder with the cross beam on the intermediate
section.
82640 2021-04-22 997

19.8.2.3 Moving the tension plates from the 20° / 40° position into the 0° position
Requirements:
- The main boom extension is lying on the ground
Fig. 1122: Preparations for dismantling the tension plates

plates, side 754.
2. Engage the auxiliary cylinder (20° / 40°). See 19.5.4.1.2.4.1

Engaging the auxiliary cylinder (20° / 40°)., side 799.
3. Pin tension plates for 0° crane operation and relieve auxiliary cyl-
inders as described in 19.5.4.1.1.7.3 Pinning the tension plates
for 0°- crane operation / relieving the auxiliary cylinders of load,
side 757.
998 82640 2021-04-22

gram)
NOTE
NOTE
Risk of damage!
cylinder of the basic boom are connected with the main boom.
82640 2021-04-22 999

19.8.2.4 Carrying out the remaining work on the main boom and MBE
For the 23.4m (76.8ft ) MBE and the 33m (108.3ft) MBE:
Fig. 1125: Electric connection on the intermediate section (schematic diagram)



rope from the front of the basic case of the main boom or from
the front of the intermediate section.

basic case of the main boom or on the intermediate section.
NOTE
When sliding the main boom extension along the ground, en-
sure that the hoist rope does not get under the sliding surfaces.
3. Luff the main boom up until the main boom extension is raised
off the ground. While this is done, the main boom extension
slides over the wooden blocks which have been placed under-
neath.
1000 82640 2021-04-22

Fig. 1126: Rope attachment points with 2-fold reeving
S2 Hoist rope fixed point S4 Hoist rope fixed point
With two-fold reeving, the rope lock of the hoist rope end must be
fastened in point (S2) on the basic boom MBE or in point (S4) on the
box top piece. Pay attention to the fitting position of the rope socket
in the box top piece.
82640 2021-04-22 1001

Fig. 1127: Hoist limit switch assembly

H Connection
5. Fit hoist limit switch (1) together with shift weight (2) in functional
configuration on the basic boom or box top piece and connect
electrically:
5.1. On the right-hand side, slide the hoist limit switch (1) over
the bolts that have been welded on and secure it against
falling out using safety pins.
5.2. Guide the hoist rope through the opening on the shift
5.3. Connect the plug of the hoist limit switch (1) to the connec-
tion (H) of the respective junction box.
Fig. 1128: Hoist limit switch in functional

configuration
The figure (see Fig. 1128, side 1002) shows the hoist limit switch
in the functioning condition. 8.6.3.3.2 Placing the hoist limit switch
in the functional state, side 368 describes how the hoist limit switch
is moved into the functional configuration.
6. Check that all bolts and locking elements are fitted correctly.
1002 82640 2021-04-22

19.8.3 Setting the Operating Angle on the Hydraulically Luffing MBE ("HAVHY")
19.8.3.1 Instructions on Risks and General Instructions
Fig. 1129: Main boom extension (schematic diagram)
1 Adjusting cylinder 2 Basic Boom MBE
Crane operation with the hydraulically luffing main boom extension

can be carried out variably at an angle of 0° to 40° to the main boom
longitudinal axis. The angle is adjusted by angling the basic boom
MBE (2). To do so, the two adjusting cylinders (1) are telescoped in
and out.
The load capacity tables which are delivered with the crane are divi-
ded into five angle levels: 0°, 10°, 20°, 30° and 40° to the main
boom's longitudinal axis. If a load is to be raised at an angle between
two angle levels (e.g. 25°), the corresponding permitted maximum ca-
pacity is calculated by crane control (interpolated). The permitted
maximum capacity is displayed in the "Crane operation" screen in the
MAX (t) field.
82640 2021-04-22 1003

WARNING
Danger of accidents through residual hydraulic ener-
gy!
When the main boom extension is removed, strong
pressures (up to a maximum of 265 bar / 3844 psi)
may build up (sunlight) on the adjusting cylinders (1).
For that reason, the pressure must be reduced appro-
priately by correspondingly qualified personnel before
repair and/or replacement work is carried out!
19.8.3.2 Procedure
Starting point:
- MBE pinned in the operating position (0°), both angle adjustment
cylinders pinned to the main boom head with pins.
- Hoist rope laid over the deflection rollers and/or carriers on the
main boom and/or main boom extension
Press the depicted button to angle the main boom extension, i.e. the
operating angle is set. If the top half of the button is pressed, the main
boom extension is luffed down, i.e. the folding-down angle is in-
creased.
If the bottom half of the button is pressed, the main boom extension is
luffed up, i.e. the folding-down angle is reduced.
1004 82640 2021-04-22

19.8.3.3 Display on crane control
1 Minimum / maximum bending 2 Additional symbol "Main boom

angle reached extension (can be luffed hydrauli-
cally)"
3 Head angle of the main boom 4 Bending angle of the main boom
extension (can be luffed hy- extension (can be luffed hydrauli-
draulically) cally)
Display of status information on the hydraulic luffing MBE (HAVHY)

1 Display: minimum / maximum bending angle (0° / 40°) achieved
Load limit device will shut down.
LLD shutdown of the crane's "luff up" movement bridged.
Display: Additional symbol "Main boom extension (can be luffed hydraulical-

2
ly)"
Display: Head angle of the main boom extension (can be luffed hydraulical-
3
ly) to the horizontal
Display: Bending angle of the main boom extension (can be luffed hydrauli-
4
cally) to the main boom
82640 2021-04-22 1005

19.8.3.4 Setting the Operating Angle at the Radio Remote Control
Fig. 1131: MBE in the load-raising position (schematic diagram)
Requirements:
- Crane with fitted MBE is in the load raising position
- Radio remote control put in operation. To do so, see the section
"Commissioning the radio remote control" in the section "Radio re-
mote control".
Fig. 1132: Radio Remote Control
1. Set the appropriate control lever assignment at the radio remote

control, with which the operating angle of the MBE can be set.
See the section "Control lever assignment" in the section "Radio
remote control".
2. Set the operating angle at the control levers of the radio remote
control in accordance with the control lever assignment. To do
so, see the section "Radio remote control".
1006 82640 2021-04-22

19.9 Dealing with faults
19.9.1 Emergency Set down in the Case of Telescoping Problems

If it is not possible to telescope in the main boom as the result of a
fault, the main boom must be emergency lowered.
Depending on the state of assembly (outriggers, counterweight), the
main boom can be set down directly. Otherwise an auxiliary crane
must be used to assist. Corresponding instructions will be given on
enquiry.
19.9.2 Retracting the hydraulic cylinders on the basic boom of the MBE
This procedure only has to be carried out if the check before fitting
has shown that the hydraulic cylinders have been extended too far.
Fig. 1133: Hydraulic valve (schematic diagram)
1. For the main boom extension with fixed operating angles: Set the
hydraulic valve on the right-hand side of the main boom for oper-
ation of the auxiliary cylinder for setting the tension plates.
gram)
2. For the main boom extension with fixed operating angles: Fit the
hydraulic hoses from the basic boom of the MBE to the flange of
the basic case.
82640 2021-04-22 1007

C CAN connection C1 CANBUS terminating plug
Before the CAN lead is connected in the MBE with hydraulic contin-
uous operating angle adjustment (HAVHY) in the next work step, the
engine ignition must be switched off (if this has not already been
done). Otherwise, there will be fault messages in crane control. If
the CAN lead was accidentally connected with the ignition switched
on, the corresponding fault message can be deleted by switching off
the ignition.

ment (HAVHY): Connect the plug of the basic boom MBE CAN
line to connection (C) on distribution box "X0550" on the left-
hand side of the main boom head.
Note on MBE with fixed operating angles (design with tension

plates): Connection (C) remains fitted with the CAN BUS terminating
plug (C1).
4. For the MBE with hydraulically smooth operating angle adjust-

ment: Dismantle hydraulic hoses (1; x 2) to the hydraulic connec-
tions (2) on the left-hand side of the main boom head.
1008 82640 2021-04-22

Fig. 1137: Retract the hydraulic cylinders

3 Rocker switch
5. Retract the hydraulic cylinders. To do so, select either rocker

switch (2) (press selector switch (1) in position "2") in the mobile
control panel. Alternatively, press rocker switch (3) in the crane
operator's cab for the HAVHY.
Fig. 1138: Terminal box

A Connection
C Connection
C1 CAN BUS terminating plug
6. For the hydraulic luffing MBE (HAVHY): Remove the CAN plug of
the MBE from connection (C) and fit the CAN-BUS terminating
plug (C1).
For the main boom extension with fixed operating angles:
7. Remove the hydraulic hoses from the basic boom of the MBE on
the basic case flange and position them on the basic boom so
that the hose ends do not touch the ground.
82640 2021-04-22 1009

Fig. 1139: Hydraulic hoses of the main boom extension
8. For the MBE with hydraulically smooth operating angle adjust-

ment: Dismantle hydraulic hoses (1; x 2) from the hydraulic con-
nections (2) on the left side of the head of the main boom and
position them on the basic boom so that the hose ends do not
touch the ground.
19.10 Main Boom Extension with Load Hook Camera / Hanging Light (Optional)
19.10.1 General Information / Operation

This segment describes how the optional load hook camera and the
optional hanging light, as described in the section "Working instruc-
tions", are used on the MBE. Use and operation of the load hook
camera and hanging light are described in the section "Working in-
structions".
Fig. 1140: Load hook camera / hanging light (schematic diagram)
The illustration shows one form of the load hook camera. The specifi-
cations apply to other types of camera in turn.
The load hook camera / hanging light are fitted on the respective top
section of the MBE in relation to the length of the fitted main boom ex-
tension. Depending on the structure of the MBE, this can be either
basic boom MBE (1) or box top piece (2).
1010 82640 2021-04-22

CAUTION
Risk of collision with the load hook camera or hang-
ing light fitted.
Observe the instructions below on the subject 'risk of
collision'.
To prevent a collision with other component groups of the crane, the

load hook camera and the hanging light may only be fitted once the
main boom extension is fitted in the operating position at the front on
the main boom head.
For the MBE with fixed operating angles, the load hook camera and
the hanging light should only be fitted after the operating angle has
been set to prevent a collision with the ground.
19.10.2 Assembling / Dismantling the Load Hook Camera
Fig. 1141: Load hook camera on the MBE (schematic diagram)
The load hook camera is fitted on the MBE (basic boom MBE or box
top piece) in the operating position on the front left. There is a corre-
sponding bracket on the respective parts of the MBE.
82640 2021-04-22 1011

Fig. 1142: Load hook camera on MBE (schematic diagram)
1 Hook camera 2 Bracket
1. Insert the load hook camera (1) with the shaft of the hanging
bracket into bracket (2) of the MBE.
Fig. 1143: Load hook camera on MBE (schematic diagram)
1 Hook camera 2 Locking spring

3 Safety chain
2. Secure load hook camera (1) using locking spring (2) fastened to
safety chain (3).
1012 82640 2021-04-22

Fig. 1144: Attachment point of load hook camera on MBE (schematic diagram)
1 Safety chain
WARNING
Risk of accidents!
The load hook camera may not be operated without
fall protection (safety chain (1)).
3. Fasten trigger snab of safety chain in the corresponding hole of

the MBE.
82640 2021-04-22 1013

Fig. 1145: Connection (schematic dia-

gram)
4. Connect the front end of the camera cable of the basic boom
MBE or of the box top piece with the connection (see arrow in
Fig. 1145, side 1014) on the load hook camera.
Dismantling is carried out in the same manner, but in the opposite

order.
When dismantled, the camera must be transported in such a way

that the camera cable connection cannot get wet.
1014 82640 2021-04-22

19.10.3 Assembling / Dismantling the Hanging Light

The following equipment is in place if the main boom extension is pre-
pared for fitting a hanging light:
Fig. 1146: Pendant light on the MBE (schematic diagram)
1 Bracket 2 Pendant light
- Brackets (1) for assembling hanging light (2) at the front on the ba-
sic boom MBE and on the box top piece
Fig. 1147: Distribution box "X0560" Fig. 1148: Distribution box "X0561"
L Electric connection L Electric connection
- Electric connection (L) on distribution boxes "X0560" (basic boom

MBE) and "X0561" (box top piece)
82640 2021-04-22 1015

Fig. 1149: Hanging light on the MBE
1 Pendant light 2 Bracket
1. Plug in the hanging light (1) on the bracket (2).
Fig. 1150: Hanging light on the MBE
1 Pendant light 2 Locking spring
NOTE
Locking springs (2) must be inserted into bracket from below.
Otherwise there is a risk of collision with the bracket of the
hanging light during crane operation.
2. Secure hanging light (1) with locking spring (2).
1016 82640 2021-04-22

Fig. 1151: Distribution box "X0560" Fig. 1152: Distribution box "X0561"
L Electric connection L Electric connection
3. Connect the plug of the hanging light with connection (L) on dis-
tribution box "X0560" on the basic boom MBE or "X0561" on the
box top piece.
Disassembly is performed analogously in the reverse direction.
When dismantled, the hanging light must be transported in such a

way that the electric cable connection cannot get wet.
82640 2021-04-22 1017

1018 82640 2021-04-22

20 Radio Remote Control (Optional)
20.1 Intended use
Fig. 1153: Radio transmitter
1 Radio transmitter 2 Radio Receiver
The radio remote control essentially consists of radio transmitter (1)

and radio receiver (2). It is used to control machines and for data
transmission. The occupational safety and accident prevention regu-
lations valid in each case must be complied with.
Proper application in accordance with regulations also includes read-
ing the operating instructions and following all safety instructions con-
tained therein.
WARNING
There is a risk of accidents when the radio remote
control is used in a manner that is not in line with
regulations.
The radio remote control may not be used in an area at
risk of explosions or to control machines for passenger
transport unless these types of use have been expressly
permitted by the manufacturer of the radio remote con-
trol. This can cause death, serious injury to persons and
extensive damage to property.
Do not use the radio remote control in areas at risk of
explosions.
Do not use the radio remote control to control ma-
chines used for the conveyance of passengers.
82640 2021-04-22 1019

WARNING
There is a risk of accidents if unauthorised changes
are made to the radio remote control.
Have specialist personnel, trained and authorised by
the manufacturer of the radio remote control, carry
out any changes.
Record all changes ex works in the master file of the
radio remote control.
Safety devices belonging to the radio remote control
may not be modified, removed or bypassed.
In particular, modifications to the entire emergency
stop system of the radio remote control are prohibi-
ted.
20.2 Safety Instructions

Read the following instructions and the operating instructions of the
manufacturer of the radio remote control carefully before working with
it. This is also particularly important for the installation, commissioning
and maintenance of the radio remote control system. The operating
instructions are part of the radio remote control system and must be
kept accessible for the responsible personnel at all times.
WARNING
There is a risk of accidents when operating the radio
remote control when it is not in faultless condition.
Only operate the radio remote control when it is in a
technically faultless condition.
Have faults and malfunctions which could impair safe-
ty repaired by specialist personnel trained and au-
thorised by the manufacturer of the radio remote con-
trol before starting operation again.
Use only original spare parts and accessories (e.g.
batteries), as otherwise the safety of the machine
could be impaired and the extended warranty will not
apply.
1020 82640 2021-04-22

DANGER
Risk to life and limb due to live components when
opening the radio receiver.
Components in the interior of the receiver could be live
which is potentially a risk to life. Contact with current-car-
rying parts causes injuries or death.
Switch off the supply voltage of the machine before
opening the receiver.
The receiver must only be opened by trained person-
nel.
WARNING
Risk to life and limb for personnel standing in the
hazardous area of the crane!
It is prohibited for persons to be in the danger zone -
particularly under the load. This also specifically ap-
plies to the operator of the radio remote control.
Select a safe location to operate the radio remote
control. The operating movements of the machine,
the load movements and the surrounding operating
conditions must be fully visible from there.
If necessary, employ a banksman.
WARNING
There is a risk of accidents if accidental crane move-
ments are carried out.
If the radio remote control is switched on and not super-
vised, it can cause accidental crane movements. This
can also occur out of sight of the crane. This can result in
death and serious injuries.
A radio transmitter which has been switched on may
not remain unsupervised.
When not using the radio transmitter, always switch it
off. This is particularly important when you change
your location, when working without the radio remote
control, during operating breaks or at the end of oper-
ation.
Always keep the radio transmitter safe from use by
unauthorised persons, e.g. lock it away or remove the
key and store it safely.
82640 2021-04-22 1021

WARNING
There is a risk of accidents due to particular hazards
when using the radio remote control.
The occupational safety and accident prevention reg-
ulations valid in each case must be complied with.
Only authorised persons who are trained accordingly
are permitted to work with the radio remote control.
Become acquainted with the functions of the radio re-
mote control and operate it cautiously. This is particu-
larly important when working with it very infrequently
or for the first time.
Keep in mind that the movement directions of the op-
erating elements can appear to be interchanged, de-
pending on location and viewing angle to the ma-
chine.
Only operate the radio transmitter using the harness
supplied in the scope of delivery. This prevents the
risk of confusion with regard to the operating ele-
ments.
1 Status LED 2 Quick STOP switch
In case of an emergency or if there are any faults, switch the radio

transmitter off immediately by actuating the quick stop switch (2).
1022 82640 2021-04-22

WARNING
There is a risk of accidents if the quick stop switch
malfunctions.
If the quick stop switch does not function, immediate
shutdown of the engine is not ensured in emergencies.
Check the function of the quick stop switch before
starting any work (as described below).
Actuate the quick stop switch with the transmitter switched on to

check the function of the quick stop switch. Then the status LED and
the displays in the transmitter go out.
If the status LED and the displays do not go out, the radio remote
control must be taken out of operation immediately. To do so, remove
the battery and the electronic key from the transmitter immediately
and contact the customer service team.
If the crane is equipped with the optional quick stop device with air
shut-off valve, unlock the shut-off valve manually (see section "En-
gine" in "Quick stop device with air shut-off valves (optional)").
82640 2021-04-22 1023

20.3 General
1 Radio transmitter, portable, with 2 Radio Receiver

control panel
The radio remote control essentially consists of the two depicted com-
ponents.
Fig. 1156: Radio transmitter with control panel
1 Key radiomatic iON 2 Start button
The transmitter is equipped with an electronic radiomatic iON key (1).

The radiomatic iON contains all of the data required for operation of
the transmitter. Operation is not possible without radiomatic iON.
Depending on the design, the radiomatic- iON can also be used for
operation of replacement transmitters which are identical in construc-
tion. The transmitter is also equipped with a start button (2).
When the radio link is activated or interrupted (e.g. in the case of net-
work failure or if the range is exceeded), the radio remote control will
respond by automatically returning to the zero position.
Release all operating elements so they can return to the zero position
and press the start button (2). Only then will the crane respond to ra-
dio commands again. This prevents any uncontrolled crane move-
ments after a disruption to the radio link.
All crane movements can be "remote controlled" from outside the cab
using this radio remote control.
Any activation of a crane function using this radio remote control unit
corresponds exactly to the corresponding operation of crane move-
ments using the operating elements in the cab.
1024 82640 2021-04-22

WARNING
There is a risk of accidents due to a time delay in the
response time of the crane.
The minimum response time for a command and the re-
sponse time of the crane are marginally increased by the
radio remote control. The time delay between releasing
the control lever and the cessation of movement can be
particularly dangerous for the person handling the load
when attaching and removing the load.
In this case, operate the radio remote control with
particular care and with foresight in mind.
WARNING
There is a risk of accidents due to self-actuating
turning of the crane superstructure if the slew gear
brake is not closed.
If a work step has been completed with the radio re-
mote control, you must close the slew gear brake
(parking brake).
WARNING
Risk of accidents due to operating the radio remote
control in case of faults in the operating range.
In the case of a defect, an emergency or if there are
any faults in the operating range, switch off the radio
remote control immediately until the fault can be recti-
fied.
The orange lamp behind the crane operator's cab starts to flash if the
radio remote control is switched on.
20.4 Radio Receiver

The radio receiver is on the superstructure.
It must be ensured that neither the radio receiver nor the antenna
come into contact with any other objects. The antenna's fitting loca-
tion can also be separate from the radio receiver - deviating from the
figure.
82640 2021-04-22 1025

There are five indicator lights (LEDs) in the cover of the radio receiver
that show the operating condition of the radio remote control:
LED Designation Function

The yellow LED is illuminated as soon as the receiver is under op-
ON erating voltage. A connection to the crane's electrical system has
been made, the internal operating voltage is applied.
The red LED illuminates when the transmitter is switched off and
goes off as soon as the transmitter is switched on and the receiver
receives a signal on its radio frequency.
HF If the "HF" LED also goes out with the transmitter switched
off, it is an indication that the radio channel is also being
used by another transmitter. If the system shuts down due
to radio interference, switch the transmitter off and monitor
whether the "HF" LED goes out anyway.
The green LED is constantly illuminated after the transmitter is
switched on, that is, the receiver has recognised its transmitter by
Si 1
the common system address (code). Safety circuit "Si 1" is ena-
bled.
The green LED refers to the internal safety circuit "Si 2", which
provides a dual shutdown of the driving commands if the com-
mand devices are at zero position, that is, "Si 2" is not illuminated.
Si 2
The "Si 2" display must light up only when one or several power
unit commands (for example, slewing, hoist, etc.) have been is-
sued.
Reports upon The yellow LED is illuminated if the receiver sends a check-back
completion message to the transmitter.
1026 82640 2021-04-22

20.5 Radio Transmitter
20.5.1 Radio transmitter, front, general
Fig. 1157: Operating Elements of the Radio Transmitter

1 Handle
Flashing green: Charging state of the
2 Status LED battery OK.
Flashing red: Battery requires charging
3 Buzzer Acoustic warning signals
Specifications on the telescoping sys-
4 Display, left tem (see section "Radio remote control"
under "Displays, left")
Specifications on load, load utilisation,
5 Display, right radius and hoist limit switch (see
20.5.4.3 Display, right, side 1033)
Pressure / rotary
6 Switch on the display lighting
switch
7 Attachment eyelets for harness
8 Harness
82640 2021-04-22 1027

20.5.2 Radio transmitter, front, crane functions

1 Control lever, left Telescopic sections / slew gear
LC input "+" = up
LC input " - " = down
2 Rotary switch re- 1st step in each direction =
spec- jump by one
tively 2nd level = 10 steps
Selection of the crane movement for
3 Rotary switch fine tuning with tumbler switch "Fine
tuning crane movements"
4 Control lever, right Hoist / luffing gear
1028 82640 2021-04-22

WARNING
Risk of accidents due to using the key-operated
pushbutton "Bridging 'Raise luffing gear'".
The safety functions of the crane are put out of operation
when using this key-operated pushbutton. This can
cause serious injury to persons and damage to property.
The section "Safety equipment" under "Bridging the
load limit device" must be observed.

Slew gear brake:
1 Toggle switch up - closed
down - open
Fine tuning crane movements: slew
2 Tumbler switch
gear left/right, luffing gear, hoists
Key-operated push-
3 Bridging "Raise luffing gear"
button
Assignment of the control levers (see
4 Rotary switch
section "Control lever assignment")
Engine start = up
5 Tumbler switch
Engine stop = down
" + " = increase engine speed
6 Tumbler switch
" - " = decrease engine speed
82640 2021-04-22 1029

20.5.3 Radio transmitter, lateral operating elements

1 Button High speed
2 Key-operated switch Transmitter on / off (preselection)
3 Button Switch on transmitter
Only with hydraulic luffing main boom
4 Button extension (HAVHY, option):
Start / switch off Hatz diesel engine
5 Switch Engine quick stop
6 Button Horn
20.5.4 Screens in the displays
20.5.4.1 General
Fig. 1161: Displays of the radio transmitter
1 Display, left 2 Display, right
The screen consists of the left display and the right display.
1030 82640 2021-04-22

20.5.4.2 Display, left
Fig. 1162: Displays and operating elements of the radio transmitter
1 Strength of received signal 2 Fault code

3 Control lever right-hand side 4 Control lever left-hand side
5 Toggle switch
Strong received signal
Weak received signal:

A weak signal decreases the quality of the radio
1
connection and can cause the connection to be bro-
ken. Change the location.
No connection to the receiver
without
Standard display: No error.
display
In the following situations, the adjacent fault code is
shown and the transmitter is locked when the radio
remote control is switched back on:
- Radio remote control switched on with open slew
gear brake.
Action:
Place toggle switch (5) in the top position "Slew
gear brake closed".
2
SI2 LOC - Control lever (3)/(4) steered when the radio re-
KED mote control is switched on.
Action:
Place the control lever in the neutral position.
- Function button activated laterally.
Action:
Release function button.
- Fault in the transmitter.
Action:
Have transmitter repaired.
82640 2021-04-22 1031

Fig. 1163: Display, left
Battery display
Charged battery
Discharged battery
1 In addition, an acoustic signal goes off and the LED
in the transmitter flashes red. Change the battery,
otherwise the transmitter will switch off after a few
minutes.
Immediately recharge the discharged battery using
the appropriate charging device.
2 Position indicator of the locking and pinning unit (LPU)
3 Selected length code (LK)
4 Display appears when selected LC has been achieved.
Engine speed display
5
The field is not filled in when the engine is switched off.
6 Bar display of the selected LC
1032 82640 2021-04-22

20.5.4.3 Display, right
Fig. 1164: Display, right
Display of load utilization as a bar diagram and percentage

1
value
Display of advanced warning / overload
Prewarning range (90 - 100 % of the load moment);
prewarning symbol is flashing.
2
Overload range (from 100 % of the load moment);
Overload symbol is flashing. The LLD switches off
the movements "Raise load", "Telescoping out" and
"Luffing gear".
Display of hoist limit
3 If the hoist end symbol lights up, the hoist limit
HE
switch has been triggered.
4 Radius
5 Max. load capacity in accordance with the load capacity table
Current gross load
6 The gross load consists of the weight of the hook block, of the
hoist rope and all load-handling devices.
82640 2021-04-22 1033

20.6 Control Lever Assignment

As soon as the radio remote control has been switched on, the posi-
tion of the corresponding rotary switch determines the control lever
assignment. In this case, it is not important which mode of control lev-
er assignment has been selected on the IC-1.
In particular, the selection options on this rotary switch also serve to
enable the control of hoist 2 (optional).
The display of the selected mode is adapted accordingly in the top

line of the IC-1 screen.
For detailed specifications on the control lever assignment modes,
see the section "Safety equipment" under "Joystick modes/control
lever assignment screen".
WARNING
Risk of accidents due to triggering unintentional
crane movements.
Before initiating a crane movement, the crane opera-
tor must check the current control lever assignment
and must ensure that the new control lever assign-
ments are carried out correctly.
1034 82640 2021-04-22

Switch po-
Mode Control lever, left Control lever, right
sition
SLH = Slew gear SRH = Luffing gear

0 "1"
SLV = Tele SRV = Hoist 1
SLH = Slew gear SRH = Hoist gear 2

"3"
SLV = Tele SRV = Hoist 1
SLH = Slew gear SRH = Luffing gear

"2"
SLV = Hoist gear 2 SRV = Hoist 1
"3" SLH = Slew gear SRH = Hoist gear 2

with
HAV-
SLV = Luffing HAVHY SRV = Hoist 1
HY
"1" SLH = Slew gear SRH = Luffing gear
with
HAV-
SLV = Luffing HAVHY SRV = Hoist 1
HY
S = control lever, R = right, L = left, H = horizontal, V = vertical
20.7 Commissioning the Radio Remote Control
1. Place the charged battery with the decals facing inward in the
corresponding compartment underneath the control panel so that
the contacts are connected and the battery clicks into position.
82640 2021-04-22 1035

2. Select the "Operating mode selection" screen.
Fig. 1166: Radio remote control key-operated switch
1 Key-operated switch
3. Switch the key-operated switch (1) to radio remote control and

remove the key.
1036 82640 2021-04-22

Fig. 1167: "Selecting the operating

mode" screen
The displayed "Radio remote control" key appears in the "Operating

mode selection" screen.
The orange lamp behind the crane cab flashes.
DANGER
Risk of accidents if the set parameters do not corre-
spond with the actual state of the crane.
If they do not correspond, the load limit device CANNOT
reliably monitor crane operation.
Select all parameters in accordance with the actual
state of the crane. This responsibility lies with the
crane operator alone.
4. Check whether the set parameters in the "Selecting the operat-

ing mode" screen correspond with the actual state of the crane.
Then either confirm as described in the following point or first
adapt the parameters.
82640 2021-04-22 1037

5. Press the key displayed in the "Selection of the operating mode"

screen to confirm the parameters.
The following "Crane operation" screen also appears with the

depicted radio remote control symbol.
It is no longer possible to change the crane configuration on

the IC-1 once crane operation with "Radio remote control" has
been confirmed as long as the radio remote control remains
active. Execution of crane movements from the cab is locked.
1038 82640 2021-04-22

WARNING
ments/disruptions.
occur when crane movements are carried out uninten-
tionally or there are unintentional accidents.
When leaving the crane operator’s cab, remove the
key of the key-operated switch (1) and lock the crane
operator’s cab.
Both keys must be kept safe from access by unau-
thorised persons.
6. Ensure that the quick stop switch is unlocked. If required, unlock

the quick STOP switch by turning it.
82640 2021-04-22 1039

1 Key-operated switch 2 "On" button

3 Status LED
7. Switch on the radio transmitter. To do so, turn key-operated

switch (3) clockwise and then actuate the "On" (2) button.
In normal cases, the status LED (1) flashes in green and both
displays are switched on - the transmitter is ready for opera-
tion.
If the status LED (1) on the transmitter lights up in red and / or

an acoustic signal sounds, it means that the battery is almost
discharged . you must immediately proceed as follows:
- replace the empty battery with a charged one.
- Recharge the discharged battery (see 20.10.2 Battery
Charging Device, side 1049).
If the empty rechargeable battery is not replaced with a fully

charged one, the transmitter will switch itself off in a few mi-
nutes.
Fig. 1172: Radio remote control display,

left
If "Sl2 Locked" appears on the transmitter, there is a fault in the trans-

mitter. Then rectify any possible faults (see "Displays in the screens").
1040 82640 2021-04-22

Fig. 1173: Receiver

1 LED "HF"
2 LED "Si1"
The radio connection to the receiver has been created if the red
LED "HF" (1) on the radio receiver goes out after the transmitter has
been switched on, and the green LED "Si1" (2) is illuminated. Con-
trol commands can then be given using the control panel of the ra-
dio transmitter.
82640 2021-04-22 1041

1 Tumbler switch - engine on/off 2 "Horn" button

3 Quick STOP switch
WARNING
Risk of accidents for people in the operating range.
Movements by the crane and the hook can cause death
or serious injury to persons in the operating range of the
crane.
Before starting operation, always:
- Press the "Horn" button (2) to warn of movements
by the crane or the hook.
- Check the proper functioning of the quick stop
switch (3).
8. Start the crane engine using the radio remote control; (engine
start: tumbler switch (1) - top).
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20.8 Crane Operation Using Radio Remote Control

All crane movements can be "remote controlled" from outside the cab
using this radio remote control.
Any activation of a crane function using this radio remote control cor-
responds exactly to the corresponding operation of crane movements
using the operating controls in the cab.
WARNING
Risk of accidents due to delayed initiation/comple-
tion of crane movements.
Use of the radio remote control will slightly increase the
minimum command and reaction time of the crane. The
time delay between releasing the control lever and the
cessation of movement can be particularly dangerous for
the person handling the load when attaching and remov-
ing the load.
Operate the radio remote control with particular care
and with foresight in mind.
WARNING
Risk of accidents due to self-actuating turning of the
crane superstructure.
After completing a work step with the radio remote
control, apply the slew gear brake (parking brake) for
safety reasons.
WARNING
Risk of accidents due to unintentional initiation of
crane movements using the radio remote control.
In the case of a defect, an emergency or if there are
any faults in the operating range, switch off the radio
remote control immediately until the fault can be recti-
fied.
82640 2021-04-22 1043

Fig. 1175: Display on the left in the radio

remote control
1 Display "Sl2 Locked"
If "Sl2 Locked" appears in the left-hand display on the transmitter,

there is a fault in the transmitter. For troubleshooting, see section
"Radio remote control" under "Displays in screens".
If the load utilisation of the crane reaches the prewarning range, the
"Caution" symbol appears in the right-hand display.
If the LLD switches crane movements off, the "Stop" symbol appears
in the right-hand display. The crane operator must then check the
cause of the shut-down in the crane control operating panel in the
crane operator’s cab. Using this information, the crane operator can
decide how to get out of the shut-down.
For other malfunctions, see 20.11 Troubleshooting, side 1051.
20.9 Putting the Radio Remote Control Out of Operation
20.9.1 Standard Switching off Procedure

1. Apply the slew gear brake. To do so, place the corresponding
toggle switch "Slew gear brake" in the control panel of the radio
transmitter in the top position.
If you switch off with the slew gear brake open, it can cause an un-
safe state of the crane when switched on again. For this reason, a
fault message is displayed (see "Displays in the screens") when the
system is switched back on and the transmitter is blocked until the
slew gear brake is closed using the toggle switch.
2. Switch off the crane engine. To do so, place the corresponding

tumbler switch "Engine start/engine stop" in the control panel of
the radio transmitter in the bottom position.
1044 82640 2021-04-22

3. In the instrument panel, switch key-operated switch (1) back to

standard crane operation.
Crane control can be operated again using the IC-1 and the
control levers.
4. Switch off the radio transmitter. To do so, turn the key-operated

switch (see arrow) anti-clockwise.
5. If not being used, remove the key (see arrow) from the radio
transmitter and store in a safe place for safety reasons.
82640 2021-04-22 1045

20.9.2 Shutting down Using the Quick Stop Switch
1 Key-operated switch 2 "On" button

3 Quick STOP switch
In a normal case, the transmitter is switched on and off using key-

operated switch (1). Only use the quick stop switch (3) in an emer-
gency and in case of faults in the operating range.
1. Press the quick stop switch (3).

If the transmitter has been switched off using the quick stop switch,
the following steps must be carried out for further transmitter opera-
tion:
2. Unlock the quick stop switch (3) by turning it.
If the optional quick stop device with air shut-off valve is fitted, the
air shut-off valve must be opened again (see section "Engine" in
"Quick stop device with air shut-off valve (optional)").
3. Switch the radio transmitter back on. To do so, actuate the (2)
"On" button.
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20.9.3 Automatic Shut-down of the Transmitter
1 "On" button
The transmitter shuts down automatically if it has not been used for a
certain period of time. This function can be activated or deactivated
and the shut-down time can be set at the master level (customer
service team). The automatic transmitter switch-off is designed for
safety reasons and increases the battery's service life. Press the "On"
button (1) to reactivate the transmitter after an automatic shut-down.
Under no circumstances does the automatic transmitter shut-down

relieve operators of their responsibility to switch off the radio trans-
mitter when it is no longer needed.
An automatic shut-down of the transmitter causes a quick stop. If

the optional quick stop device with air shut-off valve is fitted, the air
shut-off valve must be opened again (see section "Engine" in "Quick
stop device with air shut-off valve (optional)").
82640 2021-04-22 1047

20.10 Power Supply
20.10.1 Nickel Metal Hydride Accumulator Battery (Battery)
Fig. 1179: Radio transmitter, bottom side
1 Battery
As illustrated, the battery must be in the corresponding compartment

on the bottom side of the control panel of the radio transmitter.
The capacity of the battery depends on its age and the ambient tem-
perature. The capacity of older batteries decreases over time. The
battery capacity decreases more quickly with temperatures below
0° C / +32° F and above 40° C / +104° F. With proper handling, more
than 500 charging cycles can be achieved. For this reason, follow
these instructions:
- Charge the battery fully before its first use and / or after it has been
in storage for more than 6 months. Remember that the battery
achieves full capacity only after 3 - 5 charging cycles (fully charged
and discharged).
- Use only the corresponding HBC charger to charge the battery.
- Charge the battery at ambient temperatures of 0-40° C (+32-
+104° F).
- Charge the battery only if the status LED in the transmitter is flash-
ing red and an acoustic signal sounds.
- Charge the battery fully before it is stored for longer periods of
time. Otherwise the battery could become totally discharged.
- Store the battery at room temperature.
- Protect the battery from short-circuiting and always use the sup-
plied protective cap for storage.
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20.10.2 Battery Charging Device

Depending on customer requirements, an AC or DC charging device
is available.
WARNING
Risk of fire when using the charging device.
Using the charging device can cause a fire, which can
cause injury to persons and damage to property.
Only charge the batteries listed on the serial plate us-
ing the charging device.
Do not operate the charging device in areas at risk of
explosions.
Operate the charging device only at the supply volt-
age indicated underneath.
Only operate the charging device in vehicles or in en-
closed interior spaces.
Operate the charging device only within the indicated
temperature range.
Protect the charging device from overheating, dust
and humidity.
Do not cover the charging set during operation.
Disconnect the charging device from the power sup-
ply if it is not being used.
Immediately take the charging device out of operation
if there is a fault in the device or the connecting ca-
ble.
Do not make any technical modifications to the charg-
ing device or the connecting cable.
Only have an expert carry out repairs.
82640 2021-04-22 1049

Charging the battery
Fig. 1180: Battery Charging Device
1 Charging device 2 Battery
1. Connect the charging device (1) to the power supply using the
connecting cable supplied.
2. Fit the battery (2) into the charging slot of the charging set (1).
The charging procedure starts automatically.
If an FuB 9 NM or BA2220_ battery is to be charged, the adapter

must be inserted in the charging slot.
The current operating status is indicated by three LEDs:
The green
- lights up when the battery has been charged.
LED
The orange
- lights up when the battery is being charged.
LED
lights up when the battery is fully discharged or is
The red LED -
faulty.
Specifications
100 - 240 V AC (QA109600)
Operating voltage
10 - 30 V DC (QD109300 / QD309300)
Charging time 1 - 2 hours
+10° C - +40° C
Operating temperature
+50° F - +104° F
Housing material Plastic
Device protection class II
1050 82640 2021-04-22

20.11 Troubleshooting
Please check the functions with cab or cable control first.
Problem Possible cause Measures

Check battery contacts for damage or contami-
No response when the
No operating voltage nation.
transmitter is switched
present Fit a charged battery into the charging slot.
on
Charge the battery fully.
Check battery contacts for damage or contami-
nation.
Battery contacts conta-
Low voltage warning af- Charge the battery fully.
minated or damaged
ter just a short operat- Check that the charging procedure is proceeding
Battery not charged
ing time correctly.
Battery is faulty
Check the transmitter function with a fully charg-
ed or a replacement battery.
The status LED in the Receiver has no oper-
transmitter is flashing ating voltage Check the connecting cable to the receiver.
green, but control com- No radio connection. Check the functions using the LEDs in the cover
mands cannot be im- Command "Crane on" of the receiver.
plemented has not been given.
Individual commands Receiver defective
Check the connecting cable to the receiver to en-
are not being carried Connecting lead to the
sure it is fitted firmly.
out crane is disrupted
NOTE
Please contact the customer service team if none of the meas-
ures listed resolves the problem.
20.12 servicing
To a large extent, the radio remote control is maintenance-free. How-
ever, the points listed below must be observed:
- Check the functionality of the quick stop switch regularly. Dirt de-
posits on the switch could impair the mechanism and negatively af-
fect its function.
- Check the bellows and/or rubber seals of the operating elements
regularly for leak-tightness. Defective bellows and/or rubber seals
must be replaced immediately as humidity and dirt could penetrate
and impair the function of the operating elements.
- Never clean the transmitter or receiver with a high-pressure clean-
er or with sharp and pointed objects.
- The transmitter batteries must be charged and discharged regular-
ly.
82640 2021-04-22 1051

- If electrical welding is to be carried out on the crane:

- Switch off the radio remote control.
- Switch off the crane.
- Disconnect all electric connections to the receiver.
Otherwise, the receiver electronics could be destroyed.
In case of a fault
WARNING
Risk of accidents due to a defective radio remote
control.
If the radio remote control is operated even though faults
have been detected, it will result in perilous injuries to
persons and/or extensive damage to property (e. g. un-
checked driving of the crane).
If faults are detected, the responsible qualified per-
sonnel must be contacted immediately and use of the
radio remote control must be prohibited.
Do not attempt to access the radio remote control's
electrical system yourself. Otherwise, any warranty
claims will be rejected.
If required, contact the customer service team.
1052 82640 2021-04-22

21 Emergency Operation (Optional)
21.1 General
To make it possible to initiate suitable measures in case of an emer-
gency (power loss during crane operation) for recovery / deconfigur-
ing the crane, the operator has at his disposal the procedures descri-
bed in the following, depending on the individual emergency scenario:
- Hydraulic emergency lowering (see 21.2 Emergency hydraulic
lowering, side 1054)
- Electrical emergency control system (see 21.3 Electrical emer-
gency control system, side 1074).
Fig. 1181: Overview diagram - emergency actuation
WARNING
Risk of accidents when carrying out the "Emergency
actuation" procedure without the relevant knowl-
edge.
Practise the "Emergency actuation" procedure at
least once before crane operation.
The crane operator must understand / master the "Emergency actua-

tion" procedure. Only this will ensure safe operation and rapid han-
dling in emergency situations.
82640 2021-04-22 1053

21.2 Emergency hydraulic lowering
21.2.1 Emergency hydraulic lowering using an assisting crane
21.2.1.1 Intended use

"Hydraulic emergency control" which is described below is only for re-
covering small loads (load pressures < 210 bar / 3046 psi) safely if
the diesel engine or a pump fail.
Emergency operation is not equipped or suitable for maintaining nor-
mal crane operation.
21.2.1.2 Safety Instructions
WARNING
Risk of accidents when performing emergency ac-
tuation without observing the following safety in-
structions!
The safety instructions listed must be observed.
Only authorised and correspondingly trained personnel are permitted

to carry out emergency operation.
Before commissioning a component, the operator must make sure
he/she is familiar with the respective system involved. To do so:
- Read and observe the appropriate section in its entirety.
- In particular, follow all safety instructions which are also valid for
normal operation.
- Also observe the corresponding sections of the crane movements
which can be carried out (see section "Slewing the superstructure",
"Luffing", "Hoist 1" and "Hoist 2").
- Contact customer service if anything is unclear.
WARNING
Do not remain in the hazardous area of the crane.
WARNING
Risk of accidents when operating the crane when
there is insufficient visibility!
All movements of the crane and the load must be in
the field of view of the crane operator.
1054 82640 2021-04-22

NOTE
Risk of damaging the hydraulic connections!
There is a risk of damaging hydraulic hoses and connections when
moving the crane chassis with hydraulic connections in place.
After hydraulic connections have been made with the crane, do
not move the crane vehicle.
82640 2021-04-22 1055

21.2.1.3 General information (hydraulic emergency lowering using an assisting

crane)
You will find a detailed description below on how to receive assis-
tance in case of a corresponding fault.
If the crane is to provide assistance, the description of the corre-
sponding interface must also be observed (see "Interface for driving
emergency hydraulic lowering (optional)" in this section).
Fig. 1182: Hydraulic Transformer
1 Hydraulic pump of the trans- 2 Hydraulic motor of the transform-

former er
The required connections (hydraulic interfaces) are standardised. The

coupling sleeves and plugs are marked with plates.
The required auxiliary unit is a hydraulic transformer, which basically
consists of a hydraulic pump and a hydraulic motor. This type of
transformer can be obtained from the crane manufacturer.
NOTE
Risk of damage due to contamination
Always keep the transformer clean.
Operate it only in a clean environment, i.e. do not set it down
unprotected on dirty or dusty ground. There is a risk of contami-
nation for the transformer and/or hydraulic system. This can
cause the system to malfunction or fail.
Keep the transformer clean and dry.
Remove the protective caps only just before use and reattach
them immediately after used.
The hydraulic motor of the transformer is driven by an external hy-

draulic system (for example, an "assisting" crane) and it in turn drives
the transformer pump, which supplies the superstructure's hydraulic
system.
1056 82640 2021-04-22

The following movements can then be driven by activating the control

lever in the crane operator’s cab:
- Luffing
- Raising / lowering hoists
- Turning.
The crane movements are carried out at a slower pace.
The load limit device and any operating range limits that may be pro-
grammed remain unaffected, which means that they continue to be
effective.
The required hydraulic transformer and all required hoses must be

supplied by the customer or can be delivered as optional equipment.
If the transformer is supplied by the crane manufacturer, the follow-
ing hoses are supplied:
- Hoses from assisting crane/power unit to transformer, 3 pieces.
- Hoses from transformer to crane being assisted, 2 pieces.
21.2.1.4 Connections on the hydraulic transformer
Fig. 1183: Hydraulic transformer connections
LCC Leak oil connection (motor-side) 1 Pressure connection (pump-side)

T Tank connection (pump-side) PCC Pressure connection (motor-
side)
TCC Tank connection (motor-side)
The hydraulic transformer, which can be obtained from the crane

manufacturer, has the following connections:
- Motor-side, for the assisting crane/power unit:
- (TCC) - tank connection
- (PCC) - pressure connection
- (LCC) - leak oil connection
82640 2021-04-22 1057

- Pump-side, for the crane receiving assistance:

- (T) - tank connection
- (1) - pressure connection
21.2.1.5 Equipment on the Crane

Connections on the Crane
The required connections on the crane are partially behind the cov-
ers. For this reason, first unlock the flap on the crane chassis and fold
down. Tools required depending on the design of the crane: Allen key
8 mm or bit key
Connections on the crane to receive hydraulic oil from a trans-

former/power unit
Fig. 1184: Connection (P) Fig. 1185: Connection (S2)
- (P) - Pressure connection Fig. 1184, side 1058)

- (S2) - Connection S2 ( Fig. 1185, side 1058)
Further interfaces are described under 21.2.3 Interface for Drive of

the Hydraulic Emergency Lowering (Optional), side 1073.
Connections on the crane to drive a transformer
Fig. 1186: Connection (TCC) Fig. 1187: Connections (LCC) and (PCC)
- (TCC) - Tank connection Fig. 1186, side 1058)

- (LCC) - Leak oil connection ( Fig. 1187, side 1058)
- (PCC) - Pressure connection ( Fig. 1187, side 1058)
1058 82640 2021-04-22

Further equipment on the crane
Fig. 1188: Crane hydraulic stop valves
1 Stop valve nominal diameter 12 2 Stop valve nominal diameter 8
How the two stopcocks must be adjusted to recover a small load, see
21.2.1.7 Recovering a Small Load, side 1062.
The throttle is used for fine control of the slewing movement (see
21.2.1.7 Recovering a Small Load, side 1062).
21.2.1.6 Connecting the Hydraulic Transformer

Requirements:
- Crane receiving assistance in the corresponding operating configu-
ration (outrigger support area, counterweight and similar) with
small attached load.
- Configuration of the crane receiving assistance:
- Failure of diesel engine or pump
- Engine and ignition off
- Hydraulics and electrical system functioning.
If the crane's electrical system is not operational (for example, bat-

teries are discharged), "Hydraulic emergency lowering" is not possi-
ble. In this case, the crane's electrical system must first be made
ready for operation using external batteries (see the corresponding
section of the drive motor under "Jump starting").
- Configuration of the assisting crane:

- Engine and ignition off.
- Use of a standard transformer.
Below is an example of external supply by an assisting crane.
The operating instructions of the assisting crane must be observed.

When using other sources, the corresponding operating manuals
should be used.
82640 2021-04-22 1059

The transformer which must be obtained from the crane manufacturer

is described as an example below.
When using another transformer, the corresponding operating in-

structions should be used.
1. Open the protective caps on the couplings of the transformer.
1060 82640 2021-04-22

Fig. 1190: Hoses between the assisting crane and the hydraulic transformer (mo-
tor-side)
PhK Pressure connection (assisting LhK Leak oil connection (assisting

crane) crane)
ThK Tank connection (assisting PCC Pressure connection (transform-
crane) er - motor-side)
LCC Leak oil connection (transformer TCC Tank connection (transformer -
- motor-side) motor-side)
- Fig. 1190, side 1061 "top" shows the connections of the hy-
draulic transformer.
- Fig. 1190, side 1061 "bottom" shows the connections of the as-
sisting crane.
2. Connect the hydraulic couplings of the assisting crane with the

hoses on the corresponding hydraulic couplings of the hydraulic
motor (hydraulic transformer).
Follow the corresponding operating instructions for the fitting loca-

tions and descriptions of these couplings on the assisting crane.
For transformers without leak oil connection, coupling "LhK" on the

assisting crane remains free.
3. Loosen the fitted protective caps on your own crane.
82640 2021-04-22 1061

Fig. 1191: Hoses between hydraulic transformer (pump-side) and own crane
(schematic diagram)
1 Pressure connection (transform- T Tank connection (transformer -

er - pump-side) pump-side)
P Pressure connection (own S2 Connection S2 (own crane)
crane)
- Fig. 1191, side 1062 "top" shows the connections of your own
crane.
- Fig. 1191, side 1062 "bottom" shows the connections of the hy-
4. Connect the hydraulic couplings of the hydraulic pump (hydraulic

transformer) with the hoses on the corresponding hydraulic cou-
plings of your own crane (see "Equipment am crane").
21.2.1.7 Recovering a Small Load

1. Connecting the transformer (see 21.2.1.6 Connecting the Hy-
draulic Transformer, side 1059).
1062 82640 2021-04-22

Fig. 1192: Crane hydraulic stop valves Fig. 1193: Crane hydraulic stop valves
1 Stop valve (nominal diameter 12) 1 Stop valve (nominal diameter 12)
2 Stop valve (nominal diameter 8) 2 Stop valve (nominal diameter 8)
B Locked position A "Flow rate" position
B Locked position
2. Depending on the movement of the crane during emergency low-

ering, both stop valves (1) and (2) on the crane hydraulics have
to be set up as follows:
- Turn: both stop valves (1) and (2) in locked position (see
Fig. 1192, side 1063)
- Moving the luffing gear/hoist(s): Stop valve (1), nominal
width 12, in position "flow rate" (A), stop valve (2), nominal
width 8, in locked position (see Fig. 1193, side 1063).
Fig. 1194: Stop valve setting
Decisive for the function of this valve is the position of the notch (see
arrow) on the square.
- Notch parallel to the direction of the line means open.
- Notch turned 90° in relation to the direction of the line (as illustra-
ted) means locked position.
In this installation example, the position of the shut-off lever corre-

sponds to the direction of the notch. It may occur that the position of
the shut-off lever does not correspond to the direction of the notch.
If the stop valves are not put in the indicated position, part of the oil
quantity flows away and the speed of the crane movement during
"Emergency hydraulic lowering" is additionally reduced or the crane
movement cannot be made at all.
3. Set crane control to "Hydraulic emergency lowering". To do so,

switch on the ignition in the superstructure.
82640 2021-04-22 1063

This starts the IC-1 automatically.
Fig. 1195: Call up the main menu
4. Select the correct operating mode and press the key in the base
line under the "Quick menu" screen.
The "Main menu" screen appears.
5. Press the key in the main menu to switch crane control to "Hy-
draulic emergency lowering". The key changes in appearance as
shown.
In addition, the corresponding symbol appears in the "Crane

operation" screen (see arrow).
The function "Hydraulic emergency lowering" must be activated in

the IC-1. Otherwise, no further crane movements can be carried out
using the control levers of the crane operator's cab.
6. Place stop valve of the transformer in the "open" position. To do

so, turn the stop valve by 90° from the depicted locked position.
Now, the transformer is switched to the depressurised cycle.

This prevents an overheating of the hydraulic oil during longer
idle operation.
1064 82640 2021-04-22

NOTE
Risk of damage!
Only operate the transformer as long as is required for recover-
ing the load and do not let it run at idle speeds for longer peri-
ods of time. If the transformer is operated for a longer period of
time, the oil can overheat.
7. Start the engine of the assisting crane.

8. Executing a crane movement:
The following crane movements can be carried out using the "Emer-
gency hydraulic lowering" function to recover a small suspended load.
The crane movements will be carried out at a slower speed.
- Turning
Immediately before the movement is executed: turn the stop valve on
the transformer to the locked position. Then, this crane movement -
as in normal operation - is controlled by operating the corresponding
control lever.
To do so, observe the section "Slewing the superstructure".
In addition, to carry out this movement, actuate the control knob (see
arrow) to slowly increase the corresponding throttle. This ensures that
slewing can be controlled very precisely and that there is no unwel-
come movement (rocking) of the load to be recovered.
With emergency hydraulic lowering, slewing will take place automati-
cally in a closed circuit.
- Luffing
control lever.
To do so, observe the section "Luffing".
82640 2021-04-22 1065

- Raising / lowering hoists

control lever.
To do so, observe the section "Hoist 1/2".
21.2.1.8 After Recovering a Small Load
1. Place stop valve of the transformer in the "open" position. To do

so, turn the stop valve by 90° from the depicted locked position.
Now, the transformer is switched to the depressurised cycle.

This prevents an overheating of the hydraulic oil during longer
idle operation.
2. Switch off the engine of the assisting crane.

3. Switch the "Hydraulic emergency lowering" function off in the
IC-1 of the crane receiving assistance and switch off the ignition.
1066 82640 2021-04-22

Fig. 1196: Crane hydraulic stop valves
1 Stop valve 2 Stop valve

A "Flow rate" position
4. Set both stop valves (1) and (2) on the crane hydraulics back to
"flow rate" position (A).
NOTE
Risk of damage to the hydraulic system due to lack of allevia-
tion of hydraulic load!
Normal operation only with the stop valves (1) and (2) in the
"Flow" position.
5. Disconnect all connections of the transformer again and refit the

protective caps on the couplings.
6. Close all open covers again according to instructions.
82640 2021-04-22 1067

21.2.2 Emergency hydraulic lowering using the 8 kW power unit
21.2.2.1 General information (hydraulic emergency lowering using the 8 kW power

unit)
Fig. 1197: 8 kW emergency unit
The description below refers only to the 8 kW power unit which can
be obtained from the crane manufacturer.
Further information on this power unit which goes beyond the scope
of these operating instructions can be found in the manufacturer's
documents in the "Various" part.
The emergency unit weighs approx. 410 kg (904 lbs).
In addition, the relevant specifications on emergency lowering using

an assisting crane can be found under 21.2.1.1 Intended use,
side 1054, 21.2.1.2 Safety Instructions, side 1054 and "General
information (hydraulic emergency lowering using an assisting
crane)" must be observed accordingly.
1068 82640 2021-04-22

21.2.2.2 Connections on the 8 kW power unit
Fig. 1198: Connections on the 8 kW power unit
T Tank connection L Leak oil connection

B Pressure connection
The power unit has 2 pressure connections ("A" and "B"). For the
case described here, only one of the two may be connected (for ex-
ample, as in the description of connection "B").
Depending on which of the two pressure connections is connected,
the directional control valve lever must be actuated to the left or to
the right so that the power unit can supply the transformer motor.
Observe the corresponding hydraulic diagram to do so.
21.2.2.3 Connecting the Hydraulic Transformer

Requirements:
- Crane receiving assistance in the corresponding operating configu-
ration (outrigger support area, counterweight and similar) with
small attached load.
- Configuration of the crane receiving assistance:
- Failure of diesel engine or pump
- Engine and ignition off
- Hydraulics and electrical system functioning.
If the crane's electrical system is not operational (for example, bat-

teries are discharged), "Hydraulic emergency lowering" is not possi-
ble. In this case, the crane's electrical system must first be made
ready for operation using external batteries (see the section of the
corresponding drive motor under "Jump starting").
- State of the 8 kW power unit:

- Engine not running.
- Use of a standard hydraulic transformer.
82640 2021-04-22 1069

The transformer which must be obtained from the crane manufacturer

is described as an example below.
When using another transformer, the corresponding operating in-

structions should be used.
1. Set the emergency unit down safely in the area of the corre-
sponding hydraulic connections on the crane chassis.
2. Open the protective caps on the corresponding couplings of the

transformer.
3. Remove the protective caps from the required couplings on the
power unit.
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Fig. 1200: Hoses between the 8 kW power unit and the hydraulic transformer
(motor-side)
B Pressure connection (8 kW pow- L Leak oil connection (8 kW power

er unit) unit)
T Tank connection (8 kW power PCC Pressure connection (transform-
unit) er - motor-side)
LCC Leak oil connection (transformer TCC Tank connection (transformer -
- motor-side) motor-side)
- Fig. 1190, side 1061 "bottom" shows the connections of the 8
kW power unit.
4. Connect the hydraulic couplings of the 8 kW power unit (see

21.2.2.2 Connections on the 8 kW power unit, side 1069) with
the hoses of the corresponding hydraulic couplings of the hy-
draulic motor (hydraulic transformer).
For transformers without leak oil connection, coupling "LCC" on the

power unit remains free.
The required connections on the crane receiving assistance are parti-

ally behind the covers (see "Equipment on the crane").
In order to establish the hydraulic connections, the corresponding

protective caps on the transformer must be folded up and the pro-
tective caps screwed onto the crane must be removed.
82640 2021-04-22 1071

Fig. 1201: Hoses between the hydraulic transformer (pump-side) and the crane
(schematic diagram)
1 Pressure connection (transform- T Tank connection (transformer -

er - pump-side) pump-side)
P Pressure connection (crane) S2 Connection S2 (crane)
- Fig. 1201, side 1072 "top" shows the connections of the crane.
- Fig. 1201, side 1072 "bottom" shows the connections of the hy-
5. Connect the hydraulic couplings of the hydraulic pump (hydraulic

transformer) with the hoses on the corresponding hydraulic cou-
plings of the crane (see "Equipment am crane").
21.2.2.4 Recovering a Small Load

A small load is recovered in the same way as described for the same
procedure using an assisting crane (see under "Emergency hydraulic
lowering using an assisting crane", "Recovering a small load").
Observe the following differences.
The engine of an assisting crane is not started, but instead the power
unit motor. Observe the corresponding specifications in the manufac-
turer's instructions in the part "Various".
Fig. 1202: Directional control valve lever
1072 82640 2021-04-22

In addition, the directional control valve lever on the power unit must
be moved according to the pressure connection used, "A" or "B", so
that hydraulic oil is pumped from the power unit to the transformer.
21.2.2.5 After recovering a small load

After a small load is recovered, proceed in the same way as descri-
bed for the same procedure using an assisting crane (see under
"Emergency hydraulic lowering using an assisting crane", "After re-
covering a small load").
In addition, you must observe the differences listed under 21.2.2.4
Recovering a Small Load, side 1072.
21.2.3 Interface for Drive of the Hydraulic Emergency Lowering (Optional)

At this interface (optional), the crane described here can be connec-
ted to the hydraulic motor of the hydraulic transformer to act as an as-
sisting crane to carry out hydraulic emergency lowering on another
crane.
Fig. 1203: Hoses between hydraulic transformer (motor-side) and own crane
(schematic diagram)
PCC Pressure connection (top: trans- LCC Leak oil connection (top: trans-
former, motor-side) former, motor-side)
TCC Tank connection (top: transform- PCC Pressure connection (bottom:
er, motor-side) own crane)
LCC Leak oil connection (bottom: TCC Tank connection (bottom: own
own crane) crane)
- Fig. 1203, side 1073 "bottom" shows the connections of your
own crane.
Connection PCC is not a free coupling, but is a standard closed con-

nection for the supply of a steering circuit. For this reason, this con-
nection must first be disconnected before the hose of connection
PCC of the transformer can be connected here.
82640 2021-04-22 1073

21.3 Electrical emergency control system
21.3.1 Intended use

The electrical emergency control system is intended exclusively for
the purpose of enabling execution of all main crane movements such
as luffing, slewing, raising loads and telescoping in the event of an
emergency - electrical component parts failure (for example, hard-
ware malfunction of control components, CAN bus faults, etc.). It di-
rectly influences the solenoid valves of the hydraulic system by using
the vehicle cables for transmitting signals.
The drive motor and the pumps must be fully functional.
Emergency electrical control system is not equipped or suitable for
maintaining normal crane operation.
WARNING
There is an increased risk of overturning and break-
ing when carrying out crane movements with the
electric emergency control system.
There is no monitoring by crane control during crane op-
eration using the electric emergency control system (and
therefore no shut-down either). The load limit device,
monitoring of the limit switch and the operating range lim-
it are out of operation. It can result in the components be-
ing overloaded or the crane overturning.
Use only in an emergency.
You must observe and adhere to the specifications of
the corresponding capacity table.
Carry out all crane movements with particular caution
and care.
The crane operator must be in the crane operator’s
cab. From there, he can reach the quick stop button
to switch off the drive motor in an emergency or regu-
late the engine speed with the accelerator pedal de-
pending on the hydraulic oil requirements.
The crane operator/crane driver is solely responsible for any dam-

age or accidents that might be caused in this situation.
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21.3.2 Safety Instructions
WARNING
There is a risk of accidents when carrying out crane
movements with the electric emergency control sys-
tem without observing the following safety instruc-
tions.
Only authorised and correspondingly trained personnel are permitted

to operate the electrical emergency control system.
Before commissioning a component, the operator must make sure
he/she is familiar with the respective system involved. To do so:
- Read and observe the appropriate section in its entirety.
- In particular, follow all safety instructions which are also valid for
normal operation.
- Also observe the corresponding sections of the crane movements
which can be carried out - "Slewing the superstructure", "Luffing",
"Telescoping", "Hoist 1" and "Hoist 2".
- Contact customer service if anything is unclear.
WARNING
Do not remain in the hazardous area of the crane.
WARNING
Risk of accidents when operating the crane when
there is insufficient visibility!
All movements of the crane and the load must be in
the field of view of the crane operator.
82640 2021-04-22 1075

21.3.3 Components
Fig. 1204: Components of the electric emergency control system
1 Mobile Manual Control Panel 2 Mobile control unit

3 Connecting cable set
The electric emergency control system basically consists of the com-

ponents shown.
The actuation of the respective movement is accomplished by means
of the mobile manual control panel. The driver of the crane can con-
trol all functions/crane movements from the crane operator’s cab.
Specifications on using an electrical emergency control system
of another crane
Connecting cable set

There are different connecting cable sets for electrical emergency
control, depending on the crane type and delivery date. You must
ensure that it fits if a connecting cable set supplied with another
crane is to be used.
Software version of the electrical emergency control system

In order for the electrical emergency control system to function in a
crane type, it must be possible to select the corresponding crane
type (see chapter "Emergency actuation" under "Commissioning"). If
this is not the case, the software must be updated. To do so, please
consult our customer service team.
Checking the functionality

If the electrical emergency control system of another crane is to be
used, it should first be fitted as a test and the functionality must be
checked.
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21.3.4 Mobile Manual Control Panel
21.3.4.1 Rough structure
Fig. 1205: Mobile Manual Control Panel
Item Elements
Operating elements of the locking and pinning unit (LPU), see
1 21.3.4.2 Operating Elements of the Locking and Pinning Unit
(LPU), side 1078
Position sensor system of the LPU, see 21.3.4.3 Position
2
Sensor System of the LPU, side 1078
State sensor system of the LPU, see 21.3.4.4 State Sensor
3
System of the LPU, side 1079
Telescopic identification, see 21.3.4.5 Telescopic Section
4
Identification, side 1080
Function elements, see 21.3.4.6 Function Elements,
5
side 1080
Crane movements, see 21.3.4.7 Crane Movements,
6
side 1081
Accumulator loading pressure "LPU", see 21.3.4.8 Accumu-
7
lator loading pressure "LPU", side 1082
82640 2021-04-22 1077

21.3.4.2 Operating Elements of the Locking and Pinning Unit (LPU)

Button Function
unlock
lock
unpin
pin
21.3.4.3 Position Sensor System of the LPU

LED Displays of the position
Approach position locking achieved (illuminated

green)
Follow-up position locking achieved (illuminated

green)
Approach/follow-up position pinning: Not as-

signed
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21.3.4.4 State Sensor System of the LPU

Number of
LED State of the LPU
the state
unlocked and pinned (illumina-
1
ted green)
locked and pinned (illumina-
2
ted green)
locked and unpinned (illumina-
3
ted green)
locked and state change pinning
23
(illuminated yellow)
state change lock and pinned (il-
12
luminated yellow)
state lock / pinning unknown (illu-
5
minated red)
The states of the LPU correspond with the states of the LPU which
are displayed in the "Manual telescoping" screen in crane control
(see section "Telescoping" under "Manual telescoping").
82640 2021-04-22 1079

21.3.4.5 Telescopic Section Identification

The current telescopic section is displayed using different combina-
tions of the 4 yellow LEDs (BIT 1 – BIT 4). The following table must
be observed.
Telescopic sec-
Combination
tion
The number of telescopic sections varies depending on the crane

type.
21.3.4.6 Function Elements

Display shows:
- Crane type
- Current telescopic section, e. g. SEC3 (for telescopic section 3)
- Accumulator loading pressure (bar) e. g. 0082
Key Function
Selection crane type

Scroll by simultaneously pressing the button
"crane type" and one of the two arrow buttons
Selection crane movement

Scroll by simultaneously pressing the button
"enable" and one of the two arrow buttons
1080 82640 2021-04-22

21.3.4.7 Crane Movements

The crane movements are carried out by correspondingly actuating/
pressing the depicted rocker switch. The lower down the rocker
switch is pressed, the faster the selected crane movement is carried
out.
The assignment of the rocker switch depends on which crane move-

ment was previously selected (see 21.3.4.6 Function Elements,
side 1080 and the following table).
Rocker switch Movement

- Slew Gear on the Right
- lower hoists
- Lower luffing gear
- Extend telescopic drive
- Slew Gear on the Left
- Raise hoists
- Raise luffing gear
- Retract telescopic drive
LED, red Display - selected crane movement
Not assigned
Telescoping
Slew gear
Hoist 1
Hoist gear 2
Luffing gear
82640 2021-04-22 1081

21.3.4.8 Accumulator loading pressure "LPU"

Button Function
Display of pressure value (bar) in the screen
Manual reloading of the LPU accumulator
This function is only possible when Telescoping has been selected.

The loading pressure must be within the 80 - 85 bar (1160 -
1233 psi) range.
21.3.5 manufacture
The following steps must be followed with the ignition switched off.
Fig. 1206: Cover flap, left
1 Screws 2 Cover flap, left
1. Open switch box X2. To do so, carry out the following steps:
1.1. Remove the left cover flap (2). To do so, release the two
screws (1) at the bottom and then detach cover flap (2).
Switch box "X2" is behind that. If required, use the sup-
plied multi-purpose ladder as a stepladder.
1.2. Open switch box "X2" with the bit key.
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Fig. 1207: Switch box "X2"
1 PLC components 2 Mounting plate
2. Loosen mounting plate (2) at the two upper corners inside the
switch box "X2" and fold down to the front.
This clears the way for access to the control components (1).
NOTE
Risk of damage to the plugs due to improper handling.
Unplug / plug in plugs using appropriate care.
3. Unplug all connector plugs of control components (1).

This will exclude the possibility of the control system in the
crane interfering with the "emergency operation".
Remove control components if required to make it easier to unplug /

plug in the plugs. To do so, 4 screws must be unscrewed for each
one.
4. Fold the mounting plate (2) back up and secure it in place.
82640 2021-04-22 1083

Fig. 1208: Connecting the control unit
1 Distribution box X2 2 Socket X791

3 Plug X791 4 Service plug
5 Plug - control unit 6 Mobile control unit
5. Connect the mobile control unit of the emergency control system.

To do so:
5.1. Plug in connection cable plug (5) into the mobile control
unit.
5.2. Connect the plug (3) of the connecting cable to socket
"X791" (2) of distribution box "X2".
The service plug (4) of the connection cable is not plugged in - it is

used only for tasks by the service team.
6. Plug in manual control panel cable plug into the mobile control
unit.
1084 82640 2021-04-22

7. Switch on the ignition in the superstructure.

The power supply to the emergency control system and the
gear select switching to superstructure pumps is ensured
once the ignition in the superstructure has been switched on.
If the power supply is interrupted due to one or several batter-
ies failing, auxiliary power can be fed into the system via ex-
ternal start sockets (see the operating instructions of the
crane chassis, section "Engine" under "Jump starting").
WARNING
There is a risk of accidents if the wrong crane is se-
lected.
The selection of the crane type must be in accordance
with the crane which is to be operated with the electrical
emergency control system in the sequence. Incorrect se-
lection can lead to malfunctions.
Select the crane type correctly.
8. Select type of crane. In addition, at the manual control panel:
8.1. Press and hold the "Crane type" button.
8.2. At the same time, press one of the two arrow buttons.
The available selection options are scrolled through as
a result.
8.3. Interrupt scrolling by releasing the "crane type" button as

soon as the desired crane type is displayed:
Display at emergency control system Crane type

130.5 AC 130-5
160.5 AC 160-5
220.5 AC 220-5
250.5 AC 250-5
The displayed type of crane is now selected and the electrical

emergency control system is ready for operation.
9. Start the crane engine from the driver's cab and get back in the
wieder in crane operator's cab.
82640 2021-04-22 1085

WARNING
Risk of accidents if the crane operator is not at the
correct location.
The crane operator carrying out crane operation us-
ing the electric emergency control system must be in
the crane operator's cab.
21.3.6 Carrying out crane movements using the electric emergency control system
21.3.6.1 Safety Instructions
WARNING
There is a risk of overloading the components or of
the crane overturning if the safety instructions below
are not observed.
Before initiating a crane movement, ensure that

- the desired crane movement is correctly selected
- all criteria for operation of the crane movement have been fulfilled.
Carry out the crane movements at adapted speeds.
Observe all other safety instructions (see 21.3.2 Safety Instructions,
side 1075).
Ensure that there is no monitoring/shutdown by control (see 21.3.1
Intended use, side 1074).
21.3.6.2 Slew gear
WARNING
There is a risk of accidents if the basic rules for car-
rying out the crane movement "Slewing" are not ob-
served.
Handle the slew gear with care.
Select low slewing speeds and return it slowly to the
neutral position.
Proceed with particular care during operation with the
fitted fly jib or if there special local conditions.
1. Press and hold the "Enable" button.
1086 82640 2021-04-22

2. Press one of the arrow buttons. The available selection options

(crane movements) will be scrolled through as a result.
3. Interrupt scrolling and release the "Enable" button as soon as the

movement "Slew gear" is displayed.
The LED at the corresponding symbol is illuminated in red.
4. Carry out the slewing movement using the rocker switch.
Slew gear to the right
Slew gear to the left
The lower down the rocker switch is pressed, the faster the selected
crane movement is carried out.
5. Release the rocker switch slowly to brake the slewing movement.

The turning movement is brought directly to a halt due to the
fixed oil column.
The slew gear is generally operated in the closed circuit during

crane operation with the electrical emergency control system. The
position of the switch "Switch-over slew gear: open / closed circuit"
has no meaning in this case.
In addition, observe the section on this crane movement.
21.3.6.3 Hoists
Proceed analogously as described in detail for the crane movement
"Slew gear" (see 21.3.6.2 Slew gear, side 1086).
21.3.6.4 Luffing gear

Proceed analogously as described in detail for the crane movement
"Slew gear" (see 21.3.6.2 Slew gear, side 1086).
82640 2021-04-22 1087

21.3.6.5 Telescoping
21.3.6.5.1 General
"Telescoping" means retracting or extending the main boom. The
main boom consists of a basic case and several telescopic sections.
The number of telescopic sections varies depending on the crane
type.
On principle, when telescoping out the main boom, you must always
start with the smallest (furthest inward) telescopic section to be tele-
scoped. When telescoping in, you must always start with the largest
(furthest outward) telescopic section to be telescoped.
Manual telescoping is carried out without the supervision of the load
limit device and is therefore only permitted in emergency situations.
The depicted display and operating elements refer only to the
emergency control system of the telescoping and LPU functions
and are reserved only for specifically trained qualified person-
nel.
21.3.6.5.2 Telescoping the LPU
1. Press and hold the "enable" button.
2. Press one of the arrow buttons. The available selection options

(movements) will be scrolled through as a result.
3. Interrupt scrolling and release the "Enable" button as soon as the

"Telescoping" movement is displayed.
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4. Carry out the movement "Telescoping" using the rocker switch.
Extend telescopic drive
Retract telescopic drive
The lower down the rocker switch is pressed, the faster the selected
crane movement is carried out.
In addition, observe the section "Telescoping".
21.3.6.5.3 LPU states

The automatic telescopic control essentially follows sequential work
steps which are automatically run through in one circuit. In emergen-
cy operation, these must be retraced and run through manually by the
operator.
All of the LPU states described below are run through during a com-
pleted telescoping procedure. In this case, the progression of the
states is dependent on the telescoping direction. The structural de-
sign ensures that no safety-critical conditions can arise because of in-
correct operation of the locking or pinning procedures.
82640 2021-04-22 1089

Possible states of the locking and pinning unit (LPU):

State 1: LPU unlocked and pinned
The LPU can move freely and can be driven up to a telescopic sec-
tion.
State 2: LPU locked and pinned
Mechanical connection made between the telescopic cylinder and the
telescopic section. The boom section is pinned to the next larger
boom section.
State 3: LPU locked and unpinned
LPU connected with the telescopic section mechanically. The tele-
scopic section is not pinned to the next-largest telescopic section and
can be moved / telescoped.
Pinned means that the telescopic sections are connected with each
mechanically.
Secured means that the LPU with telescoping cylinder is mechanical-
ly connected with the telescopic section.
In view of the fact that a control system could fail at any time, the first
step to be carried out in the above-mentioned sequence is depend-
ent on the time of the failure. The following steps within the sequence
must be carried out as necessary so that it is possible, for example, to
move the LPU freely to the next possible pinned telescopic section.
Generally, locking procedures must only be actuated manually when
the corresponding fine position has been reached. This is the case
when the LEDs for approach position and follow-up position light up
simultaneously.
It is only then ensured that the pins will be positioned precisely in the
middle above the associated bore holes.
21.3.6.5.4 Telescopic Section Identification

Each telescopic section can be clearly identified using a bit combina-
tion. To do so, observe 21.3.4.5 Telescopic Section Identification,
side 1080.
If the LPU is in an identified telescopic section, this is shown in plain

text in the display (display e. g. "SEC 3" for telescopic section 3).
1090 82640 2021-04-22

21.3.6.5.5 Hydraulic oil supply to the LPU

Under certain circumstances, the pressure level in the LPU accumu-
lator may no longer permit a complete pinning or locking sequence
(pressure < 80 bar / 1160 psi).
In this case, the pressure can be displayed using the depicted button
in the display.
Hydraulic recharging can be carried out using the depicted button - if

necessary (80 - 85 bar/1160 - 1233 psi).
21.3.6.5.6 Move the LPU to the home position (unlocked and pinned, max. telesco-
ped in)
21.3.6.5.6.1 General
All LPU states are monitored by sensors which indicate the current
state of the mechanics. The states of the LPU are displayed using
LEDs. All final states and all their intermediate stages during the sig-
nal transitions are displayed here during the course of a fault.
If the LPU is in an intermediate stage (symbol with question mark), a

final state must be achieved by targeted control. It may under certain
circumstances be necessary to adjust the fine position of the locking
or the pinning by retracting or extending for this purpose.
The LPU must be moved to "State 1" for it to be possible to move it
freely and without load. The first step for accomplishing this is to de-
termine which state the LPU is currently in. There are 6 different op-
tions here in accordance with the display of the manual control panel.
21.3.6.5.6.2 State 1: LPU "unlocked and pinned"

The LED at the corresponding symbol is illuminated in green.
The LPU can be completely telescoped in and the basic position is
achieved.
21.3.6.5.6.3 State 12: LPU "State change lock and pinned"

The LED at the corresponding symbol is illuminated in yellow.
82640 2021-04-22 1091

1. Actuate the rocker switch to telescope the LPU to "Fine position

locking".
The LEDs at the corresponding symbols are illuminated in

green simultaneously.
2. Press the button with the corresponding symbol to "unlock" the

LPU.
As soon as unlocking and pinning has taken place, you can fully tele-
scope in and the basic position is achieved.
21.3.6.5.6.4 State 2: LPU "locked and pinned"

Required procedure identical with 21.3.6.5.6.3 State 12: LPU "State
change lock and pinned", side 1091.
21.3.6.5.6.5 State 23: LPU "locked and state change pinning"

The LED at the corresponding symbol is illuminated in yellow.
1. Actuate the rocker switch to telescope the LPU in front of the pin-
ning position (observe the telescoping direction).
2. Actuate the button with the corresponding symbol to initiate the

pinning procedure. The corresponding pin extends up to the in-
ner side of the next largest telescopic section and is lying against
it.
3. Actuate the rocker switch, moving the LPU further in the direction
of the pinning position. When the pinning position is reached, the
corresponding pin retracts into the corresponding pinning hole
due to compressive pretensioning.

locking".

1092 82640 2021-04-22


LPU.
As soon as unlocking and pinning has taken place, you can fully tele-
scope in and the basic position is achieved.
21.3.6.5.6.6 State 3: LPU "locked and unpinned"

Required procedure identical with 21.3.6.5.6.5 State 23: LPU
"locked and state change pinning", side 1092.
21.3.6.5.6.7 State 5: LPU "No information concerning the state available"

If this LED lights up, there is a serious problem in the LPU sensor
system and/or in its power supply. Without this sensor system, it is
not possible to use the emergency control system to operate the tele-
scopic section.
21.3.6.5.7 Retraction of the Boom from the LPU to the Basic Position
To ensure that all locking and pinning procedures can be run through
safely, actuate the button shown to monitor the accumulator loading
pressure. It must be (80 - 85 bar / 1160 - 1233 psi).
If necessary, recharge by actuating the push-button shown until the

required pressure value is reached.
No matter what extension state is, it is necessary for proper telescop-

ing in that all of the extended telescopic sections be telescoped in
starting with those having the largest cross-section (smallest tele-
scopic section number) and ending with those that have the smallest
cross-section (highest telescopic section number).
1. After identifying the telescopic section with the largest cross-sec-
tion which can be reached in the extended state of the LPU, ac-
tuate the depicted rocker switch, thereby telescoping out the LPU
until the section identification display indicates that the target
telescopic section has been reached.
Example: telescopic section 3 reached:

LEDs BIT 1 and BIT 4 are illuminated in yellow. "SEC3" is al-
so shown in the display as an alternative to the bit code.
82640 2021-04-22 1093

2. If it has been ensured that the correct section has been reached,
continue to telescope until the "Fine position locking" has been
achieved.
3. Press the button with the corresponding symbol to "lock" the

LPU.
Once the locking procedure has been completed successfully,

the LPU will report back the state "locked and pinned".
As long as the button is actuated, the hydraulic cylinder for carrying

out the "LPU movement" is pressurised. The button can only be re-
leased once the state of the LPU has changed (the corresponding
LED lights up).
4. Press the rocker switch briefly in the telescoping out direction to

relieve the pin to the next largest telescopic section of load. To
do so, the LPU must be moved approx. 5 mm (0.2 in) in the tele-
scoping out direction to achieve the pinning / unpinning position.
If the length measuring device of the LPU is functioning, it can be

used as an aid. If the length measuring device is not functioning, the
adjustment length must be estimated.
1094 82640 2021-04-22

5. Actuate the button with the corresponding symbol to initiate the

unpinning procedure.
Once the unpinning procedure has been completed success-

fully, the LPU reports the state "locked and unpinned".
The locked telescopic section is now only attached by the

locking pins.
If the attached telescopic section does not unpin directly, you
must drive back and forth within the millimetre range (approx.
0.1 in) in the telescoping in and out direction using the rocker
switch until the pin is relieved of load and unpins due to com-
pressive pretensioning.

LED lights up).
6. Actuate the rocker switch, thereby placing the LPU right up to the
"0% pinning position" by telescoping in.
If the length measuring device of the LPU is functioning, the pinning

position of the telescopic drive can be taken from the corresponding
table (see the section "Telescoping" under "Locking and pinning po-
sitions of the telescopic drive"). If the length measuring device does
not work, the pinning position must be estimated.
7. Actuate the button with the corresponding symbol to "pin" the

telescopic section. While doing so, slowly telescope in or out
around the pinning point until the telescopic section is pinned.
Once the pinning procedure has been completed successfully,
the LPU reports back the state "locked and pinned".

LED lights up).
82640 2021-04-22 1095


locking".


LPU. Once the unlocking procedure has been completed suc-
cessfully, the LPU reports back the state "unlocked and pinned".

out the "LPU movement" is pressurised. Only after the state of the
LPU has changed (the corresponding LED lights up) can the button
be released.
The telescoping in of one telescopic section is completed.
In order to telescope in further telescopic sections, the steps 1 - 9 lis-

ted previously must be repeated until the main boom is completely re-
tracted.
21.3.6.5.8 Example of manual telescoping procedure

The 1st telescopic section (telescopic section 1) is to be moved from
the 100% pinning hole to the 0% pinning hole.
For detailed specifications on telescopic identification, see

21.3.4.5 Telescopic Section Identification, side 1080.
The current telescoping configuration can be determined from the

LED displays. The telescoping procedure must start based on this
state.
Check the accumulator loading pressure before and during the tele-
scoping procedure (depicted button).
If required, recharge to approx. 80 to 85 bar (1160 - 1233 psi) using

the button.
1. Check that the LPU is in the state "unlocked and pinned" - the
LED at the corresponding symbol must be illuminated in green.
In this state, the LPU can be driven using the rocker switch on the
manual control panel without a telescopic section being moved.
1096 82640 2021-04-22

2. Once the LPU has been moved back fully, it must be "telescoped
out" so that it can be locked - as desired - to the fully extended
1st telescopic section. To do so, actuate rocker switch for tele-
scoping out.
The LPU is driven to the 1st telescopic section. As soon as the

LPU reaches the "Approach position locking" during driving, the
left-hand LED is illuminated in green.
As soon as the "Follow-up position locking" has also been
reached, the right-hand LED is also illuminated in green.
This means that the "Fine position" for locking has been reached.
If the "Fine position locking" is bypassed during telescoping out
by the telescopic drive extending too quickly, the left-hand LED
goes out again. The LPU is in the "Follow-up position locking".
Rocker switch in the manual control panel must be actuated for
telescoping in so that it is possible to achieve the "Fine position
locking" again. As soon as the fine position is achieved, the de-
picted LEDs are illuminated simultaneously.
3. Press the button with the corresponding symbol to "lock" the

LPU.
Observe the correct sequence: First move to the locking position,

then lock!
The locking procedure is completed as soon as the LPU is in the

state "locked and pinned".
4. Actuate the rocker switch to telescope the LPU out slightly.
5. Actuate the button to "unpin" the telescopic section. If required,

the LPU must be retracted or extended slightly using rocker
switch until the pinning procedure of the LPU has actually been
carried out. Once the unpinning procedure has been completed
successfully, the LPU reports the state "locked and unpinned".
The telescopic section is now just attached by the locking pins

and can be telescoped in.
82640 2021-04-22 1097

6. Actuate rocker switch, telescoping in the 1st telescopic section

locked to the LPU from the pinning hole 100% to the pinning hole
0%. If the length measuring device of the LPU is functioning, the
pinning position of the telescopic drive can be taken from the cor-
responding table (see the section "Telescoping" under "Locking
and pinning positions of the telescopic drive"). If the length
measuring device does not work, the pinning position must be
estimated.
7. Actuate the button with the corresponding symbol to "pin" the

telescopic section. While doing so, slowly telescope in or out
around the pinning point until the telescopic section is pinned.
The pinning procedure is completed as soon as the LPU is in the
state "locked and pinned".
Observe the correct sequence: First move to the pinning position,

then pin!

locking".


LPU.
Once the unlocking procedure has been completed success-

fully, the LPU reports back the state "unlocked and pinned".
The boom section is pinned to the next larger boom section. The tele-
scopic drive can be driven freely.
As a result, the sample manual telescoping procedure is in effect
over. Proceed analogously to telescope the other telescopic sections.
After completing emergency control and restoring all electric connec-
tions to the central electrical unit, the position of all individual tele-
scopic sections must be "taught" (set and saved) (see the section
"Telescoping" under "Manual telescoping").
The states of the locking and pinning unit are locked against each
other mechanically and cannot lead to critical situations, even if oper-
ated incorrectly.
1098 82640 2021-04-22

21.3.7 Fault Messages

Monitoring ele-
Display Comments (action)
ment
CAN-BUS - Communication between manual control panel (HMI)
and the mobile control unit (Master) disrupted.
Err0 Check that the HMI is correctly connected to the mobile control unit
"Master". If required, change cables. Contact a service technician if
the fault persists.
CAN-BUS - Communication between Master and Slave disrupted.
Check that the Master and Slave components of the mobile control
Err1 unit are correctly connected and the cables are not transposed. If
required, change cables. Contact a service technician if the fault
persists.
CAN-BUS - Communication between Master and Slave (at Slave)
disrupted.
Err2
Cables between Master and Slave transposed. Swap over the ca-
bles. Contact a service technician if the fault persists.
Controller on the wrong interface. Controller wrongly connected.
Check the connections. Controller Master must be connected to
Err3
"X9100"/"X791" and Controller Slave must be connected to
"X9101". Contact a service technician if the fault persists.
Different software releases on the Master and Slave of the mobile
Err9 control unit.
Contact a service technician.
The fault messages can be acknowledged by pressing the button

shown.
Not all errors occur in every crane type.
82640 2021-04-22 1099

1100 82640 2021-04-22

22.1 General
Emergency operation means that all the main crane movements for
recovery / deconfiguration can still be carried out even if the crane en-
gine or a pump fail. To do so, an external emergency unit must take
over the supply of the crane's hydraulics.
Fig. 1209: Emergency Unit
The description below refers only to the depicted 50 kW power unit

which can be obtained from the crane manufacturer.
Detailed information on this unit which goes beyond the scope of
these operating instructions can be found in the manufacturer's docu-
ments in the "Various" part. This information must also be observed.
DANGER
observed.
Comply with all safety instructions for emergency op-
eration which are also valid for normal operation.
WARNING
Risk of accidents when carrying out the "Emergency
operation" procedure without the relevant knowl-
edge!
Before carrying out an emergency operation, train for
this special operating mode at least once.
The crane operator must understand/master emergency operation.

Only this will ensure safe operation and rapid handling in emergency
situations.
82640 2021-04-22 1101

22.2 Emergency Unit
22.2.1 Intended use

The emergency unit may only be used for the purpose described be-
low – emergency operation of a crane.
NOTE
Risk of damage due to incorrect use!
The emergency unit may not be used for jump starting the crane
as this could cause damage to the power unit and to the crane.
22.2.2 Main Components of the Emergency Unit

A diesel engine drives 3 hydraulic pumps for the 50 kW emergency
unit described.
1 Fuel tank (diesel); filler necks 2 Diesel engine (HATZ) – detailed

under cover plate information can be found in the
corresponding manufacturer's
documents in the "Various" part
3 Junction box 4 Pumps
5 Park position for control cable
plug of the junction box
1102 82640 2021-04-22

1 Potentiometer 2 Operating and monitoring ele-

ments, (see "Operating and mon-
itoring elements")
3 Serial plate 4 Hydraulic connection (see "Con-
necting the emergency unit")
5 External Start-Socket 24 V 6 Starter batteries
22.2.3 Operating and control elements

One of the operating and control elements described below is instal-
led, depending on the design of the emergency unit.
82640 2021-04-22 1103

Operating panel "MC 714":
Fig. 1212: Operating elements
1 Engine in operation 2 Charge control

3 Oil pressure 4 Engine temperature
5 Change or clean air filter 6 Preheating
7 Ignition Switch

1 Indicator light Engine in operation
2 Indicator light Charge control
3 Indicator light Oil pressure
4 Indicator light Engine temperature
5 Indicator light Change or clean air filter
6 Indicator light Preheating
Ignition Switch
0 = Off
7 Key
1 = Operation
2 = Start
Table 20: Operating elements
1104 82640 2021-04-22

Operating panel "MC 714" with exhaust gas recirculation:

Indicator lights (1)/(2) are assigned as listed below for the engine de-
sign with exhaust return valve (EGR):
1 Engine diagnosis 2 Malfunction in the exhaust gas

recirculation system
Operating panel "ttCAN":
1 Push button - regeneration of 2 Ignition Switch

the diesel particle filter (optional)
3 Preheating display 4 Charge control
5 Air filter maintenance display 6 Maintenance interval display
7 Fault display for exhaust return 8 Regeneration of the diesel parti-
valve and diesel particle filter cle filter is activated
9 Regeneration of the diesel parti- 10 Exhaust gas temperature is too
cle filter was suppressed low
11 Engine fault 12 Warning - coolant temperature
13 Warning - oil pressure 14 Engine in operation
82640 2021-04-22 1105

Item Object/lamp Function

Push button:
1 Activate or suppress the regeneration of the diesel particle filter (see 22.2.6.4
Suppressing the regeneration of the diesel particle filter, side 1112).
Ignition Switch
0 = Off
2
1 = Operation
2 = Start
Preheating display:
3 Is illuminated at engine temperatures below 30°C. Start the engine if the display
has gone out.
4 Charge control
5 Air filter maintenance display
6 Maintenance interval display
Fault display for the exhaust return valve and diesel particle filter (see
7
22.2.6.3 Faults in the exhaust gas aftertreatment system, side 1111)
8 Regeneration of the diesel particle filter is activated
Regeneration of the diesel particle filter is suppressed (see 22.2.6.1 General

9
information on faults and displays, side 1107)
Regeneration of the diesel particle filter is not possible (see 22.2.6.1 General
10
information on faults and displays, side 1107)
11 Engine fault (see 22.2.6.2 Engine faults, side 1108)
Coolant temperature warning (see 22.2.6.1 General information on faults and

12
displays, side 1107)
Oil pressure warning (see 22.2.6.1 General information on faults and dis-
13
plays, side 1107)
14 Operating display: Engine in operation
Table 21: Operating elements
Regeneration cannot be suppressed in the "ttCAN" operating panel

design without the 'regeneration of the diesel particle filter' (1) push
button. In this case, regeneration starts automatically. The engine
may not be switched off during the regeneration procedure.
22.2.4 Specifications
In this regard, observe the manufacturer's documents in the "Various"
part.
1106 82640 2021-04-22

22.2.5 Transport and Storage
The emergency unit weighs approx. 1070 kg (2359 lbs).

The emergency unit can be transported either by attaching it to the 4
lifting lugs using the corresponding lifting tackle or with a forklift truck.
NOTE
Risk of damage due incorrect transport.
When transported using a fork lift truck, the fork lift truck must
grip under the emergency unit in the centre and it must be
moved using appropriate care.
Protect the emergency unit with the supplied tarpaulin against the ef-
fects of the weather and contamination (that is, cover it after every
use).
22.2.6 Fault finding and troubleshooting control panel
22.2.6.1 General information on faults and displays

Lamp Cause Remedy
Fault in the alternator or in
the charging current cir-
cuit of the alternator. The Inform Service.
battery is no longer being
charged.
Clean or replace the filter cartridge at the next opportunity
The filter cartridge is con- (see the lubrication and maintenance instructions in the
taminated. section 'Hydraulic system' under "Servicing the emergency
unit (optional)").
82640 2021-04-22 1107

Lamp Cause Remedy
Clean or replace the filter cartridge immediately (see the lu-

+
The filter cartridge is con- brication and maintenance instructions in the section 'Hy-
taminated. draulic system' under "Servicing the emergency unit (option-
(flashing) al)").
Carry out 500-hours maintenance (see the lubrication and

500-hours maintenance is
maintenance instructions in the section 'Hydraulic system'
due.
under "Servicing the emergency unit (optional)").
NOTE: It can cause damage to the diesel particle filter if re-
Regeneration of the diesel generation is suppressed for a long period of time. Activa-
particle filter is sup- ted the regeneration procedure as soon as possible (see
pressed. 22.2.6.4 Suppressing the regeneration of the diesel particle
filter, side 1112)!
Regeneration of the diesel
particle filter is not possi-
If possible, operate the engine with increased load.
ble: the exhaust gas tem-
perature is too low.
Increased coolant temper- Switch off the engine at the next opportunity and let it cool
ature. down.
+ Switch the engine off immediately. For details on trouble-

Coolant temperature is
shooting measures, see "Various" in the instructions for the
too high.
diesel engine.
(flashing)
Switch the engine off immediately. Check the oil level (see
the lubrication and maintenance instructions in the section
Oil pressure is too high or
'Hydraulic system' under "Servicing the emergency unit (op-
too low
tional)"). If the oil level is correct, contact your nearest
HATZ service station.
22.2.6.2 Engine faults
If there are faults, a flashing signal of the "Engine fault" lamp ap-
pears in the operating and control elements. The figure below shows
the structure using 2-2 (flashing signal short-long) as an example.
1108 82640 2021-04-22

Fig. 1216: Example of the flashing signal 2-2
1 Lamp on 2 Lamp off

3 Start signal 4 Pause
5 1. Digit / flashing short 6 2. Digit / flashing long
Flashing
signal
Section Possible causes Remedy
short-
long
Indicator light(s) or cables are Check the function and cables
defective. of the indicator lights.
Display and operating The power supply from the con- Check the power supply of the
1-1
elements trol unit is insufficient. control unit.
Other faults which are not speci-
fied in detail.
Cables of the crankshaft or cam- Check the cables. Inform
1-2 Speed sensor system
shaft sensor are defective. Service.
Air filter contaminated Service the air filter.
Charge air downstream of the
Clean the cooling elements.
aftercooler is too high.
1-3 Air flow
Cables of the charge air sensor /
intake vacuum sensor are defec- Check the cables.
tive.
Cables of the AGR sensor are
Check the cables.
Exhaust gas recircu- defective.
1-4
lation AGR cooler/valve clogged by
Clean the AGR cooler/valve.
sediment.
See 22.2.6.3 Faults in the
Overall fault of the Faults in the exhaust gas after-
1-5 exhaust gas aftertreatment
DPF system treatment system
system, side 1111.
82640 2021-04-22 1109

Flashing
signal
short-
long
Drain water at the preliminary
Water in fuel.
fuel filter.
Check the tank contents, fill
Fuel pressure is too low. up if required. Replace both
Fuel low-pressure fuel filters.
2-1
system
Ensure the fuel is cooled suffi-
Fuel temperature is too high.
ciently.
The cables of the fuel pump or
Check the cables.
sensor are defective.
Cables of the sensor system (in-
Fuel high-pressure jectors, rail pressure sensor,
2-2 Check the cables.
system pressure control valve, high-
pressure pump) are defective.
Check the oil level, top up with
engine oil if required. Use en-
Engine oil pressure is too
gine oil with a suitable viscosi-
high/too low.
Engine oil tempera- ty. Check the water hoses of
2-3 ture/engine oil pres- the oil cooler (bent hose).
sure
Engine oil temperature is too It might be necessary to clean
high. the oil cooler.
The sensor cables are defective. Check the cables.
Coolant level is too low. Top up coolant.
Engine coolant temperature too
Clean the cooling elements.
high.
3-1 Fluid cooling The coolant temperature sensor
Check the cables.
cables are defective.
Replace the temperature sen-
Temperature sensor is defective.
sor.
Glow plug cables are defective. Check the cables.
One or more glow plugs are de- Check the function of the glow
3-2 Preheating system fective. plugs.
Glow control unit (GCU) is de-
Inform Service.
fective.
1110 82640 2021-04-22

22.2.6.3 Faults in the exhaust gas aftertreatment system
Faults are indicated by the flashing of the lamp "Fault display for
exhaust return valve and diesel particle filter". For explanations on the
structure of the flashing signal, see 22.2.6.2 Engine faults,
side 1108.
Flashing
signal
flashing
pause
Check the DPF for
DPF is not leak-tight.
leak-tightness.
Pressure ratios in the die- Differential pressure sensor is de- Contact the HATZ
3-1
sel particle filter (DPF) fective. service station.
The differential pressure lead is not Check the differential
leak-tight or is clogged. pressure lead.
Cables are loose or defective. Check the cables.
Contact the HATZ
The high-current relay is defective.
service station.
4-1 High-current relay (HCR)
The glow spiral in the fuel vaporizer Replace the glow spi-
is defective. ral.
The fuse is defective. Replace the fuse.
Fuel pump to the fuel va-
5-1 Contact the HATZ
porizer The fuel pump is defective.
service station.
One or more sensors are defective:
Sensors for the diesel - differential pressure sensor
6-1
particle filter (DPF) - temperature sensors in the diesel Contact the HATZ
oxidation catalytic converter service station.
(DOC)
Power supply to the control unit out-

side of the permitted range.
Possible faults in:
Contact the HATZ
- Cables
Control unit for diesel par- service station.
10-1 - Battery
ticle filter (DPF)
- Three-phase generator
Contact the HATZ

Control unit is defective.
service station.
82640 2021-04-22 1111

Flashing
signal
flashing
pause
Check the cables,
Control unit communica- Communication between different contact the HATZ
12-1
tion control units is disrupted. service station if re-
quired.
Engine emergency pro- The engine is in the emergency pro- Contact the HATZ
16-1
gram gram. service station.
Flashing
signal
flashing
long
The diesel particle filter is heavily clogged with soot particles.
Regeneration proce- Active regeneration procedure (see
dure has been sup- 22.2.6.4 Suppressing the regener-
pressed for a longer pe- ation of the diesel particle filter,
Regeneration of the die- riod of time. side 1112).
1 sel particle filter Do not switch off the engine during
(first warning stage) The regeneration was
the regeneration procedure as far
aborted several times
as permitted by the working environ-
due to an engine stop.
ment.
Fuel vaporizer function
Check the fuel vaporizer.
restricted.
Regeneration of the die- Diesel particle filter is Replace the diesel particle filter
2 sel particle filter clogged and must be within the Hatz EasyCleanProgram
(Second warning stage) treated. and have it treated professionally.
22.2.6.4 Suppressing the regeneration of the diesel particle filter
NOTE
Risk of damaging the diesel particle filter!
If the regeneration of the diesel particle filter is suppressed for a
long time, a large amount of particles will build up in the filter. This
can damage or destroy the diesel particle filter.
Only activate the "Suppress DPF regeneration" switch when
needed and switch it off again as soon as possible.
1112 82640 2021-04-22

1. Press and hold the push button for max. 2 seconds.
The regeneration of the diesel particle filter will be suppressed

when the engine is running.
The display lights up when the regeneration of the diesel filter particle
filter is suppressed.
NOTE
Damage to the air particle filter due to long-term suppression
of the regeneration!
Reactivate the regeneration of the diesel particle filter as soon
as possible.
2. Press the push button again.
The regeneration of the diesel particle filter is reactivated.
22.3 Connecting the Emergency Unit

1. Securely put down the emergency unit next to the crane chassis.
The actual determination of the installation site must be done de-
pending on the conditions on site, the location of the connection
couplings on the crane and the length of the hydraulic hoses.
The corresponding hydraulic connections are behind a flap in the

crane chassis trim (left side, rear driver's cab). The distance be-
tween the hydraulic connections of the crane chassis and the unit
must be selected so that the hydraulic hoses can subsequently be
fitted without strain or stresses. The length of the hoses is 3 m
(9.8 ft) for both suction hoses (NW 42 and NW 35). The length for
the other hoses is 7 m (23 ft).
2. Unlock the flap on the crane chassis and fold down. Tools nee-
ded depending on the design of the crane: Allen key 8 mm or bit
key.
82640 2021-04-22 1113

3. Connect the hydraulic lines. No diesel engine (neither unit nor

crane) may be running to do this. To do so, connect the hydraulic
couplings from the emergency unit listed below with the identical
ones on the crane.
The hydraulic hoses needed to make the connection are supplied
with delivery. Due to the different nominal widths (NW) of the individu-
al couplings, they can be assigned without risk of being confused or
interchanged. In addition, the hoses are marked accordingly.
Fig. 1217: Hydraulic connections on the emergency unit Fig. 1218: Hydraulic connections on the crane
N Anticavitation (NW 25) N Anticavitation (NW 25)
P2 Pump 4 (control pressure) (NW 16) P2 Pump 4 (control pressure) (NW 16)
P1 Pump 1 (NW 16) P1 Pump 1 (NW 16)
S2 Anticavitation S2 (NW 32) S2 Anticavitation S2 (NW 32)
S1 Suction adapter S1 (NW 40) S1 Suction adapter S1 (NW 40)
B Slew gear, functions of the crane chassis (NW 16) B Slew gear, functions of the crane chassis (NW 16)
T Tank (NW 20) T Tank (NW 20)
Characteristics at the emergency unit

The hose from connection "P4" must be screwed onto connection
"P3" (as illustrated). This means that these two connections are inter-
nally bridged.
Hydraulic coupling "A" is not needed and remains closed with the
cap.
1114 82640 2021-04-22

Fig. 1219: Stop valve
4. Move the stop valve from the "open" position (dotted line) into
the locked position (continuous line).
If the stop valve is not placed in the locked position, some of the oil
will flow out and the speed of the crane movements during emer-
gency operation will be reduced additionally.
After completing emergency operation, the stop valve must be

placed back in the "open" position for normal operation. Otherwise,
this will cause knocking in the hydraulic system as there can no lon-
ger be any release of pressure.
Fig. 1220: Junction box
5. Connect the electric cables. To do so, move the control cable

plug of the emergency unit junction box out of the park position
and plug into the corresponding socket (X4250B).
82640 2021-04-22 1115

22.4 Carrying out Emergency Operation
22.4.1 General
The crane movements can only be carried out at reduced speeds

during emergency operation. This is why emergency operation is
only for completing crane work which had already been started or
for placing the crane in a safe state.
Emergency operation can be carried out for superstructure functions

(such as slewing, telescoping, luffing, raising, configuring the counter-
weight and tilting the cab, optional) as well as for functions on the
crane chassis (suspension, outriggers).
Emergency operation is not possible if the crane's electrical system

is not ready for operation (for example, if the batteries are empty).
The crane's electrical system must first be made ready for operation.
22.4.2 Before starting the emergency unit's motor

1. Connect the emergency unit (see "Connecting the emergency
unit in this section").
NOTE
Risk of damage due to the pumps running dry.
This must be done before starting the emergency unit motor,
which is described below. Otherwise, the pumps could run dry.
You must also observe the detailed specifications in the motor manu-
facturer's instructions (of the emergency unit) in the "Various" part for
the points listed below before, during and after starting the motor.
1116 82640 2021-04-22

1 Oil dipstick 2 Fuel hand pump
2. Before first starting the emergency unit motor or if the fuel sys-
tem has been run dry, bleed the system using fuel hand pump
(2).
3. Before starting the emergency unit motor, always check the oil
level at oil dipstick (1), top up motor oil if required.
22.4.3 Starting the emergency unit motor
Fig. 1222: Emergency unit - potentiometer
1. Set the potentiometer (see detail) to the average value.
82640 2021-04-22 1117

Fig. 1223: Operating elements Fig. 1224: Operating elements

1 Ignition Switch 1 Ignition Switch
2 Preheating lamp 2 Preheating lamp
3 Charge control 3 Charge control
4 Indicator light 4 Indicator light
5 Oil pressure display 5 Oil pressure display
2. Insert the ignition key in the ignition switch (1) up to the stop and
set to position "1". Battery charge indicator (3) and oil pressure
indicator light (5) are illuminated. If temperatures are below 0°C,
preheating lamp (2) is also illuminated.
3. Start the engine once the preheating display has gone out. To do
so, turn the ignition key to position "2". As soon as the engine is
running, release the ignition key. Battery charge indicator (3) and
oil pressure indicator light (5) must go out immediately after start-
ing up.
Indicator light (4) is now illuminated, indicating that the engine
is operating.
Fig. 1225: Emergency unit - potentiometer
4. Reset the potentiometer (see detail) to idle.
1118 82640 2021-04-22

5. Observe the points listed below after starting the motor:

- Check all hydraulic connections on the emergency unit and on
the crane chassis for leak-tightness. Switch the engine off im-
mediately if there are leaks.
- To achieve the maximum volume flow rate, the potentiometer
(see detail) must be set to full throttle at a later point when
carrying out emergency operation.
If the engine is equipped with an exhaust return valve (EGR), an en-

gine fault is indicated by one of the corresponding indicator lights
(not shown here, see 22.2.3 Operating and control elements,
side 1103) lighting up. In this case: Stop engine immediately, deter-
mine cause and rectify.
22.4.4 Setting crane control to emergency operation

1. Switch on the ignition in the superstructure.
This also starts the crane control.
2. Select the correct operating mode and actuate the depicted

"Crane operation" button.
The "Main Menu" screen appears.
3. Press the depicted button in the main menu to switch the crane
control to "Emergency operation".
The key changes in appearance as illustrated (from "OFF" to

"ON").
In addition, the symbol shown appears in the Crane operation

screen.
The "Emergency operation" function must be activated at the crane

control. Otherwise, no further crane movements can be carried out
using the control levers of the crane operator's cab.
82640 2021-04-22 1119

The required crane movements are controlled as during normal oper-

ation. In this regard, refer to the description in the corresponding sec-
tion.
If only crane chassis functions are to be actuated during emergency
operation, control can alternatively also be switched to emergency
operation in the cab of the crane chassis – this saves you from get-
ting into the crane operator’s cab. To do so:
- Switch on the ignition of the crane chassis.
- Switch on the depicted lockable switches in the cab of the crane

chassis. The fitted indicator light lights up.
22.5 After Emergency Operation

1. Switch off the emergency unit motor. To do so, turn the ignition
key to position "0".
The motor is switched off and the indicator lights go out.
2. Pull out ignition key

3. Switch off the "Emergency operation" function on the crane. To
do this, switch off the "Emergency operation" function at the
crane control and switch off the ignition.
After emergency operation only affecting the crane chassis, alterna-

tively switch off the pictured lockable switch located in the cab of the
crane chassis. The built-in indicator light goes off. Switch off the igni-
tion.
4. Place the stop valve back in the "open" position.
After completing emergency operation, the stop valve must be

placed back in the "open" position for normal operation. Otherwise,
this will cause knocking in the hydraulic system as there can no lon-
ger be any release of pressure.
1120 82640 2021-04-22

5. Remove hydraulic hoses between the crane and the emergency

unit.
6. Disconnect the electrical connection between the crane and
emergency unit.
7. Close all couplings on the crane, emergency unit and hydraulic
hoses using protective caps.
8. Close all open covers again according to instructions.
82640 2021-04-22 1121

1122 82640 2021-04-22

23 Dismantling and Assembly of the Main Boom (Optional)
23.1 Safety Instructions
WARNING
fied.
and qualified personnel.
WARNING
Risk of crushing when fitting and dismantling the
main boom!
When mounting and dismounting the main boom, there is
a risk of crushing between the main boom foot section
and the bearings as well as between the main boom and
superstructure frame.
No one may be in the danger zone.
In particular, observe the instructions on risks in the
section "Safety instructions" under 1.13 Assembling
and dismantling crane components, side 59 and the
procedure described below.
WARNING
ary equipment!
equipment).
Observe the detailed information on this subject in
the section "Structure of the mobile crane" under
"Getting on and down from the crane", in particular
"Getting on and off using mobile multi-purpose lad-
ders" and "Attachment eyelets for personal protective
equipment".
82640 2021-04-22 1123

DANGER
Risk of accidents if you are in the endangered area!
In particular, it is prohibited to enter the area beneath
or in the vicinity of a suspended load (main boom)
during the assembly/dismantling procedure.
WARNING
If the safety instructions are not observed, there is a
risk of accidents when assembling and dismantling
the main boom!
Be sure to observe the safety instructions listed be-
low.
- Main boom assembly and dismantling must be carried out by an

experienced team. Every individual assembly and dismantling step
must be planned exactly. All component parts must be safely and
securely supported or held using auxiliary cranes.
- Furthermore, the crane manufacturer recommends that pre-train-
ing be carried out on a safely cordoned-off piece of land to enable
the assembly team to practise all relevant procedures, under ob-
servation of all applicable health and safety measures, BEFORE
the actual on-site set-up is carried out.
- The overall responsibility for assembly and dismantling and for the
operational supervision lies solely with the crane operator.
1124 82640 2021-04-22

23.2 General
The main boom can be removed from the superstructure for repair
purposes and/or to achieve certain axle loads. During assembly or
dismantling, changing the angle of the main boom may be required.
Therefore two auxiliary cranes are required.
The transport condition without the main boom is described in the

operating instructions of the crane chassis in the "Driving" section at
"Defined driving condition".
To dismantle the main boom, the pin between the luffing cylinder and
the main boom (luffing cylinder headpin) and the one between the
main boom and the superstructure (main boom foot section pin) must
be removed. Normally, the pins are removed or installed using an en-
closed hydraulic mobile cylinder intended for this purpose.
To position the mobile cylinder and to hold the pulled bolts, locating
shells are installed directly below these two bolts on the right side of
the crane.
NOTE
Risk of collision when setting down the main boom in the
boom support device.
If the counterweight base plate is put down on the crane chassis,
there is a danger of collision between the draw bars of the counter-
weight base plate and the locating shell at the luffing cylinder head-
pin while setting the main boom down in the boom support.
This shell must therefore then be dismantled.
If the hydraulic mobile cylinder or the locating plates are not available,
the corresponding work procedures must be performed using other
suitable work equipment (e.g. work platform, work scaffolding, auxili-
ary crane etc.).
WARNING
Risk of accidents from additional hazards resulting
due to the absence of the auxiliary equipment descri-
bed and the dead weights of the pins needing to be
additionally moved etc!
Pay attention to secure stance when performing the
work.
Pick up the pin with the auxiliary crane and secure
this from falling down.
In case of any doubt, consult the crane manufacturer.
82640 2021-04-22 1125

23.3 Transport of the dismantled main boom
23.3.1 Transport dimensions and weights
Fig. 1227: Main boom AC250-5
Length "L" Width "B" Height "H" Weight

13660 44.8 2670 8.8 1775 5.8 20625 45470
Fig. 1228: Main boom AC220-5
Length "L" Width "B" Height "H" Weight

13531 44.4 2670 8.8 1810 5.9 21000 46300
Suspension loads
Suspension load Suspension load

Crane Weight of
of main boom foot of main boom
type main boom
section head
Approx.
20625 kg / Approx. 10585 kg / Approx. 10040 kg /
AC 250-5
Approx. Approx. 23336 lbs Approx. 22135 lbs
45470 lbs
Approx.
21000 kg / Approx. 10840 kg / Approx. 10160 kg /
AC 220-5
Approx. Approx. 23900 lbs Approx. 22400 lbs
46300 lbs
1126 82640 2021-04-22

23.3.2 Attachment points
Fig. 1229: Attachment points - main boom (schematic diagram)
The centre of gravity "S" of the main boom head in both crane types
is about 6.2 m (20.3 ft) from the main boom base bearing in the direc-
tion of the sheave head.
23.3.3 Lashing eyes
Fig. 1230: Lashing eyes on both sides of the main boom (schematic diagram)
Depending on the crane design, the lashing eyes are located on the
main boom.
82640 2021-04-22 1127

WARNING
Risk of accidents!
Do not hang the main boom on lashing eyes.
23.4 Before Removal

1. Support the crane on outriggers and align horizontally. The sup-
port width must be at least 5.54 m / 18.2 ft.
WARNING
Risk of accidents if the crane is not supported on
outriggers!
To fit and remove the main boom, the crane must al-
ways be supported on outriggers.
2. Ensure that:
- Telescopic sections are retracted and pinned.
- No counterweights are fitted.
- An operating mode has been selected that corresponds to the
actual crane status.
3. Unreeve the hook block or hook suspension gear and reel the
hoist rope onto the rope drum.
Fig. 1231: Hoist limit switch on the main boom head
4. Take the hoist limit switch (see arrow) at the main boom head
out of operation (see 8.6.3.3.3 Bridging the hoist limit switch
(putting it out of operation), side 369).
1128 82640 2021-04-22

Fig. 1232: Shift weight
5. Attach the shift weight to the side on the main boom head in the
transport position and secure it against falling down.
23.5 Dismantling
23.5.1 Perform Preparative Work
DANGER
Persons must stay clear of the area beneath the
raised main boom.
1. Using the luffing gear, raise the main boom to approx. 45° and
slew the superstructure approx. 15° to the side. This ensures that
the assembly personnel does not need to go under the raised
main boom during the following fitting of the luffing cylinder
mounting.
2. Set up the luffing cylinder mounting (see arrow) in the designated

area at the end of the chassis frame between the two metal
sheets. The lashing belt is attached to these plates later on, to
fasten the dismantled luffing cylinder.
NOTE
Risk of collision when the luffing cylinder mounting is not
used properly.
Use the luffing cylinder support mount for nothing else except
setting down the luffing cylinder. Otherwise remove it.
3. Slew the superstructure so that the main boom is to the rear.
82640 2021-04-22 1129

4. Lock the slew gear parking brake. To do this, actuate the switch
accordingly. The indicator light in the switch is not illuminated.
Fig. 1233: Luffing cylinder mounting
1 Luffing cylinder mounting 2 Luffing cylinder
NOTE
Risk of damage if the prescribed procedure is not observed!
The luffing cylinder support mount is constructed solely for the
weight of the luffing cylinder; the luffing cylinder is therefore not
permitted to transmit the weight of the main boom onto the luff-
ing cylinder support mount.
5. Luff down the main boom until the luffing cylinder (2) is posi-
tioned immediately above (3-5 mm / 0.1-0.2 in) the luffing cylin-
der support mount (1).
1130 82640 2021-04-22

23.5.2 Attaching the safety mast (optional) for anti-fall protection

For the following assembly procedure, it is necessary for an assistant
to go to the area from where the attachment points on the main boom
foot section can be accessed.
Fig. 1234: Safety mast on the superstructure frame
To ensure safe working at height there, the safety mast (see arrow)
needs to be attached.
1. Release safety mast from the transport position.
This is the same safety mast that can also be used for anti-fall pro-
tection when attaching the counterweight. For this reason, observe
the detailed information on handling the safety mast, section "Coun-
terweight" under " anti-fall protection using safety mast".
2. From the ground, set the safety mast down close to the fitting lo-
cation on the superstructure frame onto the crane chassis.
3. Using a corresponding stepladder, climb onto the crane chassis
and secure it from falling down using a safety belt.
82640 2021-04-22 1131

Fig. 1235: Safety mast on the superstructure frame
1 Safety mast 2 Tube
4. Insert the safety mast (1) in the corresponding tube (2) on the su-
perstructure frame.
For this reason, observe the detailed information on handling the

safety mast in the "Counterweight" section under "Anti-fall protection
using safety mast".
1132 82640 2021-04-22

Fig. 1236: Locking the safety mast

1 Locking bar
2 Tube
5. In addition, the safety mast must be secured to the superstruc-

ture frame against being pulled out. To do so, the bottom part of
the safety mast must be locked to the tube (2) in which the safety
mast is inserted using locking bar (1).
The attached safety mast exceeds the crane height of 4 m (13.1 ft).
For this reason it will have to be dismantled - before moving the
crane at the latest. To do so, proceed as described in the reverse
sequence.
82640 2021-04-22 1133

23.5.3 Attaching the main boom
Fig. 1237: Anti-fall protection on superstructure frame
1 Attachment eyelets 2 Safety mast

3 Control unit
WARNING
Risk of falling when working on the superstructure!
If the optional safety mast is not available, the fitter
must be secured against falling by other measures
(e.g. scaffolding).
1. To attach the lifting tackle to the attachment point on the main

boom foot section, proceed as follows:
1.1. Climb up the supplied multi-purpose ladder, which has
been properly positioned, in the direction of the catwalk of
the control unit (3).
1.2. Secure yourself - from the ladder - with a safety belt to the
intended attachment eyelets (1) on the superstructure
frame as soon as you can reach these.
1.3. From the ladder, enter the catwalk of the control unit.
1.4. While already secured, additionally attach yourself on the
safety mast (2).
1.5. Undo the lock on the superstructure frame and - secured
to the safety mast (2) - in the required position for attach-
ing the lifting tackle.
Since the total weight and dimensions only differ slightly, the follow-
ing specifications basically apply for both main boom lengths 70 m
(229.7 ft) and 78 m (255.9 ft).
1134 82640 2021-04-22

Before attachment, position the auxiliary cranes so as to bring the

boom head exactly into a vertical position above the corresponding
slinging points.
Fig. 1238: Attachment points - main boom (schematic diagram)
DANGER
Risk of the attachment shackles overloading and
breaking away at the main boom foot section due to
oblique pull.
Use the cross beam (as illustrated).
NO oblique pull.
2. Attach main boom to the two auxiliary cranes:

- Using a cross beam at the attachment points on the main
boom foot section: see detail "1". Depending on the design of
the device, the attachment points can also be designed as
load attachment eyes.
- using a 2-string suspension tackle on the head axle: see detail
"2".
The weight as well as the weight distribution of the respective main
boom are listed under 23.3 Transport of the dismantled main boom,
side 1126.
82640 2021-04-22 1135

DANGER
Risk to life and limb of the required auxiliary equip-
ment is overloaded!
If auxiliary cranes are overloaded, there is a risk of rup-
ture and overturning; overloaded lifting tackle can tear.
Select the auxiliary cranes and lifting tackle according
to the specified weight of the main boom (or attached
loads).
The required lifting capacity including sufficient safety
factors - in particular with regard to the simultaneous
use of 2 cranes - should be determined according to
the applicable national regulations.
3. Tensioning the lifting tackle with auxiliary cranes. The auxiliary

cranes need to take over the load of the main boom.
Fig. 1239: Distribution boxes
It is only ever permitted to create and release hydraulic connections

in the depressurised state, that is, the engine may not be running.
4. Release the hydraulic hoses between the superstructure and the

main boom. To do so, release the quick-release locks of all hy-
draulic couplings in the area of the brackets of the hydraulic
quick connections and close each of them with a protective cap.
The overview of the crane in the diagram only serves to locate the
disconnecting points of hydraulics and electrics. The position of the
superstructure "to the front" does not correspond with the actual po-
sition at this time.
1136 82640 2021-04-22

Fig. 1240: Distribution boxes
X0087 Plug X300 Distribution box
5. Disconnect the electrical connections. To do so:

5.1. Release the "X0087" plug on the "X300" distribution box.
The corresponding hose clip must also be released; other-
wise the connector cable would still be connected to the
mounting plate at the basic case.
5.2. Release the plug coupling of the two violet CAN cables.
5.3. On the version with load hook camera (option): Undo the
plug connection of the video receiver cable.
6. Connect the quick release couplings of the two supplied 10 m
(32.8 ft) hydraulic hoses at the couplings (1) and (10) of the re-
leased hydraulic hoses.
82640 2021-04-22 1137

Fig. 1241: Mobile cylinder
P Coupling T Coupling
NOTE
Risk of damage when the quick disconnect couplings are con-
nected incorrectly!
Closed or only partially open non-return valves of the quick release
couplings can cause damage to the hydraulic system.
Screw quick disconnect couplings in up to the stop.
7. Connect mobile cylinder hydraulically. To do so, attach the two

free couplings of the 10 m (32.8 ft) hydraulic hoses which were
connected in the previous work step to the crane hydraulics as
described below:
- Hose of coupling "10" of the crane hydraulics on coupling "P"
of the mobile cylinder
- Hose of coupling "1" of the crane hydraulics on coupling "T" of
the mobile cylinder
1138 82640 2021-04-22

23.5.4 Luffing cylinder headpin
23.5.4.1 Perform Preparative Work

A description is given below as to how the pin with which the luffing
cylinder and the main boom are connected is to be removed (luffing
cylinder headpin).
Fig. 1242: Axle mounting
1. First release the two inner screws (see arrows) on the axle hold-
er on the left boom side.
2. For the version with the superstructure central lubricating system
(optional): Release the connection of the lubricating lines for the
two lubricating nipples at the bearing socket of the luffing cylinder
headpin.
82640 2021-04-22 1139

Fig. 1243: Mobile cylinder on the luffing cylinder headpin
1 Support elements 2 Mobile cylinder

3 Locating plate
CAUTION
Risk of crushing when engaging the mobile cylinder!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder
and the locating shell.
3. Place the mobile cylinder (2) in the locating plate (3) on the luff-
ing cylinder headpin so that the support elements (1) of the mo-
bile cylinder are located in the inner bearing points.
The weight of the mobile cylinder is approximately 20 kg (44 lbs).
4. Start the engine.
23.5.4.2 Supplying the mobile cylinder with hydraulic oil

Enable supply of the mobile cylinder with hydraulic oil. To do so:
1. Press the depicted key in the "Quick menu" screen.
The "Main Menu" screen appears.
1140 82640 2021-04-22

2. Actuate the depicted key in the "Main Menu" screen.
The "Function display" screen appears.
3. Actuate the button for the "Telescoping" crane movement in the

"Function display" screen – it becomes "green" and specifica-
tions regarding "Telescoping" appear in the screen.
Only then does the "Enable hydraulic oil" button appear at the
bottom of the screen.
4. Actuate the "Enable hydraulic oil" button shown – it becomes

"green".
Only then is the supply of the mobile cylinder with hydraulic oil
enabled.
5. Ensure that the luffing cylinder is depressurised. To do so, call

up the "Function display" screen in the control display. Proceed
as was just described previously for "Telescoping".
6. Actuate the button for the "Luffing gear" crane movement in the
"Function display" screen – it becomes "green" and specifica-
tions regarding "Telescoping" appear in the screen.
82640 2021-04-22 1141

Fig. 1244: "Function display" screen
7. "Scroll through" the display until the end – the displays on the
current luffing cylinder pressure appear there. The displayed ac-
tual value must be in the range of "0" (display in bar). Only this
ensures that the luffing cylinder is without pressure.
If the displayed value is too high, then you must proceed as follows in
order to depressurise the luffing cylinder:
- Ensure that both auxiliary cranes have completely taken on the
main boom's load.
- Luff the luffing cylinder somewhat downwards by actuating the cor-
responding control lever until the required value has been ach-
ieved.
The pulling of the luffing cylinder headpin with the mobile cylinder
described below will not be possible until the luffing cylinder has
been depressurised.
23.5.4.3 Pulling the Luffing Cylinder Headpin
WARNING
Risk of overturning when relieving the mobile cylin-
der of load!
There is always a danger that the mobile cylinder could
tip out backwards out of the locating plate when pressure
is reduced during any of the following working proce-
dures.
1142 82640 2021-04-22

1 Clamshell 2 Control levers

3 Mobile cylinder 4 Locating plate
5 Pins
1. Extend the mobile cylinder (3) by actuating the control lever (2)
accordingly. To do so, lightly tilt mobile cylinder (3) in locating
plate (4) up and down again so that the clamshell (1) hooks onto
the cross bar of the head of bolt (5).
2. Retract the mobile cylinder (3) completely by actuating the con-
trol lever (2) accordingly. The luffing cylinder pin will be thereby
pulled by about 3/4.
1 Clamshell 2 Mobile cylinder

3 Support elements 4 Locating plate
5 Pins
3. Remove mobile cylinder (2) from locating plate (4) and fit it in the
outer bearing points with support elements (3), extend the piston
rod with the clamshell (1) and tilt it back into locating plate (4) so
that clamshell (1) hooks onto the cross bar of the head of bolt
(5).
82640 2021-04-22 1143

1 Control levers 2 Mobile cylinder
4. Retract the mobile cylinder (2) by actuating the control lever (1)
accordingly.
Fig. 1248: Luffing cylinder headpin
This pulls out the luffing cylinder headpin (see arrow) fully (fi-
nal state shown).
5. Switch off the engine.

6. Remove the mobile cylinder and keep it ready for the following
work step "Pulling the main boom foot section pin".
1144 82640 2021-04-22

Fig. 1249: Locating plate
1 Forelock 2 Coupling pins
7. Secure the luffing cylinder headpin in the locating shell (transport

position). To do this, release the coupling pins (2) from the trans-
port position and pin them as illustrated. Secure the coupling
pins (2) with tube clips (1) to prevent them from falling out.
8. Block the bottom of the luffing cylinder. To do so, place the stop
valve (see arrow) on the luffing cylinder in the locked position.
That should ensure that the luffing cylinder does not extend.
23.5.5 Main Boom Foot Section Pins
23.5.5.1 Perform Preparative Work

A description is given below as to how the pin with which the super-
structure frame and main boom are connected is to be removed
(Main boom foot section pin).
Basically, this pin is pulled analogously to the sequence described on
the previous pages concerning the luffing cylinder headpin. There
are, however difference in details.
82640 2021-04-22 1145

Fig. 1251: Locating plate (transport posi- Fig. 1252: Locating plate (operating posi-
tion, schematic diagram) tion, schematic diagram)
1 Pins (pinning) 1 Pins (pinning)
2 Pins (pivot point) 2 Pins (pivot point)
WARNING
Risk of accidents due to missing pinning!
In the following description, pin (2) must always be inser-
ted in the position shown. It is used as the pivot point and
ensures that the foldable part of the plate cannot fall
down.
Ensure that the pin (2) is always inserted as shown.
1. First unfold the locating plate of the main boom foot section pin
(right-hand side of the crane, below the main boom foot section
pin) out of the transport position (see Fig. 1251, side 1146) and
fold it into the operating position (see Fig. 1252, side 1146). To
do so, release the bolt (1), fold the folded part of the plate to the
front and pin into this position with the bolt (1). Secure the bolts
at the top and bottom with forelock.
Fig. 1253: Locating plate (schematic diagram)
2. Release both bolts (see arrows).
1146 82640 2021-04-22

3. For the version with the superstructure central lubricating system

(optional): Release the connection of the lubricating lines for the
lubricating nipples at the bearing socket of the main boom foot
section pin.
4. Start the engine and activate the hydraulic supply (see 23.5.4.1
Perform Preparative Work, side 1139 and 23.5.4.2 Supplying
the mobile cylinder with hydraulic oil, side 1140).
23.5.5.2 Pulling the Main Boom Foot Section Pin
Fig. 1254: Locating plate with mobile cylinder (schematic diagram)
1. Extend the mobile cylinder (2) completely by actuating the con-

trol lever (1) accordingly.
82640 2021-04-22 1147

1 Bracket 2 Clamshell
3 Mobile cylinder
CAUTION
Risk of crushing when engaging the mobile cylinder!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder
and the locating shell.
WARNING
Risk of overturning when relieving the mobile cylin-
der of load!
There is always a danger that the mobile cylinder could
tip out backwards out of the locating plate when pressure
is reduced during any of the following working proce-
dures.
The weight of the mobile cylinder is about 20 kg (44 lbs).
2. Position mobile cylinder (3) – as illustrated – so that the clam-

shell (2) hooks onto the cross bar of the bracket (1), which is
screwed together with the main boom foot section pin.
1148 82640 2021-04-22

1 Mobile cylinder 2 Locating plate

3 Support elements
3. Lower mobile cylinder (1) into the locating plate (2) so that sup-
port elements (3) of the mobile cylinder are set down in the inner
bearing points.

3 Locating plate
4. Retract the mobile cylinder (2) completely by actuating the con-

trol lever (1) accordingly.
This leads to the main boom foot section pin being partially
pulled – corresponding to the stroke of the mobile cylinder.
5. Place the mobile cylinder (2) into next outer bearing points of the
locating shell (3) and repeat the procedure as in the previous two
points.
6. Repeat this procedure until the support elements of mobile cylin-
der (2) are finally in the outermost bearing points of the locating
plate.
82640 2021-04-22 1149

Fig. 1258: Main Boom Foot Section Pins
The main boom foot section pin (see arrow) is now fully pulled
out.
23.5.6 Lifting out the main boom

1. Switch the engine off and remove the mobile cylinder.
2. Disconnect the hydraulic hoses from the mobile cylinder and
from the corresponding couplings on the superstructure and re-
move them. Close off free couplings with protective caps.
3. Put the loose hydraulic hoses and cables at the superstructure
into transport position. To do this, wrap the hoses and cables
with hose bundling band, place them on the light carrier pipe and
secure them against slipping with carabiner at the screw connec-
tion of the counter-weight lifting cylinder.
WARNING
Risk of accidents by the swinging main boom!
When lifting out the main boom, make sure that it
does not start swinging.
No one may come near the suspended main boom.
DANGER
Risk of crushing when lifting out the main boom.
When lifting out the main boom there is a risk of crushing
between the main boom and superstructure frame or be-
tween the main boom and the support on the ground
and/or the support of the transport vehicle.
NOTE
Risk of damage by the main boom twisting.
Make sure that main boom does not twist in the bearing points.
4. Vertically lift the main boom out of the bearing with auxiliary
cranes at the main boom foot section and luffing cylinder head.
1150 82640 2021-04-22

5. Lower the main boom onto the transport vehicle, support and
lash in place.
6. Release the lifting tackle on the main boom and remove it.
23.5.7 Concluding Work
Fig. 1259: Luffing cylinder (schematic diagram)
1 Lashing belt 2 Luffing cylinder
1. Firmly lash the luffing cylinder (2) on the luffing cylinder support
mount with the lashing belt (1).
2. Slide the main boom foot section pin manually back into the su-
perstructure frame and secure it using the screws loosened in
the 23.5.5.1 Perform Preparative Work, side 1145 section.
3. Fold back the foldable part of the locating shell into transport po-
sition. To do so, proceed in the reverse order as was described
in the 23.5.5.1 Perform Preparative Work, side 1145 section.
The locating plate in the operating position would exceed the permit-
ted transport width.
4. Retract the outriggers of the crane.
5. Fit the warning light (see arrow) in the luffing cylinder head hole
and secure. Insert the electrical supply line at the rear of the ve-
hicle in the respective socket (6-pin, rear underride guard).
To prevent the electric supply lead of the warning light being de-
stroyed, it must be fastened to the luffing cylinder so that it does not
fall onto the road surface.
82640 2021-04-22 1151

When driving the crane in this state, observe the "Driving" section at
"Defined driving condition" in the operating instructions of the crane
chassis.
23.6 Fitting the main boom

Assembly of the main boom occurs in reverse order to dismantling.
Make sure that:
- the crane is supported on outriggers correctly and is aligned (see
23.4 Before Removal, side 1128).
- main boom base and luffing cylinder set up on their bearing cor-
rectly.
- the electrical and hydraulic connections are restored in proper
fashion (plugs and plug connections with the same number, hy-
draulic couplings must open correctly).
- The O-rings for sealing of the bearing sockets of the main boom
foot section pin are checked for damage and, if necessary, re-
placed before the re-installation of the main boom.
- Depending on the crane design, a spacer is located above the
main boom foot section pin between the main boom foot section
and the superstructure frame to compensate for play. If the crane
was delivered with spacer, this must be fitted between the main
boom foot section and the superstructure frame on the cab side
during installation.
CAUTION
Risk of crushing when mounting the spacer!
Do not reach into the area between the main boom
foot section and the superstructure frame.
Mount spacer with an auxiliary aid.
1152 82640 2021-04-22

After the reattachment of the main boom foot section and luffing cylin-
der headpin, this bolt absolutely must be secured, and this is to be
done by screwing together with the respective axis holder.
The screws used for this (two for each) must be tightened up to the
prescribed torque.
Fig. 1260: Luffing cylinder head
1 Screw
Screw (zinc flake Torque

Fitting location Item
coated) Nm lbf ft
Luffing cylinder head 1 M 20 x 50, 10.9 470 ±35 347 ±26
Table 22: Torque
Fig. 1261: Main boom foot section
1 Screw
Screw (zinc flake Torque

Fitting location Item
coated) Nm lbf ft
Main boom foot sec-
1 M 24 x 100, 10.9 810 ±60 597 ±44
tion
Table 23: Torque
82640 2021-04-22 1153

DANGER
Risk of accidents due to crane not being in an opera-
tionally safe state!
No crane operation is permissible as long as these
bolts are not correctly fastened to the respective axis
holder.
NOTE
Risk of damage due to the luffing cylinder mounting not being
removed!
As soon as the main boom is fitted again, the unloaded luffing
cylinder mounting must be removed again and transported sep-
arately.
1154 82640 2021-04-22

Index of figures and tables
Index of figures
Fig. 1: Safety note (z82353)............................................................................................................................. 26

Fig. 2: Entire crane - main elements (schematic diagram).............................................................................. 70
Fig. 3: Main elements of the crane................................................................................................................... 71
Fig. 4: Main elements of the crane................................................................................................................... 72
Fig. 5: Overview of the ladders........................................................................................................................ 73
Fig. 6: Handles - crane operator’s cab............................................................................................................. 75
Fig. 7: Hinged ladder in the transport position (schematic diagram)................................................................ 76
Fig. 8: Folding ladder in the operating position................................................................................................ 77
Fig. 9: Hinged ladder in the transport position (schematic diagram)................................................................ 78
Fig. 10: Lashing strap for fastening the ladder................................................................................................. 79
Fig. 11: Permitted tread surfaces (AC 250-5/220-5)........................................................................................ 83
Fig. 12: Permitted tread surfaces (AC 160-5).................................................................................................. 83
Fig. 13: Permitted tread surfaces (AC 130-5).................................................................................................. 83
Fig. 14: Attachment eyelet PPE with plate....................................................................................................... 85
Fig. 15: Total overview..................................................................................................................................... 87
Fig. 16: Total overview..................................................................................................................................... 88
Fig. 17: Operating elements at the front of the cab.......................................................................................... 89
Fig. 18: Control panel, front............................................................................................................................. 89
Fig. 19: Front instrument panel (schematic diagram)...................................................................................... 90
Fig. 20: Instrument panel, side......................................................................................................................... 91
Fig. 23: Connections under side instrument panel........................................................................................... 93
Fig. 24: Roof console....................................................................................................................................... 94
Fig. 25: Operating elements - heating system and air conditioning (schematic diagram)............................... 95
Fig. 26: Operating elements - roof console, centre part................................................................................... 95
Fig. 27: Operating elements - roof console, rear part...................................................................................... 96
Fig. 28: Control console, right.......................................................................................................................... 96
Fig. 29: Control lever, right............................................................................................................................... 97
Fig. 30: Instrument panel arrangement, right-hand control console................................................................ 98
Fig. 31: Manual operating elements on the cab door....................................................................................... 98
Fig. 32: Operating elements in the footwell...................................................................................................... 99
Fig. 33: Control console, left............................................................................................................................ 99
Fig. 34: Control lever, left............................................................................................................................... 100
Fig. 35: Instrument panel arrangement, left-hand control console................................................................. 101
Fig. 36: Crane operator's seat....................................................................................................................... 103
Fig. 37: Crane operator's seat....................................................................................................................... 104
82640 2021-04-22 1155

Fig. 38: Setting the height and tilt of the arm console.................................................................................... 105
Fig. 39: Radio remote control - cab doors...................................................................................................... 107
Fig. 40: Operating elements - entering/exiting the crane operator’s cab....................................................... 110
Fig. 41: Outrigger Controls............................................................................................................................. 111
Fig. 42: Rocker switch - tilt crane operator's cab........................................................................................... 113
Fig. 43: Front Window.................................................................................................................................... 115
Fig. 44: Opening the front window................................................................................................................. 115
Fig. 45: Closing the front window................................................................................................................... 116
Fig. 46: Sunshades - crane operator’s cab.................................................................................................... 117
Fig. 47: Sun shades in the roof window......................................................................................................... 118
Fig. 48: Vertical window shades.................................................................................................................... 119
Fig. 49: Sunshade, front................................................................................................................................. 119
Fig. 50: Interior cab lights............................................................................................................................... 120
Fig. 51: Racks and storage options (schematic diagram).............................................................................. 121
Fig. 52: Additional display.............................................................................................................................. 123
Fig. 53: Additional display.............................................................................................................................. 124
Fig. 54: Operating screen (schematic diagram)............................................................................................. 124
Fig. 55: Engine/hydraulics data...................................................................................................................... 126
Fig. 56: Info screen "Diesel particulate filter"................................................................................................. 126
Fig. 57: Crane control "Engine display" screen (schematic diagram)............................................................ 127
Fig. 58: Engine data....................................................................................................................................... 128
Fig. 59: Indicator lights "Engine display" screen............................................................................................ 128
Fig. 60: Crane control menu "Automotive driving"......................................................................................... 129
Fig. 61: "Automotive driving" screen.............................................................................................................. 129
Fig. 62: Pedal for speed adjustment.............................................................................................................. 130
Fig. 63: "Automotive driving" screen.............................................................................................................. 130
Fig. 64: Foot switch - horn in the cab............................................................................................................. 132
Fig. 65: Dual button - Engine START/STOP.................................................................................................. 135
Fig. 66: Displays............................................................................................................................................ 137
Fig. 67: Engine operating elements in the cab............................................................................................... 144
Fig. 68: Dual button - Engine START/STOP ................................................................................................. 150
Fig. 69: Instrument panel, side....................................................................................................................... 158
Fig. 70: Plate - Risk of overturning................................................................................................................. 161
Fig. 71: Outrigger support area (schematic diagram).................................................................................... 161
Fig. 72: Schematic structure of the slew gear................................................................................................ 163
Fig. 73: "Switch-over slew gear" switch......................................................................................................... 164
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Fig. 76: "Slew gear brake" foot pedal (schematic diagram)........................................................................... 165
Fig. 77: Slewing angle / slewing direction (schematic diagram).................................................................... 166
Fig. 78: Display of "Current slewing angle".................................................................................................... 167
Fig. 79: Switch "Open / close the slew gear parking brake".......................................................................... 168
Fig. 80: "Slew gear brake" foot pedal............................................................................................................. 169
Fig. 81: Control levers - crane operator’s cab................................................................................................ 170
Fig. 84: Foot pedal "Slew gear brake" (schematic diagram).......................................................................... 172
Fig. 86: Slew gearbox (schematic diagram)................................................................................................... 174
Fig. 87: Mirror on the right-hand side of the superstructure frame (schematic diagram)............................... 174
Fig. 88: Camera on the superstructure frame (schematic diagram).............................................................. 175
Fig. 89: Counterweight Combination 5.1 t (11.2 kip)...................................................................................... 178
Fig. 90: Counterweight Combination 13.1 t (28.9 kip).................................................................................... 178
Fig. 93: Counterweight Combination 29,9 t (65.9 kip).................................................................................... 180
Fig. 96: Counterweight Combination 46 t (101.4 kip)..................................................................................... 181
Fig. 97: Counterweight Combination 51.6 t (113.8 kip).................................................................................. 182
Fig. 98: Counterweight Combination 70,2 t (154.8 kip).................................................................................. 182
Fig. 99: Counterweight Combination 70.2 t (154.8 kip).................................................................................. 184
Fig. 100: Multi-purpose ladder....................................................................................................................... 186
Fig. 101: Set-up location of the multi-purpose ladder.................................................................................... 186
Fig. 102: Safety mast..................................................................................................................................... 187
Fig. 103: Safety mast (schematic diagram)................................................................................................... 188
Fig. 105: Safety mast fully inserted into the receptacle................................................................................. 190
Fig. 108: Safety mast..................................................................................................................................... 192
Fig. 109: Counterweight plate with attachment hooks................................................................................... 195
Fig. 110: Counterweight plate with attachment hooks................................................................................... 195
Fig. 111: Counterweight plates, in pairs......................................................................................................... 196
Fig. 112: Counterweight plates, in pairs......................................................................................................... 196
Fig. 113: Counterweight plate with lifting tackle............................................................................................. 196
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Fig. 114: Attached counterweight plate.......................................................................................................... 197

Fig. 115: Attached counterweight plate.......................................................................................................... 198
Fig. 116: Counterweight plates...................................................................................................................... 199
Fig. 117: Counterweight plates...................................................................................................................... 200
Fig. 118: Attached counterweight plates........................................................................................................ 201
Fig. 119: Counterweight plates with saddle weight........................................................................................ 202
Fig. 120: Assembly assistant climbing up onto the counterweight stack....................................................... 203
Fig. 121: Counterweight plates with saddle weight........................................................................................ 204
Fig. 122: Slewing the Superstructure............................................................................................................. 205
Fig. 123: "Counterweight display" screen...................................................................................................... 206
Fig. 127: "Manual fitting" screen.................................................................................................................... 212
Fig. 128: Mushroom-shaped ends of the piston rods (schematic diagram)................................................... 213
Fig. 129: "Manual fitting" screen.................................................................................................................... 214
Fig. 130: Display: Counterweight control bridged.......................................................................................... 217
Fig. 131: Standard Counterweight................................................................................................................. 218
Fig. 132: Standard counterweight + saddle weights...................................................................................... 218
Fig. 133: Counterweight Elements................................................................................................................. 219
Fig. 134: Counterweight Elements................................................................................................................. 220
Fig. 135: Configuring...................................................................................................................................... 226
Fig. 136: Configuring...................................................................................................................................... 229
Fig. 137: Key-operated pushbutton for bridging the LLD (schematic diagram)............................................. 236
Fig. 138: Box - key-operated pushbutton....................................................................................................... 237
Fig. 139: Key-operated pushbutton for bridging the LLD (schematic diagram)............................................. 238
Fig. 140: Box - key-operated pushbutton....................................................................................................... 239
Fig. 141: Operating panel of crane control (schematic diagram)................................................................... 241
Fig. 142: "Selecting the operating mode" screen (schematic diagram)......................................................... 242
Fig. 143: "Selecting the operating mode" screen........................................................................................... 243
Fig. 144: Start screen (schematic diagram)................................................................................................... 243
Fig. 145: "Selecting the operating mode" screen (schematic diagram)......................................................... 243
Fig. 146: "Crane operation" screen................................................................................................................ 244
Fig. 147: "Main menu"screen......................................................................................................................... 244
Fig. 148: Power Control................................................................................................................................. 245
Fig. 149: IC-1 screen..................................................................................................................................... 245
Fig. 151: Display of current configuration information.................................................................................... 247
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Fig. 154: Load utilisation display (schematic diagram).................................................................................. 249
Fig. 155: "Quick menu" screen...................................................................................................................... 250
Fig. 156: Base line (schematic diagram)........................................................................................................ 251
Fig. 157: Quick menu (schematic diagram)................................................................................................... 251
Fig. 158: Displays crane operation screen..................................................................................................... 252
Fig. 164: Display of load and radius............................................................................................................... 258
Fig. 165: "Main menu"screen - "System setup"............................................................................................. 259
Fig. 166: "Main menu" screen - "Crane operation"........................................................................................ 260
Fig. 167: "Main menu"screen - Service.......................................................................................................... 260
Fig. 168: "Main menu"screen - "Diagnosis"................................................................................................... 261
Fig. 169: Main Menu...................................................................................................................................... 262
Fig. 170: Quick menu..................................................................................................................................... 262
Fig. 171: Submenus....................................................................................................................................... 263
Fig. 172: "System setup (user)" screen......................................................................................................... 264
Fig. 173: "System setup (user)" screen......................................................................................................... 265
Fig. 174: "Colour profile settings" screen....................................................................................................... 265
Fig. 175: "Setup IC-1 Remote" screen ("Setup Teleservice") (schematic diagram)...................................... 266
Fig. 176: "System setup (extended)" screen.................................................................................................. 268
Fig. 177: "System setup (extended)" screen.................................................................................................. 269
Fig. 178: Calling up the "Crane operation" screen......................................................................................... 271
Fig. 180: Calling up the "Selecting the operating mode" screen.................................................................... 271
Fig. 182: "Operating mode selection" screen ................................................................................................ 274
Fig. 183: "Operating mode selection" screen................................................................................................. 275
Fig. 184: "Operating mode selection" screen................................................................................................. 276
Fig. 185: Check of entered parameter values................................................................................................ 277
Fig. 186: "Table view" screen........................................................................................................................ 278
Fig. 189: "Search configuration for load case" input screen.......................................................................... 281
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Fig. 190: "Configurations" screen ................................................................................................................. 282

Fig. 191: "Configurations" screen ................................................................................................................. 282
Fig. 192: "Length code LK" screen (schematic diagram)............................................................................... 283
Fig. 193: Simulation screen "Capacities dependent on slewing angles" (schematic diagram)...................... 284
Fig. 194: Simulation screen "Capacities dependent on slewing angles"....................................................... 285
Fig. 197: Example AC 250-5.......................................................................................................................... 288
Fig. 198: Example AC 220-5.......................................................................................................................... 288
Fig. 199: Example AC 160-5.......................................................................................................................... 288
Fig. 200: Example AC 130-5.......................................................................................................................... 288
Fig. 201: Simulation screen "Capacities dependent on slewing angles" - "Input area"................................. 289
Fig. 202: Assignment of the display area to the crane................................................................................... 289
Fig. 205: Simulation screen "Capacities dependent on slewing angles" - "Base line" (schematic diagram). 292
Fig. 210: Calling up the "Operating range limit" screen................................................................................. 295
Fig. 211: "Operating range limits" screen...................................................................................................... 296
Fig. 214: Keys for activating / deactivating the operating range limits........................................................... 299
Fig. 215: "Operating range limit" screen - slewing angle limit........................................................................ 300
Fig. 216: "Operating range limit" screen - radius limits.................................................................................. 301
Fig. 217: "Operating range limit" screen - "Virtual wall"................................................................................. 302
Fig. 218: "Operating range limit" screen - "Virtual wall"................................................................................. 303
Fig. 219: Taught points.................................................................................................................................. 303
Fig. 220: "Operating range limit" screen - height limit.................................................................................... 304
Fig. 221: Structure of the "Joystick modes" screen....................................................................................... 305
Fig. 225: Control levers.................................................................................................................................. 309
Fig. 226: "Parameter settings" screen........................................................................................................... 310
Fig. 227: "Parameter settings" screen........................................................................................................... 311
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Fig. 228: "Datalogger" screen........................................................................................................................ 312

Fig. 229: "Datalogger" screen........................................................................................................................ 315
Fig. 230: "Info" screen.................................................................................................................................... 316
Fig. 231: "Info" screen.................................................................................................................................... 316
Fig. 232: "Operating hour meter" screen....................................................................................................... 317
Fig. 233: "Function display" screen................................................................................................................ 318
Fig. 234: "Dismantling the main boom" button............................................................................................... 319
Fig. 235: "I/O view" screen............................................................................................................................. 320
Fig. 236: "CAN View" screen (schematic diagram)........................................................................................ 320
Fig. 237: "Load Sensing View" screen........................................................................................................... 322
Fig. 238: "Load Sensing View" screen........................................................................................................... 323
Fig. 239: "Joystick diagnostics" screen.......................................................................................................... 324
Fig. 240: "Fault messages" screen................................................................................................................ 325
Fig. 241: "Outrigger support area" display (schematic diagram)................................................................... 326
Fig. 242: "Capacity radar" screen.................................................................................................................. 328
Fig. 243: "Capacity radar" screen.................................................................................................................. 329
Fig. 244: "IC-1 Remote" screen ("Teleservice") (schematic diagram)........................................................... 330
Fig. 245: "Maximum load" display.................................................................................................................. 332
Fig. 246: "Net load" display............................................................................................................................ 332
Fig. 247: "Outrigger support area" screen (schematic diagram).................................................................... 334
Fig. 250: Capacity table sample - top area.................................................................................................... 340
Fig. 251: Capacity table sample - middle area............................................................................................... 341
Fig. 252: Capacity table sample - bottom area.............................................................................................. 342
Fig. 253: Sample of capacity with special capacity........................................................................................ 343
Fig. 254: "Hook height" button ...................................................................................................................... 346
Fig. 255: "Hook height" button ...................................................................................................................... 346
Fig. 256: "Error messages" screen................................................................................................................ 347
Fig. 257: Display of connection problems...................................................................................................... 350
Fig. 258: Assignment of the release buttons (schematic diagram)................................................................ 352
Fig. 260: Movement speed in percent............................................................................................................ 354
Fig. 261: Movement speed in percent............................................................................................................ 355
Fig. 263: Movement speed in percent for high speed mode.......................................................................... 356
Fig. 264: Wind speed indicator on adjustable bracket................................................................................... 362
Fig. 265: Adjusting the wind speed indicator................................................................................................. 363
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Fig. 266: Adjusting the wind speed indicator................................................................................................. 364

Fig. 267: Distribution box on the main boom head........................................................................................ 365
Fig. 268: Overview of the hoist limit switch (schematic diagram).................................................................. 366
Fig. 269: Component parts of the hoist limit switch....................................................................................... 367
Fig. 270: Restrainer in the park position........................................................................................................ 369
Fig. 271: Hoist limit switch weight (schematic diagram)................................................................................ 371
Fig. 272: Main boom...................................................................................................................................... 381
Fig. 273: Representation of "wind"................................................................................................................. 385
Fig. 274: Projection surface........................................................................................................................... 388
Fig. 275: Calculation procedure..................................................................................................................... 390
Fig. 278: Calculation of the permitted wind speed in m/s.............................................................................. 396
Fig. 279: lowered wind speed in m/s.............................................................................................................. 397
Fig. 280: lowered wind speed in mph............................................................................................................ 397
Fig. 281: Example 1: lowered wind speed in m/s........................................................................................... 397
Fig. 282: Example 1: lowered wind speed in mph......................................................................................... 397
Fig. 283: Example 1: Calculation of the permitted wind speed in m/s........................................................... 397
Fig. 284: Example 1: Calculation of the permitted wind speed in mph.......................................................... 397
Fig. 285: Example 2: lowered wind speed in m/s........................................................................................... 398
Fig. 286: Example 2: lowered wind speed in mph......................................................................................... 398
Fig. 287: Example 2: Calculation of the permitted wind speed in m/s........................................................... 398
Fig. 288: Example 2: Calculation of the permitted wind speed in mph.......................................................... 398
Fig. 289: Wind Speed Reduction Diagram..................................................................................................... 399
Fig. 290: Diagram example 1......................................................................................................................... 400
Fig. 291: Diagram example 2......................................................................................................................... 401
Fig. 292: Effect of the roughness of the ground............................................................................................. 406
Fig. 293: Beaufort table.................................................................................................................................. 410
Fig. 294: Rotor............................................................................................................................................... 416
Fig. 295: Components of the camera system (schematic diagram)............................................................... 417
Fig. 296: Camera surveillance monitor.......................................................................................................... 418
Fig. 297: Operating elements and display elements (schematic diagram).................................................... 419
Fig. 298: Operating elements and display elements (schematic diagram).................................................... 420
Fig. 299: Load hook camera (schematic diagram)......................................................................................... 421
Fig. 300: Hook camera................................................................................................................................... 422
Fig. 301: Load hook camera on the main boom head (schematic diagram).................................................. 423
Fig. 302: Load hook camera (schematic diagram)......................................................................................... 426
Fig. 303: Hanging light on the main boom head (schematic diagram)........................................................... 428
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Fig. 304: Distribution box "X0550" (schematic diagram)................................................................................ 429

Fig. 305: Components of the Main Boom (schematic diagram)..................................................................... 434
Fig. 306: Locking and Pinning Unit (LPU) (schematic diagram).................................................................... 436
Fig. 307: States of the Locking and Pinning Unit (LPU) (schematic diagram)............................................... 437
Fig. 308: "Tele Display" Screen (schematic diagram).................................................................................... 439
Fig. 309: "Manual telescoping" screen........................................................................................................... 440
Fig. 311: LPU state "locked and pinned"....................................................................................................... 443
Fig. 312: LPU state "locked and unpinned"................................................................................................... 443
Fig. 313: LPU state "locked and pinned"....................................................................................................... 444
Fig. 314: LPU state "unlocked and pinned"................................................................................................... 444
Fig. 315: Operating panel of crane control (schematic diagram)................................................................... 447
Fig. 316: Control Levers in the Crane Operator's Cab................................................................................... 447
Fig. 318: Entry length code "LK1" (schematic diagram)................................................................................ 448
Fig. 319: "Telescoping display" screen (schematic diagram)........................................................................ 449
Fig. 320: "Tele Display" screen (schematic diagram).................................................................................... 450
Fig. 324: "Length code (LC) selection" screen (schematic diagram)............................................................. 454
Fig. 330: Display of the control lever assignment.......................................................................................... 460
Fig. 332: "Telescoping display" screen.......................................................................................................... 461
Fig. 333: "Length code (LC) selection" screen............................................................................................... 461
Fig. 334: "Length code (LC) selection" screen............................................................................................... 461
Fig. 340: "Telescoping display" screen.......................................................................................................... 467
Fig. 341: Partial screen "Telescoping display"............................................................................................... 468
82640 2021-04-22 1163


Fig. 348: unlocked and pinned....................................................................................................................... 474
Fig. 349: locked and pinned........................................................................................................................... 474
Fig. 350: locked and unpinned....................................................................................................................... 474
Fig. 351: Calling up the "Teach telescope" screen (schematic diagram)....................................................... 475
Fig. 352: "Length code (LC) selection - teaching" screen (schematic diagram)............................................ 476
Fig. 357: Principle sketch of the main boom (schematic diagram)................................................................ 481
Fig. 358: Pinning positions, telescopic sections (schematic diagram)........................................................... 482
Fig. 360: Example - pinning position 100 % (schematic diagram)................................................................. 484
Fig. 361: "Manual telescoping" screen (schematic diagram)......................................................................... 485
Fig. 369: "Teach telescope" screen (schematic diagram).............................................................................. 491
Fig. 370: "Teach telescope" screen (schematic diagram).............................................................................. 491
Fig. 371: "Teach telescope" (schematic diagram)......................................................................................... 492
Fig. 372: Extension state of the telescopic sections (schematic diagram)..................................................... 492
Fig. 375: "Quick menu" screen (schematic diagram)..................................................................................... 501
Fig. 376: "Table view" screen (schematic diagram)....................................................................................... 501
Fig. 377: "Table view" screen (schematic diagram)....................................................................................... 502
Fig. 378: "Pinned capacities" screen............................................................................................................. 502
Fig. 379: "Unpinned capacities" screen......................................................................................................... 503
1164 82640 2021-04-22


Fig. 386: "Selecting the operating mode" screen: Crane configuration......................................................... 508
Fig. 391: Main boom in the transport condition (schematic diagram)............................................................ 510
Fig. 392: Luffing the main boom (schematic diagram)................................................................................... 511
Fig. 393: Optional stop valve on the main boom (schematic diagram).......................................................... 512
Fig. 394: Control levers - crane operator’s cab.............................................................................................. 514
Fig. 395: Slew display in the "Crane operation" screen................................................................................. 515
Fig. 396: Stop valve - luffing cylinder............................................................................................................. 515
Fig. 397: Control lever, right........................................................................................................................... 518
Fig. 398: Camera and display........................................................................................................................ 520
Fig. 399: Hoist 2 (width / height).................................................................................................................... 521
Fig. 400: Hoist 2 (depth)................................................................................................................................ 521
Fig. 401: Hoist 2 with rope shackle................................................................................................................ 523
Fig. 402: Hoist 2 with pins.............................................................................................................................. 523
Fig. 403: Hoist 2 on the superstructure frame................................................................................................ 525
Fig. 407: Connection...................................................................................................................................... 527
Fig. 408: Connections (schematic diagram).................................................................................................. 528
Fig. 409: Supply line...................................................................................................................................... 529
Fig. 410: Supply line...................................................................................................................................... 530
Fig. 411: Hoist 2 (schematic diagram)........................................................................................................... 531
Fig. 412: Hoist 2 on configuration frame (schematic diagram)...................................................................... 532
Fig. 413: Counterweight support - crane chassis........................................................................................... 532
Fig. 416: Attaching the assembly unit (schematic diagram).......................................................................... 535
Fig. 417: Assembly of hoist 2 (schematic diagram)....................................................................................... 536
82640 2021-04-22 1165


Fig. 420: Hoist 2 below superstructure frame (schematic diagram)............................................................... 538
Fig. 421: Connections erection cylinder hoist 2 (schematic diagram)............................................................ 538
Fig. 422: Collecting plate (schematic diagram).............................................................................................. 539
Fig. 423: Hoist 2 on superstructure frame (schematic diagram).................................................................... 539
Fig. 424: Mobile control panel........................................................................................................................ 539
Fig. 427: Hoist 2: Erection cylinder retracted (schematic diagram)............................................................... 541
Fig. 429: Configuration frame (schematic diagram)....................................................................................... 542
Fig. 430: Configuration frame (schematic diagram)....................................................................................... 543
Fig. 431: Rotary transmitter H2 on the left control lever................................................................................ 544
Fig. 432: Hoist camera (schematic diagram)................................................................................................. 544
Fig. 433: Connection - hoist camera (schematic diagram)............................................................................ 545
Fig. 434: Crane operator’s cab display.......................................................................................................... 545
Fig. 435: Camera hoist gear 2 (schematic diagram)...................................................................................... 545
Fig. 436: Crane operator's cab operating elements (schematic diagram)..................................................... 550
Fig. 437: Operating element of the heater timer............................................................................................ 551
Fig. 438: Display............................................................................................................................................ 551
Fig. 439: Operating elements - crane operator’s cab..................................................................................... 571
Fig. 440: Air conditioning (schematic diagram).............................................................................................. 573
Fig. 441: Air conditioning (schematic diagram).............................................................................................. 573
Fig. 442: Operating element with combination gas heating rotary switch...................................................... 576
Fig. 443: Operating element with gas heating sliding switch......................................................................... 577
Fig. 444: Operating element with sliding switch............................................................................................. 579
Fig. 445: Operating element with sliding switch............................................................................................. 580
Fig. 446: Operating element - gas heating..................................................................................................... 581
Fig. 447: Operating element - gas heating..................................................................................................... 581
Fig. 448: Rope guard pin............................................................................................................................... 583
Fig. 449: Small and large rope shackle.......................................................................................................... 584
Fig. 450: Spin Stabilizer................................................................................................................................. 584
Fig. 451: Chain shift weight............................................................................................................................ 585
Fig. 452: Chain shift weight............................................................................................................................ 585
Fig. 453: Carrying equipment (schematic diagram)....................................................................................... 586
Fig. 454: Rope end connection with press fitting (schematic diagram).......................................................... 588
Fig. 455: Rope end connection with press fitting (schematic diagram).......................................................... 589
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Fig. 456: Rope socket (schematic diagram).................................................................................................. 590

Fig. 457: Rope socket (schematic diagram).................................................................................................. 591
Fig. 458: Assembling the rope socket............................................................................................................ 592
Fig. 460: Main boom head (schematic diagram)............................................................................................ 594
Fig. 461: Hook block (schematic diagram)..................................................................................................... 595
Fig. 462: Main boom head............................................................................................................................. 595
Fig. 464: Rope shackles................................................................................................................................ 597
Fig. 465: Main boom head and hook block.................................................................................................... 598
Fig. 466: Hook block...................................................................................................................................... 599
Fig. 467: Main boom head............................................................................................................................. 599
Fig. 468: Shift weight..................................................................................................................................... 600
Fig. 469: Shift weight with spring cotter pin................................................................................................... 600
Fig. 470: Shift weight with spring cotter pin................................................................................................... 601
Fig. 471: Rope with shift weight..................................................................................................................... 601
Fig. 472: Handling the hook blocks (schematic diagram).............................................................................. 607
Fig. 473: Rear - crane chassis....................................................................................................................... 609
Fig. 474: Rear - crane chassis....................................................................................................................... 610
Fig. 475: Hook block with weight frame......................................................................................................... 611
Fig. 477: Hook blocks support....................................................................................................................... 612
Fig. 478: Weight frame above rear................................................................................................................ 613
Fig. 479: Transport position on the rear......................................................................................................... 614
Fig. 481: Support........................................................................................................................................... 616
Fig. 482: Standard hook blocks, ID no. 574................................................................................................... 616
Fig. 483: Standard hook blocks, ID no. 617................................................................................................... 616
Fig. 484: Vario hook blocks............................................................................................................................ 618
Fig. 485: Reeving 8-, 7-fold............................................................................................................................ 619
Fig. 486: Reeving 7-, 6-, 5-, 4-, 3-fold............................................................................................................ 620
Fig. 487: Reeving 3-, 2-, 1-fold...................................................................................................................... 621
Fig. 488: Reeving 10-, 9-fold.......................................................................................................................... 622
Fig. 490: HD attachment................................................................................................................................ 625
Fig. 491: Hoist Limit Switches........................................................................................................................ 626
Fig. 493: Connection - hoist limit switch (schematic diagram)....................................................................... 628
82640 2021-04-22 1167

Fig. 494: incorrect rope guidance of rope line 4............................................................................................. 629

Fig. 495: correct rope guidance of rope line 4............................................................................................... 630
Fig. 496: correct complete reeving................................................................................................................. 630
Fig. 497: Reeving 14-, 12-fold........................................................................................................................ 631
Fig. 498: Rope shackles................................................................................................................................ 633
Fig. 500: Large rope shackle in the transport position on hoist 2.................................................................. 633
Fig. 501: Central lubricating system AC 250-5, AC 220-5............................................................................. 635
Fig. 502: Central lubricating system AC 160-5, AC 130-5............................................................................. 636
Fig. 503: Fitting location - lubricant pump (schematic diagram).................................................................... 637
Fig. 504: Rotary switch, blue, "Pause time" and red, "Operating time".......................................................... 638
Fig. 505: Control board.................................................................................................................................. 638
Fig. 506: Lubricating nipple - lube pump........................................................................................................ 639
Fig. 507: Head sheave (length / height)......................................................................................................... 641
Fig. 508: Head sheave (width)....................................................................................................................... 641
Fig. 509: Head sheave................................................................................................................................... 642
Fig. 510: Head sheave in the assembly position........................................................................................... 644
Fig. 511: Head sheave (schematic diagram)................................................................................................. 645
Fig. 518: Hoist rope........................................................................................................................................ 651
Fig. 522: Distribution box "X0550" on the main boom head (schematic diagram)......................................... 655
Fig. 523: Distribution box "X0560.1" on the head sheave (schematic diagram)............................................ 655
Fig. 525: Shift weight on the head sheave (schematic diagram)................................................................... 658
Fig. 531: Assembly jib.................................................................................................................................... 663
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Fig. 532: Assembly jib (schematic diagram).................................................................................................. 664

Fig. 534: Attachment Points........................................................................................................................... 667
Fig. 536: Transport position - crank (schematic diagram).............................................................................. 668
Fig. 538: Head of the assembly jib................................................................................................................. 671
Fig. 540: Reeving diagrams (schematic diagram)......................................................................................... 673
Fig. 545: Distribution box (schematic diagram).............................................................................................. 678
Fig. 546: Distribution box (schematic diagram).............................................................................................. 678
Fig. 547: "Operating mode" screen................................................................................................................ 679
Fig. 548: Hydraulics bracket (schematic diagram)......................................................................................... 681
Fig. 549: Shift weight on the assembly jib (schematic diagram).................................................................... 681
Fig. 550: Shift weight on the assembly jib...................................................................................................... 682
Fig. 555: Main boom extension with fixed operating angles.......................................................................... 685
Fig. 556: HAVHY (hydraulically infinitely adjustable)..................................................................................... 686
Fig. 558: Bracket for attaching the ladder (schematic diagram).................................................................... 690
Fig. 559: Auxiliary rod (schematic diagram)................................................................................................... 691
Fig. 560: Attachment eyelets (schematic diagram)........................................................................................ 692
Fig. 561: Hook with corresponding size......................................................................................................... 692
Fig. 562: Hook with incorrect size.................................................................................................................. 692
Fig. 563: Attachment eyelets (schematic diagram)........................................................................................ 693
Fig. 564: Attachment points / Attachment eyelets (schematic diagram)........................................................ 693
Fig. 565: Fastening of the MBE (schematic diagram).................................................................................... 694
Fig. 566: Main boom extension in the transport position (schematic diagram).............................................. 695
Fig. 567: Raising loads with the box top piece folded down is prohibited (schematic diagram).................... 696
Fig. 568: Wind speed indicator / hazard light on the main boom head (schematic diagram)........................ 697
Fig. 569: Main Components of the Main Boom Extension............................................................................. 698
82640 2021-04-22 1169

Fig. 570: Combination of the Main Components............................................................................................ 699

Fig. 571: Main boom extension (HAVHY) (schematic diagram).................................................................... 701
Fig. 572: Hydraulic hoses during MBE operation (schematic diagram)......................................................... 701
Fig. 573: Hydraulic hoses during MBE operation (schematic diagram)......................................................... 702
Fig. 574: Roller adapters (schematic diagram).............................................................................................. 703
Fig. 575: Hose drum...................................................................................................................................... 705
Fig. 576: Hose drum transport dimensions.................................................................................................... 705
Fig. 577: Hose drum (schematic diagram)..................................................................................................... 706
Fig. 578: Hose drum...................................................................................................................................... 706
Fig. 579: Hose drum...................................................................................................................................... 706
Fig. 580: Hose drum...................................................................................................................................... 707
Fig. 581: Attaching the assembly unit............................................................................................................ 707
Fig. 582: Hose drum...................................................................................................................................... 707
Fig. 583: Hose drum...................................................................................................................................... 708
Fig. 584: Hose drum...................................................................................................................................... 708
Fig. 585: Hose drum...................................................................................................................................... 709
Fig. 586: Hose drum...................................................................................................................................... 709
Fig. 587: Position of the superstructure (schematic diagram)........................................................................ 710
Fig. 588: Position of the superstructure (schematic diagram)........................................................................ 712
Fig. 590: MBE operating modes.................................................................................................................... 714
Fig. 591: Fastening the basic boom MBE / box top piece (schematic diagram)............................................ 716
Fig. 592: Folding cylinder MBE (schematic diagram).................................................................................... 716
Fig. 593: Basic boom MBE with fixed operating angles (schematic diagram)............................................... 717
Fig. 594: Fastening the MBE on the main boom basic case (schematic diagram)........................................ 717
Fig. 595: MBE with rollway (schematic diagram)........................................................................................... 718
Fig. 596: Pivot point MBE (schematic diagram)............................................................................................. 719
Fig. 597: Telescoping display (schematic diagram)....................................................................................... 720
Fig. 598: Folding cylinder (schematic diagram)............................................................................................. 721
Fig. 599: 11.4 m (37.4 ft) MBE in the transport position (schematic diagram)............................................... 722
Fig. 600: 21 m (68.9 ft) MBE in the transport position (schematic diagram).................................................. 722
Fig. 601: Preparations on the MBE (schematic diagram).............................................................................. 723
Fig. 602: Preparations on the basic crane unit (schematic diagram)............................................................. 724
Fig. 603: Fold the main boom extension off the rollway (schematic diagram)............................................... 724
Fig. 604: Fold the MBE to the front (schematic diagram).............................................................................. 725
Fig. 605: Electrically connect the MBE (schematic diagram)......................................................................... 725
Fig. 606: Tension plates in the 0°position (schematic diagram).................................................................... 725
Fig. 607: Adjusting cylinder............................................................................................................................ 726
1170 82640 2021-04-22

Fig. 608: Fitting the hoist rope, reeving the hook block (schematic diagram)................................................ 726
Fig. 609: Remaining work on the basic boom MBE....................................................................................... 727
Fig. 610: Remaining work on the basic crane unit (schematic diagram)....................................................... 727
Fig. 611: Main boom extension (schematic diagram).................................................................................... 728
Fig. 612: Basic boom MBE with auxiliary reeving rope.................................................................................. 728
Fig. 613: Preparing the hydraulic hoses for assembly (schematic diagram)................................................. 730
Fig. 614: Electric connections - basic boom MBE.......................................................................................... 731
Fig. 616: Electric connection on the basic case of the main boom (schematic diagram).............................. 732
Fig. 617: Course of rope, main boom head (schematic diagram).................................................................. 732
Fig. 619: Hydraulic valve................................................................................................................................ 733
Fig. 620: Fold out the rollway (schematic diagram)....................................................................................... 734
Fig. 623: MBE folding procedure (schematic diagram).................................................................................. 736
Fig. 626: MBE attachment points (schematic diagram)................................................................................. 739
Fig. 627: MBE connecting parts (schematic diagram)................................................................................... 741
Fig. 632: Folding the MBE............................................................................................................................. 745
Fig. 634: Locking bar (schematic diagram).................................................................................................... 746
Fig. 635: Pinning point I bottom head axle (schematic diagram)................................................................... 747
Fig. 638: Optional load hook camera connection (schematic diagram)......................................................... 749
Fig. 639: Hoist limit switch weight.................................................................................................................. 750
Fig. 640: Bolts support and control panel (schematic diagram)..................................................................... 750
Fig. 641: Carrying out fitting of the tension plates (schematic diagram)........................................................ 751
Fig. 642: Fitting the tension plates (schematic diagram)............................................................................... 751
Fig. 643: Relieving the bolts (schematic diagram)......................................................................................... 751
Fig. 644: Top bolt - main boom head (schematic diagram)........................................................................... 752
Fig. 645: Tension plate, 0° position (schematic diagram).............................................................................. 752
82640 2021-04-22 1171

Fig. 646: Hydraulic connections from the basic boom of the MBE (schematic diagram)............................... 753
Fig. 647: Hydraulic valve................................................................................................................................ 754
Fig. 648: Hydraulic connections from the basic boom of the MBE................................................................ 754
Fig. 649: Tension plate.................................................................................................................................. 755
Fig. 652: Auxiliary cylinder and cross beam.................................................................................................. 756
Fig. 658: Auxiliary cylinder (schematic diagram)........................................................................................... 759
Fig. 660: Carrying out fitting of the tension plates.......................................................................................... 759
Fig. 661: Fitting the tension plates................................................................................................................. 760
Fig. 662: Relieving the bolts........................................................................................................................... 760
Fig. 663: Top bolt - main boom head............................................................................................................. 760
Fig. 664: Basic boom MBE with box top piece............................................................................................... 761
Fig. 665: Setting the MBE down on the ground............................................................................................. 761
Fig. 666: Hydraulic connections from the basic boom of the MBE (schematic diagram)............................... 762
Fig. 672: Tension plates on the main boom head (schematic diagram)........................................................ 766
Fig. 673: Angling the MBE............................................................................................................................. 767
Fig. 674: Angling the MBE (schematic diagram)............................................................................................ 768
Fig. 675: Auxiliary cylinder (schematic diagram)........................................................................................... 768
Fig. 677: Adjusting cylinder on the main boom head (schematic diagram)................................................... 769
Fig. 679: Hydraulic hoses of the main boom extension (schematic diagram)................................................ 771
Fig. 680: Bolts, intermediate elements (schematic diagram)......................................................................... 772
Fig. 682: Adjusting cylinder on the main boom head..................................................................................... 772
1172 82640 2021-04-22


Fig. 687: Rope guidance - MBE (schematic diagram)................................................................................... 775
Fig. 688: Rope guidance, basic boom MBE (schematic diagram)................................................................. 775
Fig. 689: Reeving the basic boom MBE......................................................................................................... 776
Fig. 692: Distribution box "X0560"................................................................................................................. 777
Fig. 694: Hazard light / anemometer, basic boom MBE................................................................................ 778
Fig. 697: Preparations on the crane and MBE............................................................................................... 781
Fig. 698: MBE in 0° position.......................................................................................................................... 781
Fig. 699: Preparations on the basic boom MBE ........................................................................................... 782
Fig. 700: Preparations on the basic boom MBE............................................................................................ 782
Fig. 701: Preparations on the main boom...................................................................................................... 782
Fig. 702: Folding the MBE at the side on the main boom.............................................................................. 783
Fig. 703: Carrying out Remaining Work......................................................................................................... 783
Fig. 704: Basic Boom MBE............................................................................................................................ 784
Fig. 706: Basic Boom MBE............................................................................................................................ 785
Fig. 711: Carrying out fitting of the tension plates.......................................................................................... 788
Fig. 712: Engaging the auxiliary cylinder....................................................................................................... 788
Fig. 713: Positioning the auxiliary cylinders................................................................................................... 788
Fig. 716: Hydraulic connections of the basic boom MBE (schematic diagram)............................................. 790
Fig. 719: Retracting the auxiliary cylinder...................................................................................................... 792
Fig. 721: Tension plate (schematic diagram)................................................................................................. 793
82640 2021-04-22 1173


Fig. 723: Auxiliary cylinder............................................................................................................................. 794
Fig. 728: Preparations for dismantling the tension plates.............................................................................. 795
Fig. 729: Engaging the auxiliary cylinder....................................................................................................... 796
Fig. 730: Assuming the pinning position........................................................................................................ 796
Fig. 733: Hydraulic connections of the basic boom MBE (schematic diagram)............................................. 798
Fig. 734: Auxiliary cylinder of the tension plates............................................................................................ 799
Fig. 741: Rod end.......................................................................................................................................... 802
Fig. 744: Bolts in intermediate elements........................................................................................................ 803
Fig. 745: Removing the hydraulic hoses (schematic diagram)...................................................................... 804
Fig. 746: Rope guidance, basic boom MBE................................................................................................... 805
Fig. 747: MBE connecting parts..................................................................................................................... 805
Fig. 749: Hydraulic valve (schematic diagram).............................................................................................. 806
Fig. 750: Fold out the rollway (schematic diagram)....................................................................................... 807
Fig. 752: Folding cylinder with auxiliary rod................................................................................................... 808
Fig. 753: Terminal box................................................................................................................................... 809
Fig. 754: Optional load hook camera connection........................................................................................... 809
Fig. 755: Hoist limit switch in functional configuration.................................................................................... 810
Fig. 756: Pinning MBE (schematic diagram).................................................................................................. 810
Fig. 757: Locking bar (schematic diagram).................................................................................................... 811
Fig. 758: MBE folding procedure................................................................................................................... 812
1174 82640 2021-04-22


Fig. 764: Transport position - MBE................................................................................................................ 815
Fig. 765: Fold in rollway (schematic diagram)............................................................................................... 817
Fig. 766: Preparations on the MBE................................................................................................................ 818
Fig. 767: Fastening the Box Top Piece to the Main Boom ............................................................................ 818
Fig. 770: Fold the MBE to the front (schematic diagram).............................................................................. 820
Fig. 772: Tension plates in the 0°position (schematic diagram).................................................................... 820
Fig. 774: Put on the hoist rope, reeve the hook block.................................................................................... 821
Fig. 776: Fastening the box top piece to the basic boom MBE (schematic diagram).................................... 822
Fig. 779: Fastening the box top piece to the main boom basic case (schematic diagram)........................... 823
Fig. 782: Connection between box top piece and basic boom MBE............................................................. 824
Fig. 783: MBE in transport position................................................................................................................ 825
Fig. 784: Pinning - box top piece / basic boom MBE (schematic diagram).................................................... 825
Fig. 785: Bolt in locked position (schematic diagram).................................................................................... 826
Fig. 786: Fastening the box top piece to the basic case of the main boom................................................... 826
Fig. 787: Preparations on the MBE................................................................................................................ 828
Fig. 790: Fold the MBE to the front................................................................................................................ 829
Fig. 792: Folding the Box Top Piece to the Front.......................................................................................... 830
Fig. 793: Electrically connect the box top piece............................................................................................. 830
Fig. 794: Tension plates in the 0° position..................................................................................................... 831
Fig. 795: Adjusting cylinder ........................................................................................................................... 831
Fig. 797: Remaining work on the box top piece............................................................................................. 832
82640 2021-04-22 1175

Fig. 799: Basic boom MBE with auxiliary reeving rope.................................................................................. 833
Fig. 804: Box top piece with auxiliary reeving rope........................................................................................ 838
Fig. 805: Connection between box top piece / basic boom MBE (schematic diagram)................................. 839
Fig. 806: Folding the box top piece / basic boom MBE.................................................................................. 840
Fig. 807: Locking bar on the basic boom MBE.............................................................................................. 840
Fig. 808: Pinning the box top piece / basic boom MBE................................................................................. 840
Fig. 812: Rope guidance - box top piece (schematic diagram)...................................................................... 843
Fig. 814: Rope guidance, basic boom MBE................................................................................................... 844
Fig. 815: Reeving the box top piece.............................................................................................................. 845
Fig. 816: Reeving the box top piece.............................................................................................................. 845
Fig. 817: Hoist limit switch on box top piece.................................................................................................. 846
Fig. 818: Hoist limit switch in functional configuration.................................................................................... 846
Fig. 819: Hazard light / anemometer, box top piece...................................................................................... 847
Fig. 821: Preparations on the basic crane unit and MBE............................................................................... 849
Fig. 822: Tension plates................................................................................................................................. 849
Fig. 823: Adjusting cylinder ........................................................................................................................... 850
Fig. 824: Preparations on the box top piece.................................................................................................. 850
Fig. 825: Folding the Box Top Piece at the Side on the Basic Boom MBE.................................................... 850
Fig. 826: Preparations on the basic boom MBE............................................................................................ 851
Fig. 827: Preparations on the main boom...................................................................................................... 851
Fig. 828: Folding the Main Boom Extension at the Side on the Main Boom.................................................. 852
Fig. 830: Carrying out Remaining Work......................................................................................................... 853
Fig. 832: Box top piece.................................................................................................................................. 854
Fig. 833: Box top piece.................................................................................................................................. 854
Fig. 834: Main boom extension...................................................................................................................... 855
Fig. 835: Box top piece.................................................................................................................................. 856
1176 82640 2021-04-22


Fig. 837: Electric connection on the basic case of the main boom................................................................ 857
Fig. 838: Auxiliary reeving rope - box top piece............................................................................................. 857
Fig. 840: Fastening the box top piece / basic boom MBE.............................................................................. 858
Fig. 842: Fastening the box top piece / basic boom MBE.............................................................................. 859
Fig. 848: MBE components............................................................................................................................ 862
Fig. 849: Rollway on the main boom (schematic diagram)............................................................................ 863
Fig. 850: MBE components............................................................................................................................ 864
Fig. 851: Attachment points / attachment eyelets.......................................................................................... 865
Fig. 852: MBE attachment points................................................................................................................... 866
Fig. 854: Main boom extension (MBE) with fixed operating angles............................................................... 869
Fig. 856: Main boom extension with hydraulic continuous operating angle adjustment (HAVHY)................ 869
Fig. 859: Load relief connection on the basic boom MBE (schematic diagram)............................................ 871
Fig. 861: Course of rope on the main boom head (schematic diagram)........................................................ 873
Fig. 862: Course of rope on the main boom head......................................................................................... 873
Fig. 863: Fitting the basic boom MBE ........................................................................................................... 874
Fig. 864: Fitting the basic boom MBE............................................................................................................ 874
Fig. 873: Optional load hook camera connection (schematic diagram)......................................................... 878
82640 2021-04-22 1177


Fig. 878: MBE lowered onto the ground........................................................................................................ 880
Fig. 887: Connect the MBE electric cables.................................................................................................... 885
Fig. 888: Adjusting cylinder (schematic diagram).......................................................................................... 885
Fig. 892: Hydraulic hoses of the main boom extension (schematic diagram)................................................ 888
Fig. 900: Preparations on the basic crane unit.............................................................................................. 892
Fig. 903: Main boom extension with hydraulic continuous operating angle adjustment (HAVHY)................ 893
Fig. 905: Remaining work on the box top piece............................................................................................. 893
Fig. 911: Fitting the box top piece to the basic boom MBE............................................................................ 896
1178 82640 2021-04-22


Fig. 913: Fitting the box top piece.................................................................................................................. 897
Fig. 917: Fitting the box top piece to the basic boom MBE............................................................................ 899
Fig. 923: Main boom extension, right-hand side............................................................................................ 901
Fig. 927: Connect the MBE electric cables.................................................................................................... 902
Fig. 928: Adjusting cylinder (schematic diagram).......................................................................................... 902
Fig. 929: Fitting the box top piece.................................................................................................................. 903
Fig. 931: Design variants of the intermediate section.................................................................................... 904
Fig. 932: Main boom extension 23.4 m (76.8 ft)............................................................................................ 904
Fig. 933: Preparations on the basic crane unit.............................................................................................. 905
Fig. 936: Main boom extension with hydraulically smooth operating angle adjustment (HAVHY)................ 906
Fig. 941: Course of rope - main boom head.................................................................................................. 908
Fig. 942: Fitting the intermediate section....................................................................................................... 909
Fig. 943: Connect the intermediate section electric cables (schematic diagram).......................................... 909
Fig. 944: Basic boom MBE fitting (schematic diagram)................................................................................. 909
Fig. 947: Connecting the basic boom MBE electrically (schematic diagram)................................................ 911
Fig. 948: Hydraulic hoses on the main boom extension................................................................................ 911
Fig. 949: Design variants of the intermediate section.................................................................................... 912
82640 2021-04-22 1179

Fig. 950: Intermediate section fitting (schematic diagram)............................................................................ 912

Fig. 951: Intermediate section fitting (schematic diagram)............................................................................ 913
Fig. 953: Optional load hook camera (schematic diagram)........................................................................... 914
Fig. 960: Basic boom MBE and intermediate section.................................................................................... 918
Fig. 962: Connect the intermediate section electric cables (schematic diagram).......................................... 918
Fig. 965: Tension bar..................................................................................................................................... 919
Fig. 968: Hydraulic hoses on the main boom extension................................................................................ 920
Fig. 973: Connecting the intermediate section electrically and hydraulically (schematic diagram)............... 923
Fig. 978: Remove connecting line (schematic diagram)................................................................................ 925
Fig. 981: Connect the mobile control panel cable (schematic diagram)........................................................ 926
Fig. 982: Optional load hook camera (schematic diagram)........................................................................... 927
Fig. 984: Hydraulic connections (schematic diagram)................................................................................... 928
Fig. 985: Basic boom MBE and intermediate section.................................................................................... 929
Fig. 987: Intermediate section fitted (schematic diagram)............................................................................. 930
1180 82640 2021-04-22

Fig. 989: Fitting the hydraulic hoses (schematic diagram)............................................................................. 932
Fig. 991: Electric connection on the intermediate section (schematic diagram)............................................ 933
Fig. 997: Course of the rope, MBE (schematic diagram)............................................................................... 936
Fig. 998: Rope path, MBE.............................................................................................................................. 937
Fig. 1000: Reeving the basic boom MBE....................................................................................................... 937
Fig. 1002: Design variants of the intermediate section.................................................................................. 939
Fig. 1003: main boom extension 33,0 m (108.3 ft)........................................................................................ 940
Fig. 1004: Preparations on the basic crane unit............................................................................................ 940
Fig. 1005: Main boom extension (MBE) with fixed operating angles............................................................. 941
Fig. 1006: Main boom extension (MBE) with fixed operating angles............................................................. 941
Fig. 1007: Main boom extension with hydraulically smooth operating angle adjustment (HAVHY).............. 941
Fig. 1008: Put on the hoist rope, reeve the hook block.................................................................................. 941
Fig. 1009: Remaining work on the box top piece........................................................................................... 942
Fig. 1010: Load relief connection on the basic boom MBE (schematic diagram).......................................... 942
Fig. 1011: Fitting the intermediate section..................................................................................................... 943
Fig. 1012: Connect the intermediate section electric cables (schematic diagram)........................................ 943
Fig. 1013: Basic boom MBE fitting (schematic diagram)............................................................................... 943
Fig. 1015: Fitting the tension plates............................................................................................................... 944
Fig. 1016: Connecting the basic boom MBE electrically (schematic diagram).............................................. 945
Fig. 1017: Hydraulic hoses on the main boom extension.............................................................................. 945
Fig. 1018: Fitting the box top piece to the basic boom MBE.......................................................................... 945
Fig. 1019: Electrically connect the box top piece........................................................................................... 946
Fig. 1020: Fitting the intermediate section, basic boom and box top piece................................................... 946
Fig. 1021: Preparation for angling ................................................................................................................. 946
Fig. 1022: Tension plate................................................................................................................................ 946
Fig. 1024: MBE lowered onto the ground...................................................................................................... 947
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Fig. 1026: Connecting the intermediate section electrically and hydraulically (schematic diagram)............. 948
Fig. 1029: Connecting the basic boom MBE electrically (schematic diagram).............................................. 949
Fig. 1030: Adjusting cylinder.......................................................................................................................... 949
Fig. 1033: Remove connecting line (schematic diagram).............................................................................. 951
Fig. 1034: Course of the rope, MBE (schematic diagram)............................................................................. 952
Fig. 1036: Rope guidance, basic boom MBE (schematic diagram)............................................................... 953
Fig. 1037: Rope guidance, basic boom MBE................................................................................................. 953
Fig. 1038: Reeving the box top piece............................................................................................................ 954
Fig. 1040: Main boom extension 35.4 m (116.1 ft)........................................................................................ 955
Fig. 1044: Remaining work on the basic boom MBE..................................................................................... 957
Fig. 1046: Connecting the intermediate section electrically and hydraulically............................................... 958
Fig. 1047: Fitting the Intermediate Sections.................................................................................................. 958
Fig. 1049: Connect the intermediate sections................................................................................................ 959
Fig. 1050: Fitting the basic boom MBE.......................................................................................................... 959
Fig. 1052: Electrically connect the basic boom-MBE..................................................................................... 959
Fig. 1054: Intermediate sections ................................................................................................................... 960
Fig. 1056: Course of rope – intermediate sections........................................................................................ 963
Fig. 1061: Main boom extension 45.0 m (147.6 ft)........................................................................................ 965
1182 82640 2021-04-22

Fig. 1065: Remaining work on the box top piece........................................................................................... 966
Fig. 1067: Connecting the intermediate section electrically and hydraulically............................................... 967
Fig. 1070: Connecting the intermediate sections........................................................................................... 968
Fig. 1073: Electrically connect the basic boom-MBE..................................................................................... 969
Fig. 1077: Remove connecting line (schematic diagram).............................................................................. 970
Fig. 1082: Rope guidance, basic boom MBE................................................................................................. 974
Fig. 1085: MBE lengths.................................................................................................................................. 977
Fig. 1087: Course of rope on the main boom head....................................................................................... 978
Fig. 1089: Course of rope on the intermediate section.................................................................................. 979
Fig. 1090: Course of rope, basic boom MBE (schematic diagram)............................................................... 980
Fig. 1091: Course of rope, basic boom MBE................................................................................................. 981
Fig. 1092: Course of rope, basic boom MBE................................................................................................. 982
Fig. 1093: Course of rope - box top piece...................................................................................................... 983
Fig. 1094: MBE 11.4 m (37.4 ft)..................................................................................................................... 984
Fig. 1095: MBE 21.0 m (68.9 ft)..................................................................................................................... 984
Fig. 1096: 23.4 m / 76.8 ft MBE..................................................................................................................... 984
Fig. 1097: MBE 33 m / 108.3 ft...................................................................................................................... 984
Fig. 1098: Basic Boom MBE.......................................................................................................................... 985
Fig. 1099: Box top piece................................................................................................................................ 985
Fig. 1100: Pins support and control panel (schematic diagram).................................................................... 986
Fig. 1101: Basic boom MBE 0° operating angle............................................................................................ 987
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Fig. 1102: Position of the superstructure (schematic diagram)...................................................................... 988

Fig. 1103: Preparations for angling the MBE................................................................................................. 988
Fig. 1104: Angling the MBE........................................................................................................................... 989
Fig. 1105: Remaining work on the main boom and MBE............................................................................... 989
Fig. 1106: "Operating Mode Selection" Screen............................................................................................. 989
Fig. 1107: Removing the hoist limit switch..................................................................................................... 991
Fig. 1108: Basic boom MBE with box top piece............................................................................................. 991
Fig. 1109: Electric connection on the intermediate section (schematic diagram).......................................... 992
Fig. 1110: Mobile control panel...................................................................................................................... 992
Fig. 1111: Electric connections for mobile control panel (schematic diagram).............................................. 992
Fig. 1112: Carrying out fitting of the tension plates (schematic diagram)...................................................... 993
Fig. 1113: Move the bolts from the 0° position into the 20°/40° position (schematic diagram)...................... 993
Fig. 1114: Setting the MBE down on the ground........................................................................................... 993
Fig. 1115: Hydraulic hoses (schematic diagram)........................................................................................... 994
Fig. 1116: Auxiliary cylinder and cross beam................................................................................................ 995
Fig. 1118: Retracting the auxiliary cylinder.................................................................................................... 996
Fig. 1121: Rope slip-off protection sheave of the intermediate section......................................................... 997
Fig. 1122: Preparations for dismantling the tension plates............................................................................ 998
Fig. 1123: Engaging the auxiliary cylinder..................................................................................................... 998
Fig. 1124: Hydraulic connections from the basic boom of the MBE (schematic diagram)............................. 999
Fig. 1125: Electric connection on the intermediate section (schematic diagram)........................................ 1000
Fig. 1126: Rope attachment points with 2-fold reeving................................................................................ 1001
Fig. 1127: Hoist limit switch assembly......................................................................................................... 1002
Fig. 1128: Hoist limit switch in functional configuration................................................................................ 1002
Fig. 1129: Main boom extension (schematic diagram)................................................................................ 1003
Fig. 1130: "Crane operation" screen............................................................................................................ 1005
Fig. 1131: MBE in the load-raising position (schematic diagram)................................................................ 1006
Fig. 1132: Radio Remote Control................................................................................................................ 1006
Fig. 1133: Hydraulic valve (schematic diagram).......................................................................................... 1007
Fig. 1134: Hydraulic connections from the basic boom of the MBE (schematic diagram)........................... 1007
Fig. 1135: Distribution box "X0550" (schematic diagram)............................................................................ 1008
Fig. 1136: Hydraulic hoses of the main boom extension (schematic diagram)............................................ 1008
Fig. 1137: Retract the hydraulic cylinders.................................................................................................... 1009
Fig. 1138: Terminal box............................................................................................................................... 1009
Fig. 1139: Hydraulic hoses of the main boom extension............................................................................. 1010
1184 82640 2021-04-22

Fig. 1140: Load hook camera / hanging light (schematic diagram)............................................................. 1010
Fig. 1141: Load hook camera on the MBE (schematic diagram)................................................................. 1011
Fig. 1142: Load hook camera on MBE (schematic diagram)....................................................................... 1012
Fig. 1143: Load hook camera on MBE (schematic diagram)....................................................................... 1012
Fig. 1144: Attachment point of load hook camera on MBE (schematic diagram)........................................ 1013
Fig. 1145: Connection (schematic diagram)................................................................................................ 1014
Fig. 1146: Pendant light on the MBE (schematic diagram).......................................................................... 1015
Fig. 1149: Hanging light on the MBE........................................................................................................... 1016
Fig. 1150: Hanging light on the MBE........................................................................................................... 1016
Fig. 1153: Radio transmitter......................................................................................................................... 1019
Fig. 1156: Radio transmitter with control panel............................................................................................ 1024
Fig. 1157: Operating Elements of the Radio Transmitter............................................................................. 1027
Fig. 1161: Displays of the radio transmitter................................................................................................. 1030
Fig. 1162: Displays and operating elements of the radio transmitter........................................................... 1031
Fig. 1163: Display, left................................................................................................................................. 1032
Fig. 1164: Display, right............................................................................................................................... 1033
Fig. 1166: Radio remote control key-operated switch.................................................................................. 1036
Fig. 1167: "Selecting the operating mode" screen....................................................................................... 1037
Fig. 1168: "Crane operation" screen............................................................................................................ 1038
Fig. 1172: Radio remote control display, left................................................................................................ 1040
Fig. 1173: Receiver...................................................................................................................................... 1041
Fig. 1175: Display on the left in the radio remote control............................................................................. 1044
82640 2021-04-22 1185


Fig. 1179: Radio transmitter, bottom side.................................................................................................... 1048
Fig. 1180: Battery Charging Device............................................................................................................. 1050
Fig. 1181: Overview diagram - emergency actuation.................................................................................. 1053
Fig. 1182: Hydraulic Transformer................................................................................................................ 1056
Fig. 1183: Hydraulic transformer connections............................................................................................. 1057
Fig. 1184: Connection (P)............................................................................................................................ 1058
Fig. 1185: Connection (S2).......................................................................................................................... 1058
Fig. 1186: Connection (TCC)........................................................................................................................ 1058
Fig. 1187: Connections (LCC) and (PCC)...................................................................................................... 1058
Fig. 1188: Crane hydraulic stop valves........................................................................................................ 1059
Fig. 1190: Hoses between the assisting crane and the hydraulic transformer (motor-side) ....................... 1061
Fig. 1191: Hoses between hydraulic transformer (pump-side) and own crane (schematic diagram) ......... 1062
Fig. 1194: Stop valve setting........................................................................................................................ 1063
Fig. 1195: Call up the main menu................................................................................................................ 1064
Fig. 1197: 8 kW emergency unit.................................................................................................................. 1068
Fig. 1198: Connections on the 8 kW power unit.......................................................................................... 1069
Fig. 1200: Hoses between the 8 kW power unit and the hydraulic transformer (motor-side) ..................... 1071
Fig. 1201: Hoses between the hydraulic transformer (pump-side) and the crane (schematic diagram)..... 1072
Fig. 1202: Directional control valve lever..................................................................................................... 1072
Fig. 1203: Hoses between hydraulic transformer (motor-side) and own crane (schematic diagram).......... 1073
Fig. 1204: Components of the electric emergency control system.............................................................. 1076
Fig. 1205: Mobile Manual Control Panel...................................................................................................... 1077
Fig. 1206: Cover flap, left............................................................................................................................. 1082
Fig. 1207: Switch box "X2"........................................................................................................................... 1083
Fig. 1208: Connecting the control unit......................................................................................................... 1084
Fig. 1209: Emergency Unit.......................................................................................................................... 1101
Fig. 1212: Operating elements..................................................................................................................... 1104
1186 82640 2021-04-22

Fig. 1216: Example of the flashing signal 2-2.............................................................................................. 1109

Fig. 1217: Hydraulic connections on the emergency unit............................................................................ 1114
Fig. 1218: Hydraulic connections on the crane............................................................................................ 1114
Fig. 1219: Stop valve................................................................................................................................... 1115
Fig. 1220: Junction box................................................................................................................................ 1115
Fig. 1222: Emergency unit - potentiometer.................................................................................................. 1117
Fig. 1225: Emergency unit - potentiometer.................................................................................................. 1118
Fig. 1226: Stop valve................................................................................................................................... 1120
Fig. 1227: Main boom AC250-5................................................................................................................... 1126
Fig. 1228: Main boom AC220-5................................................................................................................... 1126
Fig. 1229: Attachment points - main boom (schematic diagram)................................................................. 1127
Fig. 1230: Lashing eyes on both sides of the main boom (schematic diagram).......................................... 1127
Fig. 1231: Hoist limit switch on the main boom head................................................................................... 1128
Fig. 1232: Shift weight................................................................................................................................. 1129
Fig. 1233: Luffing cylinder mounting............................................................................................................ 1130
Fig. 1234: Safety mast on the superstructure frame.................................................................................... 1131
Fig. 1235: Safety mast on the superstructure frame.................................................................................... 1132
Fig. 1236: Locking the safety mast.............................................................................................................. 1133
Fig. 1237: Anti-fall protection on superstructure frame................................................................................ 1134
Fig. 1238: Attachment points - main boom (schematic diagram)................................................................. 1135
Fig. 1239: Distribution boxes....................................................................................................................... 1136
Fig. 1240: Distribution boxes....................................................................................................................... 1137
Fig. 1241: Mobile cylinder............................................................................................................................ 1138
Fig. 1242: Axle mounting............................................................................................................................. 1139
Fig. 1243: Mobile cylinder on the luffing cylinder headpin........................................................................... 1140
Fig. 1244: "Function display" screen............................................................................................................ 1142
Fig. 1248: Luffing cylinder headpin.............................................................................................................. 1144
Fig. 1249: Locating plate.............................................................................................................................. 1145
Fig. 1250: Stop valve................................................................................................................................... 1145
Fig. 1251: Locating plate (transport position, schematic diagram).............................................................. 1146
Fig. 1252: Locating plate (operating position, schematic diagram).............................................................. 1146
Fig. 1253: Locating plate (schematic diagram)............................................................................................ 1146
82640 2021-04-22 1187

Fig. 1254: Locating plate with mobile cylinder (schematic diagram)............................................................ 1147
Fig. 1258: Main Boom Foot Section Pins..................................................................................................... 1150
Fig. 1259: Luffing cylinder (schematic diagram).......................................................................................... 1151
Fig. 1260: Luffing cylinder head................................................................................................................... 1153
Fig. 1261: Main boom foot section............................................................................................................... 1153
Index of tables
Table 1: Warning symbols............................................................................................................................... 30

Table 2: Parameter settings........................................................................................................................... 310
Table 3: Calculation table.............................................................................................................................. 393
Table 4: Typical body shapes and resistance coefficients............................................................................. 402
Table 5: Beaufort scale.................................................................................................................................. 404
Table 6: Beaufort scale.................................................................................................................................. 405
Table 7: Roughness classes.......................................................................................................................... 407
Table 8: Relation between the 3-second wind gust speed and wind speed.................................................. 408
Table 9: Relation between the 3-second wind gust speed and wind speed.................................................. 409
Table 10: Dynamic pressure in relation to height above ground in m/s......................................................... 412
Table 11: Dynamic pressure in relation to height above ground in mph........................................................ 413
Table 12: Procedure for wind speeds............................................................................................................ 414
Table 13: Telescoping direction depending on type of telescoping............................................................... 445
Table 14: Definition of the hook blocks.......................................................................................................... 604
Table 15: Standard hook blocks.................................................................................................................... 617
Table 16: Vario hook blocks........................................................................................................................... 618
Table 17: Transport Dimensions and Weights............................................................................................... 641
Table 18: Transport Dimensions and Weights............................................................................................... 663
Table 19: Hook block type 80, 3-sheave........................................................................................................ 673
Table 20: Operating elements...................................................................................................................... 1104
Table 21: Operating elements...................................................................................................................... 1106
Table 22: Torque.......................................................................................................................................... 1153
Table 23: Torque.......................................................................................................................................... 1153
1188 82640 2021-04-22

Technical Documentation
c/o Tadano Demag GmbH

Europaallee 2
66482 Zweibrücken
Germany
Tel. +49 (0) 6332 830
info.demag@tadano.com
www.tadano.com

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Operating instructions Superstructure

The only warranty applicable to our products is the corresponding

1 Safety Instructions ....................................................................... 25

2 Structure of the Mobile Crane ..................................................... 69

3 Crane operator's cab ....................................................................87

3.5.1 General .........................................................................................109

4 motor ........................................................................................... 123

4.5.1 Setting the Required Engine Speed ............................................. 143

5 Supporting the Crane on Outriggers from the Crane Opera-

6 Slewing the Superstructure .......................................................161

7 Counterweight ............................................................................ 177

7.2.11 Counterweight Combination 51.6 t (113.8 kip) ............................. 182

8 Safety Equipment ....................................................................... 221

8.1.7.3 Calling up the "System setup (user)" screen ................................ 264

8.1.7.26 Operating screen "Capacities dependent on slewing angles" /

9 Working Instructions ..................................................................373

9.3.2 Camera system by the Motec company (optional) ....................... 426

10.4.3.3 Input and Monitoring Screens at Crane Control (Manual Tele-

11 Luffing ......................................................................................... 511

13 Hoist 2 (optional) ........................................................................ 521

14 Heating and Ventilation ..............................................................547

14.1.7.6 Overview of heater assembly fault code .......................................566

16 Central lubricating system (optional) ....................................... 635

17 Head Sheave (Optional) ............................................................. 641

18 Assembly Jib (Optional) ............................................................ 663

19 Main Boom Extension (Optional) .............................................. 685

19.5.1 General .........................................................................................715

20 Radio Remote Control (Optional) ............................................1019

20.11 Troubleshooting ..........................................................................1051

21 Emergency Operation (Optional) ............................................ 1053

22 Emergency Operation (Optional) ............................................ 1101

23 Dismantling and Assembly of the Main Boom (Optional) .... 1123

Index of figures ........................................................................ 1155

Index of tables ......................................................................... 1188

1.2 Warning Information

Fig. 1: Safety note (z82353)

1 Pictogram 2 Sign for danger / risk

Points "4" and "5" can also be combined.

Particularly important or further information is indicated without a sig-

This is an example for an indication of particularly important or fur-

1.2.4 Warning symbols

General warning sign

Warning, explosive substances

Warning, radioactive substances or ionising radiation

Warning, laser radiation

Warning, non-ionising radiation

Warning, magnetic field

Warning, obstacles at ground level

Warning, risk of falling

Warning, low temperature/frost

Warning, risk of slipping

Warning, electrical voltage

Warning, forklift trucks

Warning, hanging load

Warning, toxic substances

Warning, hot surface

Warning, automatic start-up