AC200 1 33312b Part1 - en

Translation
of the Original Operating Instructions

AC200−1
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.
200−1−0000−001c_en 1/1
Index
Manufacturer’s Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Operating Conditions and Computed Design of the Crane . . . . . . 13
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Classification of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.3 Classification of the Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.5 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.6 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3.7 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.8 Scrapping / Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.9 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 25
1.3.10 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.2 Selection and Qualifications of Personnel . . . . . . . . . . . . . . . . . . . . 33
1.4.3 Particular Types of Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4.4 Combination of Hazards with Combined Operation
of Two or More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4.5 Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4.6 Crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4.7 Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.4.8 When Assembling and Dismantling Crane Components . . . . . . . . 75
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 85
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 87
2 Structure of the Mobile Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Basic Crane Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Superstructure (Components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Safety−relevant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.1 Ladders, Holding Devices and Antifall Guards . . . . . . . . . . . . . . . . 7
2.4.2 Spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.3 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Decals (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.1 CE Crane Identification Plate / Factory Plate or
Crane Identification Sign / Factory Sign (Specific to Country) . . . 43
2.5.2 Safety Signs (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.5.3 Safety Signs (only USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix to section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
200−1−1000−312b_en 1
Index
4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Entering / leaving the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.1 Adjusting the Crane Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.2 Sun shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.3 Lighting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.4 Open / close window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 Engine control/monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.2 Starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.3 To be observed after starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.4 Warming up the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.5 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 Operating hour display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Automatic driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Coolant preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7 Diesel soot particle filter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7.1 Checking the filter for levels of contamination . . . . . . . . . . . . . . . . . 31
7 Supporting the crane on outriggers from the

crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 Slewing and Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.1.1 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.1.2 Braking the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2 Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.3 Slewing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Slewing Gear and Superstructure Locking Device in the
Position “Operation of the Crane” during Dolly Preparation . . . . . . 21
8.4.1 Activating and Closing the Slew Gear Brake after
Dolly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.4.2 Superstructure locking device: Removing the
”Locked” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
200−1−1000−312b_en 2
Index
9 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1 Important Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 Operating Elements / Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . 3
9.3 Counterweight Elements / Attachment Points . . . . . . . . . . . . . . . . . 9
9.3.1 Nominal Weights and Transport Dimensions . . . . . . . . . . . . . . . . . . 9
9.3.2 Attaching the Counterweight Elements . . . . . . . . . . . . . . . . . . . . . . . 11
9.4 Assembling the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.4.1 Preassembly of the Counterweight on Superstructure Frame . . . 13
9.4.2 Suspending the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.4.2.1 Automatic Fitting of the Counterweight . . . . . . . . . . . . . . . . . . . . . . . 19
9.4.2.2 Manual Fitting of the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.4.3 Mounting the Counterweight (F) to the Superstructure . . . . . . . . . 27
9.5 Assignment of the Counterweights to the
Different Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.5.1 Counterweight Combination 0 t (0 kip) . . . . . . . . . . . . . . . . . . . . . . . 31
9.5.2 Counterweight Combination 5.9 t (13.0 kip) . . . . . . . . . . . . . . . . . . . 31
9.5.3 Counterweight Combination 9.0 t (19.9 kip) . . . . . . . . . . . . . . . . . . . 31
9.5.4 Counterweight Combination 13.3 t (29.3 kip) . . . . . . . . . . . . . . . . . . 33
9.5.14 Counterweight Combination 59.9 t (132.1 kip) (Optional) . . . . . . . 39
9.5.15 Counterweight Combination 68.5 t (151.0 kip) (Optional) . . . . . . . 41
9.6 Operation with a Fitted Counterweight Combination . . . . . . . . . . . 41
200−1−1000−312b_en 3
Index
10 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 Electronic Crane Information System . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1.1 Control and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.1.2 Operation of the IC−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.1.3 System Start / Switching the System off . . . . . . . . . . . . . . . . . . . . . . 15
10.1.4 Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1.5 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1.6 Crane Operation Screen (Main Menu: 202.1) . . . . . . . . . . . . . . . . . 31
10.1.7 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1.7.1 System Screen (Main Menu: 201.1) (Quick Menu: E12) . . . . . . . . 43
10.1.7.2 Background Lighting (Main Menu: 201.2) . . . . . . . . . . . . . . . . . . . . . 45
10.1.7.3 Crane Operation Screen (Main Menu: 202.1) . . . . . . . . . . . . . . . . . 45
10.1.7.4 Operating Mode Selection Mask (Main Menu: 202.2;
Quick Menu E21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.7.5 Error Message (Main Menu: 202.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.1.7.6 Control Lever Function (Main Menu: 202.4; Quick Menu: E23) . . 57
10.1.7.7 Operating Hour Counter (Main Menu: 202.5) . . . . . . . . . . . . . . . . . . 59
10.1.7.8 Parameter Mask (Main Menu: 203.1; Quick Menu: E22) . . . . . . . . 61
10.1.7.9 Crane Information (Main Menu: 203.2) . . . . . . . . . . . . . . . . . . . . . . . 65
10.1.7.10 Emergency Operation (Main Menu: 203.3) . . . . . . . . . . . . . . . . . . . 65
10.1.7.11 Setting the Operating Range Limit
(Main Menu: 203.4; Quick Menu: E24) . . . . . . . . . . . . . . . . . . . . . . . 67
10.1.7.12 Hoist Data Logger (Optional) (Main Menu: 203.5) . . . . . . . . . . . . . 73
10.1.7.13 Diagnosis Control Lever (Main Menu: 204.1;
Quick Menu: E31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1.7.14 Diagnosis Control In−/Outputs (Main Menu: 204.2;
Quick Menu: E32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1.7.15 Diagnosis CAN−Bus (Main Menu: 204.3; Quick Menu: E33) . . . . 79
10.1.7.16 Diagnosis Load Sensing System
(Main Menu: 204.3; Quick Menu: E34) . . . . . . . . . . . . . . . . . . . . . . . 87
10.1.7.17 Datalogger (Optional) (Main Menu: 204.5) . . . . . . . . . . . . . . . . . . . . 89
10.1.7.18 “Function diagnosis” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.7.19 Select Main Menu (Quick Menu: E 11) . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.7.20 Telescoping Information System (Quick Menu: E 51) . . . . . . . . . . . 93
10.1.7.21 Support Pressure Display / Inclination Display /
Outrigger Support Area Display
(Optional) (Quick Menu: E 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.7.22 Operation Mode of the Hydraulic Pumps (Quick Menu: E 53) . . . 95
10.1.7.23 Assignment of Movements of Hydraulic Pumps
(Quick Menu: E 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.1.7.24 “Active Working Area Limitations” (Quick Menu: E 61) . . . . . . . . . 97
10.1.7.25 Engine Display (Quick Menu: E 62) . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.1.8 Setting the Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.1.9 Loading Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1.10 Load Monitoring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1.11 Bridging Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
200−1−1000−312b_en 4
Index
10.1.11.1 Bridging Shutdown of Movement Which Decreases

the Load Moment ”Raise Luffing Gear” . . . . . . . . . . . . . . . . . . . . . . . 107
10.1.11.2 Set−up Button
(only EN 13000 design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.1.11.3 Bridging the Shutdown of all Movements . . . . . . . . . . . . . . . . . . . . . 111
10.1.11.3.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.1.11.3.2 Control Elements (Shut−down of all Movements):
“EN 13000” Compared to
“Non−EN 13000”−Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.2 Behaviour of Crane Control Depending on Load . . . . . . . . . . . . . . . 115
10.2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.2.2 EN 13000−Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2.2.1 Configuration Operation (EN 13000) . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.2.2.2 Standard Crane Operation (EN 13000) . . . . . . . . . . . . . . . . . . . . . . . 121
10.2.2.3 Operation with Activated Set−up Button (EN 13000) . . . . . . . . . . . 123
10.2.2.4 Operation with Bridged Crane Control
(Bridging all Movements) (EN 13000) . . . . . . . . . . . . . . . . . . . . . . . . 127
10.2.3 Non−EN 13000−Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.2.3.1 Configuration Operation (Non−EN 13000) . . . . . . . . . . . . . . . . . . . . 129
10.2.3.2 Standard Crane Operation (Non−EN 13000) . . . . . . . . . . . . . . . . . . 131
(Bridging All Movements)
(Non−EN 13000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.3 Dead man’s handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.3.2 Arrangement of the Dead Man’s Switches . . . . . . . . . . . . . . . . . . . . 135
10.3.3 Activating the Dead Man’s Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.4 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.4.1 Fine tuning of the movement speed . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.4.2 High speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.5 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.5.1 Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.5.1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.5.2 Bridging the Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
10.5.3 Lower Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.5.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.5.3.2 Bridging Lower Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.6 Electric Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.7 Malfunction Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.7.1 Malfunction−free Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.7.2 Failure of the ”Touchscreen”
of the Crane Controls Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.7.3 Failure of the Crane Control Display
(DLOG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.7.4 Failure of the Crane Control (CAN Stop) . . . . . . . . . . . . . . . . . . . . . 159
200−1−1000−312b_en 5
Index
11 Notes on Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Wind Forces on the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.1 Measuring the Wind Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.2 Behaviour in Relation to the Wind Speed . . . . . . . . . . . . . . . . . . . . . 5
11.2 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.3 Operation with Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . 19
11.4 Operation Planning / Monitoring Safety Measures . . . . . . . . . . . . . 21
11.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.4.2 Condition of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.4.3 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.5 Conversion of Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Locking and Pinning Unit (LPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.1 Bringing the Main Boom in the Road Travel Condition . . . . . . . . . . 11
12.3 Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12.4 Select the hydraulic supply for telescoping . . . . . . . . . . . . . . . . . . . 19
12.5 Controls / Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.6 Telescoping Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.6.2 Telescoping Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.6.3 Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.6.4 Input of the Length Code − Selection of the
Main Boom Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.6.5 Manual Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.6.6 Teaching the extension sequence of the telescopic sections . . . . 49
12.6.7 Locking and Pinning Positions of the
Telescopic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.7 Extension Lengths of the Telescopic Sections . . . . . . . . . . . . . . . . . 53
12.7.1 Overview Length Code − Main Boom Length . . . . . . . . . . . . . . . . . 53
12.7.1.1 Display via the Telescopic Operating Mode Mask . . . . . . . . . . . . . . 53
12.7.1.2 Display via the Operating Mode Preselection Mask . . . . . . . . . . . . 53
12.7.2 Monitoring the Extension Lengths During the
Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.7.3 Extension Sequence of the Telescopic Sections . . . . . . . . . . . . . . . 55
12.8 Load capacities in the pinned condition . . . . . . . . . . . . . . . . . . . . . . 57
12.9 Lifting Capacities in the Unpinned Condition . . . . . . . . . . . . . . . . . . 57
12.9.1 Lifting Capacities in Intermediate Positions . . . . . . . . . . . . . . . . . . . 59
12.9.2 Telescoping Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
200−1−1000−312b_en 6
Index
13 Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1 Luffing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.2 Lifting loads using luffing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13.3 Bring the luffing gear into function . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
13.4 Selecting hydraulic supply for luffing gear . . . . . . . . . . . . . . . . . . . . 9
13.6 Luffing speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13.6.1 Luffing up main boom in high speed mode . . . . . . . . . . . . . . . . . . . . 13
13.6.2 Fine−tuning downward luffing (”luffing gear down”) . . . . . . . . . . . . . 13
13.7 Bridging Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13.7.1 Overriding shutdown of movement ”Raise luffing gear” . . . . . . . . . 15
14 ”Hoist 1” Hook Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 Raising and Lowering the Load with Hoist 1 . . . . . . . . . . . . . . . . . . 3
14.2 Hoist Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
14.3 Camera Surveillance of the Hoist (Optional) . . . . . . . . . . . . . . . . . . 9
15 Hoist 2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Information on Transport and Attachment Points . . . . . . . . . . . . . . 3
15.1.1 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1.2 Transport Dimensions / Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.2 Fitting and Removing Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.2.1 Fitting and Removing Hoist 2 with the Auxiliary Crane . . . . . . . . . . 7
15.2.1.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15.2.2 Fitting and Removing Hoist 2 with Your Own Crane . . . . . . . . . . . . 13
15.2.2.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.2.2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15.3 Fitting and Removing the Additional Top Rollers . . . . . . . . . . . . . . . 19
15.4 Rope Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
15.5 Hook Operation with Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15.5.1 Control Lever Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15.5.2 Hoist Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
15.6 Camera Surveillance of the Hoist (Optional) . . . . . . . . . . . . . . . . . . 29
16 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Engine−Dependent Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Engine−Independent Heating with Coolant Preheating System . . 5
16.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.2.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2.3 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.2.4 Heating operation without pre−set times . . . . . . . . . . . . . . . . . . . . . . 11
16.2.5 Heating operation with preselection . . . . . . . . . . . . . . . . . . . . . . . . . . 13
16.2.6 Rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16.3 Air Conditioning Equipment (Standard, Optional) . . . . . . . . . . . . . . 21
16.4 Auxiliary AC system (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
16.5 Petrol gas heating (engine−independent), optional . . . . . . . . . . . . . 25
200−1−1000−312b_en 7
Index
17 Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.2 Load Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17.2.1 Hoist Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17.2.2 Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
17.2.2.4 Hook Block Types / Transport Dimensions / Weights . . . . . . . . . . . 33
17.3 Reeving the Hoist Rope on the Main Boom Head . . . . . . . . . . . . . . 35
17.4 Reeving the Hoist Rope on the Main Boom Headwith
Auxiliary Sheaves (HD attachment, optional) . . . . . . . . . . . . . . . . . . 37
17.4.1 Information on Transport and Attachment Points . . . . . . . . . . . . . . 37
17.4.1.1 Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
17.4.1.2 Transport Dimensions / Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
17.4.2 Fitting and Removal of One−Sided Fitted HD Attachment . . . . . . 39
17.4.3 Fitting and Removal of Double−sided Fitted HD attachment . . . . . 41
18 Main Boom Extension (MBE) (Optional) . . . . . . . . . . . . . . . . . . . 1

18.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18.3 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
18.3.1 Transport Instructions for the MBE in the Transport Position . . . . 9
18.3.2 Transport Instructions for Separate Transportation . . . . . . . . . . . . . 13
18.4 Folding up and down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
18.4.1 General Instructions for Folding over the Equipment . . . . . . . . . . . 17
18.4.2 Folding the 9 m MBE (29.5 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
18.4.2.1 9 m (29.5 ft) MBE fitted in the transport position . . . . . . . . . . . . . . . 21
18.4.2.1.1 Folding from the Transport into the Operating Position . . . . . . . 21
18.4.2.1.2 Folding from the Operating into the Transport Position . . . . . . . 37
18.4.2.2 17 m (55.8 ft) MBE Fitted in the Transport Position . . . . . . . . . . . . 47
18.4.2.2.1 Folding over the 9 m (29.5 ft) MBE from the Transport
into the Working Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
18.4.2.2.2 Folding the 9 m MBE from the Operating to the
Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
18.4.3 Folding over the 17 m MBE (55.8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . 51
18.4.3.1 Folding the 17 m (55.8 ft) MBE from the Transport
to the Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
18.4.3.2 Folding the 17 m (55.8 ft) MBE from the Operating
to the Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
18.5 Fitting and Removing for Separate Transportation . . . . . . . . . . . . . 61
18.5.1 General Instructions for Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
18.5.3 Closing the Electric Safety Chain for
Operation with Main Boom Extension (MBE) . . . . . . . . . . . . . . . . . . 67
200−1−1000−312b_en 8
Index
18.5.3.1 Electric Connections on the Main Boom Head . . . . . . . . . . . . . . . . 69

18.5.3.2 Electric Connections on the Intermediate Sections (1)
or Intermediate Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.5.3.3 Electric Connections on the Basic Boom . . . . . . . . . . . . . . . . . . . . . 73
18.5.3.4 Electric Connections in the Tip Section . . . . . . . . . . . . . . . . . . . . . . . 75
18.5.4 Fitting the 9 m MBE (29.5 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
18.5.5 Fitting the 17 m MBE (55,8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
18.5.5.1 Fitting the Basic Boom MBE (3) and
Tip Section (4) Individually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Tip Section (4) Folded Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
18.5.5.3 Preparation for Raising Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
18.5.6 Fitting the 25 m MBE (82 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.5.6.1 Fitting the Intermediate Section 2 (2) . . . . . . . . . . . . . . . . . . . . . . . . 89
18.5.7 Fitting the 33 m MBE (108.3 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
18.5.7.1 Fitting the Intermediate Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
18.5.8 Converting from One Length to Another . . . . . . . . . . . . . . . . . . . . . . 105
18.6 Reeving the Hoist Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
18.6.1 ... for Setting the Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
18.6.1.1 Reeving the Rear Deflection Roller on the
Basic Boom MBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
18.6.1.2 Feeding the Hoist Rope through the Sheaves on the
Intermediate Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
18.6.2 ...for Raising Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
18.7 Setting the Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
18.7.1 Switching from the 0 − Degree to the 20 − Degree Position . . . . . 117
18.7.2 Switching from the 0 − Degree to the 40 − Degree Position . . . . . 121
18.7.3 33 m (108.3 ft) MBE Supported on the Ground
(Setting the Operating Angles 20 Degree and 40 Degree) . . . . . . 123
18.8 Telescoping the Main Boom with the MBE
Fitted in the Load−raising Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
18.9 Raising Loads with the
9/17 m (29.5 ft / 55.8 ft) MBE Folded in the
Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
18.10 Operation with Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . 129
18.11 Emergency Removal in the Case of Telescoping Problems . . . . . 129
200−1−1000−312b_en 9
Index
21 Head Roller (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

21.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21.2 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21.3 Folding from the Transport Position to the Operating Position . . . 7
21.4 Folding from the Operating Position to the Transport Position . . . 17
21.5 Separate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
21.6 Assembly and Removal of the Head Roller during
Separate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
21.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
31 Dismantling and Assembly of the Main Boom (Optional) . . . 1

31.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31.2 Dismantling the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31.2.1 Preparation for dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31.2.2 Retracting the Luffing Cylinder Head Pin . . . . . . . . . . . . . . . . . . . . . 9
31.2.3 Extracting the Boom Foot Pin / Lifting the Main Boom . . . . . . . . . . 15
31.3 Assembly of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

34.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
34.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
34.3 Important Information before Using the Radio Remote Control . . 5
34.4 Radio Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
34.5 Control Elements of the Radio Transmitter . . . . . . . . . . . . . . . . . . . 9
34.7 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
34.8 Starting Operation of the Radio Remote Control . . . . . . . . . . . . . . . 17
34.9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
34.10 Battery Charging Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
34.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
34.12 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
36 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
36.2 Connecting the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.3 Recovering a Small Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
200−1−1000−312b_en 10
Index
41 Runner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.2 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.3 Separate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
41.4 Fitting and Removing the Runner for Separate
Transportation (in the Folded Position) . . . . . . . . . . . . . . . . . . . . . . . 13
41.5 Converting from the Folded Position to the
Load Raising Position (and Vice Versa) . . . . . . . . . . . . . . . . . . . . . . 17
41.5.1 Converting to Load Raising Position . . . . . . . . . . . . . . . . . . . . . . . . . 17
41.5.2 Converting to the Folded Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
41.6 Folding from the Folded Position to the
Transport Position (and Vice Versa) . . . . . . . . . . . . . . . . . . . . . . . . . 27
41.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
41.6.2 Folding into the Transport Position . . . . . . . . . . . . . . . . . . . . . . . . . . 29
41.6.3 Folding into the Folded Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
41.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
46 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . . 3

46.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
46.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
46.3 Setting the interval and operating times . . . . . . . . . . . . . . . . . . . . . . 7
46.3.1 Generalinformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
46.3.2 Setting the interval time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.3.3 Setting the operating time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.4 Additional lubrication impulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.5 Manual lubrication in the case of an emergency . . . . . . . . . . . . . . . 11
46.6 Filling the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
200−1−1000−312b_en 11
Manufacturer’s Specifications
Manufacturer’s Specifications
The operating, lubricating and maintenance instructions included

here are valid for the mobile crane detailed below.
A quality management system as per DIN EN ISO 9001 forms the
basis of this crane’s construction and its manufacture.
Crane classification (as Mobile Crane

per DIN 15001,
15018 T3)
Crane Type AC 200−1
Construction number ___________________
Manufacturer Terex Demag GmbH

Dinglerstraße 24
D−66482 Zweibrücken
Phone: +49 6332 83−0
Fax: +49 6332 16715
www.terexcranes.com
200−1−1001c_en 1/1
Foreword
Foreword
For you,
as owner of a crane manufactured by us, we have produced this

manual, comprising the most important instructions for its opera-
tion, lubrication and maintenance.
These instructions should enable you to familiarise yourself with
your crane and to use the operating applications as intended.
The instructions must always be kept to hand at the operating
site.
The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
Part 3 − Lubrication and maintenance instructions for the
superstructure
Part 4 − Lubrication and maintenance instructions for the crane
chassis
Part 5 − Various
Please note that the information contained in this manual corres-

ponds to the state of machine engineering at the time the litera-
ture was drawn up. Deviations in the technical specifications, fi-
gures and dimensions are therefore possible.
In such cases we make every effort to bring your documentation

up to date by sending you modified pages.
But we must ask for your kind cooperation. For it is only you who
can ensure, that such modifications will be included into your ori-
ginal documentation.
This has to be applied also and especially for the part of the docu-
mentation that is permanently with the crane.
200−1−1002d_en 1/13
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Foreword
Pass this manual on to your crane operator and driver and to

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

malfunctions attributable to improper use and operation and/or
inadequate maintenance.
Should you discover any mistakes when reading this manual or

if you have further suggestions and hints, please contact:
Terex Demag GmbH

Dept. 111600
Postfach 1552
D−66465 Zweibrücken
The editors would welcome your involvement.
”Putting experience into practice”
200−1−1002d_en 3/13
4/13 200−1−1002d_en
Foreword
Handover of the crane
The crane is delivered to you from the works ready for operation,
and is already supplied with fuel and hydraulic oil.
All lubrication points have been greased.
If the crane is delivered from the works with a protective coating

(preserving wax), this does not necessarily have to be removed.
It provides added protection against corrosion.
The protective coating can be removed using:
Washing thinners, e.g. Conrad thinners RV 5339 E 45430

Cold cleaners, e.g. Allpur 150 X or Purtex 65
Stream spray gun
Before commissioning
you should inspect the crane thoroughly together with our service
engineer.
Spare parts
When ordering spare parts, please refer to the first page of our
spare parts catalogue:
”Instructions on using the catalogue”
Use only original spare and wear parts authorized by the crane
manufacturer.
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Foreword
Customer service
Please contact our customer services team with any questions

concerning your crane. Always quote the type designation and
construction number of your crane in all correspondence.
Within Germany
Tel: 0180−300 3090
Fax: 06332/831711
E−mail: Demag−Service−Germany@terex.com
From abroad
Tel: (49)06332/83−0
Fax: (49)06332/16715
E−mail: info@terex−demag.com
or contact your nearest TEREX−Demag dealership.
Modifications to the crane
We would point out that any modifications to the crane (e.g. the
purchase of boom parts, etc.) may invalidate the information in
these operating instructions or make it insufficient.
After modifications or repairs to parts which affect the safety of

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

tions which you carry out or have carried out on your crane.
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Foreword
...and you can find your way around this manual as follows:
From the example given here, you can see how fast and accura-
tely I can arrive at the required information.
WHAT do I want to know ?
I would like to know for instance what control elements are pro-
vided for outriggers.
WHERE do I find the information required above ?
The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
superstructure
crane chassis
Part 5 − Various
These parts are divided by index sheets. I need Part 2 because
the outriggers are part of the crane chassis.
1. I look for the index sheet ”1” (for Part 1), and open the super-
structure operating instructions at this point and find the
Contents of Part 1.
2. I glance over the bold headings of the sections until I come

to Section 11, Working Instructions”.
3. In this Section11 I then find ”Wind speeds” as item 11.1.

The page details on the right−hand side of the page refer to
the page number within the section.
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Z 26 350
10/13 200−1−1002d_en
Foreword
HOW do I find the page in Section 11 ?
1. I take the pages of Part 1 and flick through the pages as

shown in (Z 26 350).
Whilst doing this, I always keep the top, right−hand edge
(1, Z 26 350) in view.
As soon as the required section number appears, I stop flik-
king through the pages.
The name and number of the section are on the top right−hand
edge (1, Z 26 350) of each page.
2. Then, with the help of the page number on the bottom right−
hand edge (2, Z 26 350), I decide whether I must flick back-
wards or forwards in order to reach the page number requi-
red.
The page number within the section is given on the bottom right−
hand side (2, Z 26 350) of each page. This number is given along
with the total number of pages in the section. This means, for in-
stance, that 3 is given as the page number in the contents and
the page itself is numbered 3/39. This makes for better orienta-
tion within a section.
Please note that this option of fast and accurate access to

specific information as described above does not exempt
you from reading the instructions carefully and in full before
the crane is operated for the first time and at regular intervals
afterwards.
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Foreword
The headings and corresponding symbols ”Danger”, ”Caution”

and ”Note” are used in these operating instructions as follows:
DANGER !
”Danger” is used for operation procedures, mounting se-

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

quences etc. where failure to observe the stipulations made
may result in damage to the crane or equipment.
NOTE:
”Note” is used to indicate an important operation or mounting pro-

cedure or to draw attention to further information.
Information such as “left” and “right” of the crane must always be

understood as looking in the direction of travel.
200−1−1002d_en 13/13
Safety Information 1
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1 Safety Instructions
1.1 General
This section ”Safety Instructions” provides a compact and

general overview of hazards which can occur in connection with
the operation of the crane superstructure and crane chassis.
Where necessary, these safety instructions are referred to and
dealt with in further detail in the corresponding sections of the
operating instructions.
The safety instructions for lubrication, maintenance and service

work can be found in Lubrication and Maintenance Instructions.
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1.2 Intended Use
The crane is designed for lifting loads.
Risk to life and limb!

The mobile crane must never be used for entertainment
purposes, for example, lifting of persons for shows, bun-
gee jumping (leaping / bouncing from an elastic rope),
dinner−in−the−sky or lifting of other structures with people
on the structure or underneath it (e.g. lifting of tents)!
This is improper use of the crane and constitutes extreme
danger to life and limb!
The crane is not intended for lifting people. It is prohibited to

transport people with personnel carrying equipment!
Risk of accidents!
In many cases, there have been serious injuries when
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 smallest of
errors can have fatal consequences.
The crane may only be used to lift people in a so−called ”man

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

listed on the following two pages are fulfilled.
The crane operator carries the responsibility.
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General requirements
− The use of mobile cranes for lifting persons is permitted by

national law in the country of the crane’s current operation.
Specific regulations for the use of man baskets 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 man basket 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 observed.
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Requirements concerning the equipment
− With the exception of the man basket being the load, the
crane is used as intended and described in the respective
operating manual.
− The crane is checked and no damage / defects are found
prior to lifting persons.
− The man basket fulfils the requirements in accordance with
national law and / or standards and is used as intended.
− The man basket 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 aperture from opening. It is required by
national law to either close the lock manually and to lock or
to use an automatically operated, spring−loaded safety
catch.
Requirements concerning tests before use
− Prior to lifting persons, an overload test lift (approval test) with

an overload of 125% of the lifting capacity of the man basket
has been carried out. This must be done at each new
construction site and after every modification or repair to
verify the safe performance of the man basket and the lifting
tackle (relocation of the crane on a larger construction site
does not require a new overload test).
− Prior to lifting persons, a test lift has been carried out with an
unoccupied man basket, 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.
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Requirements for use
− The rope pull is limited to 50% of the maximum line pull.

− The crane is used at 50% of the maximum capacity of the
relevant load capacity table.
The crane is designed exclusively for assembly operation.

The crane is not suitable any other or further use, i.e. unit load
changeover or grab crane operation. The manufacturer shall not
be held liable for any damage which results. The operator carries
full responsibility for this type of use.
Risk of accidents!
It is prohibited to use the crane to pull free fixed loads !
Intended use also includes the observation of all load tables, the
operating instructions − in particular with regard to the specified
assembly sequence − and the lubrication and maintenance
specifications.
If operation of the crane for part−load handling or another type

of use is required, please contact the crane manufacturer.
The use of two hoists to raise the load (2−hook operation) is not
permitted.
Special load cases are however permitted in consultation with the
crane manufacturer.
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1.3 Operating Conditions and Computed Design of the

Crane
1.3.1 General
The crane has been constructed using state of the art technology
and in accordance with recognised safety regulations.
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
intended use, paying attention at all times to safety and potential
hazards, and in observance of the operating instructions. In
particular have any malfunctions which might impair safety
rectified immediately.
The term ”operating instructions” refers to the operating

instructions and the lubrication and maintenance instructions.
1.3.2 Classification of the Crane
The crane is classified as follows in accordance with ISO 4301

and EN 13000:
− Operating class => U1
− Collective class => Q2
− Crane group => A1
All important components of the crane are designed and

manufactured for normal assembly operation. This assumes that
crane operations under full load, crane operations with lower load
and operating breaks occur in a ratio that is typical for an
assembly crane. More exacting operating conditions necessarily
lead to a shorter life expectancy for the crane.
Operating conditions or types of use other than assembly

operation require the permission of the manufacturer and
normally lead to a reduction in the lifting capacities.
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1.3.3 Classification of the Engines
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 operating conditions which are laid
down in European standards.
The winches of your crane are classified as follows:

Power unit group: M........
Load collective: Q....... (L.......)
Factor of the load collective: Km = .......
Theoretical Service Life D = .......
The respectively applicable values can be obtained from the

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 Instructions).
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1.3.4 Workplace Ergonomics
The noise levels listed in the following table can occur at the
crane operator’s workplace in the crane operator’s cab. To
reduce noise during crane operation, we recommend keeping
the cab doors and windows and the cover flaps of all drive units
closed.
− Engine idle (550 min−1/rpm) < 75 dB(A)
− Maximum speed of the engine without load < 85 dB(A)
(2750 min−1/rpm)
− Engine speed with the highest engine tor- < 80 dB(A)
que without load (1300 min−1/rpm)
Measurements were taken using a noise level measuring unit

with the test microphone at the ear position of the crane operator.
The A−assessed equivalent permanent sound level at the
operator’s seat measured over the shift duration of 8 hours is
below 70 dB(A). For this purpose, measurements were taken
during operation on construction sites using dosimeters.
Outside of the crane operator’s cab or when the cab door is open,
the crane operator and the auxiliary personnel are exposed to
higher noise levels. For this reason, you may only work with ear
muffs there.
The crane operator is protected against mechanical vibrations by

means of a tilting seat which can be adjusted to his weight. The
crane operator’s seat offers infinite adjustment options for the
seat height and tilt, backrest and armrests. It is therefore possible
to select the optimum working position for every driver.
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 lower
body is exposed (feet and seat) is below 0,5 m/s2 (1.6 ft/s2).
Both values are therefore below the statutory specifications.
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1.3.5 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 manufacturer in the load capacity tables.
The load capacity table supplied with the crane specify limit
values which may not be exceeded.
The load limit of the winches is effectively 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.
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1.3.6 Required Ambient Conditions
The permitted temperature range for operating the crane is

−20 °C to +40 °C (−4°F to +104 °F), if the maximum or minimum
temperature occurs only a few days a year .
Optional equipment for other operating conditions can be

supplied.
The crane can be operated under full load up to a height of

1000 m (3281 ft) above mean sea level. It is not hazardous to
operate the crane up to an operating height of 2000 m (6562 ft)
above mean sea level.
The crane can also be operated without danger with high / low
relative air moisture.
Continuous operation in aggressive air (e.g. harbours, chemicals

industry, steelworks etc.) combined with high relative air moisture
can require an adapter kit / optional equipment.
High levels of dust require the filter to be changed more

regularly. Dust concentration levels of up to 35 mg/m3 are
permitted for a short period of time.
Observe the corresponding regulations in the lubrication and

maintenance instructions.
With an oncoming wind the crane operator must follow the rules
outlined in the operating instructions. See section ”Working
instructions”.
The ground on which the crane is supported on outriggers − or

on which it drives − must have sufficient load−bearing capacity.
Detailed information on the ground’s load−bearing capacity can
be found in the section “Working instructions” or “Outriggers”,
depending on the type of machine.
The demands on the road for the various driving states are
described in the “Driving” section.
Use of the crane in a potentially explosive atmosphere or in

operating conditions where combustible gas can be drawn in is
only permitted following corresponding conversion.
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1.3.7 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 erection crane.
The load capacity tables that are authorised for the crane are
based on assembly operation only. General cargo handling
or grab operation can only be permitted following express
permission from the manufacturer under suitable
conditions.
− the entire number of the crane’s load cycles in this time is less
than 32 000 (e.g. 5 − 10 strokes / day on 200 days / year).
A “LOAD CYCLE” encompasses processes which begin when a

load is raised and end when the crane is ready to raise the next
load.
− the type of load (load collective) of the entire crane shows

values no worse than the following:
∗ for 1/10 of the load cycles the crane is placed under max.
load
∗ for 4/10 of the load cycles with 50 % of the max. load
∗ for 5/10 of the load cycles with 33 % of the max. load
“Load” in this context refers to the sum of the load, load−handling

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

carried out properly, the theoretical service life can be more than
20 years.
Harder operating conditions naturally lead to a reduction in the
service life.
However, the regulations for determining the remaining

theoretical service life in the “Inspections of the crane”
section in the lubrication and maintenance instructions
must be observed for the winches.
Some components (e.g. ropes) are not designed for the

entire service life of the crane, but must be replaced after a
certain amount of time.
Observe the instructions in the lubrication and maintenance
instructions.
1.3.8 Scrapping / Disposal
If the crane (or components thereof) are scrapped, you must

ensure professional disposal.
In particular, no poisonous materials (fuel, oil etc.) or materials
which are hazardous to the environment (for example, plastics)
may be released into the environment.
In this case, the individual country regulations must be adhered
to.
1.3.9 Standards and Calculation Regulations
The calculation of the crane corresponds to the requirements of

ISO 4301 and EN 13000.
For countries in which other regulations and standards apply,

special−case service life calculations can be carried out.
If required, these calculations must be specially ordered by the
crane operator. The operating conditions for the crane are not
altered, however it may be necessary to limit the lifting capacities.
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1.3.10 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 the crane may only be operated in the vicinity of
airports, landing areas and flight safety facilities (so−called
protected or safety zones) following permission from the
corresponding authorities (for example in Germany −
”Landesluftfahrtbehörde” − national aeronautical authority,
”Wehrbereichsverwaltung” − military district administration,
”Deutsche Flugsicherung GmbH” − German Air Navigation
Services).
In Germany, more information can be obtained from:

Deutsche Flugsicherung GmbH (DFS)
Kaiserstraße 29−35
D−63067 Offenbach a. M.
Tel. 069/8054−0
These regulations apply in Germany. In other countries, the

corresponding national regulations must be observed.
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1.4 Safety Regulations
While carrying out power−driven erection and assembly

procedures only the crane operator is allowed on the crane
(and he must be in the crane operator’s cab).
The crane operators of cranes which are controlled using
radio remote control must be outside of the danger zone of
the moving crane components and the load.
Remaining personnel must remain clear of the hazardous
area on and around the crane.
The only exception to this rule is when the counterweight
is being fitted and when a load is being attached or released
with the help of a fitter.
When stacking the counterweight the person attaching the

equipment must leave the crane and the slewing area as
soon as the erection work is completed. During stacking,
the person attaching the equipment must remain outside
the hazardous area.
When attaching and disconnecting the load, particular care

should be taken as a result of swinging loads or hook
blocks. The person attaching the equipment must be profi-
cient in handling hook blocks.
Once the load has been attached or released, the fitter must
leave the slewing or hazardous area immediately.
The fitter must be easily recognisable to the crane operator.

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These means of identification should be in a distinctive co-
lour and where possible of an identical design and must be
exclusive to the fitter.
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1.4.1 Organisational Measures
In addition to the operating instructions, applicable national

regulations 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 may involve, for example, handling hazardous

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

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.
The operating instructions should be supplemented by any other

instructions that are necessary, including supervisory and
reporting duties for any special operating occurrences, for
example with regard to work organisation, operating procedures,
allocated personnel etc.
Keep a complete and legible set of all safety and hazard
instructions on the crane at all times.
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.
In case of poor visibility or darkness, the immediate area in front

of the crane operator’s cab, the outriggers and the winches must
be illuminated by the spot lights, which are fitted on the crane
(rear outside lighting, front outside lighting, side outside lighting).
Other surrounding areas (load, load path, slewing range, driving

path, and similar) must be lit using suitable means, independent
of the crane. The responsibility for this belongs to the crane
operator.
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1.4.2 Selection and Qualifications of Personnel
In order to operate a crane optimally within its proper parameters,

the crane operator and personnel working on maintenance,
assembly and dismantling must be properly qualified and trained.
The crane operator / owner is responsible for providing this
training.
Use only reliable, trained and/or experienced 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.
Clearly specify all areas of responsibility:

− for operation, configuration and maintenance.
− for the crane driver, also with regard to his responsibilities as
a result of 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 experienced member of staff .
Personnel who are authorised with the activities on the crane

must have read the operating instructions before starting
operation, and especially the section ”Safety instructions”!
It is too late to start during operation!
This applies especially to personnel who only work on the crane
occasionally − e.g. for configuration or maintenance work.
Check − at least now and then − to make sure that all personnel
are working safely and are following the operating instructions.
Personnel are not allowed to wear their hair long, wear loose
clothing or jewellery, including rings. There is a risk of injury, e.g.
as a result of being caught or dragged by moving parts.
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1.4.3 Particular Types of Hazard
1.4.3.1 Electric Energy
High voltage
With high voltage lines, any direct contact with the boom or the
hoist rope is always dangerous.
With high voltage lines above 1000 V current can be transferred
even as the lines are approached.
This hazard should be prevented by the following measures:

− Switch leads to current−free.
− Cover and / or fence off the danger zone.
Both measures may only be carried out by qualified

electrical specialists.
If these 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.
Danger 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).
The safety clearance must still be available for unfavour-

able crane or load positions.
Allow for possible swinging of the load or swinging out of
the free line as a result of the wind.
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If, however, the crane accidentally comes into contact with high
voltage power lines:
− Move 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 those outside not to approach or touch the crane.
If the crane operator leaves the crane or if another person

approaches and touches the crane, they will receive an
electric shock.
Even the ground around the crane is carrying an electric
current. Therefore every step on the crane, to the crane or
away from the crane is potentially dangerous (step volt-
age)!
− Arrange for the voltage to be switched off.

− Only leave the crane when you are sure that the
touched/damaged line has definitely been disconnected
from the power source.
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High−frequency radiation / operating in vicinity of

transmitters
Charging
It can cause dangerous electrical charging if track−free mobile

cranes are used in the vicinity of transmission systems (e.g. radio
transmitters).
In this case, the following measures must be taken:

− agreement with the operator of the transmitter (possibly
switching off the transmitter).
− grounding (of the track−free mobile crane).
In order to protect the rotating connection the grounding
cable must be fastened directly to the superstructure of the
crane or to the main boom.
Risk of injury!
If the prescribed measures are not taken the persons con-
necting the charged components to ground will be violently
and painfully electrified at touch.
Interference with the crane electrics
At the same time, the crane electrical system, especially the load
limit device, cannot be considered function safe, depending on
the strength and frequency of the transmitter.
The risk of the load limit device being influenced by

high−frequency radiation is minimised by state of the art
technology (shielding). However, it cannot be fully discounted,
especially under extreme circumstances.
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).
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Lightning
If storms are approaching, if possible lower the crane equipment

and leave the crane.
If this is not possible, lower the load from the hook, switch off the
engine and leave the crane.
Only remain in the crane operator’s cab if you cannot carry out
these measures in good time.
Under no circumstances must the crane operator approach

the crane or its immediate vicinity during the storm. Warn
any other people in the vicinity of the crane.
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, especially:
∗ load limit device; if defective, there is a fault message in the
display.
∗ Limit switches; to see if they are functioning.
∗ inductive proximity switch for function.
− Luffing and outrigger cylinder with a visual check for external
damage caused by voltage flashovers or fusing.
By retracting and extending the relevant cylinders several
times, check if there are suspected internal leaks due to
damaged seals.
− hoists, especially for damage to the ball and roller bearings.
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Z 29 800 Z 29 801
Z 29 802
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1.4.3.2 Gas, Dust, Steam, Smoke
Only operate combustion engines and fuel−operated heaters in

sufficiently ventilated spaces. Make sure that sufficient
ventilation is provided before operating in restricted spaces.
Follow the applicable regulations for the operating site.
Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth de-
fects, and other reproductive harm.
1.4.3.3 Crushing / jolting

(Z 29 800)
For the points listed below, please also refer to the more detailed
description in the corresponding Chapters of the operating
instructions.
− Hook block / load when rotating the superstructure
1.4.3.4 Snagging / Dragging

(Z 29 801, Z 29 802)
instructions.
− Head sheaves and deflection rollers
− Hook Block
− Winches
− Slew ring toothing (slewing pinion)
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1.4.3.5 Crushing / Shearing

(Z 29 800)
instructions.
− when extending and retracting the main boom
− when lowering the main boom on the foot bearing of the
superstructure frame
− when slewing the superstructure
− when extending and retracting outriggers and cylinders
− when releasing the suspension lock following the outrigger
procedure in the vicinity of the wheels
− near the hook block or the load during uncontrolled
movements
− when stacking the counterweights
− when fitting and removing hoist 2
− when fitting and removing the main boom or the
superstructure
− when tilting the crane operator’s cab
− when fitting and removing / erecting additional equipment
(optional), as, e. g., main boom extension.
1.4.3.6 Risks of Slipping, Tripping, Falling

(Z 29 803)
Only the catwalks and ladders stipulated here should be used.

There are sufficient options for holding on and attachment
eyelets for personal protective equipment fitted there. In addition,
the catwalks are designed to be slip−resistant (for example,
sand, corrugated metal plate or similar).
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1.4.4 Combination of Hazards with Combined Operation

of Two or More Cranes
1.4.4.1 Operating Areas of Several Cranes Overlap
If the operating areas of several cranes overlap, there is a risk of

collisions.
The operating company or its representative must:
− specify the working procedure 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 safe functioning of the equipment for the communication of
the crane operators (for example, walkie talkies, etc.) must be
checked before beginning crane operations.
If spotters are used, suitable signals must be agreed between the

spotters and the crane operators. In this regard, please refer to
section 1.5 of this section ”Safety Instructions”.
Crane operators must operate the crane in such a way that

uncontrolled movements and subsequent collisions are avoided.
They must receive suitable training and instructions to this end.
1.4.4.2 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:
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∗ The mass (the weight) and the centre of gravity of the load
must be known exactly.
∗ The load must be shaped in such a way as to avoid extra
hazards during the lifting procedure.
∗ The other cranes which are taking part in the operation must
have nearly the same lifting capacity.
∗ Additional dynamic load effects when the load is raised and
set down and load effects as a result of environmental
influences (e.g. wind) must be allowed for during planning.
The actual danger is during joint lowering of the load. Using

the relevant reeving and control. the lowering speeds of
both cranes must be as similar as possible, otherwise there
is danger of the slow crane becoming overloaded.
The accident prevention regulation “Cranes” of the
employer’s liability insurance association (BGV D6) can be
used as an aid. It contains regulations and safety instruc-
tions for operation with several cranes. It especially notes
that sufficient safety reserves must be planned for each
crane and that the full load value of the load capacity table
may never be used.
If there are any doubts concerning the accuracy of the data,
e.g. the accuracy of the details with regard to mass and the
position of the centre of gravity of the load, the safety re-
serves must be increased accordingly.
Before carrying out heavy−duty operations, the crane

manufacturer should be consulted to see whether the crane can
be fitted with any additional safety devices (e.g. limiters) or
whether the lifting capacity needs to be restricted additionally for
the operation in question.
Avoid pulling a load sideways or at an angle!
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1.4.5 Driving Operation
1.4.5.1 Before Driving
In order to ensure the safety and operational readiness of the

crane, the checks and maintenance work must be carried out in
accordance with the lubrication and maintenance instructions.
In particular, check the effectiveness of the brakes, steering and

signal and lighting equipment daily; if the crane is used
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
(actuate the horn before starting the engine for example!)
If you cannot see the hazardous area, a spotter (or banksman)

must be used (see section 1.5) !
This also applies if normal voice communication is not possible
as a result of an increased noise level.
Keep the windows clean to maintain good visibility at all times.
Make sure that all accessories are stored safely and cannot
cause an accident.
When driving on public roads, highways and precincts observe

the relevant traffic safety regulations and make sure that the
crane is properly equipped for road travel.
In the case of the axle loads a differentiation is made between

the technically possible load (technical driveability) and the load
permitted in accordance with the road traffic regulations.
”Technical driveability” is only permitted on construction sites or
private roads (with the exception of countries which permit axle
loads over 12 t / 26.4 kip).
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Axle loads over 12 t (26.4 kip) are not authorised for road travel
in countries subject to EU regulations (or to reduced axle loads).
If the crane is driven on the road with axle loads above
12 t (26.4 kip), thenthe crane operator assumes sole
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 increased.
Deceleration for the brakes (EEC: 50 %) reduces in proportion to
the increase in the axle load or the transport weight of the crane.
1.4.5.2 During Travel
When driving on the road, the main boom must be lying on the
travel rest in the transport position and the telescopic sections
must be secured against undesired telescoping out!
For crane types with pinnings between the telescopic sections,
these must be pinned.
For crane types with telescoping cylinders and rope drives, the
main boom must be secured against undesired telescoping out
using a rod or a rope.
On a slope always adapt the speed of the crane to the local

conditions. Never shift gear once on the slope, but change to a
lower gear ›‹before reaching the slope.
When passing flyovers, bridges, tunnels, electric lines etc. make

sure that there is sufficient overhead clearance.
When towing, follow the towing regulations with respect to the

prescribed transport position, permitted speed and distance
travelled.
Additional persons may only drive along when sitting in the

prescribed and regulated seats (with safety belts, etc.).
For crane types which have a chassis cab (driver’s cab) no−one
may be taken along in the crane operator’s cab!
Emergency exit from the cab:

For crane types which have a chassis cab, the passenger door
may be used as an emergency exit.
For crane types which only have a cab on the superstructure, the
front window of the cab which can be opened widely can be used
as an emergency exit.
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1.4.6 Crane operation
1.4.6.1 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, motor operation, hydraulic oil pressures and wind
speeds.
Check whether outside conditions such as wind, snow, poor

visibility, unfavourable temperatures etc. could limit crane work.
Compare the conditions with the corresponding sections in the
operating instructions.
Make sure that the ground has sufficient load−bearing capacity

when supporting the crane on outriggers.
Maintain a safe distance between the supported crane and
slopes and ditches.
Depending on the machine type, there are detailed notes on both
subjects in the sections “Working instructions” or “Outriggers”.
Before commencing work at the operating site, familiarise

yourself with the working environment. The working environment
includes, for example, obstructions in the operating and traffic
areas, the load−bearing capacity of the ground and the
necessary safety precautions required to cordon off the
construction site from public traffic areas.
To operate the crane, unhindered sight of the crane, load and

load path must be ensured. If this is not ensured, banksmen must
be used.
Either signals for communication (see section 1.5, from page 81)
must be agreed between the banksman / person
attaching/detaching the load and the crane operator or a
communication system (for example, voice radio) must be used.
If a communication system is used, it must be provided by the
crane operator.
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Carry out the necessary measures to ensure that the crane is

operated in a safe and functional condition.
Before commencing work, check that all crane movements are

functioning correctly and safely.
Operate the crane only if all safety guards and equipment are
fitted and functional.
Check the correct function of the brakes, signal and lighting

equipment, limit switches and overload cut−off device daily, for
cranes that are seldom used − every time that they are operated.
If a radio remote control is used on the crane, radio transmitters,

atmospherical interferences or other radio remote controls
transmitting on the same frequency can disrupt the radio
transmission.
For this reason, the function of the radio remote control or the
radio transmission must be checked before the actual operation.
If faults in radio transmission cannot be rectified by changing the
operating frequency, you must not use the radio remote control
or disruptive radio transmitters or other radio remote controls
must be switched off.
Observe the charging state of the batteries.
Before commencing work with the crane make sure that no−one
is in the hazardous area. If necessary give a warning sign
(actuate the horn before starting the engine for example!)
As oil can be emitted during maintenance and assembly work,

suitable containers and binding agents must be kept available
and ready.
Wherever required or stipulated the personnel must wear

personal protective gear (e.g. safety harnesses, safety clothing,
goggles, face mask etc.)
Remember that protective equipment does not offer 100%

protection! A helmet can protect you against small falling
objects, but not against falling loads!
You should therefore remain attentive and safety−con-
scious at all times!
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The weight of the load must be known.
It is difficult to calculate the load weight during dismantling

work. If a load that is attached to the crane is released from
its previous connection to other parts and is too heavy, the
crane will be unavoidably destroyed or will tip over,
regardless of the load limit switch.
When dismantling hollow components (pipelines, cement
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 allowed in the load
capacity tables of the crane, but allow for a safety buffer.
Select the correct boom length and reeve the hoist rope in
accordance with the individual load case.
Before reeving and before starting crane work, check the status
of all accessible ropes (including the end connections), winches
and sheaves.
Select the lifting tackle in accordance with the weight of the load,
the type of attachment and the angle of inclination.
Only hook blocks supplied by the crane manufacturer may be

used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.
Pay attention to the rules and regulations for working with load
handling equipment (attachment ropes etc.) and load handling
devices (lifting beams etc.). Never use lifting tackle and load
handling devices if there is any doubt as to their lifting capacity.
Check to make sure that the lifting tackle and all load handling
devices are in perfect condition.
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1.4.6.2 During Operation of the Crane
When carrying out power−driven working procedures

(raise / lower load) only the crane operator is allowed on the
crane (and he must be in the crane operator’s cab). Remain-
ing personnel must remain clear of the hazardous area on
and around the crane.
For cranes which are controlled using radio remote con-
trol, the crane operator must be outside of the danger zone
of the moving crane components and the load.
The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work immediately if persons fail to leave the hazardous area
in spite of the warning.
Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision.
The load must never come into contact with the framework of the
crane (boom system, superstructure, crane chassis, outriggers
etc.).
The crane operator may only start movements if he has good
visibility of the hazardous areas.
When working from the crane operator’s cab, keep the windows
clean in order to ensure a good view.
In case of poor visibility suitable persons must be selected as
spotters and must be instructed on the correct signals before
commencing work (see section 1.5)!
This is also the case if it not possible to communicate verbally or
via voice radio due to increased noise levels.
Depending on the equipment type, a radio remote control can be
supplied to enable the crane operator to monitor potentially
hazardous areas directly, which could otherwise only be
monitored by a banksman.
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In order to allow immediate reaction when the crane is subjected

to changing environmental conditions, it is prohibited to switch off
the drive of the crane when a load is attached and / or to leave
the crane operator’s cab.
An exception is only permitted in emergency situations. 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 poss-
ible, any movements which have been started should be
completed using the control lever.
Before raising a load, you must always make sure that the hook
block is positioned vertically over the load’s centre of gravity.
During crane operation, the outrigger control box must be locked.

The chassis cab must be locked in cranes which have one.
The engine of the crane chassis must be switched off in cranes
with an engine in the crane chassis and crane superstructure.
The erected crane without load may only be left without the
supervision of a trained crane operator if certain conditions are
met (see operating instructions, section ”Parking”).
The carrying 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 warnings on the crane .
Avoid any actions which may impair safety (e.g. risk to the
stability of the crane).
Never slew loads over people.
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When working from the crane operator’s cab:

Only start the crane engine from the driver’s seat. Only actuate
the control lever from the cab.
Special buttons (dead man’s buttons) are fitted in the crane

operator’s cab to prevent accidental activation of crane
movements.
A crane movement can only be driven as long as one of the
buttons is activated.
Dead man’s buttons and limit switch bridging may only be
activated as long as the corresponding control lever is in the
“neutral position” and the initiated working movement has been
completed.
RISK OF ACCIDENTS!
Actuation of one of these buttons when the control lever is
fully deflected leads to an abrupt activation or braking of
the corresponding movement.
Keep the controls lever within reach as long as a load is

suspended on the crane or the crane is driven.
For all crane movements, pay particular attention to the load, for
unladen operation the load−handling device, and the boom tip!
Watch the slewing radius of the counterweight etc.
In all crane movements, approach the limit ranges especially

slowly and carefully. Limit ranges can be recognised, for example
in the utilization display of the LLD.
Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision.
The load must never come into contact with the framework of the
crane (boom system, superstructure, crane chassis, outriggers
etc.).
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Dragging and scraping of the load is prohibited during crane

operation.
It is prohibited to pull loads free that have become lodged.
Do not jump from the crane. Do not jump from the crane.Use the
ladders and the handrails provided.
Secure the doors with the available locks to prevent them

slamming open or closed.
Check the crane at least once a shift to check for any visible signs
of damage or faults. Any changes (including to operating
behaviour) should be reported immediately to the point / person
responsible. If necessary, switch off and safeguard the crane.
In case of a malfunction on the crane, switch off the crane

immediately and secure it. Have any faults rectified immediately !
Pay attention to the procedures for switching equipment on and

off as well as the behaviour of the indicator lights as outlined in
the operating instructions.
In case of poor visibility and darkness always switch on the

outside lighting. The inside lighting should be switched off to
enable proper sight of the load and the immediate environment
of the crane.
Always keep the operating instructions at the crane operating site

in the storage compartments provided. They are in the
superstructure on the back wall of the cab. For crane types with
a driver’s cab on the crane chassis, the storage compartment is
on the inside in the driver door.
Be aware of the location and availability of fire warning and fire

fighting equipment.
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.
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Set the computer of the load limit device in accordance with the
load capacity tables supplied.
Observe the permitted wind speeds!
The superstructure may only be slewed when the crane is

supported on outriggers. Note that slewing is only permitted for
certain crane configurations (e.g. with regard to outrigger support
area, counterweight etc.).
For some crane types, there are load capacity tables “Free on
wheels”. Only then is it permitted to slew the superstructure when
not supported on outriggers.
Always observe the instructions in the load capacity tables!
Slewing of the superstructure in the overload range (load limit
device has shut down) is generally prohibited.
In an emergency the wide−opening front window can be used as

an exit.
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1.4.6.3 Following Crane Operation
When you leave the crane:

∗ the load must be detached from the crane hook or set down
on the ground.
∗ the engine must be switched off and all control levers must
be put in the neutral position or in the ”Locked” position!
∗ the heating must be switched off.
∗ the parking brake of the crane chassis must be applied (if not
already occurred)!
∗ the crane must be secured to prevent unauthorised use and
accidental movement.
If the crane is parked on steep ground, the travel gear must be

additionally secured with chocks, the slew brake applied and the
main boom secured.
Close all control panels that are fitted with a lock when they are
not being used.
Depending on the crane type, there are mobile control panels on
the crane which are connected with cables. Remove them when
they are no longer needed.
If your crane is equipped with a radio remote control, keep it in a

safe place. Make sure that the batteries are recharged.
When parking the crane pay attention to the permitted wind

speeds (also for the time when the crane is at a standstill). If
necessary telescope in and set down the main boom!
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1.4.7 Power Supply Failure
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 circulation also comes to a standstill. As
soon as the control pressure reaches zero, all actuators return
spring−loaded to the zero position, regardless of the position of
the pilot control lever.
In the hydraulic circuits which are directly relevant to safety, there

is redundant braking of the winches and cylinders as a result of
the locked position or additional retaining brake.
Winches and cylinders
The oil column on the lever side of the winch motors and cylinders
is safeguarded by means of load−independent brake valves
(lowering brake valves). The winches and cylinders can no longer
be moved in the event of a failure to the power supply. The lower
brake valves are directly fitted to the winch motors and cylinders
(no hose lines).
As the described case is extremely seldom, there is no in−built

option for lowering a load on the hook. Such cases must be
reported to Customer Service.
If hoses or pipes should burst, therefore, there will be no

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.
Driving the crane in the erect (configured) condition
When the crane is driven in the configured position, the load rests
on the suspension cylinders. These are not equipped with pipe
burst valves, in order to guarantee problem−free suspension
behaviour during driving of the crane. To avoid hazardous
situations, the regulations outlined in the operating instructions
for the crane chassis, section ”Driving the Crane”, ”Driving in the
Configured Condition” must be strictly observed.
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1.4.8 When Assembling and Dismantling Crane

Components
Although all possible protective and safety measures have

been provided, there is still a risk of crushing during
assembly and dismantling work.
To avoid these remaining dangers the following rules must
be observed.
In these operating instructions, the standard, normal assembly

sequence is described.
The equipment must be dismantled exactly in the reverse order

(unless otherwise stated).
Crane equipment must under no circumstances be assembled

and dismantled by untrained personnel. This also applies to staff
providing temporary help.
Incorrect assembly can result in danger to life and limb.
Due to danger by slipping, stumbling and falling, you may not

step on the superstructure, main boom and equipment (for
example, main boom extension).
Exceptions are only permitted if access areas are provided.
However, this requires additional safety measures. Safe
measures for walking are then described in the corresponding
section of the operating instructions.
All assembly work is to be carried out with the help of suitable

accessories (ladders, hoist platforms, scaffolding, auxiliary crane
etc.). The assembling personnel must be sufficiently secured.
Furthermore access is only permitted to areas where there is no
risk of falling.
Normal assembly prescribes that all component parts which are

transported separately are transported near to the ground with
suitable auxiliary cranes and lifting tackle (ropes) − and are safely
connected to the basic crane.
200−1−1010h_en 75/87
1
76/87 200−1−1010h_en
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.
Persons in the vicinity of suspended loads are exposed to

the danger of being hit or crushed by loads swinging side-
ways.
During the assembly procedure, or at any other time, per-

sonnel must never walk or stand beneath loads, especially
before the load has been properly attached!
If, during assembly work, certain crane movements have to be

carried out, the crane operator must ensure that no−one is in the
hazardous area affected.
A fastening procedure is only completed once the hanging crane

element is firmly connected to the stable, set down crane
component, for example by knocking in a pin of an intermediate
section or by tightening all screws of a screwed connection with
the prescribed torque, etc.
A safe distance should be kept from unavoidable crushing

hazard points, in particular outrigger struts, between the
superstructure and crane chassis, cylinders, on the telescopic
boom and on the entire lattice mast fly jib, 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 the auxiliary
assembly crane is running.
Connecting bolts are always knocked in from the outside inwards

during the assembly of fly jibs, unless the operating instructions
expressly state otherwise.
Only when all pins of a component have been driven in are the
auxiliary bolts and clip pins to be fitted.
200−1−1010h_en 77/87
1
78/87 200−1−1010h_en
Connecting bolts 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 falling or folding movements are to
be expected due to the releasing procedure. In case of doubt,
a service specialist from the crane manufacturer should be
consulted.
In particular the knocking out of bolts must be carefully planned

and it must be ensured that no−one is standing inside the fly jib,
at risk of being crushed. The falling movement of a bolt which has
been knocked out, a released rope or another component must
be carefully planned and safeguarded.
Make sure that no tools are forgotten following the completion of

work. Falling or flung tools can cause risk to life and limb!
Sometimes it is required to bridge limiters (for example, limit

switches) when assembling and removing crane components.
This can also lead to additional hazards. The systems may
therefore only be bridged if this is required in the operating
instructions for a certain piece of work.
200−1−1010h_en 79/87
1
80/87 200−1−1010h_en
1.5 Hand Signals
If the crane operator cannot oversee the operation and working

direction (and/or hazardous areas) from the crane operator’s cab
(or driver’s cab), a spotter must be used.
This also applies if normal spoken communication is not possible
as a result of the increased noise level.
Only responsible and reliable persons who know the sym-

bols may be employed as spotters.
The banksman should position himself in a safe location

from where he can SEE the LOAD and can BE SEEN clearly
by the CRANE OPERATOR.
The spotter must be easily recognisable for the crane oper-

ator. The spotter should wear one or more suitable means
of identification e.g. jacket, helmet, collars, armbands, sig-
nalling discs.
These signs of identification must be in a distinctive colour
and uniform in design and must be worn exclusively by the
spotter.
If the load is attached by several people, only one person

may give the signals. These must be made known to the
crane operator.
If the crane operator does not fully understand a signal, he

should not carry out any movement with the crane. Before
commencing work the crane operator and spotter must work
out a signal for this scenario.
200−1−1010h_en 81/87
1
Z 26 024
82/87 200−1−1010h_en
1.5.1 General Hand Signals

(Z 26 024)
1. START
Caution, note the following hand signals
Arms stretched out sideways horizontally, palms facing

forwards.
2. STOP !
Interruption, end movement
Right arm raised, palm of the right hand facing forwards.
3. END
of a movement
The hands folded at chest height.
4. DANGER !
Emergency stop
Both arms upwards, palms turned to the front.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
200−1−1010h_en 83/87
1
Z 26 026
84/87 200−1−1010h_en
1.5.2 Hand Signals for Working Movements

(Z 26 026)
1. RAISE load
Right arm up, palm of the right hand facing forwards, moving
slowly in a circle.
2. LOWER load
Right arm down, palm of the hand facing inwards, moving
slowly in a circle.
3. RAISE boom
Signal with a hand. Right arm stretched outwards, thumb
pointing upwards.
4. LOWER boom
Signal with a hand. Right arm stretched outwards, thumb
pointing downwards.
5. TELESCOPE OUT boom

Signal with both hands. Thumbs pointing outwards.
6. TELESCOPE IN boom
Signal with both hands. Thumbs pointing inwards.
200−1−1010h_en 85/87
1
Z 26 025
86/87 200−1−1010h_en
1.5.3 Hand Signals for Driving Movements

(Z 26 025)
1. Drive FORWARDS
Arms angled upwards; palms facing inwards; lower arms
making slow movements towards the body.
2. Drive BACKWARDS
Arms angled upwards; palms facing outwards; lower arms
making slow movements away from the body.
3. Drive to the RIGHT (seen from the spotter)

Right arm stretched out more or less horizontally, palm of the
right hand facing downwards, small movements in the
direction indicated.
4. Drive to the LEFT (seen from the spotter)

Left arm stretched out more or less horizontally, palm of the
left hand facing downwards, small movements in the
direction shown.
200−1−1010h_en 87/87
Structure of the Mobile Crane 2
2 Structure of the Mobile Crane
2.1 Technical data
Length See part 2, section 2 “Crane

Height chassis” under “Technical
Width data”
Max. load capacity see load capacity tables
Max. main boom length 67.8 m (222.4 ft)
Max. system length with main
100 m (328.1 ft)
boom extension
Max. rope speed hoist 120 m/min (394 ft/min)
Drive motor OM 906 LA
170 kW (228 HP)
810 Nm (597 lbf−ft)
Operating voltage 24 V
Further technical data on possible optional equipment can be

found in the section of the individual component or in the section
“Various” of this document.
The load capacity tables contained in the brochure are only for
information purposes.
Only the load tables supplied with the crane may be used
for operating the crane.
200−1−1020−001g_en 1/55
2
9 10
12
11
2
8
3
4
R
7 5
6
L
Z 104 351
2/55 200−1−1020−001g_en
2.2 Basic Crane Terms

(Z 104 351 schematic diagram)
The basic terms of a mobile crane are described in the following.

They are relevant for understanding the procedures which must
be carried out at the superstructure.
Further terms which are relevant for operation of the chassis are
described in the section “Crane chassis” of the operating
instructions of the chassis.
(1) − Main Boom
(2) − Luffing cylinder
(3) − Hoist rope
(4) − Hoist(s)
(5) − Crane operator’s cab
(6) − Crane chassis
(7) − Counterweight
(8) − Hook block (with sheaves)
(9) − Runner / boom point
(10) − Head sheave, foldable sideways
(11) − Hook suspension gear
(12) − Main Boom Extension (MBE)
(L) − Outrigger length

(B) − Support width
(R) − Radius between the slew ring centre to the centre of
gravity of the hook block or of the hook suspension
gear
The radius (R) can also be described as the utilization or load

radius.
200−1−1020−001g_en 3/55
2
1
2
13
3
10
11 4
12
8 15
6 5
7
14 9
Z 200 625
4/55 200−1−1020−001g_en
2.3 Superstructure (Components)

(Z 200 625)
(1) − Hook block (with sheaves) or hook suspension gear

(without sheaves)
(2) − Main Boom
(3) − Superstructure frame
(4) − Hoist 1
(5) − Counterweight
(6) − Slew Ring Connection
(7) − Slew Gear
(8) − Crane operator’s cab
(9) − Hydraulic carrier
(10) − Diesel engine (right−hand side of the vehicle)
(11) − Fuel tank
(12) − Hydraulic oil reservoir (right−hand side of the
vehicle)
(13) − Luffing cylinder
(14) − Main electrical unit superstructure (behind the cover)
(15) − Hoist 2 (can be removed, optional)
Some of the listed elements can only be seen and are accessible
after opening / removing the corresponding covers.
200−1−1020−001g_en 5/55
2
4a 2a 5
1e
3b
3a
1b
1a
Z 200 626 Z 200 628
”a”
1a
Z 104 353
6/55 200−1−1020−001g_en
2.4 Safety−relevant Components
2.4.1 Ladders, Holding Devices and Antifall Guards

(Z 200 626, Z 200 628, Z 104 353 schematic diagrams)
The crane is equipped with ladders, holding devices and antifall

guards. They must be used to access the crane and to get down
from it.
It must be ensured that:

− all corresponding safety equipment is fitted.
− all safety equipment is in the condition required for operation
(for example, hinged rails placed in the functioning position).
− all safety equipment can be accessed and used without any
restrictions (free of snow, contamination, etc.).
In addition to suitable and safe accessories provided, only

the ladders described may be used to access the
superstructure. There are sufficient gripping points to hold
on to. The catwalks are designed so that they are
slip−resistant (sand, corrugated sheet metal, or similar).
200−1−1020−001g_en 7/55
2
”a” 91
1a
1a
Z 104 353 Z 104 812
8/55 200−1−1020−001g_en
(1a) − Ladder, hinged
Risk of accidents!
When they are not in use and for transportation, the hinged
ladders (1a) must be folded up and secured in the transport
position.
Transport position of the hinged ladders (1a)

Fold up the hinged ladders (1a) on the crane chassis and lock as
shown in figure (Z 104 353 “a”).
Risk of accidents! Risk of damage!

If these ladders remain folded down or are not secured in
the transport position, they can shift suddenly and could
cause damage or injury.
Operating position of the hinged ladders (1a)

(Z 104 812 Schematic diagram)
Release lock (”a”, Z 104 353) and swing out ladder (1a) laterally
by 90°. Fold back bracket (91) downward / inward at a right angle
and fold the ladder up to the chassis so that the bracket (91) is
supported at the tyre.
This ensures a stable ladder position and a suitable angle for
going up and down the ladder.
Risk of stumbling! Risk of falling!

Before getting onto the hinged ladders (1a), ensure that
bracket (91) is folded in properly and is supported at the
tyre.
There is a risk of stumbling and falling if the bracket
remains folded in or even folded outward instead of
inward when the ladder is used.
200−1−1020−001g_en 9/55
2
4a 2a 5
1e
3b
3a
1b
1a
Z 200 626 Z 200 628
2b
1b 1a 1b
Z 200 629
10/55 200−1−1020−001g_en
(Z 200 626, Z 200 628, Z 200 629)
(1b) − Ladder, fixed

AC 200−1 ’Standard’: on both sides
AC 200−1 L: left only
AC 200−1 P: not present
(1e) − Attachable ladder, not fixed
Ladder is equipped with attachment hooks, allowing it to be

attached to appropriate positions as necessary.
Before climbing up onto the ladder, make sure that it is

attached securely to stable points of attachment.
Ladder (1e) must be placed onto the chassis and secured as

well (Z 200 628).
Using ladder (1e) as an example, fig. (Z 200 628) shows how
ladders are to be secured.
(2a) − Ladder, integrated in the superstructure cover

This ladder can be removed to enable access to the
components behind it.
To do so, open the fastener at the triggering button
(31: magnifying glass “B”) and lift ladder (2a) out of
the top and lower attachment hooks (magnifying
glass “A”).
The weight of the ladder is approx. 8 kg (18 lbs).
Risk of falling!
The ladder may only be removed while in a safe position,
secure against falling!
When fitting the ladder back in place, make sure that it is
properly hooked into all 4 attachment hooks.
200−1−1020−001g_en 11/55
2
2b 4a 2a 5
3b
3a
1b
”X” 1a
Z 171 174 Z 200 626
4 ”A” 12
1.
2.
11
12
”B”
Z 171 175
12/55 200−1−1020−001g_en
(Z 171 174 schematic diagram, Z 200 626)
(2b) − Ladder, hinged

(Locked using spring pins, see detail “X”,
Z 171 174)
When the main boom extension is swung from the transport

to the working position or vice versa or when working with
the main boom extension folded, the ladder (2) must be
folded up against the tank.
Risk of falling!
This ladder may only be used to carry out servicing− and
repair work. Proceed with appropriate caution!
(3a/b) − Platforms on the crane operator’s cab
(4a) − Handle outside of the crane operator’s cab

(5) − Rail (in transport position)
Using the rail on the superstructure frame

When stepping into the area defined by the rail (5), the rail must
always be placed from the transport position (”A”) into the
“operating position” (”B”) immediately after leaving the relevant
ladder.
Risk of falling!
If this does not happen, there is a risk of falling when
walking in this area due to the insufficient height of the rail!
200−1−1020−001g_en 13/55
2
4 ”A” 12
1.
2.
11
12
”B”
Z 171 175
14/55 200−1−1020−001g_en
To fold up, remove the locking bolt (11) and fold the hinged upper
section of the rail through 180° so that the guide pins (12) first
slide forwards (1st stage) and then downwards (2nd stage) up
to the stop.
The upper section of the rail folded into the vertical position then
remains safely in this position ”B” due to its own dead weight.
Immediately before leaving the area, fold down the upper part of
the rail again and secure. Otherwise the crane height of 4 m
(13.1 ft) would be exceeded.
Proceed in the same way as when folding up the rail, only in the
reverse order.
Risk of crushing!
When folding down the rail there is a risk of crushing
between the hinged and fixed part of the rail!
Proceed with appropriate caution!
200−1−1020−001g_en 15/55
2
6
2−EXPLICIT
3−EXPLICIT
71
Z 55 536 Z 160 642
66
Z 104 583
16/55 200−1−1020−001g_en
(Z 55 536, Z 160 642)

(6) − Folding / sliding ladder
Depending on the crane’s DBM−supply, a folding /
sliding ladder is delivered with it.
The supplied folding / sliding ladder (6) can be fastened to the

main boom extension for transportation.
− If the folding / sliding ladder (6) is attached the 4 locks (71,

tensioning straps) must be undamaged and hooked in place.
The ladder weighs approx. 8 kg (18 lbs).
Holding device for attaching the folding / sliding ladder

Depending on the design of the crane, there are metal plates on
the crane to attach the ladders safely during the corresponding
working procedure.
Risk of accidents!
When working with ladders, always make sure they are
seated firmly and safely!
If there are holding devices for attaching the ladders,
additionally secure the ladders by hanging them in the
designated holding devices! Make sure that the ladder
hooks lock in correctly as shown in figure (Z 104 583)!
200−1−1020−001g_en 17/55
2
66
Z 104 583 Z 65 146
Z 65 147
18/55 200−1−1020−001g_en
(Z 104 583, Z 65 146, Z 65 147)
Attachment eyelets (66)
Depending on the design of the crane, there are attachment

eyelets for attaching suitable personal protective equipment. In
this case, country−specific regulations on personal protective
equipment might have to be adhered to.
Risk of accidents!
The diameter of the attachment eyelets is 25 mm (1 in). A
suitable hook of the corresponding size must be used for
attachment (see Z 65 146)!
Excessively large hooks (Z 65 147) are not permitted to be
used! There is a danger of the hook sliding out!
All attachment eyelets (66, Z 104 583) are marked with

corresponding adhesive signs. The attachment eyelets
thus marked are not to be used except exclusively for
attaching the hook of the personal protective equipment!
Under no circumstances are they to be used to hang
individual crane component parts to an auxiliary crane!
Danger of overloading! RISK OF BREAKAGE! Danger of the
attached objects falling down!
Risk of falling!
When working at heights, the ladders must be attached and
personnel must be secured against falling with personal
protective equipment during the entire assembly
procedure.
200−1−1020−001g_en 19/55
2
20/55 200−1−1020−001g_en
2.4.2 Spotlights
Depending on the version, spotlights are mounted on the

superstructure:
− on the basic case of the main boom, electrically adjustable
from the cab,
− at the front of the cab,
− at the back of the cab,
− at the hoists, manually adjustable.
2.4.3 Emergency Exit
The front window of the superstructure can be opened wide to the

front. It is therefore suitable as an emergency exit. On the cab of
the crane chassis the passenger door can be used as an
emergency exit.
200−1−1020−001g_en 21/55
2
Danger! UVV
MAX
O.K.
Danger
of tipping!
Km/h
31 29 25 2 3 24 4
26
STGO 1) Axle loads Speed 4) Speed 4)
category up to [kg] [mph] [mph]
26
28
36 14 13 12 11 10 9
Fahrzeug ist mit
Wabco−Tecalan−Kunststoffrohren
ausgerüstet.
Motor Stop 7 6 5
Vorsicht bei Schweißarbeiten!
Zulässige Hitzeeinwirkung auf drucklose Leitungen:
max. 130?C und max. 60 min.
7 bar 9 bar 10 bar
WABCO 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 656
30 32 33 34 28
7 6 5
7 bar 9 bar 10 bar
4 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 640
22/55 200−1−1020−001g_en
2.5 Decals (General)

(Z 200 656, Z 200 640)
Each individual sign can be clearly identified by its item no. which
can usually be found on each sign. The depiction of the individual
signs can be found in the table on the following pages.
Obtain all signs specified in the following and make sure

they are in a legible condition!
No. Item no. Drawing Meaning

no.
529 018 40 Z 104 361 Sign: Hydraulic oil (on the hydraulic oil
tank)
HYDRAULIC OIL
Specification as per operating manual!
(Language variant, see appendix
directly after this section)
2 529 017 40 Z 104 358 Warning sign: Slewing, telescoping and
luffing prohibited without extended
outriggers!
3 512 216 40 Z 104 359 Warning sign:
Driver instructions and precise following
of the operating instructions are
required prerequisites for safe crane
operation; for this reason the operating
instructions must be read and
understood by the crane operator
before starting operation of the crane
for the first time!
4 001 218 98 Z 104 360 Warning sign: Danger zone
Unauthorised persons are warned to
keep out of working range of crane.
5 529 019 40 Z 104 379 Sign: 10 bar (145 psi) for 385/95 R 25
(14 R25)
(16 R25)
(17.5 R25) or 525/80 R 25 (20.5 R25)
200−1−1020−001g_en 23/55
2
Danger! UVV
MAX
O.K.
Danger
of tipping!
Km/h
31 29 25 2 3 24 4
26
26
28
36 14 13 12 11 10 9
Fahrzeug ist mit
ausgerüstet.
Motor Stop 7 6 5
7 bar 9 bar 10 bar
WABCO 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 656
30 32 33 34 28
7 6 5
7 bar 9 bar 10 bar
4 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 640
24/55 200−1−1020−001g_en
(Z 200 656, Z 200 640)

no.
148 956 12 Z 104 365 Sign: Connections for emergency
activation
9 289 512 12 Z 104 368 Designation light 1.0 %
10 668 778 40 Z 104 382 Sign: Differential lock
11 529 013 40 Z 104 383 Sign: Wheel nuts
12 529 015 40 Z 104 384 Sign: Engine stop
13 224 197 40 Z 104 364 Warning sign: Caution during welding
work
This vehicle is equipped with Wabco
Tecalan plastic pipes.
Caution during welding operations!
Permissible exposure to heat of
unpressurised lines:
Maximum 130° C and max. 60 min..
WABCO.
14 192 264 12 Z 200 655 CE crane identification sign / factory
sign
(see segment 2.5.1 on page 43)
Alternatively:
180 371 12 Z 200 655 Crane identification sign / factory sign
(see segment 2.5.1 on page 43)
529 011 40 Z 104 362 Sign: Diesel (on the fuel tank)
113 054 12 Z 104 363 Sign: Quick coupling
The couplings must be applied up to the
stop.
(depending on the crane design)
200−1−1020−001g_en 25/55
2
26/55 200−1−1020−001g_en

no.
Z 550 079 Warning sign for speed limit for
activated construction site steering
programs
Z 550 080 Warning sign for diagonal steering (crab
steering, crab walk):
Crab steering
Not allowed for road travel,note signal
lamp!
183 666 12 Z 104 366 Warning sign for folding / assembling
the main boom extension:
The pinning on the main boom head
AND on the side centre of motion may
not be released at the same time.
183 666 12 Z 63 905 Warning sign: Risk of crushing hands
Serious injury can result from contact
with moving components.
Keep away from moving components.
183 666 12 Z 63 910 Warning sign: Risk of crushing bodies
People can be killed or severely injured
when they come into contact with
moving components.
Keep away from moving components.
Secure components before carrying our
work.
200−1−1020−001g_en 27/55
2
28/55 200−1−1020−001g_en

no.
180 187 12 Z 200 627 Warning sign: Risk of falling, danger of
uncontrolled movements with the slew
gear brake with free running mode for
dolly operation (optional: Dolly)
DANGER:
Risk of falling or danger of uncontrolled
slewing movement.
If the slew gear brake is in free running
mode for driving with the dolly, the
superstructure can slew in an
uncontrolled manner.
Activate free running mode only for
driving with the dolly when the main
boom is fastened to the dolly.
Deactivate free running mode before
the main boom is disconnected from the
dolly.
Read and make sure you understand
the operating instructions for changing
between the positions for raising loads
and the dolly travel position.
217 605 12 Z 63 729 Warning sign: Risk of falling, danger of
uncontrolled movements with the slew
gear brake with free running mode for
dolly operation in the crane operator’s
cab (optional: Dolly).
Warning:
Risk of falling or danger of uncontrolled
slewing movement.
This crane is equipped for driving with
the dolly with free running mode / float
position.
Do not work with the crane with free
running mode / float position activated
(slew gear brake and valves!).
Read and make sure you understand
the operating instructions for changing
between the positions for raising loads
and the dolly travel position.
200−1−1020−001g_en 29/55
2
Danger! UVV
MAX
O.K.
Danger
of tipping!
Km/h
31 29 25 2 3 24 4
26
26
28
36 14 13 12 11 10 9
Fahrzeug ist mit
ausgerüstet.
Motor Stop 7 6 5
7 bar 9 bar 10 bar
WABCO 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 656
30 32 33 34 28
7 6 5
7 bar 9 bar 10 bar
4 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 640
30/55 200−1−1020−001g_en
(Z 200 656, Z 200 640)

no.
24 000 207 12 Z 104 385 Sign (design for Germany):
Operating regulations for cranes in ac-
cordance with the accident prevention
regulation ”Cranes” (BGV D6)
25 529 775 40 Z 104 386 Warning sign: Risk of tilting when
slewing and not supported on outriggers
(United Kingdom).
26 180 373 12 Z 104 387 Sign: GB STGO−Plate Cat C
(Design for United Kingdom, see
segment “Driving in the United
Kingdom”)
Z 104 395 Information sign on vehicle height
(national regulations)
28 586 023 40 Z 104 388 Sign: Heavy transport!
(specific to country, if existing, see
appendix directly after this section)
29 Z 104 389 Warning instructions (design for Italy)
30 Z 104 390 Sign: Chassis cab (length, width,
weight) (design for France)
31 313 082 12 Z 104 391 Sign: Speed limit 85 km/h (specific to
country)
32 001 546 12 Z 104 392 Sign: 70 km/h (design for Italy)
33 313 910 12 Z 104 393 Sign: 80 km/h (specific to country)
34 313 909 12 Z 104 394 Sign: 90 km/h (specific to country)
200−1−1020−001g_en 31/55
2
Danger! UVV
MAX
O.K.
Danger
of tipping!
Km/h
31 29 25 2 3 24 4
26
26
28
36 14 13 12 11 10 9
Fahrzeug ist mit
ausgerüstet.
Motor Stop 7 6 5
7 bar 9 bar 10 bar
WABCO 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 656
30 32 33 34 28
7 6 5
7 bar 9 bar 10 bar
4 17,5 R25 16,00 R25 14,00 R25
20,5 R25
Z 200 640
32/55 200−1−1020−001g_en
(Z 200 656, Z 200 640)

no.
Z 104 367 Crane identification sign (design for the
Netherlands)
36 Z 64 217 Manufacturer ’s sign (design for the
USA)
Z 104 369 Warning sign, general (main boom, left−
and right−hand side) (design for China)
275 912 12 Z 104 378 DANGER!
Risk of electrocution:
Persons can be killed or seriously
injured if they come into contact with
high−voltage lines.
Always consult the owner of the
high−voltage lines.
The electric current must be switched
off or the high−voltage line must be
removed or insulated before the
machine begins operation.
(design for Russia)
200−1−1020−001g_en 33/55
2
Z 104 361de
O.K.
512 216 40
Z 104 358 Z 104 359
Z 104 360de Z 104 379
Z 104 380 Z 104 381
Z 104 365 Z 104 368
34/55 200−1−1020−001g_en
Z 104 382de Z 104 383de
Fahrzeug ist mit

ausgerüstet.
Vorsicht bei Schweissarbeiten!
Zulässige Hitzeeinwirkung auf drucklose
Leitungen:
max. 130°C und max. 60 min.
WABCO
Z 104 384 Z 104 364de
Z 104 362de Z 104 363
200−1−1020−001g_en 35/55
2
Z 550 079 Z 550 080de
Z 104 366 Z 63 905
Z 63 910 Z 200 627
36/55 200−1−1020−001g_en
UVV
Z 63 729 Z 104 385

Danger!
Danger
of tipping!
Z 104 386 Z 104 387
Z 104 395 Z 104 388de
200−1−1020−001g_en 37/55
2
Z 104 389 Z 104 390
MAX
Km/h Z 104 391 Z 104 392
Z 104 393 Z 104 394
kraankenmerk
kraanken maximale max.viucht maximale kraangroep
getal last bij max. gieklengte
last
tm t m m
Z 104 367 Z 64 217
38/55 200−1−1020−001g_en
Z 104 369
Z 104 378
200−1−1020−001g_en 39/55
2
19a
19a.1
Maschine Nr: 19a.2

Von:
Motortyp: 19a.3
Motor−Nummer:
Typgenehmigung
19a.4
(gemäß Richtlinie 97/68/EG)
19a.5
Z 70 543
19b.1 19b
19b.2
19b.3
19b.4
19b.5
19b.6
19b.7
Z 80 011
40/55 200−1−1020−001g_en
For cranes delivered after January 2011:
EU−Flex
(Z 70 543)
No. Meaning
19a Information sign: EU−Flex
Details on the vehicle emissions regulations of the
engine used
Only valid for the European economic region
19a.1 Details on the running machine number
19a.2 Details of the number of the authorised engines
19a.3 Details of the engine type
19a.4 Details of the engine number
19a.5 Details of the authorisation number
USA−TPEM
(Z 80 011)
No. Meaning
19b Information sign: USA TPEM
Details on the vehicle’s emissions regulations of the
engine used. Only valid for the USA
19b.1 Designation of the sign
19b.2 Company name and logo
19b.3 Year of initial operation
19b.4 Contact address
19b.5 Declaration of conformity in accordance with U.S.

EPA Emission Standards
19b.6 Declaration of conformity in accordance with
California Emission Standards
19b.7 TPEM serial number
200−1−1020−001g_en 41/55
2
Terex Demag GmbH 1.10 Terex Demag GmbH
WMG 1.11 WMG
1.12
1.13
1.1 1.14
1.2 1.15
1.3
1.4
1.5
Jahr der ersten Jahr der ersten
Inbetriebnahme Inbetriebnahme
1.6
1.7
1.8
1.9 19226412 18037112
Z 200 655
42/55 200−1−1020−001g_en
2.5.1 CE Crane Identification Plate / Factory Plate or

Crane Identification Sign / Factory Sign (Specific to
Country)
(Z 200 655)
Legend:
1.1 Crane type
1.2 Vehicle type
1.3 Construction number
1.4 Maximum lifting capacity
1.5 First year of operation
1.6 Year of construction
1.7 Engine output superstructure
1.8 Engine output carrier
1.9 Exhaust air emission value
1.10 Vehicle manufacturer
1.11 Vehicle identification number
1.12 EU operating approval
1.13 Permitted overall vehicle weight
1.14 Permitted overall weight of the towed vehicle
1.15 Permitted axle load
200−1−1020−001g_en 43/55
2
1 4 3 13 12 9 7 6 5
10
11 7 1 5 6 7 1
2 4 3 1
1 7 1 7
Z 200 630
44/55 200−1−1020−001g_en
2.5.2 Safety Signs (CE)

(Z 200 630)
Item Item no. Type of risk / Meaning

1 511 675 98 Warning: Crushing / jolting
2 511 676 98 Warning: Dragging / entanglement
3 511 678 98 Warning: Danger of falling
4 511 684 98 Prohibited: Access prohibited
5 511 679 98 Warning: Danger of fire
6 511 682 98 Prohibited: Open fire
Prohibited: Access for unauthorised
7 511 683 98
personnel
8 511 677 98 Warning: Crushing
9 511 680 98 Warning: Suspended load
10 511 685 98 NOTE: Fire extinguisher
The fire extinguisher supplied is located in the cab of the crane

chassis.
11 511 686 98 NOTE: First aid
First aid box − and other equipment in accordance with the road
traffic licensing regulations − must be stored in the chassis cab.
12 512 150 98 Sign: CE

13 289 506 12 Sign: 107 dB(A); details of the sound
power levels outside of the cab
All safety instructions on the crane must be complete and in

legible condition.
200−1−1020−001g_en 45/55
2
5 1 2−7−8−13−1415 9 5 18 10
5
20
4
22
14
23 12 17 5 6 9 1 23 9 5 6 5
12 12 11 5 5 11 24
5
10
4 11
25
5 6 9 25 5 25 1 5 6 5 9 20 18 16 26 1 9 9
19
Z 200 631
46/55 200−1−1020−001g_en
2.5.3 Safety Signs (only USA)

(Z 200 631)
Each individual sign can be clearly identified thanks to the item

number on each sign. The depiction of the individual signs can
be found in the table on the following pages.
All safety instructions on the crane must be complete and

fully legible.
Item Item no. Figure no. Type of risk / Meaning

1 178 722 12 Z 63 901 DANGER: Voltage (high)
2 178 702 12 Z 63 902 DANGER: Voltage
4 178 705 12 Z 63 904 Risk due to machines
5 178 706 12 Z 63 905 Risk of crushing hands
6 178 707 12 Z 63 906 Risk due to outriggers
7 178 708 12 Z 63 907 Warning before crane operation
8 178 709 12 Z 63 908 Warning: Raising persons
9 178 710 12 Z 63 909 RISK OF FALLING
10 178 711 12 Z 63 910 Risk of crushing bodies
11 178 712 12 Z 63 911 DANGER: Pulling in
12 178 713 12 Z 63 912 Fire hazard
13 178 714 12 Z 63 913 Crane operation
14 178 715 12 Z 63 914 Risk of tilting!
15 178 716 12 Z 63 915 Hand Signals USA
16 511 685 98 Z 63 916 Fire extinguisher
The fire extinguisher supplied is located in the cab of the crane

chassis.
200−1−1020−001g_en 47/55
2
5 1 2−7−8−13−1415 9 5 18 10
5
20
4
22
14
23 12 17 5 6 9 1 23 9 5 6 5
12 12 11 5 5 11 24
5
10
4 11
25
5 6 9 25 5 25 1 5 6 5 9 20 18 16 26 1 9 9
19
Z 200 631
48/55 200−1−1020−001g_en
(Z 200 631)
Item Item no. Figure no. Type of risk / Meaning

17 178 718 12 Z 63 917 Warning: Risk of combustion
18 178 719 12 Z 63 918 Warning: Blower
19 178 720 12 Z 63 919 DANGER: Pressure
20 178 721 12 Z 63 920 DANGER: Battery
22 178 727 12 Z 63 922 DANGER: to passenger
23 178 728 12 Z 63 923 Welding prohibited
24 178 729 12 Z 63 924 DANGER: Assembly work
25 179 564 12 Z 63 921 DANGER: Oil stream
26 511 686 98 Z 63 925 Note: First aid
27 283 340 12 Z 104 646 Note: Country of origin
First aid box − and other equipment in accordance with the road
traffic licensing regulations − must be stored in the chassis cab.
200−1−1020−001g_en 49/55
2
Z 63 901
Z 63 902
Z 63 904
50/55 200−1−1020−001g_en
Z 63 905 Z 63 906
Z 63 907 Z 63 908
Z 63 909
200−1−1020−001g_en 51/55
2
Z 63 910 Z 63 911
Z 63 912 Z 63 913
Z 63 914
52/55 200−1−1020−001g_en
Z 63 915
200−1−1020−001g_en 53/55
2
Z 63 916 Z 63 917
Z 63 918 Z 63 919
Z 63 920
54/55 200−1−1020−001g_en
Z 63 922 Z 63 923
Z 63 924 Z 63 925
Z 63 921 Z 104 646
200−1−1020−001g_en 55/55
Appendix to section 2
Specification as per operating manual! Unauthorised persons are

warned to keep out of
Hydraulic Oil working range of crane.
Z 104 361en Z 104 360en
Differential locks
Should only be used when the crane is

Wheel Nuts
stationary, if required care must be taken to
get smooth slow movement by careful use of Check with torque wrench as per
the clutch and accelerator! operating manual and re−check after
50 km!
The locks must only be used for short
duration to improve traction in poor ground
conditions, and should not be used with
locked suspension, or when turning!
Z 104 382en Z 104 383en
This vehicle is equipped with Wabco

Tecalan nylon pipes.
Caution during welding operations!
Permissible exposure to heat of
unpressurised lines:
DIESEL
Not more than 130 °C for 60
minutes.WABCO EN 590
Z 104 364en Z 104 362en
200−1−1021−001_en 1/2
2
Crab
steering
Not allowed for road travel,note
signal lamp!
Z 550 080en
2/2 200−1−1021−001_en
Crane Operator’s Cab 4
200−1−1040−286b_en 1/37
4
1 2 3 4 5 7 8 9 10 11
1 2 3
0 4
17
29
40
38 28
23
39
22
21
20
18
19
Z 200 674
2/37 200−1−1040−286b_en
4 Crane Operator’s Cab
4.1 Controls and Displays

(Z 200 674)
No. Element Designation Function

1 P 1212 Display Revolution counter
2 P 1367 Display Engine oil pressure
3 P 1351 Display Engine temperature
4 P 3251 Display Hydraulic oil temperature
5 P 0460 Display Level fuel tank
7 A 5155 Timer Control of the
engine−independent heater
8 S 5152 Rotary switch Fan
9 R 5170 Rotary switch Thermostat
10 S 5183 Luminous switch Circulation on/off
11 S 5176 Luminous switch Air conditioning equipment on/off
17 Switch box Main electrical unit cab
18 Lever Release cab door
19 S 9333 Self−return rocker Extend / retract platform (no. 22)
switch
20 B 1251 Pedal Speed adjustment of the engine
21 B 8806 Pedal Slew gear brake
22 Step Cab entry / exit
23 S 7111 Foot switch Horn
27 Display Camera Surveillance of the Hoist
(*)
28 Operating panel Radio / CD
(*) = Optional
200−1−1040−286b_en 3/37
4
1 2 3 4 5 7 8 9 10 11
1 2 3
0 4
17
29
40
38 28
23
39
22
21
20
18
19
Z 200 674
4/37 200−1−1040−286b_en
(Z 200 674)

Warning light: Display of the state of the load
− green limit device and of the load
38 utilization of the crane
− yellow
− red (see section “Safety equipment”)
39 Key−operated Bridging the load limit device

pushbutton (function only for control software
in accordance with EN 13000)
(**)
40 Flashing light: Operating mode radio remote
control (*)
− blue
(*) = Optional
(**) = You can check whether the crane is equipped with control
software in accordance with EN 13000 by selecting the
“Information” screen in crane control. In this case, there is a
corresponding note there.
200−1−1040−286b_en 5/37
4
v h
26 25
34
35
36
42 43
24
41 44
45 47
46 48
49 51
50 52
53 56
54 55
Z 200 675
6/37 200−1−1040−286b_en
(Z 200 675)

24 Left control lever Control of the crane movements
(control lever assignments, use of
the control levers, see section 10)
25 Hoist rotation Vibration display: Hoist 2 (*)
indicator rotating
26 Self−return rocker Fine tuning (%) of movement
switch speed
34 Push button w/o function
35 Push button Fine tuning (%) of movement
speed (together with item 26)
36 Button Dead man’s handle
Risk of accidents!
Control lever assignment:
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the
current function of the lever is before he commences a
crane movement.
Otherwise there is risk of accidents if accidental crane
movements are triggered!
200−1−1040−286b_en 7/37
4
v h
26 25
34
35
36
42 43
24
41 44
45 47
46 48
49 51
50 52
53 56
54 55
Z 200 675
8/37 200−1−1040−286b_en
(Z 200 675)

41 S 6540 Luminous switch Hazard light
42 S 6421 Luminous switch Rotaflare light
43 S 1262 Luminous switch Dash board illumination
44 S 6130 Luminous switch Lighting equipment operating
range; front and rear of the cab
45 S 6211 Luminous switch Lighting equipment outrigger
area;
integrated on the crane chassis in
the covers
46 S 6140 Luminous switch Lighting equipment operating
range, can be adjusted
electrically;
fitted on the basic boom section,
left−hand side (*)
47 S 6145 Luminous Adjustment of 1. spotlight on the
pushbutton basic boom section of the main
boom (*) (Pos. 46)
48 S 6120 Luminous switch Lighting equipment
superstructure;
left−hand side to the rear (*)
49 S 5251 Luminous switch Roof window wiper, 2−level
(intermittent / continuous)
50 S 5261 Luminous Windscreen washing system
pushbutton
51 S 5253 Luminous switch Wiper, front, 2−level (intermittent /
continuous)
52 S 9310 Self−return rocker Tilt cab
switch
53 Indicator light Release radio remote control
54 Key switch Release radio remote control
55 S 6140 Luminous switch Lighting equipment:
2. spotlight
on the basic boom section of the
main boom, left−hand side (*)
56 S 6145.1 Luminous Adjustment of 2. spotlight on the
pushbutton basic boom section of the main
boom (*) (Pos. 55)
(*) = Optional
200−1−1040−286b_en 9/37
4
24V
61 62 63 64
24V
65 66
67 68
Z 200 383
10/37 200−1−1040−286b_en
(Z 200 383)

61 S 1260 Luminous touch Quick stop of the engine
contact
62 S 300 Ignition lock Engine start / engine stop
63 Adjustment knob Tilt adjustment of the monitor
64 Monitor Intelligent Control System (IC−1)
65 X 5453 Service socket Cigarette lighter and power supply
24V DC
66 X 5452 Service socket Power supply 24V DC
67 Service socket USB connection for crane controls
(optional)
68 Service socket Ethernet RJ45 CAT 5 − connec-
tion for crane controls (optional)
200−1−1040−286b_en 11/37
4
24V
71
74
75 76
78
Z 200 384
12/37 200−1−1040−286b_en
(Z 200 384)

71 S 9380 Luminous Raise / lower counterweight
pushbutton
red
74 S 0960 Luminous switch Unlock / lock superstructure
red locking device
75 S 8805 Luminous switch Release / block the slew gear
red brake (slew gear parking brake)
76 S 8817 Luminous switch Switchover slew gear: open /
yellow closed circuit
78 S 1210 Luminous switch Engine chassis; START / STOP
green
200−1−1040−286b_en 13/37
4
24V
81 82 83 84 85
89
1
86 90
87
88
Z 200 385
14/37 200−1−1040−286b_en
(Z 200 385)

81 H 0451 Indicator light Battery charge indicator
82 H 1363 Indicator light Monitor engine oil level
83 H 1377 Indicator light Engine stop
84 H 1260 Indicator light Engine quick stop
85 H 1375 Indicator light Engine fault: if indicator light is
illuminated, switch off the engine
and check
86 H 1335 Indicator light Fault chassis engine:
− Air filter clogged
− Fault engine
− Malfunction transmission
− Filter hydraulic oil
chassis clogged
87 H 1372 Indicator light Air filter monitor
88 H 0420 Indicator light Monitoring of the fuel level,
warning on “reserve”
89 H 3350 Indicator light Hydraulic oil filter control
90 H 3351 Indicator light Hydraulic oil temperature control
200−1−1040−286b_en 15/37
4
24V
101 102
100
108 103
107 104
106 105
Z 200 386
16/37 200−1−1040−286b_en
(Z 200 386)

100 S 4331 Double key Outriggers complete,
retract / extend vertically
101 S 4316 Double key Outriggers front left,
retract / extend horizontally
102 S 4315 Double key Outriggers front right,
103 S 4319 Double key Outriggers front right,
104 S 4321 Double key Outriggers rear right,
105 S 4317 Double key Outriggers rear right,
106 S 4318 Double key Outriggers rear left,
107 S 4322 Double key Outriggers rear left,
108 S 4320 Double key Outriggers front left,
200−1−1040−286b_en 17/37
4
24V
111
112
113
114
115
116
Z 200 387
18/37 200−1−1040−286b_en
(Z 200 387)

111 H 7924 Indicator light State of the key−operated
pushbutton item 112
112 S 7924 Key−operated Activate the setup button (function
pushbutton only for control software in
accordance with EN 13000, (**);
otherwise:
Load limit device bridged (instead
of item 39)
113 H 7270 Indicator light Hoist limit switch bridged
114 S 7270 Key−operated Bridging of the hoist limit switch
pushbutton
115 H 7925 Indicator light Load−moment−reducing
movement “raise luffing gear”
bridged
116 S 7925 Key−operated Bridging of the
pushbutton load−moment−reducing
movement “raise luffing gear”
(**) = You can check whether the crane is equipped with control
software in accordance with EN 13000 by selecting the
“Information” screen in crane control. In this case, there is a
corresponding note there.
200−1−1040−286b_en 19/37
4
v h
14 15
30
31
32
16
Z 200 676
20/37 200−1−1040−286b_en
(Z 200 676)

16 Right control lever Control of the crane movements
(control lever assignments, use
of the control levers, see section
10)
14 Self−return rocker Fine tuning (%) of movement
switch speed
15 Hoist rotation Vibration display: Hoist 1 rotating
indicator
30 Push button High speed
31 Push button Fine tuning (%) of movement
speed (together with item 14)
32 Button Dead man’s handle
Risk of accidents!
Control lever assignment:
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the
current function of the lever is before he commences a
crane movement.
200−1−1040−286b_en 21/37
4
”A”
41
”B” 42
22
43
32
Z 52 909
32 31
18
52
19
Z 52 910 Z 52 967
22/37 200−1−1040−286b_en
4.2 Entering / leaving the cab

(Z 52 909, Z 52 910, Z 52 967)
Depending on the position of the cab relative to the crane

chassis, access is via ladder assembly (43) or integrated steps
in the frame of the crane chassis.
To open the cab door from the outside use the lockable door
catch (41). The door lock is unlocked and the cab door can be
opened (or closed) using handle (42).
To enter / leave the cab, platform (22) should be completely

extended. To retract and extend the platform, use rocker switch
(19).
The opened cab door is locked in place when it reaches its end
position, to avoid it closing accidentally.
To close the cab door first press lever (18) lightly outwards. A
spring then releases the lock on the cab door. The door can then
be slid closed using handle (31).
Risk of crushing!
When closing the door, there is a risk of crushing between
the door and the cab frame. Therefore use the handles
provided to avoid placing your hands in dangerous areas!
Also make sure that your hand is not trapped between the
handle (31) and grip (52) of the front window.
To open the cab door from the inside press lever (32) lightly
backwards. The cab door opens and can be pushed open using
handle (31).
Platform (32) at the front of the crane operator’s cab is foldable.

It should, where possible, be kept in the lowered position (”B”)
where it can be used as a step.
200−1−1040−286b_en 23/37
4
52
Z 52 911
24/37 200−1−1040−286b_en
4.3 Tilting the Cab

(Z 52 911)
To enable work with the crane to be followed more easily, the cab
can be tilted backwards using hydraulic cylinders (max. 18°).
Press self−return rocker switch (52) up − tilt cab forwards.

Press self−return rocker switch (52) down (on the symbol) − tilt
cab backwards.
There is a risk of crushing when tilting the cab!

Persons must stay clear of the hazardous area!
200−1−1040−286b_en 25/37
4
9
8
7 4
6
Z 52 912
26/37 200−1−1040−286b_en
4.4 Workplace Ergonomics
4.4.1 Adjusting the Crane Operator’s Seat

(Z 52 912)
The crane operator is protected against mechanical vibrations by

means of a hydraulically dampened seat. In addition, the seat
can be adjusted individually to the weight of the individual crane
operator.
The seat offers infinite adjustment options for the seat height and
tilt, backrests and armrests. This enables the seat to be set to the
optimum operating position for every operator.
The seat can be adjusted infinitely variably using the following

equipment:
(1) − Control knob for angle adjustment of the arm rests
Risk of crushing!
The arm rests can be folded away. When folding down from
the upright into the horizontal position, there is a risk of
crushing between the armrest and the side console.
(2) − Control knob for setting the lumbar support

(3) − Control element for adjusting the backrest
(4) − Bar for horizontal adjustment of the seat (without
console)
(5) − Control knob for weight adjustment
(6) − Bar for horizontal adjustment of the seat (with console)
(7) − Luminous switch seat heating on / off
After it is switched on, the seat heating is thermostat controlled,

i.e. it switches off and on automatically to maintain a certain
temperature, as long as the switch is switched to position “On”.
The integrated indicator light lights up.
(8) − Control element for adjusting the angle of the seat

surface
(9) − Control element for vertical adjustment of the seat.
200−1−1040−286b_en 27/37
4
21
22
23
Z 52 960
31
Z 52 961
28/37 200−1−1040−286b_en
4.4.2 Sun shield

(Z 52 960, Z 52 961)
The crane operator’s cab is fitted with roll−down sun visors on the
roof window, rear window and side window. These can be
lowered down to the desired level as required to avoid being
dazzled by the sun or the cab becoming too warm.
The window shade on the roof window can be moved backwards

and forwards as required on the corresponding flap (21).
The vertical window shades can be pulled down to the desired

position on the corresponding flap (23). Once the shade has
been pulled down to the required level, it stays in that position.
To roll the shade back up, pull it down slightly first using the lever
on the cord (22). The window shade is then rolled up fully.
The sun visor (31, Z 52 961) on the front window can be pivoted
around into different positions as required.
200−1−1040−286b_en 29/37
4
41 42
Z 52 962
43
44
Z 52 963
30/37 200−1−1040−286b_en
4.4.3 Lighting equipment

(Z 52 962, Z 52 963)
The interior cab light (41) is located to the rear of the roof of the
cab and is actuated using switch (42).
Switch (42) has three possible positions:
− upper position (as shown in ”Z 52 962”): Light OFF
− middle position: Light OFF
− bottom position: Light ON.
In addition there is a reading light in the right−hand corner of the

instrument panel (44, Z 52 963). It is fitted on a flexible arm (swan
neck) and can therefore be pivoted into any position within its
extension radius.
It is switched on and off on the light itself using switch (43).
200−1−1040−286b_en 31/37
4
46
47.1
47
47.2
Z 52 964
32/37 200−1−1040−286b_en
4.4.4 Open / close window
4.4.4.1 Side window, rear window

(Z 52 964)
The side window (Z 52 964) which forms the upper part of the cab
door and the window in the rear wall of the cab are sliding
windows.
When closed, the catch (47) on the window element and the fixed
counterpiece (46) on the cab frame support are locked together.
To open the individual window press the catch on the gripping

piece together (47.2) as shown in figure (Z 52 964). The locking
nose (47.1) is lifted and the window element can be closed /
opened.
Risk of crushing!
When closing, there is risk of crushing between the window
element and the door / cab frame support. Only use the
handles provided to ensure that your hand does not get
caught!
200−1−1040−286b_en 33/37
4
51
”A”
52.1
52.2
”B”
52
Z 52 965
34/37 200−1−1040−286b_en
4.4.4.2 Front window

(Z 52 965)
The front of the cab is fitted with a large front window.
When closed, the two handles (52) are in position (”A”). The
corresponding locking nose (52.2) is then in the transverse
position behind the fixed locking plate (52.1) on the cab frame.
To open the front window turn both handles inward by 90°. They
are then in position (”B”). Press the window element outwards
lightly with your hand. The window is then opened completely by
means of the two gas−operated positioners (51).
In order to close the front window, the window element must be

pulled down using both handles (52), against the holding
pressure of the gas−operated positioners. Then bring both
handles (52) back to position (”A”).
RISK OF DAMAGE!
If you only pull on one side on one handle (52) to close the
window element, it causes the front window to twist. This
damages the window seal.
For this reason, always pull at both handles (52) to close the
window.
Risk of crushing!
When closing the window there is a risk of crushing
between the window element and the cab frame. Use the
handles provided to ensure that your hands are not caught
in the hazardous areas!
In case of emergency, the wide−opening front window can be

used as an emergency exit.
200−1−1040−286b_en 35/37
4
61
62a
63
62b
Z 53 493
36/37 200−1−1040−286b_en
4.4.5 Storage
(Z 53 493)
There are a number of storage areas in the cab where things can
be put down:
− on top of the instrument panel
− behind the seat of the crane operator (e.g. for storing the
operating instructions)
− plastic elements (63) in the footwell, right−hand side
− ashtray (61) on the right−hand side panel and further ones in
the consoles of the control levers.
− fold−out cup holders (62a) and (62b) on the consoles
beneath the control levers.
These cup holders must be folded out to hold drinks

containers. This is shown for cup holder (62a) in the drawing.
When the cup holders are not needed, they should be folded
back in. This is shown for cup holder (62b) in the drawing
opposite.
200−1−1040−286b_en 37/37
Engine 5
5 Engine
The engine OM 906 LA is a six−cylinder engine with direct

injection, exhaust turbocharger and charge air cooling. It has
particularly low pollutant emissions and has an electronic control
system (control devices and sensors).
Safety measures for engines with electronic control devices
The following safety measures must be observed to

prevent injury to persons and damage to the engine,
components or cables.
− Only start the engine when the batteries are properly

connected. Do not disconnect the batteries when the engine
is running.
− Only start the engine when the speed sensor is connected.
− Never use a boost charger to start the engine.
Jump starting only with separate batteries.
− For rapid charging of the batteries, the battery terminals must
be disconnected. Follow the operating instructions for the
boost charger.
− The batteries must be disconnected when electric welding
work is carried out, and the ”+” and ”−” cables are connected
to one another.
− The lines of the control units may only be disconnected and
connected when the electrical system is switched off.
− Switching the poles of the supply voltage for the control units
(e.g. by connecting the poles of the batteries incorrectly) can
lead to the destruction of the control units.
− Tighten the connections on the injection system with the
prescribed tightening torque.
− With forecast temperatures of over 80°C (176°F) (e.g. dry
furnaces) the control devices must be removed.
− For measurements on plug connections, use only suitable
test lines (connecting set of the engine manufacturer).
− Telephones and radio equipment which are not connected to
an external antenna can cause malfunctions to the vehicle
electronics and endanger the operating safety of the engine.
200−1−1050−166a_en 1/37
5
Cable channel 60X25X405 (30) 1−4,7
9
A0303
F1 25 A F8 25 A F15 10A F22 10 A F29 10 A
F2 10 A F9 15A F16 10 A F23 10A F30 10 A
F3 10 A F10 10A F17 10 A F24 10A F31 10 A
F4 10 A F11 10 A F18 10 A F25 10 A F32 10A
X1
X2
X3
X4
X5
X6
F5 10 A F12 10 A F19 10 A F26 10 A F33 2A
F6 10 A F13 10 A F20 2A F27 10 A F34 15A
(31)
F7 25 A F14 10A F21 10 A F28 25A F35 25A
A0513
Cable channel 60X25X31

A0565
V11 V22 K5 K10 K5 K10
V10 V21
K3 K6
X2 V9 XV2 V20 X2 X2
V8 V19 K4 K9 K4 K9
V7 V18
A0583
17
A0561
A0564
K2 K5 K3 K8 K3 K8
V6 V17
V5 V16
V4 V15 K2 K7 K2 K7
X1 XV1 X1 X1
V3 V14
K1 K4 V2 V13
V1 V12 K1 K6 K1 K6
Cable channel 60X40X370
17a
A0562 A0563
K3 K6 K3 K6
X2 X2 15 18 12 21
(28)
K2 K5 K2 K5
Cable channel 73X49X23,5

A1157
ADM
X1 X1
17b
K1 K4 K1 K4
X0859
X0701 X0858
K8000
F36
X0703 X0705
VOLTAGE CONVERTER
A5162
K0552 K0551
20
A0154
B5252 B5253
Z 53 436
85
Z 53 437
2/37 200−1−1050−166a_en
Engine 5
5.1 Engine control/monitoring

(Z 53 436, Z 53 437)
Detailed information on this subject as well as fault codes

can be found in the operating instructions of the engine
manufacturer (see part 5 of these documents).
These must be observed in addition to the basic information
given below.
The engine is equipped with a fully electronic control system incl.

self−diagnosis, that, in addition to the engine and the
corresponding sensors, comprises the following components:
− MR−control device (direct on the engine)
− ADM adaptation module (17a) incl. FR−control device in the
area of the main electrical unit (17) in the crane operator’s
cab.
They are connected together by means of a CAN (Controller Area

Network) line, via which all necessary data / information can be
exchanged.
If the engine monitoring system recognises a fault, this is

displayed (indicator light “85”, Z 53 437), saved in the control
devices as a fault code and evaluated.
Depending on the faults that occur, a safety or emergency
program can be activated.
Fault messages are read from a diagnosis device (to be

connected to the socket “17b”). Please contact our customer
service department in this regard.
The gravity of the fault can only be determined using the

diagnosis unit.
The following applies therefore: as soon as indicator light
(85, Z 53 437) lights up and displays an engine fault, the
engine must be switched off immediately and the cause of
the fault determined (to prevent damage to the engine).
Operation of the crane is only permitted again once the fault
has been rectified.
Risk of accidents!
If this is not possible due to an existing hazardous
situation, different engine running characteristics
(emergency running program) or possible engine damage
are to be expected. Proceed with appropriate caution!
200−1−1050−166a_en 3/37
5
Z 53 438
4/37 200−1−1050−166a_en
Engine 5
5.2 Starting
5.2.1 Before starting

(Z 53 438)
Before operating the engine for the first time, the operating
instructions of the engine manufacturer for the diesel engine
OM 906 LA must be observed. These are enclosed in part 5
of this documentation.
The following points are primarily limited to information
which specifically affects the crane.
1. Check before starting:

− the hydraulic oil level
− the engine oil level
− the coolant level.
To proceed, observe the corresponding sections of the

maintenance and lubrication instructions of the superstructure.
− the fuel level on the fuel gauge (5).
The display on the fuel gauge (5) is only correct when the
ignition in the crane chassis is switched off.
200−1−1050−166a_en 5/37
5
81
62
62a
Z 53 439
23
20
Z 53 440
6/37 200−1−1050−166a_en
Engine 5
5.2.2 Starting procedure

(Z 53 439, Z 53 440)
Before starting, check that all control levers are in the off
position.
1. Insert the ignition key in the “0” position in the ignition lock
(62) and turn clockwise up to the second notch.
After about 1 s, only the charge control lamp (81) is lit up.
The key−operated switch (62a) of the ignition lock is a

four−position switch:
− Position ”0”: Position ”off”. The key can be removed in
this position.
− Position ”P”: parking position. Voltage supply for radio,
fan, aircraft warning light. The key can be
removed in this position.
− Position ”1”: notch position ”on”. The ignition is switched
on.
− Position ”2”: switch position ”start”. The engine starts.
Before starting the engine or carrying out crane

movements the crane operator must actuate the horn using
foot switch (23), in order to warn persons who are in the
vicinity of the crane.
2. Place the setpoint sensor, i.e. pedal (20) in the idle position.
The engine speed can alternatively be adjusted using the

IC−1 control. This is described on the next page.
200−1−1050−166a_en 7/37
5
Z 53 441
81
Z 53 443
8/37 200−1−1050−166a_en
Engine 5
(Z 53 441, Z 53 443)
To adjust the engine speed via the IC−1 control press the key
in the displayed mask “Quick Menu” (Z 53 441, left−hand
side). The “engine display” mask appears.
Here the engine speed can be regulated between maximum and

minimum by using the arrows or moving the slide control (1).
The current speed is displayed directly beneath the slide control
switch and additionally behind the corresponding symbol.
3. Turn the ignition key further up to the stop and hold in this
position until the engine starts. If required, stop the starting
procedure after max. 20 s and repeat again after approx.
60 s.
When the engine is running, the charge control light (81) must
go out.
Release the ignition key as soon as the engine starts. On no

account should the starter be operated with the engine
running.
If the indicator light (81) does not go out, there is a fault in the
power supply.
The corresponding instructions in the operating
instructions of the engine manufacturer must be observed.
200−1−1050−166a_en 9/37
5
Z 53 456
85
87
Z 53 448
10/37 200−1−1050−166a_en
Engine 5
5.2.3 To be observed after starting

(Z 53 456, Z 53 448)
− Directly after starting, check the oil pressure on pressure

gauge (2).
The oil pressure is also displayed via the mask “engine
display” of the IC−1. To call up this mask, observe the
description on page 9.
Do not rev up the engine if there is no oil pressure displayed.
If, after 10 seconds. no oil pressure is displayed, switch off
the engine and determine the cause of the fault.
Once the operating temperature has been reached, the

engine oil pressure must not fall below the following values:
− 2.5 bar (36.3 psi) for rated speed
− 0.5 bar (7.3 psi) for idle speed.
If the pressure falls below these values, switch off the engine
and determine the cause of the fault.
− If the indicator light (85) lights up, there is an engine fault.
Switch off the engine immediately and determine the cause

of the fault (to avoid damage to the engine).
has been rectified.
Risk of accidents!
If this is not possible due to an existing hazardous
situation, different engine running characteristics
(emergency running program) or possible engine damage
are to be expected. Proceed with appropriate caution!
− If the indicator light (87) lights up, service the air filter (see
maintenance and lubrication instructions of the
superstructure).
200−1−1050−166a_en 11/37
5
3 4
Z 53 457
82 85
89 90
Z 53 455
12/37 200−1−1050−166a_en
Engine 5
(Z 53 457, Z 53 455)
− If indicator light (90) lights up, the hydraulic oil temperature

is too high.
Allow the diesel engine to continue running at lower

temperatures to enable the hydraulic oil to be cooled down
again using the oil cooler.
The round instrument (4, Z 53 457) should also be observed
in this respect. The hydraulic oil temperature must not exceed
approx. 85°C (185°F).
− If the indicator light (89) lights up, service the hydraulic oil filter
(see maintenance and lubrication instructions of the
superstructure).
This only applies when the hydraulic oil is at operating
temperature.
At low temperatures, it may be that this light does not go out for
a while, without there being a fault.
− Observe the coolant temperature on round instrument (3).

The coolant temperature is also displayed via the mask
“engine display” of the IC−1. To call up this mask, observe the
If the maximum permitted temperature is exceeded, indicator
(85) lights up.
As soon as indicator light (85, Z 53 455) lights up, indicating

that there is an engine fault, the engine must be switched off
immediately and the cause of the fault determined (to avoid
damage to the engine).
has been rectified.
− If the indicator light (82) lights up, check the engine oil level
(see operating instructions of the engine manufacturer).
The engine oil amount (%) is also displayed via the mask
“engine display” of the IC−1. To call up this mask, observe the
This display of the motor oil level (%) is only meant as addi-
tional information. The monitoring of the oil level may only
be done using the oil−level stick.
Depending on the version, it is possible that this display
function is not possible for technical reasons. The respec-
tive display at the IC−1 will then always be 0%.
If this is the case, the indicator light (82) is not displayed ei-
ther.
200−1−1050−166a_en 13/37
5
88
Z 53 452 Z 53 453
31
32
33
Z 56 113
14/37 200−1−1050−166a_en
Engine 5
(Z 53 452, Z 53 453, Z 56 113)
− If the indicator light (88) lights up, fuel must be added; the fuel
level in the tank of the crane chassis is in the reserve range.
For the fuel level observe the fuel gauge (5).
Fuel gauge (5) normally shows the fuel level in the tank of the
crane chassis. Only for the option “Separate fuel tank (extra
tank)” is the level of this extra tank displayed. The display on the
fuel gauge (5) is only correct when the ignition in the crane
chassis is switched off.
This extra tank enables different fuels to be used in the
superstructure and crane chassis.
Observe also the corresponding points in the operating
instructions of the crane chassis, section 2 “crane chassis”.
Refuelling is normally carried out by filling the tank of the crane

chassis (see operating instructions and maintenance and
lubrication instructions of the crane chassis).
In emergencies, the superstructure tank (32, Z 56 113, shown
without mounting parts and covering) can also be filled directly
via a filler neck (31).
In the superstructure there is only a buffer tank (max. 45 l; 11.9

gal). It is filled automatically using a pump from the tank of the
crane chassis. When the level of the fuel in the tank of the crane
chassis falls into the reserve range, no more fuel is supplied to
the superstructure tank. Indicator light (88) lights up. There are
then approx. 35 l (9.2 gal) remaining in the superstructure tank.
This ensures that movements that have been started can be
completed.
On the side of the superstructure tank (32) there is a shut−off

lever (33). This must be closed during normal operation. It
can − in exceptional cases − be opened to allow fuel to run
back from the superstructure tank into the chassis tank.
In this case, the cover of this superstructure tank must be
opened slightly to vent the system. After ending the
procedure, close the filler cap again.
200−1−1050−166a_en 15/37
5
23
20
Z 53 440
16/37 200−1−1050−166a_en
Engine 5
(Z 53 440)
− At extreme minus temperatures do not place the cold engine

under full load.
Before the engine can be operated under full load, the

hydraulic oil must be warmed to operating temperature.
Information on warming up the hydraulic system can be
found in section 5.2.4 of these operating instructions.
Switch off the engine immediately if:

− the oil pressure falls or fluctuates violently.
− the output and speed falls without the position of pedal
(20) being changed.
− the exhaust is smoking heavily.
− the coolant and oil temperature climbs abnormally.
− abnormal noises suddenly occur in the engine or
turbocharger.
200−1−1050−166a_en 17/37
5
21
Z 59 740
18/37 200−1−1050−166a_en
Engine 5
5.2.4 Warming up the hydraulic system

Warming up the hydraulic system is only required when:
− in relation to the ambient temperature the oil viscosity is
between 1000 and 1600 cSt (that means, with a standard
hydraulic oil filling between −13°C (+8.6°F) and −18°C
(−0.4°F), see Table)
and
− the hydraulic oil has cooled down to the ambient temperature
after a longer standstill (approx. 8 to 10 hours).
5.2.4.1 Hydraulic oil

(Z 59 740)
Make sure that, in relation to the oil temperature and

viscosity, a suitable hydraulic oil is added. The
corresponding oil viscosity depends on the oil that is used.
Information in this respect can be found in the following
table.
Standard hydraulic oil fill for average temperatures

Oil Diesel engine
Oil viscosity
Shell Tellus TX 46 temperatur speed
(cSt)
e (°C /5F) (U/min / rpm)
−18°C below 1000
Starting without load (1) 1600
(−0.45F) (idle)
−13°C
MIN 1000
(+8.65F)
Operation (2) MAX
+92°C
MAX 10
(+197.65F)
The conditions that are listed in the table must be observed.

Otherwise safe operation of the crane cannot be guaranteed
and hydraulic components cannot be damaged.
When using comparable oils, make sure that these

correspond to the recommended oils, especially with regard
to the listed characteristics.
200−1−1050−166a_en 19/37
5
21
Z 59 740
20/37 200−1−1050−166a_en
Engine 5
5.2.4.2 Warming up procedure

(Z 59 740)
1. Make sure, using the following table, that a correct hydraulic

oil is added in relation to the prevailing temperatures. The
viscosity of the oil must be below 1600 cSt.
2. Start the diesel engine.
The correspondingly permitted engine speeds are specified in

the following table.
Standard hydraulic oil fill for average temperatures

Oil Diesel engine
Oil viscosity
Shell Tellus TX 46 temperatur speed
(cSt)
e (°C /5F) (U/min / rpm)
−18°C below 1000
Starting without load (1) 1600
(−0.45F) (idle)
−13°C
MIN 1000
(+8.65F)
Operation (2) MAX
+92°C
MAX 10
(+197.65F)
As soon as the diesel engine is running − first in idle −, the

hydraulic pumps are automatically started. The hydraulic oil is
then circulated in the depressurised state and is warmed up.
The hydraulic system must run itself warm until the viscosity of
the oil is below 1000 cSt.
With a running time of 30 minutes and approximately 1000 (U/min

/ rpm) the hydraulic oil is warmed by 4° C (7° F) to 5° C (9° F).
3. After this carry out all movements again after approx. 10 to

15 minutes without load. The warming up procedure is then
completed.
200−1−1050−166a_en 21/37
5
23
20
Z 53 440 Z 53 454
61
84
62
62a
Z 53 449
22/37 200−1−1050−166a_en
Engine 5
5.2.5 Switching off
5.2.5.1 Switching off in normal situations

(Z 53 440, Z 53 454, Z 53 449)
1. Place the pedal for speed adjustment (20) in the ”idle”

position or set the corresponding speed on the ”engine
display” mask of the IC−1.
To call up this mask, observe the description on page 9.
After operating with full engine output or high coolant

temperature, leave the engine running without load for 1 − 2
minutes at idle speed.
2. Turn ignition key (62a, Z 53 449) anti−clockwise (to

position ”0”) and remove the ignition key.
When leaving the crane, remove the ignition key and lock the
cab.
200−1−1050−166a_en 23/37
5
61
84
62
62a
Z 53 449
Z 58 696
24/37 200−1−1050−166a_en
Engine 5
5.2.5.2 Switching off with the quick−stop device

(Z 53 449, Z 58 696)
In an emergency, the engine can be switched off in either the

crane chassis or the superstructure by pressing the emergency
stop switch (position “61” in the superstructure). These buttons
latch into place when they are in the actuated position. Bother
engines will be switched off. The indicator light (84) in the
superstructure lights up.
For the design version with air shut−off valve (1) the air intake
duct of the superstructure and chassis engine is mechanically
shut off.
Use the quick stop button (61) to switch off the engine only
in an emergency.
Before starting the engine again, this quick stop” button
must be unlocked again. To this end, turn the button slightly.
Optionally, the crane can be equipped with two additional engine

stop buttons. These are located on the left− and right−hand side
of the crane chassis in the area near the outrigger controls.
These two emergency engine stop buttons are only guaranteed

to work if the parking brake is applied in the chassis cab and the
transmission is in “Neutral”.
Design with air shut−off valves (1)
Irrelevant of manual activation, if a certain maximum speed is

exceeded, this engine shutdown is initiated automatically. At the
same time, the fuel supply is cut off.
If the engine is to be restarted, the respective air blocking valve

has to be manually released. To this end return the lever (2) for
the superstructure engine to the starting position.
The position of the air block valve in the chassis engine must also
be checked and unlocked if required.
Risk of damage!
The engine may not be started with the air blocking valve
closed. Repeated starting attempts lead to engine damage.
Check before restarting that none of the air conducting
hoses (including charge air hoses) has become loosened as
a result of the emergency switch off and that there is nothing
to reduce their permeability.
200−1−1050−166a_en 25/37
5
2B
1B
2A
1A
4
3
Z 200 336
26/37 200−1−1050−166a_en
Engine 5
5.3 Jump starting

(Z 200 336)
Observe the operating instructions for the crane chassis.

Section 5 “Engine”, sub−point “Jump starting with external
batteries”.
200−1−1050−166a_en 27/37
5
Z 53 451
28/37 200−1−1050−166a_en
Engine 5
5.4 Operating hour display

(Z 53 451)
The operating hour display is located in the bottom line of the

”engine display” mask. To call up, use the key in the
displayed “Quick Menu” mask (Z 53 451, left−hand side).
Use the arrows or the slide control switch (1) to display the
operating hours
5.5 Automatic driving

(Z 53 451)
With “automatic driving” the engine speed is automatically

adjusted as the control lever is moved. This ensures comfortable
working processes as the engine speed does not need to be
additionally activated by the crane operator.
To activate “automatic driving” press key in the displayed

“Quick Menu” mask (Z 53 451, left−hand side). The “engine
display” mask appears. Press button here. It is highlighted
in green.
To switch off “automatic driving” press key again. In the

deactivated state, the button is grey in colour.
5.6 Coolant preheating
Please see section 16 “Heating”.
200−1−1050−166a_en 29/37
5
30/37 200−1−1050−166a_en
Engine 5
5.7 Diesel soot particle filter (optional)
If the crane is equipped with a diesel soot particle filter, the engine
can be operated with diesel fuel as well as with bio diesel (RME
= rape methyl ester) in accordance with DIN EN 14214.
To this end, the diesel soot particle filter is burned clean.
Vegetable oil fuels which are not in accordance with DIN EN

14214 may not be used due to the risks of malfunctions.
Diesel soot particle filters of this type must be cleaned regularly.

To this end, the diesel soot particle filter is burned clean.
In accordance with the manufacturer’s specifications, the

diesel soot particle filter should be cleaned once a day.
The procedure for burning the filter clean is explained in the

lubrication and maintenance instructions.
Before starting the crane check that the vehicle is not

connected up for this cleaning process.
The following contains instructions for using and monitoring the

diesel soot particle filter.
The instructions below must be observed in order to avoid

damage to the engine and other components and to ensure
full availability of the engine.
5.7.1 Checking the filter for levels of contamination
To determine the level of clogging in the diesel soot particle filter,

the exhaust resistance pressure in the filter is evaluated.
At an exhaust resistance pressure of 150 mbar (2.2 psi) under

load or full throttle, the diesel soot particle filter must be burned
clean.
200−1−1050−166a_en 31/37
5
130.1 130.2 130.3
130.4
130.7 130.5
130.6
130
Z 200 377
32/37 200−1−1050−166a_en
Engine 5
5.7.1.1 Display/ datalogger diesel soot particle filter
(Z 200 377)
The pressure sensor that measures the exhaust resistance

pressure is connected to a corresponding display instrument
(130, Z 200 377) in the crane operator’s cab.
When the engine is placed under (full) throttle the display gauge
can be observed.
Description of the display gauge (130, Z 200 377)

130.1 Control button: acoustic signal
130.2 Control button: optical signal
130.3 Scroll (menu control)
130.4 Display
130.5
The entire row of buttons is only active in service
130.6
mode
130.7
When the diesel particle filter has to be cleaned the buttons 130.1
and 130.2 flash.
The acoustic and optical signal can be switched off by pressing
the corresponding button, but is reactivated after an engine start.
Button (130.3) is used to switch between the display of the

exhaust temperature, the exhaust resistance pressure and the
engine speed.
Exhaust resistance Measure
pressure
< 125 mbar (1.8 psi) To work further, observe the exhaust
resistance pressure
125 mbar (1.8 psi) Burn the soot particle filter free as soon
< 150 mbar (2.2 psi) as possible
> 150 mbar (2.2 psi) Burn the soot particle filter free as soon
as possible
The display (130) datalogger may only be switched over to

service mode by authorised personnel.
200−1−1050−166a_en 33/37
5
34/37 200−1−1050−166a_en
Engine 5
5.7.1.2 Fault messages on the display
If there is a fault in the operation of the diesel soot particle or in

the burning device, the following messages can appear on the
display
Fault message Display Remark (measure)

A button on the display box is jamming.
Fault: 11 Press the button again (several times if required) to rectify the
malfunction.
No communication between the data box and the display box.
Fault: 21
Check the plug and harness to switch the ignition off and on again.
Different software versions on the data box and display box.
Fault: 23
Contact your dealer.
Hose or pipe damaged or damage to the filter.
Fault: 31 Check the pressure line. If the pressure line is OK, please send the data
box to your dealer to be checked.
There is no change in pressure for 10 minutes.
Fault: 32 Source of fault: blocked pressure line. In this case, please clean the
pressure line in accordance with the maintenance instructions.
There is no change in temperature for 10 minutes.
Fault: 33
Check that the probe is still attached correctly on the filter.
Temperature sensorprobe fault
Fault: 34
Fit new harness with a new temperature sensor.
The switching point is reached for the upper pressure threshold.
Raise the exhaust temperature by increasing the engine load
Fault: 36 correspondingly. The increased exhaust temperature means that the
particle filter can burn more soot, causing the exhaust resistance
pressure to fall back to a normal level and the displays to go out.
Caution: Do not overheat the engine!
Filter check failure
Fault: 38 This message is switched off by confirming with the return button. Have
the filter checked in the workshop and replace if necessary.
The data cannot be displayed.
Fault: 41
Contact your dealer.
The date could not be displayed.
Fault: 51
Repeat the procedure and contact your dealer.
The time could not be displayed.
Fault: 52
Repeat the procedure and contact your dealer.
200−1−1050−166a_en 35/37
5
36/37 200−1−1050−166a_en
Engine 5
If, with the engine running, a current engine speed of 0 is

displayed, check the electric connections and/or have checked
by customer service. The alarm outputs are without function in
this case.
In this case, there would be no message if the diesel soot

particle filter requires burning free.
The system must be repaired as soon as possible to prevent
damage to the engine and other components and to ensure
that the engine remains functional.
5.7.1.3 Operation with diesel soot particle filter
If the crane engine is operated over a longer period of time while

stationary, the engine should regularly be run at higher revs. This
will prevent the diesel soot particle filter clogging too quickly.
200−1−1050−166a_en 37/37
Supporting the crane on outriggers from the crane operator’s cab 7
7 Supporting the crane on outriggers from the crane

operator’s cab
In order to support the crane on outriggers from the crane

operator’s cab, you must follow the procedure as well as the
danger and safety instructions detailed in section 12, part 2.
The outriggers should generally be set using the

operatingelements in the ladders (see section 12, part 2).
However, it is possible to operate the outriggers from the crane
operator’s cab for follow−up levelling.
This should only be done in exceptional cases and only when the
crane operator has a clear and unobstructed view of all outrigger
jacks.
(If necessary, a banksman should be used)
200−1−1070b_en 1/3
7
101 102
100
74
108 103
75
107 104
106 105
Z 200 650
2/3 200−1−1070b_en
Supporting the crane on outriggers from the crane operator’s cab 7
Proceed as follows:
(Z 200 650)
− Slew superstructure to the rear (see section 8) and lock the

superstructure using button (74).
− Activate slewing gear parking brake (75, S8805).
The outriggers are controlled using the following buttons:

100 S4331 Dual button All outriggers,
retract/extend vertically
101 S4316 Dual button Front left jack,
retract/extend horizontally
102 S4315 Dual button Front right jack,
103 S4319 Dual button Front right jack,
104 S4321 Dual button Rear right jack,
105 S4317 Dual button Rear right jack,
106 S4318 Dual button Rear left jack,
107 S4322 Dual button Rear left jack,
108 S4320 Dual button Front left jack,
Risk of crushing between the wheels and road surface

when the crane is lowered onto its wheels by retracting the
outriggers.
Before lowering, make sure that this area is completely free
of people.
The equipment may only be operated in areas where the

crane operator can see the outrigger jacks directly or via
the mirrors. Check all mirror positions before operating the
outriggers.
200−1−1070b_en 3/3
Slewing the Superstructure 8
200−1−1080e_en 1/23
8
Z 200 293
2/23 200−1−1080e_en
8 Slewing the Superstructure
Danger of tipping over!
The superstructure may be slewed only with the mobile

crane supported on outriggers
After supporting the crane on outriggers and fitting the

counterweight, the current outrigger support area must be
checked before slewing the superstructure (Z 200 293).
Observe the specifications in the separate load capacity

tables. With a reduced outrigger support area, only the
maximum permitted counterweight specified in the lifting
table may be fitted.
If larger counterweights are fitted, contrary to these
specifications, the superstructure must not be slewed.
Danger of tipping over!
Depending on the fitted counterweight it is only permitted

to slew the superstructure in the range of reach in which
there are still load capacity values in the load capacity
tables.
Nevertheless, due to the load limit device, slewing
movements are NOT switched off when loading in the
overhang ranges where load capacities have not been
specified in the carrier load tables. This is why there is a
danger of tipping over to the front!
It is generally prohibited to slew the superstructure in the

overload range (load limit device “LLD” is switched off).
200−1−1080e_en 3/23
8
Z 200 294
4/23 200−1−1080e_en
Risk of accidents!
There are the following risks when slewing the

superstructure:
− Risk of crushing in the area of the disconnecting point
between the superstructure and the chassis.
− Risk of being crushed between the back end of the
superstructure (counterweight) and obstacles in the
vicinity.
Therefore persons must stay clear of the slewing range at
all times!
Never slew over people.
Do not jump from the slewing crane.
Risk of accidents!
It is prohibited to slew the superstructure if the

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

However, if crane control is bridged after a malfunction,
there risk still exists.
Determine and rectify the cause of the fault immediately.
Risk of accidents!
In machines that are equipped with a dolly or dolly
preparation, the extension lock of the locking bolt must be
loosened, the slewing gear brake may not be openly
blocked and the ball valve of the luffing gear must be open
(see 8.3).
Running direction in the display of the IC−1 (Z 200 294)

The position of the superstructure / main boom to the rear is
defined as position 0°/360° within crane control. In order to rotate
the superstructure to position 90° for example, the superstructure
must make a clockwise quarter rotation.
In order to check the superstructure rotation movement on the

display in addition to the angle details, there is a metal sheet with
a tip on the front of the superstructure in the area of the slew ring.
This ”arrow” is easily viewed from the superstructure cab.
200−1−1080e_en 5/23
8
A6
74
Z 200 651
6/23 200−1−1080e_en
8.1 Slewing and Braking
8.1.1 Slewing the Superstructure

(Z 200 651)
Proceed as follows to rotate the superstructure:
1. Support the crane on outriggers and align in accordance with

the regulations (see operating instructions of the crane
chassis, section 12).
2. Start the superstructure engine.
3. If required, adapt control lever assignment.

(see section 8.2 or section 10)
4. Raise main boom so that it cannot become entangled with

other crane components (see section 13).
5. Release the mechanical superstructure locking device by

pressing switch (74). The indicator light in the switch lights
up. The locking pin (2) is extended outwards from the locking
strip (3). Each state is depicted at the point “A6”−”current
configuration information” on the display of the IC−1.
200−1−1080e_en 7/23
8
75
Z 160 643
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
8/23 200−1−1080e_en
(Z 160 643, Z 160 635)
6. Release the interlock of the slew gear brake by pressing

switch (75). The indicator light in the switch lights up.
7. Initiate the slewing movement by activating one of the keys
of the “dead man’s switch” and carefully steering control
lever (24) / (16) in the corresponding direction.
To prevent unintentional activation of crane movements, both

control levers (24/16) are fitted with an additional button (dead
man’s handle). Button (36) in the control lever (24) and button
(32) in control lever (16).
Optionally, another dead man’s switch can be fitted as a seat
contact switch.
The dead man’s switches must only be activated (pressing and
releasing the hand keys, sitting on / getting up from the crane
operator’s seat, for optional seat contact switch) if the control
levers are in the “neutral position” and/or the initiated working
movement has been completed.
The dead man’s switches can be activated alternately during a
crane movement.
Risk of accidents!
If the dead man’s switches are activated / released when
the control lever is steered, without that dead man’s switch
or another one already activated, it will cause the
corresponding movement to be initiated / braked abruptly.
Only initiate a working movement when the dead man’s
switch is activated.
Only release a dead man’s switch while a working
movement is being carried out if another one is activated.
Only release the dead man’s switches, or only get up from
the crane operator’s seat (if there is an optional seat
contact switch) when the working movement been
completed.
200−1−1080e_en 9/23
8
75
Z 160 643
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
10/23 200−1−1080e_en
(Z 160 643, Z 160 635)
Risk of accidents!
Only by adapting the acceleration or speeds of all crane

movements can you prevent the load or the hook block
from swinging out, causing risk of crushing or crashing
when a movement is switched off.
RISK OF ACCIDENTS!
You must take the current position of the control levers into
consideration.
Control levers (24) / (16) may not be switched directly to the

opposite movement, but must first rest in the neutral
position. A countermovement may only be initiated after a
cessation of movement.
Risk of damage.
Never initiate a slewing movement using the control lever
without first having unpinned the superstructure or released
the slew gear brake!
200−1−1080e_en 11/23
8
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
21
75 76
Z 160 644
12/23 200−1−1080e_en
(Z 200 677, Z 160 644)
8.1.2 Braking the Superstructure

To brake the superstructure, proceed as follows:
1. Select the brake circuit function (open or closed circuit) with

switch (76).
2. Return the corresponding control lever (24 or 16) slowly to

the neutral position.
− When the function “open brake circuit” has been
selected on the luminous switch (76) (indicator light in the
switch lights up), the slewing movement is gently
completed. Press down pedal (21) until the superstructure
comes to a standstill.
− When the function “closed brake circuit” has been
selected on the luminous switch (76) (indicator light in the
switch does not) light up, the slewing movement is braked
directly to a standstill.
Handle the slew gear and slew brake with care! Select low
slewing speeds! Brake carefully!
This especially applies for operation of the crane with the
main boom extension / fly jib or special local site
conditions.
If the function “Release slew gear brake” is selected using switch

(75), the brake is released immediately if the pedal (21) is not
activated.
By pressing brake pedal (21), the brake is applied in proportion

to both operating modes.
200−1−1080e_en 13/23
8
21
75 76
Z 160 644
14/23 200−1−1080e_en
(Z 160 644)
If switch (75) “Release slew gear brake” has been pressed

(indicator light in the switch is illuminated) and pedal (21) is not
activated, the slewing gear is switched to free−wheel in the “open
braking circuit”.
When raising a load, oblique pull is automatically avoided.
RISK OF ACCIDENTS!
It is possible that the wind will influence it or cause

unintentional rotation!
A non−controlled movement of the superstructure is

possible.
When the slew gear brake is released, the superstructure

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

breaks or at the end of work, the slew gear brake must be
locked. Press switch (75). The indicator light in the switch
must not light up.
200−1−1080e_en 15/23
8
A AS
E23
E
Z 200 298
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
16/23 200−1−1080e_en
8.2 Control Lever Assignment
(Z 200 298, Z 200 677)
Depending on the crane equipment, different modes (IC−1) can

be selected. By actuating the button “E23” a picture of the current
control lever assignment is shown in area “E” of the crane
operating mask. By selecting a new mode (e.g. mode 4), you can
display the corresponding control lever function. The newly
selected mode becomes active after you select the ”Save”
symbol (disk) to quit the display. The current control lever
assignment is displayed at point “AS” in the field “A”.
Mode 1: SLH = slew gear SRH = luffing gear

SLV = tele SRV = hoist 1
SLV = hoist 2 SRV = hoist 1
Mode 3: SLH = slew gear SRH = hoist 2
Mode 4: SLH = luffing gear SRH = slew gear

Mode 6: SLH = slew gear SRH = tele
SLV = luffing gear SRV = hoist 1
(S = control lever, R = right (16), L = left (24), H = horizontal,

V = vertical)
Risk of accidents!
consideration.
200−1−1080e_en 17/23
8
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
A
B
C
D
Z 200 035
18/23 200−1−1080e_en
8.3 Slewing Speed
(Z 160 635, Z 200 035)
The slew gear is electrically pre−controlled. Slewing speed

depends on the position of control lever.
In addition, a fine setting can be achieved using button (26/14)
in the control lever (24/16) (button to the right − rapid; button to
the left − slow).
As long as the speed is being regulated via button (26/14), the
corresponding percentage is shown in the display of the load limit
device (A, Z 200 035) (see also chap. 10).
Make sure you have a low slewing speed (lower range) in the
following cases:
− when working with loads > 30% of the load capacity
− with a long boom
− working with main boom extension fitted
200−1−1080e_en 19/23
8
A B
75B
32 75A
81
80
Z 200 647
20/23 200−1−1080e_en
(Z 200 647)
8.4 Slewing Gear and Superstructure Locking Device in

the Position “Operation of the Crane” during Dolly
Preparation
Machines with dolly preparation are equipped with a slew gear

brake, which can be blocked when in the open state.
Furthermore, in dolly preparation the locking pin (80) of the
superstructure locking device can be locked.
For “operation of the crane” the slew gear brake may not
be openly blocked or the locking pin (80) of the super-
structure locking device be locked.
Risk of tilting when raising the boom!

Only raise the boom from the dolly or the main boom
surface if the slew gear brake is closed again. Before
raising the boom make sure that the slew gear brake is
actually closed!
8.4.1 Activating and Closing the Slew Gear Brake after

Dolly Operation
Procedure for unlocking and closing the slew gear brake after the
dolly operation:
1. Start the superstructure engine.
2. Open hydraulically the slewing gear brake which is still set

out of function by pressing the switch (75A); indicator light in
the switch begins to glow.
3. Pull out shift lever (32) until you can feel it locking in place
(shift path 55 mm (2.2 in) position ”B”).
4. Close slew gear brake by pressing switch (75B); Indicator

light in the switch goes out.
In this state the slew gear brake is activated again, i.e. set to
”operation of the crane”. ”Dolly operation” is prohibited.
200−1−1080e_en 21/23
8
A B
75B
32 75A
81
80
Z 200 647
22/23 200−1−1080e_en
8.4.2 Superstructure locking device: Removing the

”Locked” Position
(Z 200 647)
1. Support crane on outriggers and level out

(large outrigger support area)
2. Raise main boom slightly from the main boom support from
the dolly until there is free space between the main boom and
the dolly or the main boom support.
Slew superstructure clockwise to the side.
3. Release screw (81) from the locking pin (80) of the

superstructure locking device.
The superstructure locking device is set to ”operation of the

crane” again. The locking pin remains in the raised state,
however, it is no longer locked or mechanically secured.
200−1−1080e_en 23/23
Counterweight 9
9 Counterweight
9.1 Important Assembly Instructions
When fitting and removing individual counterweight

elements, there is risk of crushing between the individual
counterweight elements, between counterweight and
superstructure frame, between counterweight and chassis
(counterweight support) as well as between counterweight
base frame and the individual counterweight elements!
To avoid these risks, the safety instructions in section 1,
sub−point ”When Assembling and Dismantling Crane
Components” must be observed.
Especially make sure you keep a sufficient safety distance.
You stack the individual counterweights with the help of

another trained person, who as an exception, is also on the
crane with the crane operator during fitting or removal of
the counterweights. This person must leave the crane and
the endangered area immediately after the actual
configuration has been completed.
The crane operator must always have visual contact with
this person and must make sure that there is no−one else
in the endangered area. Before the superstructure is
rotated, the crane operator must make sure that this person
has left the crane and the endangered area.
When turning, there is a risk of crushing between the
counterweight and obstacles in the vicinity.
It is forbidden to remain under hanging loads or in areas
where there is risk of loads falling.
All counterweight elements must always be attached at the

prescribed attachment points.
Make sure that the attached element is not crooked or
swinging when raised.
The counterweight is hung in the desired configuration
from the crane cab.
The crane operator operates the erection and pinning
cylinders using buttons.
200−1−1090−212a_en 1/41
9
Z 200 027
71A
71B
74
75
Z 200 215 Z 160 646
2/41 200−1−1090−212a_en
Counterweight 9
The execution of the relevant movements are displayed to the

crane operator on the display of the IC−1. In order to see the
relevant display in field ”E” (Z 200 027), you select the ”Quick
menu E57”.
If the support bases are reduced, the largest counterweight

assigned to the loading status specified in the table may be
assembled as a maximum. If a larger counterweight is
used, there is a danger of tipping over to the rear during
slewing
9.2 Operating Elements / Auxiliary Equipment

1. Counterweight cylinders
(Z 200 215, Z 160 646)
When the button (71, S9380) is activated, the piston rods

of the counterweight cylinder (1) on the left and right side
of the superstructure are driven down (71B) or up (71A)
together.
200−1−1090−212a_en 3/41
9
E57.1
E57.2
71A
E57.3
E57.4
E57.5
E57.6
E57.7 71B
E57.8
E57.9
A14 E57.13 E57.11 E57.10
E57.12 E57.10.1
Z 160 647
Z 200 202 Z 200 134
4/41 200−1−1090−212a_en
Counterweight 9
2. Control display on IC−1 (see also section 9.4.2, page 17).
After button (E57, Z 200 134) has been selected, the

counterweight configuration view appears at (E) (Z 160 647).
This displays the current status information for the state of the
counterweight fitting.
E57.1: Bridging switch for malfunctions
When you select this switch, the lock fitting functions are
switched off during counterweight fitting.
Before bridging the counterweight, a warning sign will

ensue. This must be acknowledged.
The crane operator should know the instructions on
configuring the counterweight from the manual. He must be
aware of the endangered area, especially of the risk of
people being crushed.
Danger of crushing and damage!

If the counterweight has been bridged, there is no
monitoring by the SPS (Z 200 202).
By pressing the switching surface 1, this mask can be exited with

bridging.
By pressing the switching surface 2, the bridging will be active:
In Z 160 647, the symbol for bridging is displayed.
The symbol (25, Z 200 202) then appears in the crane operating
mask.
E57.2: Switch−over ”Manual fitting − automatic fitting”
Counterweight automatic: Green/Grey = On/Off
E57.3: Status of the current condition of theremoval
procedure
E57.4: visual display of the current condition of
thefitting procedure and/or when the
counterweightis fitted the selected counterweight
combinationin the operating mode selection
mask
E57.5: Extension state of the counterweight lift cylinder
in %
200−1−1090−212a_en 5/41
9
E57.1
E57.2
71A
E57.3
E57.4
E57.5
E57.6
E57.7 71B
E57.8
E57.9
A14 E57.13 E57.11 E57.10
E57.12 E57.10.1
Z 160 647
6/41 200−1−1090−212a_en
Counterweight 9
(Z 160 647)
E57.6: Top cross bar:

Counterweight lift cylinder in upper end position
E57.7: Arrow symbols for the movements Raise
andLower.
E57.8: Bottom cross bar:
Counterweight lift cylinder in the lower
endposition
E57.9: current hydraulic pressure in the
counterweighthoist cylinders
E57.10: Angular indicator
mask, which displays angle positions which are
important for the fitting procedure
E57.10.1: Line display of the position the superstructure is
currently in
E57.11: Display which shows if the superstructure may
be rotated in the current counterweight state:
red arrow: it is not permitted to rotate
green arrow: it is permitted to rotate
E57.12: Display which shows if the superstructure may
be rotated when the counterweight lift cylinder is
retracted in the counterweight:
red arrow: it is not permitted to rotate
green arrow: it is permitted to rotate
E57.13: Symbolic display of switch 71 on theinstrument
panel
Green/Red = release/no release for raising
orlowering
When the switch is activated, the relevant page is
depicted in grey.
A14: indicates the current superstructure angle
200−1−1090−212a_en 7/41
9
E
C D
B
A
Z 200 206
8/41 200−1−1090−212a_en
Counterweight 9
9.3 Counterweight Elements / Attachment Points
9.3.1 Nominal Weights and Transport Dimensions

(Z 200 206)
Metric measuring units:

Pos. Nominal weight Transport dimensions
Length Width Height
kg mm mm mm
A 5890 kg 2450 mm 1370 mm 1000 mm
B 7410 kg 2990 mm 2145 mm 395 mm
C 8815 kg 2990 mm 2145 mm 320 mm
D 8815 kg 2990 mm 2145 mm 320 mm
E 8685 kg 2990 mm 2145 mm 380 mm
F* 3110 kg 2950 mm 1425 mm 250 mm
G 12925 kg 1635 mm 1795 mm 1275 mm
H 12925 kg 1635 mm 1795 mm 1275 mm
Centering aids 25.7 kg 1105 mm 250 mm 250 mm

Centering aids 35.6 kg 1105 mm 300 mm 300 mm
US measuring units:
Pos. Nominal weight Transport dimensions
Length Width Height
lbs in in in
A 12990 lbs 96.5 in 54.0 in 39.4 in
B 16340 lbs 117.7 in 84.5 in 15.6 in
C 19440 lbs 117.7 in 84.5 in 12.6 in
D 19440 lbs 117.7 in 84.5 in 12.6 in
E 19145 lbs 117.7 in 84.5 in 15.0 in
F* 6860 lbs 116.1 in 56.1 in 9.8 in
G 28495 lbs 64.4 in 70.7 in 50.2 in
H 28495 lbs 64.4 in 70.7 in 50.2 in
Centering aids 56.7 lbs 43.5 in 9.8 in 9.8 in

Centering aids 78.5 lbs 43.5 in 11.8 in 11.8 in
Optionally, the counterweight element (F*) can be supplied

separated so that special axle loads can be achieved. For
relevant instructions, see 9.4.3 on page 27.
200−1−1090−212a_en 9/41
9
E
C D
B
A
Z 200 206
10/41 200−1−1090−212a_en
Counterweight 9
9.3.2 Attaching the Counterweight Elements

(Z 200 206)
All counterweight elements must be attached at the prescribed

attachment points. None of the attachment points may be loaded
over the max. permitted values. They are as follows:
− Attachment hooks on base plate (A):
max. 7 t (15 432 lbs) per hook.
− Attachment hooks on the counterweight section (B):
max. 5 t (11 023 lbs) per hook.
− Attachment hooks on the counterweight section (F):
max. 2 t (4409 lbs) per hook.
− Bollards which are cast into cast−iron components in
accordance with the specifications of maximum
permissible load indicated on each bollard:
− on counterweight element (C, D, E):
max. 5 t (11 023 lbs) per bollard
max. 8 t (17 636 lbs) per bolt
− on saddle counterweights (G, H):
max. 7 t (15 432 lbs) per bollard
max. 7 t (15 432 lbs) per bolt
The indicated attachment hooks and bollards are marked with

the corresponding max. permitted value.
The optional centering aids are required for transportation of the

counterweight elements without base plate (A) on the chassis
frame to fulfill the special axle load regulations. Assembly is
described in section “Driving” in segment “Additional
components counterweight support” of the chassis operating
instructions.
The centering aids are designed so that they can be attached
directly to a lifting tackle with hook.
RISK OF ACCIDENTS!
The parts must not swing out or dangle at an angle when they
are raised. If necessary, lifting chains fitted with shortening
claws must be used.
The securing equipment must be supplied by the customer.
Only use load handling attachments which are suitable for

the counterweight elements to be raised and are sufficiently
dimensioned.
It is especially important that only flat lifting slings made of
plastic are used for attaching to the cast bollards.
200−1−1090−212a_en 11/41
9
Z 200 098 Z 200 201
E
C D
B
A
Z 200 206
12/41 200−1−1090−212a_en
Counterweight 9
9.4 Assembling the Counterweight
9.4.1 Preassembly of the Counterweight on Superstructure

Frame
− The appropriate counterweight combination is preassembled
on the superstructure frame on the counterweight support
(see section 9.5, page 31).
For this purpose, guide lines are welded onto the chassis frame
as a visual centering aid. There are suitable indentations on the
lower part of the counterweight for this reason (Z 200 201).
(Z 200 098; similar depiction)

The counterweight support is between the chassis cab and the
fastening of the superstructure frame (slew ring).
If the support bases are reduced, the largest counterweight

assigned to the loading status specified in the table may be
assembled as a maximum. If a larger counterweight is
used, there is a danger of tipping over to the rear during
slewing
(Z 200 206)
All counterweights are equipped with grooves and cams.

Generally, any configuration may only be continued when the
grooves of all components lying on top are exactly flush with and
lying on top of the corresponding cams.
200−1−1090−212a_en 13/41
9
F B−E
E
C D
B
A
Z 200 206 Z 200 099
14/41 200−1−1090−212a_en
Counterweight 9
(Z 200 206)
Load capacities for fitting and removing the counterweight

elements
Generally, you can fit and remove all counterweight combinations
using your own crane. The load capacity tables 0 t (0 lbs) are
valid for the resulting load types.
Only lifting tackle with sufficient dimensions may be

deployed.
In order to attach the individual counterweight element, or

several elements together, there is corresponding lifting tackle in
accordance with the regulations of the corresponding load
capacity tables (optional). This suspension gear can be ordered
at the crane manufacturer.
− all attachment points (load blocks, cast bolts, bollards) are
marked with the corresponding permitted load.
− with the sections ”A − F” the centre of gravity is exactly
between the load blocks and bolts.
− when fitting the section (F) on the superstructure frame using
the auxiliary crane, this must be attached diagonally with 2
chains to avoid damaging the superstructure hydraulic tank.
− the sections (A) and (B) form one unit. They are
alwaysmarked with a serial number (SN xxxxx −A and SN
xxxxx −B) and must not be replaced ormixed with sections
with other serial numbers.
− to attach the saddle weights (G and H) the sections (C and
D) must be seated (identically). The saddle weights must be
hung in the upper one of the two plates (D).
− The plates (E and F) can be positioned either before or after
the saddle weights have been hung.
200−1−1090−212a_en 15/41
9
E57.1
E57.2
71A
E57.3
E57.4
E57.5
E57.6
E57.7 71B
E57.8
E57.9
A14 E57.13 E57.11 E57.10
E57.12 E57.10.1
Z 160 647
Z 200 134 Z 200 207
16/41 200−1−1090−212a_en
Counterweight 9
9.4.2 Suspending the Counterweight

Starting status for assembling the counterweight is:
− The counterweight configuration to be fit is set down on the
chassis.
− The counterweight cylinder is retracted.
− Rotate the superstructure back so that it is approx. +/− 10° to
the longitudinal axle.
You can fit the counterweight manually or during automatic

operation:
Basic procedure:
− Turn the superstructure back: main boom angle 4,5° or
355,5°
− Telescope counterweight lift cylinder into the kidney−shaped
grooves of the counterweight sections.
− Rotate superstructure to position ”0° back”.
− Retract counterweight lift cylinder: The draw bar of the
counterweight and the rod end of the hydraulic cylinder are
designed so that the counterweight is raised to the
superstructure frame.
After the button (E57, Z 200 134) has been activated, a depiction
of the present state of the counterweight appears at ”E”
(Z 160 647).
You are in manual operation once the counterweight
configuration view has been switched on. The symbol (E57.2) is
displayed ”grey”. The hand symbol is not crossed out.
For a list of the individual display elements, see 9.2, page 3.
Once the counterweight is fitted after the fitting procedure, and

has been set in the operating mode preselection mask, the
current counterweight is depicted at (E57.4).
The status display (E57.3) then is ”S:0”.
200−1−1090−212a_en 17/41
9
E57.1
E57.2
71A
E57.3
E57.4
E57.5
E57.6
E57.7 71B
E57.8
E57.9
A14 E57.13 E57.11 E57.10
E57.12 E57.10.1
Z 160 647
Z 200 207
18/41 200−1−1090−212a_en
Counterweight 9
9.4.2.1 Automatic Fitting of the Counterweight

(Z 160 647, Z 200 207)
− Activate button (E57.2):

In automatic operation, the “hand symbol” is thencrossed
through and the symbol shown “green”.
− Depending on its assignment, the pilot sensor which
introduces the superstructure rotation movement must be
activated:
The rotation direction must be selected so that you approach
the angle range 4.5° to 355.5° from the outside.
(Example: the superstructure is at 10°: The pilot sensor must
be activated so that the superstructure rotates anticlockwise
when viewed from above.)
Throughout the entire fitting procedure, the pilot sensor must
now be held in this direction.
After fitting has been completed, the superstructure remains
in the ”0° back position”, even though the pilot sensor is still
held to the side.
The pilot sensormust then be released temporarily. When the
pilot sensor is activated again, the crane is back in the crane
operation state.
− During the fitting procedure, the individual operating steps
are followed in accordance with the description of the ”Basic
Procedure” at the start of this point 9.4.2, page 17.
− On the display the individual steps can be followed.
− If you started with a rotation angle between 355.5° and 4.5°
at the beginning of the fitting procedure, the fitting procedure
is interrupted depending on the rotation direction when the
counterweight lift cylinder is lowered.
The automatic fitting procedure is continued when the pilot

sensor is steered out of the opposite direction.
The slew gear is in the closed circuit (see section 8) during the
fitting procedure. This setting cannot be modified.
The control system also assumes control of the engine speed, in
order to achieve a sufficient sensibility.
200−1−1090−212a_en 19/41
9
E57.1
E57.2
71A
E57.3
E57.4
E57.5
E57.6
E57.7 71B
E57.8
E57.9
A14 E57.13 E57.11 E57.10
E57.12 E57.10.1
Z 160 647
Z 200 134 Z 200 207
20/41 200−1−1090−212a_en
Counterweight 9
(Z 160 647, Z 200 134, Z 200 207)
Example Fitting the Counterweight with Automatic

Operation:
Automatic operation can only be selected when the top cylinders

or the counterweight are fitted.
Activate automatic operation and steer out the pilot sensor for the
slew gear. The configuration procedure is now carried out by the
program.
The configuration procedure is completed when status S:3 has
been achieved. The pilot control sensor must be moved back
once to the neutral position, so that the slew gear is released
again. The colour of the automatic display changes from ”green”
to ”grey”.
Exception: If automatic operation starts at 0° +/− 5.5° the pilot

sensor must be steered out in the other direction after status S:2
has been achieved.
9.4.2.2 Manual Fitting of the Counterweight

− After the button (E57, Z 200 134) has been activated, the
crane is the mode for manual operation. The ”hand symbol”
(E57.2) has NOT been crossed out in this case.
− During the fitting procedure, the individualsteps are carried
out (as described for 9.4.2, page 17) byalternate actuation of
the pilot lever and theswitch (71) in the instrument panel
− Depending on its assignment, the pilot sensor which
introduces the superstructure rotation movement must be
activated:
The rotation direction must be selected so that you approach
the angle range 4.5° to 355.5° from the outside.
(Example: the superstructure is at 10°: The pilot sensor must
be activated so that the superstructure rotates anticlockwise
when viewed from above.)
− ”S:0” (E57.3) indicates the start and end state. The
counterweight which was activated in the operating mode
preselection mask is displayed.
− When an angle range of approx. 5° or 355°
”superstructure−to−chassis−angle” is reached a line appears
(E57.10.1) on the display (E57.10), which marks the current
angle.
200−1−1090−212a_en 21/41
9
E57.13
E57.3
E57.4 E57.6
E57.7
E57.8
E57.12
71A
71B
Z 160 648
22/41 200−1−1090−212a_en
Counterweight 9
(Z 160 648)
(Example: the superstructure is at 10°: After starting theslewing

movement in the direction “0°−to the rear position” whenthe 5°
angle range is reached, the line (E57.10.1) appears at the left
end of the display (E57.10) which indicates the current rotation
angle.)
− The rotation movement must be continued until the line is in
the coloured area at 4.5° or 5 355.5° , depending on the fitting
direction.
− Status (E57.3) is then changed to ”S:1”.
If you leave the coloured angle area (4.5° or. 355.5° +/− 1° ), the
status display (E57.3) jumps back to ”S:0”.
− Throughout the entire rotation movement, the rotation circuit

(E57.11) is displayed in ”green”. This means it is permitted to
rotate the superstructure.
200−1−1090−212a_en 23/41
9
E57.13
E57.3
E57.4 E57.6
E57.7
E57.8
E57.12
71A
71B
Z 160 648
24/41 200−1−1090−212a_en
Counterweight 9
(Z 160 648)
− Extending the counterweight lift cylinder by activating the

switch (71B) in the instrument panel (only possible in the
”S:1” status):
The arrow symbol then appears at (E57.7). At (E57.6) the bar
then disappears.
− If the counterweight lift cylinder is completely extended, a bar
appears at (E57.8).
When you let go of switch (71B), the arrow symbol
disappears at (E57.7).
The permitted rotation direction is displayed in ”green” at
(E57.12).
− Continued rotation of the superstructure in the ”0° back
position”. Status (E57.3) changes to ”S:2”.
− S:3: Position, which the cylinders in the counterweight are in,
and in which it is permitted to raise. The arrow of display
(E57.13) which is pointing upwards is shown in ”green”.
− Retraction of the counterweight lift cylinder by activating the
switch (71A). While switch (71) is activated, the arrow symbol
appears at (E57.7). The cross bar disappears from (E57.8)
after you remove the counterweight lift cylinder from the
bottom end position.
− When the counterweight lift cylinder has reached its top end
position, the figure changes to a status ”S:0” display. Then
the figure of the counterweight set in the operating mode
preselection mask is displayed.
Example Fitting the Counterweight without Automatic

Operation:
Rotate superstructure to 4.5°, S:1.

Actuate the button “counterweight downwards” untilcondition S:2
is reached.
Continue to rotate the superstructure on 0°, S:3.
Activate button “Counterweight up“ until state S:0 has
beenreached and Release slew gear has been achieved.
The fitting procedure is thereby completed. They are removed

in a similar manner in the reverse sequence.
200−1−1090−212a_en 25/41
9
2 1
1
G
C D
B
A
Z 200 209
F2 F1 F3
F Z 56 052
26/41 200−1−1090−212a_en
Counterweight 9
9.4.3 Mounting the Counterweight (F) to the Superstructure
Non−separate Design
The counterweight element (F, Z 200 209) is designed as usual

as a complete section.
Separate Design
In order to achieve special axle loads during driving, the

counterweight element (F, Z 56 052) can optionally be supplied
in a separate design.
The exterior component (F2) weighs 1100 kg (2426 lbs). The
interior component (F1) weighs 2010 kg (4431 lbs).
In order to achieve special axle loads, only the interior

components (F1) is fitted to the crane.
If both components are to be fitted onto the crane at the same

time, the interior component (F1) and the exterior component
(F2) must be screwed together with 3 metal shackles (F3).
Fitting the counterweight element (F)

(Z 200 209, Z 56 052)
The section (F) (non−separate and separate design) can be fitted

either with an auxiliary crane or with your own crane.
The section (F1) (separate design) can only be fitted using your
own crane.
Fitting with the auxiliary crane:

(Z 200 209, Z 56 052)
When fitting section (F) on the superstructure frame using

the auxiliary crane, this must be attached diagonally with 2
chains, in order to avoid damage to the superstructure
hydraulic tank.
− Pin section (F) on the superstructure frame using pin (1).

(Z 200 209, Z 56 052)
200−1−1090−212a_en 27/41
9
2 1
1
G
C D
B
A
Z 200 209
F2 F1 F3
F Z 56 052
28/41 200−1−1090−212a_en
Counterweight 9
Assembly with your own crane:

− Stack counterweights stack (A − F) or (A − F1) on the
counterweight support of the chassis.
− Fit the counterweight stack on the superstructure frame.
− To lock: remove bolts (1) from retainers (2) and insert in the
bolt eye of the section.
− Make sure that the pins are locked correctly.
− When the section is not pinned on the superstructure, the
pins (1) are inserted in the holder (2).
− The section (F) or (F1) is dismantled in the same wayin the
reverse sequence.
200−1−1090−212a_en 29/41
9
2 1
D
B C
A
Z 200 209
30/41 200−1−1090−212a_en
Counterweight 9
9.5 Assignment of the Counterweights to the Different

Configurations
The regulations in section 6 of the operating instructions of the

chassis must be adhered to for driving (axle loads, transportation
state).
Configurations other than the ones described in the following
may not be set, even if they seem to be possible. There is a
considerable risk of damage to the crane’s component group.
9.5.1 Counterweight Combination 0 t (0 kip)

For the counterweight combination 0 t (0 kip), no counterweight
elements are required to raise the permissible load in accordance
with the load capacity tables.
The swinging through radius on the superstructure from the

centre of the slew ring to the rear edge of the superstructure
frame is approx. 4170 mm (13.7 ft).
9.5.2 Counterweight Combination 5.9 t (13.0 kip)

(Z 200 209)
(A) − 5890 kg (12990 lbs)
The swinging radius on the superstructure from the centre of the

slew ring to the rear edge of the counterweight is approx.
4450 mm (14.6 ft).

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(F) − 3110 kg (6860 lbs)
Procedure for fitting section (F) see 9.4.3, page 27.

4450 mm (14.6 ft).
200−1−1090−212a_en 31/41
9
2 1
D
B C
A
Z 200 209
32/41 200−1−1090−212a_en
Counterweight 9

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)

4800 mm (15.7 ft).

(A) − 5890 kg (12990 lbs)
(C) − 8815 kg (19440 lbs)

4800 mm (15.7 ft).

(Z 200 209)
Raising loads:
(A) − 5890 kg (12990 lbs)
(B) − 7410 kg (16340 lbs)
(F) − 3110 kg (6860 lbs)

4800 mm (15.7 ft).
200−1−1090−212a_en 33/41
9
2 1
D
B C
A
Z 200 209
34/41 200−1−1090−212a_en
Counterweight 9

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(C) − 8815 kg (19440 lbs)
(F) − 3110 kg (6860 lbs)
Section (F) pinned on the superstructure frame using bolt (1).


4800 mm (15.7 ft).

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)

4800 mm (15.7 ft).

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(F) − 3110 kg (6860 lbs)

4800 mm (15.7 ft).
200−1−1090−212a_en 35/41
9
2 1
D
B C
A
Z 200 209
36/41 200−1−1090−212a_en
Counterweight 9

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)

4800 mm (15.7 ft).

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)
(F) − 3110 kg (6860 lbs)

4800 mm (15.7 ft).

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)
(E) − 8685 kg (19145 lbs)

4800 mm (15.7 ft).
200−1−1090−212a_en 37/41
9
2 1
D
B C
A
Z 200 209
38/41 200−1−1090−212a_en
Counterweight 9

(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)
(E) − 8685 kg (19145 lbs)
(F) − 3110 kg (6860 lbs)

4800 mm (15.7 ft).

(Optional)
(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)
(F) − 3110 kg (6860 lbs)
(G) − 12925 kg (28495 lbs)
(H) − 12925 kg (28495 lbs)

4950 mm (16.2 ft).

The plates (F) can be positioned either before or after the saddle
counterweights have been hung.
To attach the saddle counterweights (G) and (H) sections (C and

D − identical) must be fitted. The saddle counterweights must be
attached in the upper of the sections (D).
200−1−1090−212a_en 39/41
9
2 1
D
B C
A
Z 200 209
40/41 200−1−1090−212a_en
Counterweight 9

(Optional)
(Z 200 209)
(A) − 5890 kg (12990 lbs)

(B) − 7410 kg (16340 lbs)
(C) − 8815 kg (19440 lbs)
(D) − 8815 kg (19440 lbs)
(E) − 8685 kg (19145 lbs)
(F) − 3110 kg (6860 lbs)
(G) − 12925 kg (28495 lbs)
(H) − 12925 kg (28495 lbs)

4950 mm (16.2 ft).
To attach the saddle counterweights (G) and (H) sections (C and

D − identical) must be fitted. The saddle counterweights must be
attached in the upper of the sections (D).
The sections (E) and (F) can either be fitted before or after
attaching the saddle counterweights.
9.6 Operation with a Fitted Counterweight Combination
Due to physical reasons, the counterweight can sink slightly

when fitted.
In order to avoid damage to the counterweight hoist unit, you
must check regularly whether the counterweight is still
firmly fitted to the superstructure frame.
Otherwise, the electrical limit switch which releases
superstructure slewing could ”lose the signal” under
unfortunate conditions.
This would result in the superstructure slewing movement
locking.
In this case the counterweight must be pulled up to the
superstructure frame again by activating the double button
71B, as described above.
200−1−1090−212a_en 41/41
Safety Equipment 10
Z 200 378
200−1−1100−286d_en
1/159
10
64
Z 200 379
2/159 200−1−1100−286d_en
Safety Equipment 10
10 Safety Equipment
(Z 200 379)
−You can determine the software status of the IC−1 in the system
screen (201.1) in the Quick menu (E12) (see section 10.1.7.1 on
page 43).
10.1 Electronic Crane Information System

The electronic crane information system IC−1 (Intelligent
Control System) (64) combines several devices which supply
the crane operator with important information for operating the
crane within the parameters set by the manufacturer:
− Device for overload safety (load limit device LLD).

− Telescoping information system (see section 12).
− Display of several crane configurations such as e.g. support
pressure, tilt, crane configuration, load capacities, etc.
− Warning (optical and acoustic) in case of prohibited
conditions.
The crane information system used (incl. load limit device) is an

operating help. It supplies the crane operator with important
information concerning crane data such as e.g. length and angle
of the boom, sheave head height, nominal load capacity, the total
load hanging from the boom, etc. and warns when an overload
state is being approached or when the hook block is nearing the
boom head.
This safety device is no substitute for the judgement and

experience of the crane operator and use of recognised safe
operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility for
safe operation of the crane.
200−1−1100−286d_en
3/159
10
64
Z 200 379
4/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 379)
If, when raising a load or lowering the main boom with load the
permissible load moment / the permissible load is exceeded, the
load moment increasing movements as well as ”raise luffing
gear“ and ”raise load on hook“ are switched off. ”Lower load on
hook“ is permitted.
Load moment deactivation should only be activated in

exceptional cases. It must never be used for normal
operation.
Before a load is raised, its weight must be known. The safety

device may not be used to determine the weight.
The load limit device must be set by the crane operator for
the individual crane configuration. This means that the
crane operator must change the load limit device as well
when the crane configuration is changed.
The crane operator is responsible for the correct setting by
acknowledging the crane configuration.
The load limit device functions automatically only when
each setting has been adjusted correctly.
The load limit device can be monitored using the overload

recorder (optional). See section 10.1.7.17, page 89.
200−1−1100−286d_en
5/159
10
64
Z 200 379
6/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 379)
The load may only be picked up using the hoist during hook
operation.
If the load is still in contact with the ground and raising of

the hoist has been shut down, the load is too heavy. The
movement ”raise main boom” may not be enabled!
”Raise main boom” must never be used to raise the load!
It is essential for the operating safety of the crane that the

IC−1 crane control functions in its original condition.
Necessary updates can be obtained from the after−sales
service department of the crane manufacturer.
Risk of crushing!
Despite using automatic safety devices, swinging of the

load cannot always be avoided during shutdown!
It can only be avoided by adjusting the acceleration / speed
of all crane movements!
Also take note of the continuous load utilisation display
with preliminary warning at 90 % of the permissible load
utilisation prior to switch−off!
Risk of crane control system being influenced!

The danger that the load limit device is influenced by
high−frequency radiation is minimised as far as the
technology allows it (shields). However, it cannot be totally
excluded, particularly under extreme conditions such as
e.g. proximity to very powerful transmitters.
200−1−1100−286d_en
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10
64.1 64.11
64.2 64.12
64.3 64.13
64.4 64.14
64.5 64.15
62 64.6 64.16
64.7
64
64.10 Z 200 380
8/159 200−1−1100−286d_en
Safety Equipment 10
10.1.1 Control and Display Elements

(Z 200 380)
(62) Ignition start switch:

Position ’1’ All consumers are switched off
Position ’2’ Ready for ignition: External starting
procedure
Position ’3’ The ignition is switched on
Position ’4’ Starting position for engine
(64) Visualisation computer (DloG) with touchscreen display

see for this section 10.1.2.
Depending on the design of the visualisation computer (DloG), it

will have the following devices for operation and display:
(64.1) On / off switch

If the IC−1 needs to be rebooted: to do so: Switch off the
ignition (switch ignition start switch A 11 to position ’1’);
wait for at least 30 seconds, press switch for at least 3
seconds; switch the ignition back on (switch ignition start
switch A 11 to position ’3’)
(64.2) Brightness “+” (manual)
(64.3) Brightness “−” (manual)
(64.4) not assigned
(64.5) Temperature warning
If the temperature in the computer is smaller than 05 C (325 F) the
LED illuminates red and the computer is heated internally. When
the temperature is more than 05 C (325 F) the computer then
starts automatically. The heating procedure can take between
one and eight minutes, depending on the outside temperature.
The computer is ready for operation as soon as the red LED
(Temp, 64.5) goes out and the green LED (Power, 64.7) lights up.
If the operating and display element cancels the operation
(monitor goes black) and at the same time the temperature
warning light comes on, then the ambient temperature may be
too high. The cab will then need to be cooled down with the air
conditioner. As soon as the temperature has once again fallen to
an acceptable level, the operating and display element will
attempt once again to dial into the CAN network.
(64.6) Hard disk access
(64.7) Operating condition
200−1−1100−286d_en
9/159
10
64.1 64.11
64.2 64.12
64.3 64.13
64.4 64.14
64.5 64.15
62 64.6 64.16
64.7
64
64.10 Z 200 380
1 2
Z 56 172
10/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 380)
(64.10) USB ports
(64.11) Moves the mouse pointer up
(64.12) Moves the mouse pointer down
(64.13) Moves the mouse pointer to the left
(64.14) Moves the mouse pointer to the right
(64.15) On / off switch for key mouse control
(64.16) Causes a mouse click (touch)
Attaching stick−on labels to the screen will cause damage to

it.
10.1.2 Operation of the IC−1

(Z 200 380, Z 56 172)
In this system, all functions are operated by ”touching” the

illustrated switches or surfaces, i.e. all settings of the safety
equipment are carried out entirely via the monitor (64).
By touching an active switch surface, a selection window for

parameter selection is opened (3) or the display switches to a
further selection window.
When a selection window is opened, a list of selection options is
opened in upward or downward direction next to the selected
button. One of the options must be selected from the selection
list. If the set value is not to be modified, then the previous value
must be selected again from the selection list.
The values selected are always dependent on the previously

selected settings. This means if, for example, crane operation
without main boom extension is selected, then no values for
parameter settings with main boom extension will be offered.
These switches will only appear in ”grey”. All parameters that can
be set appear on a switch with a black frame.
200−1−1100−286d_en
11/159
10
1 2
Z 56 172
12/159 200−1−1100−286d_en
Safety Equipment 10
(Z 56 172)
In principle, the following applies:
Memory symbol: selected setting is saved,

Diskette
and the display is changed (2)
Exit symbol: the display is left without
Door
saving the modified settings (1)
the displayed values must be changed or at
”Red”
least confirmed, otherwise the settings
entries
cannot be saved for crane operation.
Operation at ambient temperatures in excess of 50C

(1225F)
To avoid malfunctioning of the crane controls display, the air

conditioner should be used to cool the cabin both before and
during crane operations when ambient temperatures are in
excess of 50°C (1225F). Direct sunlight should then be avoided
on the display.
An appropriate cooling−down stage should be prescribed if
necessary for the period before work begins.
200−1−1100−286d_en
13/159
10
1
74.4 t 8,50 m 1
2a
Z 60 358
1
74.4 t 8,50 m 1
1 11.8 t
74.4 t
8,50
Z 60 359
14/159 200−1−1100−286d_en
Safety Equipment 10
10.1.3 System Start / Switching the System off
The IC−1 is automatically started when the ignition is switched

on. At the same time, a system check is made automatically.
Momentary ”error” displays appearing during the automatic

check serve to test the functional reliability of the system, and are
of no importance to you.
Initialisation of the monitor

(Z 60 358 principle diagram, Z 60 359 principle diagram)
The monitor is initialised by the CAN bus master on the CAN bus
after the system has been started. Depending on the
temperature of the computer (monitor), the display of the
previously set crane status with the ”Initiate CAN ...” screen
positioned above it appears after an appropriate warm−up time.
The (2a) symbol means that the computer is receiving data from
the CAN bus.
The “Initiate CAN ...” screen automatically closes after a

successful initialisation − The “Operating mode selection”
(Z 60 359 principle diagram) screen appears. The header (1)
colour changed from red to blue; the CAN status changed from
“STOP” to “OK”.
The CAN status can have the following conditions:

STOP crane operation not permissible
a subscriber is missing, but not relevant
OK crane operation permissible
If the initialisation does not follow, proceed as described starting

on page 19.
200−1−1100−286d_en
15/159
10
1
74.4 t 8,50 m 1
1 11.8 t
74.4 t
8,50
Z 60 359
Z 200 645
16/159 200−1−1100−286d_en
Safety Equipment 10
If the assembly or operating condition remains unchanged, the

screen can be exited via .
If the assembly or operating condition has been changed, then

the specifications in the screen must be adjusted accordingly. In
order to be able to transfer the modifications to the control
system, the screen must be exited in this case via .
In both cases, the ”Crane operation” screen then appears

(Z 200 645 principle diagram).
A detailed description on operating mode selection can be found
in section 10.1.7.4, from page 47, and in the “Crane operating
mask” in section 10.1.6, from page 31.
The starting point for employing the IC−1 functions are mainly the
“Crane operating mask, (Z 200 645 principle depiction)” − and in
that specifically the area “E”, the mask “Quick menu” (from
page 39) − and the mask “Main menu” (see section 10.1.5, from
page 27).
Using these screens the desired functions can be selected by

calling up the corresponding submenus (see section 10.1.7, from
43).
200−1−1100−286d_en
17/159
10
74.4 t 8,50 m 1
2a
3
Z 60 360 Z 60 361
1
74.4 t 8,50 m 1
Z 60 365
18/159 200−1−1100−286d_en
Safety Equipment 10
Initialisation does not follow − no connection to CAN bus

master
(Z 60 360 principle diagram, Z 60 361 principle diagram,

Z 60 365 principle diagram)
If the monitor is not initialised by the CAN bus master, the

progress display (3) runs to the end.
The CAN status is at “STOP”.
The (2a) symbol means that the computer is receiving data from
the CAN bus. It is thus lacking the Guarding signal from the bus
master (PLC A0621).
This state leads to fault message E 102 (Z 60 361 principle

diagram). There is no fault message on the screen.
The “Initiate CAN ...” screen does not close automatically. The
two keys and ”CAN reset” (Z 60 360 principle diagram)
become active and must be actuated manually:
1st option: actuate ”CAN reset”: the initialisation is restarted. If

that does not work:
2nd option: actuate: The (Z 60 365 principle diagram)

screen for selecting the operating mode appears with a red
header (1) and the CAN status is at “STOP”. No crane operation
is permitted. In this state, the (Z 60 365 principle diagram) screen
cannot be exited by pressing the key, it can only be exited
by pressing the key.
The present error must be found and corrected − e.g. with help
from the diagnostics screen after exiting the (Z 60 365 principle
diagram) screen by pressing . It is only then that the
initialisation can be restarted.
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10
1
74.4 t 8,50 m 1
2b
Z 60 362
Z 60 363
20/159 200−1−1100−286d_en
Safety Equipment 10
Initialisation does not follow − no CAN bus signal

If the monitor does not receive data from the CAN bus, the
“Initiate CAN ...” screen appears as seen in the picture (Z 60 362
principle diagram).
The CAN status is at “STOP”.
The (2b) symbol means that there is a disconnection.
This state leads to fault message E 101 (Z 60 363 principle

diagram).
Possible causes are:

− Complete bus failure
− Disconnection, physical error in CAN bus system.
As long as the crane can be driven with active jumper switches,

i.e. the CAN bus functions, the following errors could be present:
− Lloose CAN plug connection to the monitor
− Disconnection in the cable to the monitor
− Defective CAN card in the monitor
The “Initiate CAN ...” screen does not close automatically.

Proceed as described on the previous page.
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10
Z 200 101
22/159 200−1−1100−286d_en
Safety Equipment 10
Switching off (Power Control)

(Z 200 101)
When the electric power supply fails, or after switching off the
ignition, the display changes automatically to the ”Power control”
screen. The remaining time (starting at 15 min.) up to switching
off the computer is displayed here. If the ignition is switched on
again within this time, the display changes directly to the
”Operating mode selection” screen. IC−1 is immediately ready for
use again.
The ignition can be checked after three minutes. If the ignition is

switched on and then switched off directly after, it can take
approx. three minutes until the ”Power control” screen is
selected.
200−1−1100−286d_en
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10
E11
D18
Z 56 175
24/159 200−1−1100−286d_en
Safety Equipment 10
10.1.4 Menu Display

To operate the crane, the main menu and the crane operation
screen are primarily used.
Some submenus can only be selected at the main menu and
some can only be selected at the crane operation screen.
Some submenus can only be selected at the main menu and
some can only be selected at the crane operation screen.
The actual main menu is explained at 10.1.5.
The crane operation screen is described under 10.1.6.
The selectable submenus are described under 10.1.7.
(Z 56 175)
By pressing the ”E11” button in the crane operation screen, the

display switches to the main menu.
By pressing the ”202.1” button in the main menu, the display

switches to the crane operation screen.
To exit subdisplays or submenus that do not offer storage or exit

options (e.g. display of outrigger pressure) the ”D18” button is
used in the crane operation screen.
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10
201:
201.1 201.2
202:
202.1 202.2 202.3 202.4 202.5
203:
203.1 203.2 203.3 203.4 203.5
204:
204.1 204.2 204.3 204.4 204.5 204.6
Z 57 684
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Safety Equipment 10
10.1.5 Main menu

(Z 58 684)
The main menu is the central point of access for crane

application. From here you can call up the display screens listed
below. The relevant screen is called up by pressing the buttons.
The name, time and version number of the software are
displayed in the top section of the screen.
201 System settings (Systemeinstellung)
System screen (user settings) (see section

201.1
10.1.7.1 on page 43).
Switches background lighting off. The
201.2 background illumination is switched on by
pressing on the screen centre.
202 Crane operation (Kranbetrieb)
Crane operation screen (LLD) see section

202.1
10.1.6 from page 31;
Operating mode preselection screen (load
202.2
tables) (see section 10.1.7.4 on page 47)
Opens the dialogue ”fault message” (see
202.3
section 10.1.7.5 on page 55)
Opens the pop−up to select the control
202.4 level assignment, e.g. for hoist 2 (see
section 10.1.7.6 on page 57).
Operating hours display (see section
202.5
10.1.7.7 on page 59)
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10
201:
201.1 201.2
202:
202.1 202.2 202.3 202.4 202.5
203:
203.1 203.2 203.3 203.4 203.5
204:
204.1 204.2 204.3 204.4 204.5 204.6
Z 57 684
28/159 200−1−1100−286d_en
Safety Equipment 10
(Z 57 684)
203 Service
Parameter screen. Setting of the crane

203.1 functions, e.g. slewing gear (see section
10.1.7.8 on page 61)
Opens the dialogue for crane information
203.2
(see section 10.1.7.9 on page 65)
Activation and deactivation of the function
203.3 Emergency operation (optional) (see
section 36)
Operating range limits screen: Setting of a

203.4 set operating range (see section 10.1.7.11
on page 67).
Hoist data logger (optional): This is where
the stored hoist data can be read off using
203.5
the USB port. (see section 10.1.7.12 on
page 73)
204 Diagnosis
Diagnosis joystick (see section 10.1.7.13 on

204.1
page 77)
Diagnosis all control inputs / outputs (see
204.2
Diagnosis CAN bus (see section 10.1.7.15
204.3
on page 79)
Diagnosis load−sensing (see section
204.4
10.1.7.16 on page 87).
Data logger mask (optional): The written
204.5 crane data is displayed here (see section
10.1.7.17 on page 89)
Call up the screen “function diagnosis“ (see
204.6
Depending on the design of the display, the indicated functions

are assigned to the buttons. As soon as the desired crane
parameters have been selected, the display is exited after
confirming or saving. Functions which are not enabled although
available as an option are displayed in “grey”.
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10
B C
E
Z 56 174
1 2 3 4 5 6 7 8 9 10 11
A 12
B C
D E
Z 550 040
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Safety Equipment 10
10.1.6 Crane Operation Screen (Main Menu: 202.1)

(Z 56 174)
The crane operating mask is the display for normal work with
the crane.
The load limit device screen (crane operating screen) is divided

into five areas. The positions ”A” to ”D” are already specified.
Position ”E”, in contrast, can be assigned various free panels as
required.
All current and selected crane parameters are indicated in this

display. Further crane settings can be activated or other crane
information can be called up by calling up the quick menu.
(Z 550 040)
(A) − Current configuration information

1 Designation of the type of operating mode:
HA− main boom
HAV − main boom extension
MS− runner
2 Counterweight
3 Outrigger span / standing on wheels
4 Reeving number
5 Longitudinal code no. LC
6 Pinning state superstructure / chassis
7 CAN bus status
8 Permissible rotation range
9 Assignment of the pilot control sensor
10 Warning buzzer
After the warning buzzer sounds out, it can be
acknowledged by pressing the loudspeaker symbol, and is
switched off in doing so.
If new criteria is added which would cause the warning buzzer to

sound the warning buzzer goes off again.
11 Time display
12 Software version
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10
B C
E
Z 56 174
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
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Safety Equipment 10
(Z 56 174, Z 56 675)
(B) Display of the max. load, the current load and the current
radius. By pressing the net button, the current load is
tared.
For erecting in longitudinal code (LC 1), the rigging
symbol is displayed instead of a maximum load. Raising
of loads is not permissible (see section 10.1.9, page 103).
(C) − Continuously changing indication of the current crane

utilisation as a ’bar display’ with shown percentage
screen / overload screen.
For loading in longitudinal code (LC 1), the whole field
(C) is shown in red with stars instead of the bar display 3
stars are displayed in the red field. Raising of loads is not
permissible (see section 10.1.9, page 103).
Load Bar of the load utilization display
Normal range Load utilization display (C) is green
(below 90%)
Prewarning Load utilization display (C) becomes
range yellow
(90% − 100%)
Overload range Load utilization display (C) becomes red
(100%)
When the overload range has been reached the load limit device
switches off the load moment increasing movements and the
luffing gear is raised.
In addition to the displays of the load utilization display, further

acoustic and visual warning signals are emitted within and
outside of the crane operator’s cab. See segment 10.2 “Crane
control characteristics in relation to loading” (from page 115) in this
regard.
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10
B C
E
Z 56 174
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
34/159 200−1−1100−286d_en
Safety Equipment 10
(Z 56 174, Z 56 675)
(D) − Here the current status information is displayed for the

crane condition (Z 57 675):
1 When a fault occurs the fault button is displayed.
2 Lower limit switches 1 + 2 (red = not bypassed,

black = bypassed).
3 Function emergency operation (optional) is active (see

section 36).
4 Load moment limit (red = not bypassed,

black = bypassed).
5 Warning support pressure
6 Display of current wind speed
7 Counterweight fitting surveillance bridged
8 Display of warning (8.1) or stop signals (8.2)
9 Tilt display
200−1−1100−286d_en
35/159
10
B C
E
Z 56 174
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
36/159 200−1−1100−286d_en
Safety Equipment 10
(Z 56 174; Z 57 675)
10 Operating range limit active. Can be deactivated by
acknowledgement
11 Length main boom
12 Max. main boom length
13 Display − HATZ diesel engine in operation (only for option:
hydraulic luffing main boom extension)
14 High speed
15 Display for rigging mode. Raising of loads is not
permissible, see section 10.1.9 on page 103.
16 Display slewing angle. When ”Slewing angle” is switched
off the text is displayed in red.(positive counting direction in
clockwise direction when seen from above).
17 Display: if open brake circuit of the slewing gear brake is
switched (see section 8 “Slewing the superstructure”).
18 Button for calling up the quick menu.
19 Radius indicator
20 Display of the relevant longitudinal codes and radius step
for the load limit device
21 Display min. / max. radius
22 Angle main boom
23 Display min. / max. main boom angle.
24 Movement of tele is only possible with bridging of LLD.
25 Head height
26 Radio remote control active Screen will not receive any
operating actions.
27 Angle main boom head
28 Display − folding−out angle between the main boom
extension to the main boom (0° to 40°) (only for option:
hydraulic luffing main boom extension)
29 Display − angle of the main boom extension to the
horizontal (only for option: hydraulic luffing main boom
extension)
30 Hoist limit switch (red = not bypassed, black = bypassed)
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10
B C
E
Z 56 174
E11 E12
E21 E22 E23 E24
E31 E34
E32 E33
E52 E53
E51 E54
E61 E62 E63 E64

Z 56 176
38/159 200−1−1100−286d_en
Safety Equipment 10
(Z 56 174, Z 56 176)
(E) − Quick menu:

In addition to the display mask of the main menu, further
masks can be called up here:
Main menu, refer to section 10.1.5 on

E11
page 27.
System screen, see section 10.1.7.1 on
E12
page 43.
Operating mode preselection screen, see
E21
section 10.1.7.4 on page 47.
Parameter screen, see section 10.1.7.8 on
E22
page 61.
Pilot control assignment, see section
E23
10.1.7.6 on page 57.
Operating range limits, see section
E24
10.1.7.11 on page 67.
Diagnosis control lever, see section
E31
10.1.7.13 on page 77.
Diagnosis all control inputs / outputs, see
E32
Diagnosis CAN bus, see section 10.1.7.15
E33
on page 79.
Diagnosis load−sensing system, see
E34
Telescoping information system, see
E51
section 12 ” Telescoping”
”Support pressure / inclination indicator”,
E52
see section 10.1.7.21 on page 93.
200−1−1100−286d_en
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10
B C
E
Z 56 174
E11 E12
E21 E22 E23 E24
E31 E34
E32 E33
E52 E53
E51 E54
E61 E62 E63 E64

Z 56 176
40/159 200−1−1100−286d_en
Safety Equipment 10
(Z 56 174, Z 56 176)
Operation mode of the hydraulic pumps,

E53
see section 10.1.7.22 on page 95.
Movement assignment hydraulic pumps
E54 (together with ”E53”), see section 10.1.7.23
on page 97.
Display ”Active working area limitations“,
E61
see sect. 10.1.7.24 on page 97.
Switches to engine display, see section
E62
10.1.7.25 on page 97.
Display switches to mask: “Erect
E63 counterweight”, see section 9
“Counterweight”
Display switches to mask: “HAVHY” to
control of the hydraulic main boom
E64
extension, see corresponding section 18
“Main boom extension” (optional)
200−1−1100−286d_en
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10
Z 60 020
42/159 200−1−1100−286d_en
Safety Equipment 10
10.1.7 Submenus
Description of the main menu’s submenus and of the crane
operation screen.
10.1.7.1 System Screen (Main Menu: 201.1) (Quick Menu: E12)
The following settings can be selected / changed:
(Z 60 020)
Sprache / Selection of the language setting
Language:
Einheit / Unit: Selection of unit depiction.
You can choose between the metric and the
imperial system.
Datum / Date: Setting option for the date.
Zeit / Time: Setting possibility for time
Audio: not allocated
Kalibrierung / Crane application is ended by pressing the
Calibration: button. After this, different items have to be
pressed on the display as prompted. After
the calibration has ended, the crane
application is automatically started.
The settings ’Demag Pin” as well as ”Server” are only accessible

for internal employees or customer services.
The following settings can only be selected:

APP: Version number of crane software.
OS−IPC Version number of operating system.
CPU−FAN− Display of the current ventilating fan speed.
RPM: Not possible with all devices. If the fan does
not have a tachometer, squares are
displayed on screen.
CPU: Display of the current IPC CPU
temperature.
Software: A pop−up dialogue is opened by activating
the button. The version numbers of all
configuration or parameter files are listed.
Speichern / If changes have been made to language,
Save: unit, date, time or audio, they must be
confirmed by activating the button
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10
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Safety Equipment 10
10.1.7.2 Background Lighting (Main Menu: 201.2)
Switches background lighting off. The background

illumination is switched on by pressing on the screen centre.
10.1.7.3 Crane Operation Screen (Main Menu: 202.1)
see section 10.1.6 at page 31.
200−1−1100−286d_en
45/159
10
Z 56 187
Anwahl nicht korrekt!
Z 56 186
46/159 200−1−1100−286d_en
Safety Equipment 10
10.1.7.4 Operating Mode Selection Mask (Main Menu: 202.2;

Quick Menu E21)
The individual rigging mode parameters are displayed and

set in the operation type preselection screen.
In the operation type preselection screen, you can choose

between the lifting capacity table view, the parameter view and
the search lifting load view. When the operation type preselection
window is selected, the parameter view is displayed first.
(Z 56 187)
Parameter view
The individual rigging mode parameters are displayed and

set in the parameter view. A ”crane symbol” (2) is displayed
on the tab.
If changing a parameter results in another parameter being
changed as well, the second parameter is displayed in red.
Values in “red” must be confirmed by the operator. This
means that you must press the button again.
If a configuration state parameter cannot be set due to the current

crane state, it is subsequently depicted with a red background.
In this case, there are two possible depiction options, depending
on the state of the crane control software:
− The symbol of the configuration state parameter appears
with a red background (here: crane configuration).
− The configuration state parameter appears with a red

background (abbreviation of the crane configuration in this
case: HA).
Selection options that contain only one parameter cannot be

changed.
If a parameter is displayed in red, the screen cannot be left by
saving. The info screen shown in figure Z 56 186 is then
displayed. ”Incorrect selection!” (“Anwahl nicht korrekt!”).
The previously set configuration state is disregarded when you
leave using Exit. The screen automatically changes to the last
shown screen.
The operating mode selection screen is always called up when
the computer is started again. The crane operation screen is
started up when this screen is exited for the first time.
200−1−1100−286d_en
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10
Ungültiger LK / LK−Relevant!
Z 550 043 Z 52 988
48/159 200−1−1100−286d_en
Safety Equipment 10
Exiting / saving
Precondition for changing the operation type

∗ The current LLD relevant longitudinal code and the selected
longitudinal code must be available in the newly selected
operation mode.
The system first checks if the current extension sequence of the

tele cylinders (longitudinal code LC) exists for the selected
configuration state when exiting the screen using Save. If this
requirement has not been met, an information window appears
with the text: Invalid LC / LC−relevant! (’Ungültiger LK / LK−Rele-
vant!’ ) (Z 550 043).
The operation type preselection screen is not exited.
If the check results in authorisation, the set rigging mode is

transferred to the SPS. While data is being transmitted to the
SPS, the display shown in figure Z 52 988 appears.
200−1−1100−286d_en
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10
1 2 3
4
14
5
13
11
9 7 6
Z 56 177
Z 56 165 Z 56 166
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Safety Equipment 10
Load capacity chart view
(Z 56 177)
By pressing ”table” in the operating mode screen, the loads
of the set configuration state are indicated.
1 Longitudinal code LC
2 Main boom end length
3 Maximum carrying load determined by the reeving
4 Scroll bar
5 Load capacity
6 Table identification
7 Scroll bar
9 Information on special load capacities: An information

dialogue is opened by pressing this button. This button is
only visible if a special load capacity actually exists.
11 Unpinned loads
13 Minimum reeving
14 Radius
Searching possible rigging modes
(Z 56 165, Z 56 166)
The load and radius can be determined by pressing ”Search”
in the operating mode screen, and the system automatically
searches possible configuration states.
The data is entered using the buttons ”Load” and ”Radius”. An

entry window appears for entering the appropriate value.
The search is started using the Magnifying Glass button.
All found configuration states are entered in the bottom selection

element after the search.
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10
Z 58 686
52/159 200−1−1100−286d_en
Safety Equipment 10
LC list: Pinning condition of the main boom to the

longitudinal code (LC)
(Z 58 686)
LC By pressing ”LC” (LK) in the operation type screen, a pinning

condition assigned to a longitudinal code can be observe.
200−1−1100−286d_en
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10
Z 54 562
Z 54 563
54/159 200−1−1100−286d_en
Safety Equipment 10
10.1.7.5 Error Message (Main Menu: 202.3)
(Z 54 562 principle diagram, Z 54 563)
Press button / to call up the list of the existing PLC

(SPS) errors (Z 54 563).
In any case, all error messages are retained until they have been
viewed. This is especially useful for identifying errors which only
occur for a short time, and then disappear automatically.
The corresponding symbol can − with the exception of the ”Main

menu” screen − also appear in various other screens as soon as
an error occurs or is cancelled.
− the list of error messages is either empty or all error

messages have already been displayed once
− new (not yet displayed) errors have arisen, or existing

errors are cancelled − or both at the same time
Risk of accidents!
As soon as an error is displayed, shut off operations and
immediately have the error identified and eliminated!
Faults must be rectified by qualified specialist personnel
(customer services, for example).
If personnel who are not qualified try to rectify faults, it can
cause serious injury to people and / or damage to objects!
Providing the update key is white in the ”Error messages”

(Z 54 563) screen , the list shows the current status for the
error messages.
Currently red, must be updated by tapping the key. This
may be necessary again should the symbol stay red.
If − when the ”Error messages” screen is open − new errors occur,

or are cancelled, or both at the same time, the update key
is red. It must then be tapped, if necessary, repeatedly − until it
is white again.
Only after this is the list of displayed errors complete, and the
screen can be exited via .
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10
Z 60 141
1 2 3 4 5 6 7 8 9 10 11
A 12
B C
D E
Z 550 040
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Safety Equipment 10
10.1.7.6 Control Lever Function (Main Menu: 202.4; Quick

Menu: E23)
Depending on the crane equipment, different modes (IC−1)

can be selected. After the ”E23” button has been selected,
an image will appear in area ”E” of the crane operation
screen to show the current control lever function. By
selecting a new mode (e.g. mode 4), you can display the
corresponding control lever function. The newly selected
mode becomes active after you select the ”Save” symbol
(disk) to quit the display. The current control lever function is
shown in position ”9” in field ”A”.
(Z 60 141; Z 550 040)



V = vertical)
Risk of accidents!
If the configuration of the control levers is changed, it must
be checked, that the crane movements are carried out
properly with the new configuration!
It is the crane operator’s responsibility to check the current
control lever configuration before initiating a crane
movement!
200−1−1100−286d_en
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10
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
Z 60 142
Z 60 146
58/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 667)
The speeds of the crane movements ”Slewing gear“, ”Hoist 1“,

”Hoist 2” and ”Luffing gear down” can be finely tuned additionally.
The movements that are carried out via the x−axis (horizontal
movement of pilot control lever) of the individual pilot control lever
can be regulated via the corresponding self−return rocker switch
(14 / 26). The movements that are carried out via the y−axis
(vertical movement of the pilot lever) of the corresponding pilot
lever, can be regulated via the corresponding self−return rocker
switches (14 / 26) and simultaneously pressing the button (31 /
35) on the top end of the pilot lever in the direction of driving
always on the left).
Programming control lever
(Z 60 142)
If a dialogue ”pilot control assignment” is started from the main

menu, an additional button ”set−up” appears.
The set−up button provides the option of programming a left

control to be a right control. This option is protected by a special
PIN and can only be carried out with the help of our customer
services.
10.1.7.7 Operating Hour Counter (Main Menu: 202.5)
(Z 60 146)
The operating hours of the crane movements slewing gear,
hoists, luffing gear and tele unit are shown here. The display
of the operating hours is in ”Hours : minutes”.
The appropriate crane movement can be selected in the bottom

left corner of the display.
For the hoist unit (H1−L, H1−S) a difference is made between

load and rope load.
200−1−1100−286d_en
59/159
10
2 2
1 1
3 3
4 5 4 5
Z 550 046 Z 56 188
Z 60 028 Z 60 029
60/159 200−1−1100−286d_en
Safety Equipment 10
10.1.7.8 Parameter Mask (Main Menu: 203.1; Quick Menu: E22)
(Z 60 026)
The solenoid valve data for the individual crane functions is

set in the parameter menu. This enables driver−specific
settings to be saved and changed for the activation mode of
the hydraulic valves for the individual movements. When
changing to the mask, the data set ”slew gear left” of the
SPS is always displayed first.
Selection of a crane function
The pop−up dialogue is opened by pressing the ComboBox (1,

Z 550 046, Z 56 188).
A new function can be selected here. The SPS sends your data
to the display as soon as you have made your selection.
Entering a parameter
The entry dialogue (Z 60 028) is opened by activating a

parameter button (2, Z 550 046).
The valid entry area is indicated behind the OK symbol. If this

area is exceeded, the entry is indicated in red. The last symbol
entered can be deleted with the arrow. The entry is saved by
pressing the diskette and directly transmitted to the SPS. Entry
is cancelled via the Exit button.
Selection of a stored data record
Selecting a stored data set
The menu window (Z 60 029) is opened by clicking on the menu

button (3, Z 550 046).
1. Load setting 1
2. Load setting 2
3. Load setting 3
4. Load Demag factory setting
5. Load current setting of the SPS
6. Save settings
7. Exit parameter menu
200−1−1100−286d_en
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10
1 2
2
3 1
5
3
6
7 4 5
Z 60 029 Z 550 046
62/159 200−1−1100−286d_en
Safety Equipment 10
(Z 60 029)
This is where different settings can be loaded or saved. The

parameter menu is ended via the Exit symbol (7).
If a new setting is loaded from the computer it must be saved with

the disc symbol (6). That means that the setting will then be
transmitted to the SPS.
The default setting cannot be modified. For the functions ”tele in

and out” and ”slew gear brake” only the default setting can be
selected, i.e. the crane operator cannot make a personal setting.
Status display
(Z 60 029)
Data set that is currently saved in the SPS ( 1, 2, 3, D ). If the

data set of the SPS does not correspond with any data sets
stored on the computer, SPS appears in the symbol.
Otherwise, the number of the corresponding data set is
displayed.
Steering value of the control lever
Output current
Graphic display
(Z 550 046)
The graphics display can be changed by activating the button

(position 5). The options available are the time ramp and the
PWM ramp (PWM = pulse width modulation).
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2 1
2
1 3
5
3
6
4 5 7
Z 550 046 Z 60 029
AC200−1
33000 (75/75)
33000_1
Z 200 641
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Safety Equipment 10
Copying a data set
(Z 550 046, Z 60 029)
If for example the factory setting is to be assigned to setting 1, the

procedure is as follows:
The factory settings are loaded using the menu window

(identified by a ”D”)
and stored via the menu window with the ”diskette symbol”.
Afterwards load setting 1 from the menu window.
Then load the current SPS setting via the menu window into
the data set setting 1.
At 4 in figure Z 550 046 the icon for the data record ”setting 1” can
be seen.
Finally press ”Save” at the menu window to finish.
10.1.7.9 Crane Information (Main Menu: 203.2)
(Z 200 641)
Display of crane type, construction number, validity of the
software used, information on the load capacity table set and
a note on EN 13000 conformity.
Depending on the software used there is a note missing on the

validity of the used software and / or information on the load
capacity table set.
If the crane is equipped with control software in accordance with

EN 13000, “EN13000” can be found here.
10.1.7.10 Emergency Operation (Main Menu: 203.3)
See section 36.
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Z 60 147
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10.1.7.11 Setting the Operating Range Limit (Main Menu: 203.4;

Quick Menu: E24)
(Z 60 147)
The crane operator can define the following limits so that the
crane or boom do not enter existing danger zones, e.g. near
overhead power lines:
− Slewing angle limit

− Radius and height limit
− Operating range limit by virtual wall
The setting of operating range limits does not relieve the

crane operator of his responsibility for safe crane operation.
He must ensure that he fully understands and follows the
indicated instructions and applications.
Make sure you deactivate any activated limits as soon as

operation within a limited operating range is finished.
Otherwise this could lead to an unintentional and abrupt
shutdown during a later crane operation without limits,
which accordingly causes the hook block / load to swing out
widely.
Access to the screen for setting an operating range is

achieved using this button. The limits which are active are
displayed in “green”. The button Operating range limits must
be pressed again to deactivate the set operating range, the
button is then displayed in “grey”.
The position (1) indicates the current position of the main boom
head.
Activation of the slewing angle limit.
The background behind the buttons is “green” when the
slewing angle limit is active.
Setting and saving the left slewing angle
Setting and saving the right slewing angle
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Z 60 147
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Safety Equipment 10
(Z 60 147)
Follow the instructions for this in section 17 ”Slewing the

superstructure”.
Especially make sure that the selected limit angle
(= shutdown point) actually ensures sufficient distance to
the danger area in extreme situations (e.g. the hook block
swinging out after the crane motion has been switched off).
All crane movements must always be carried out with
adapted speed.
After setting the angle limits, carry out a test run to check
that the crane movements are shut down at the intended
points.
Activation of the max. radius limit.
Setting and saving the max. radius.
Activation of the min. radius limit.
Setting and saving the min. radius.

adapted speed.
Activation of the wall limit.
Setting and saving wall point ”A”.
Setting and saving wall point ”B”.
Switching over of the operating range to the wall.
When the inverted display is switched on the background is

displayed in ”green”.
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Z 60 147
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When setting and saving a wall a minimum distance of 8 m

(26.25 ft) between the wall points must be adhered to.
If the distance is too small, the wall area will be displayed in
”red”.
In particular, make sure that the selected limit (= shutoff

point) guarantees sufficient safety clearance from the
hazardous area in extreme situations (e.g. if the hook block
swings out when a crane movement is shut down)!
adapted speed.
Activation of the height limit.
Setting and saving the height.

adapted speed.
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1 2 3 4 5 6
Z 57 685
67 64.10
Z 56 192 Z 56 193
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Safety Equipment 10
10.1.7.12 Hoist Data Logger (Optional) (Main Menu: 203.5)
Press this button to open the mask “hoist data logger” for
reading off the stored hoist data using the USB port.
Hoist data logger mask
(Z 57 685)
1 Info line: shows the next step to be carried out
2 Status line: shows the current system status
3 Control field “Connect”: Starts initialisation of the USB stick
4 Control field “Copy”: Starts the transfer of data to the USB

stick
5 Fault display: is displayed when a system error occurs
6 Symbol for leaving the mask
Procedure
1. By touching the button “hoist data logger” (203.5) in the main

menu, switch to the hoist data logger mask;
2. Insert the USB stick in the USB port in the instrument panel
(optional) (67, Z 56 192) or on the bottom of the display
instrument for the crane control (DLOG) (64.10, Z 56 193)
and wait for 10 seconds;
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Z 57 686 Z 57 687
Z 57 688 Z 57 689
Z 57 690 Z 57 691
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3. Press the control panel “Connect” (3, Z 57 686);
While the USB stick is being initialised, a progress display

appears in the info and status lines (Z 57 687)
If the USB stick is not initialised correctly, the message: “Error:

USB stick could not be initialised” (Z 57 688) appears
Once the USB stick has been initialised, the status line displays:
“O.K.: USB stick initialised” (Z 57 689)
4. Press the control field “Copy” (4, Z 57 689)
While the data is being copied, a progress display appears in the

info and status lines.
If the data is not copied to the USB stick correctly, the status line
displays the message: “Error: error in data transfer (Z 57 690)”
Once the data has been transferred to the USB stick, the info line
displays the message: “You can now remove the USB stick” and
the status line displays: “O.K.: data transfer has been
successfully completed (Z 57 691)”
The USB stick can now be connected to a standard PC and the

data transferred.
For evaluation, a special program is required which creates an
EXCEL file from the data.
The data can then be evaluated as required.
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Z 60 030
1
2
Z 60 031
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Safety Equipment 10
10.1.7.13 Diagnosis Control Lever (Main Menu: 204.1; Quick

Menu: E31)
(Z 60 030)
After touching this button, the operation of the control lever
can be checked by moving the control lever.
10.1.7.14 Diagnosis Control In−/Outputs (Main Menu: 204.2;

Quick Menu: E32)
(Z 60 031)
The individual inputs and outputs of the control unit can be
checked in the IO menu. If the selected unit is a CPU unit,
software version (1) is displayed above the ComboBox (2).
The various units can be selected by pressing the
ComboBox (2).
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1 2 3 4
Z 56 156
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Safety Equipment 10
10.1.7.15 Diagnosis CAN−Bus (Main Menu: 204.3; Quick

Menu: E33)
The individual control system components exchange data via the

so−called CAN bus (CAN = Controller Area Network), similar to
a computer network.
(Z 56 156)
The status of each individual CAN participant can be
checked in the CAN diagnosis menu. The status of a
participant is OK if the bits B1 and B2 are at 1. This
information is important for our service department in case of
a fault.
In addition, the possibility exists of using the CAN logger to view

bus error lists (Emergency) or logs of guarding errors.
Configuration of the CAN participants is also possible in special
cases.
CAN−screen
1 Table of bus participants
2 Key data
3 Bus status
4 CAN logger button
”Bus participants” table
B1 B2 Description
0 0 Participant is not on the ”bus”
0 1 Pre−operational node:
Participant was set to Pre−operational by
the Master.
1 0 Stopped
Participant was set to stopped by the
Master.
1 1 Operational
Participant is on the bus and is behaving
correctly, meaning that it is participating in
guarding (normal operative state)
All bus participants are listed in the table. The state of the bus
participants is described by two status bits, the meaning of which
can be obtained from the following table. Under normal operating
conditions, B1 and B2 are set to 1.
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1 2 3 4
Z 56 156
3A
a:
b:
Z 56 157
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Basic data
(Z 56 156)
Three additional key data are displayed at the position (2,

Z 56 156) of the CAN screen (Z 56 156) which can also offer
indication of possible errors.
The three numerical values mean the following, in the sequence
shown:
− Overruns (OR): number of messages lost at the time of
reception (PDO)
− Java State (JS): shows in the form of numerical values the
status that the Java application has assumed. There are
three possible statuses: Pre−operational = 127,
Operational = 5, Stopped = 4.
− Task State (TS): shows which status the CAN Demon (CAN
Task) has assumed. Here, too, there are three possible
statuses: Pre−operational = 127, Operational = 5,
Stopped = 4.
Communications between CAN Task and application are
disrupted when there are different values in TS and JS. Display
in error−free normal operation: ”CAN−OR−JS−TS: 0−5−5”
Bus status
(Z 56 157)
The current bus status is displayed at the position (3, Z 56 156)

of the CAN screen (Z 56 156).
The green bar means that the DloG data is being received by the
CAN bus (Z 56 157, Figure ”a”).
If a red bar is visible that is interrupted by a lightning symbol, then
the computer is receiving no data from the bus (Z 56 157, Figure
”b”).
Communications between the application and the CAN Task can

be tested by pressing the monitor symbol (3A, Z 56 157).
If the connection is OK, then the monitor screen of the symbol
needs to be changing back and forth between blue and green.
CAN logger button
(Z 56 156)
At the position (4, Z 56 156) of the CAN screen (Z 56 156) there

is a button with which on can switch over to the CAN logger.
The call up needs to be enabled through the use of a PIN code.
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3
4
4
3
5
2
7
1
6
1
Z 56 158 Z 56 159
5
6
Z 56 160 Z 56 161
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Safety Equipment 10
Appearance of an error
(Z 56 158)
Two additional buttons are displayed in the event of a CAN error:
The monitor is completely restarted when the ”Reboot IPC”

button (6) is actuated.
The ”Reset CAN” button (5) causes a restart of the program parts
that are responsible for communications with the CAN card.
CAN−Logger
(Z 56 159, Z 56 160)
If the number of messages (MSG) at the position (1, Z 56 159) is

> 0, then the CAN lists can be transmitted from the PLC to the
DloG computer by pressing the ”PLC” button (SPS) (7, Z 56 159).
Depending on the quantity, the data transfer may take several
seconds.
The pop−up shown in the illustration (Z 56 160) will be displayed
during the transfer.
Status of the CAN bus participant
The numerals entered at the position (2, Z 56 161) describe the

status of the CAN bus participant.
0= Not present
1= Configured, but without message
4= Stopped
5= Operational
127 = Pre−Operational
Actuating ”Save” (5, Z 56 161) causes the data on the PLC to be

saved on the DloG computer.
Actuating ”Reset” (6, Z 56 161) causes the data on the PLC to be
deleted.
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4 4B
5
6
Z 56 161 Z 56 162
4B
Z 56 163
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One can switch to the error list display (Z 56 162) by actuating the
”Emergency” button (4, Z 56 161).
Error list display
If the number of messages (MSG) is > 0, then the CAN

emergencies can be transmitted from the PLC to the DloG
computer by pressing the ”PLC” button (SPS) (7, Z 56 162).
Illustration (Z 56 163) shows the error lists displaywith the errors
that were transmitted.
One can switch back to the CAN logger view (Z 56 161) by

actuating the ”State” button (4B, Z 56 163).
General fault messages independent of the screen currently

present.
If the master PLC (A0624) fails, then the E102 error message is
reported: ”Display gets no data from A0621.”
The DloG and its connection to the CAN bus are running in
orderly fashion in such cases.
If the computer is receiving no signals from the CAN bus, then

error E101 is reported: ”Monitor is receiving no CAN data”.
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1: 2:
3: 4:
5:
5
Z 200 637
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Safety Equipment 10
10.1.7.16 Diagnosis Load Sensing System

(Main Menu: 204.3; Quick Menu: E34)
(Z 200 637)
Actuating this key causes the ”LS” screen for diagnostics of
the electrical ”Load Sensing” system to be called up.
The operating mode of the pumps − “coupled” or “disconnected”

is displayed in this screen. At the same time the pump pressure
and the electric control of each pump can be read off.
Depending on the mode selection the screen display changes.

The left−hand mode key can be pressed. The
selected mode is displayed top left in the left−hand key area.
LS control is deactivated using key . The button is shown

in red . In addition, symbol is displayed on the screen.
To exit the screen press key .
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Z 60 148
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10.1.7.17 Datalogger (Optional) (Main Menu: 204.5)
(Z 60 148)
The Data logger saves every set configuration of the crane.
The current configuration state is displayed in grey fonts (1).
The date and time show when these configurations were set.
Anzahl / No: The number of data sets currently stored

Aktuell / Current: The currently visible data sets
LMB / 0= Enabled
LLD:
1= Not enabled
CAN: 0= CAN bus OK

1= CAN bus error
U−LMB 0= Bridging switch load limit device not

actuated
1= Bridging switch load limit device actuated
U−HES: 0= Bridging switch HES (hoist limit switch) not

actuated
1= Bridging switch HES (hoist limit switch)
actuated
U_AUF 0= Bridging switch UP (luff up) not actuated

1= Bridging switch UP (luff up) actuated
TELE_M: 0 = Tele automatic active

1= Tele manual active
LK / LC: Selected length code
LK−RV / The relevant length code for the load

LC−RV: calculation
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Z 60 148
Z 54 587
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EIN: Hoist rope reeving
AUSL: Current crane load
MAX: Maximum load
Last / Current load

load:
RAD: Current radius
RAD−RV Radius relevant to load calculation
HA−W: Current boom angle
HA−KW: Current main boom head angle
HA−L: Current main boom length
DREHW: Current superstructure slewing angle
10.1.7.18 “Function diagnosis” screen

(Z 54 587)
Press this button to call up the ”function diagnosis” screen.
Pressing to open a pull−down menu and make the required

selection.
For the selected function, the setpoint and actual values can be
compared to diagnose an existing malfunction.
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1
8.20 8.20
8.20 [m] 8.20
3
2
Z 200 431
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Safety Equipment 10
10.1.7.19 Select Main Menu (Quick Menu: E 11)
Change from quick menu to the main menu
10.1.7.20 Telescoping Information System (Quick Menu: E 51)
see section 18”Telescoping”
10.1.7.21 Support Pressure Display / Inclination Display / Outrigger

Support Area Display
(Optional) (Quick Menu: E 52)
(Z 200 431)
Display of the support pressures (1) as well as the inclination
(2).
The display bars are coloured red if the support pressures
are in the limit range.
Outrigger Support Area Display (Optional)
If thecrane is equipped with an outrigger support area display,

there is a length measuring device on each strut in order to
register the position of each strut (see section 12, part 2).
The value displayed under (3, Z 200 431) in the mask of the
support pressure gauge in the IC−1 indicates the pinning position
of each strut.
In figure (Z 200 431) the struts are supported in the 8.2 m
(26.9 ft) pinning position.
Risk of overturning!
The support position of each strut is ONLY displayed.
The value which corresponds to the value of the support
position is not passed on to the LLD (LMB).
There are NO instructions and NO shut−down if the
displayed outrigger support area does not correspond with
the outrigger support area set in the IC−1.
Risk of accidents!
Observe the instructions and warnings on tilting and
accident risks in connection with the outrigger support
area display, which can be found in section 12 of the
chassis operating instructions.
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E53
E54
5
Z 200 638
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Safety Equipment 10
10.1.7.22 Operation Mode of the Hydraulic Pumps (Quick

Menu: E 53)
(Z 200 638)
Connects the pumps (P1) and (P2) together for the
movements luffing, telescoping, hoist 1 and hoist 2 or
disconnects them.
(Hydraulic decoupling of movements can improve the
sensitivity of the driven “disconnected” movements.)
In the upper left−hand corner of the ”E53” button, you can
see the number of the current operating mode.
Procedure on changing the operating mode:

You can select the operating mode by pressing ”E53” until you
find the mode (BA) you want. On ”E53” and ”E54” you can see
the movements and the pumps that have been assigned to them.
Oper Driven Fed Description
ating movement through
mode pump
1 Luffing The maximum movement speeds can be achieved in
Telescoping (P1) and this operating mode.
(P2)
Hoist (2) together
Hoist (1)
2 Luffing No effect on crane movements luffing and telescoping
(P1) by the crane movements of hoist 1 and hoist 2.
Telescoping
Reduced end speed.
Hoist (2)
(P2)
Hoist (1)
3 Luffing No effect of the crane movements luffing, telescoping
Telescoping and hoist 2 by the crane movement of hoist 1.
(P1)
Reduced end speed.
Hoist (2) (Can only be selected with a control lever assignment of
Hoist (1) (P2) which hoist 2 is a participant.)
4 Luffing (P1) Operating mode can be advantageous if the crane
movements luffing and hoist 1 are to be driven very
sensitively.
Hoist (1) (P2) Movements controlled by pumps; no LS control.
Reduced Final Speed.
5 Luffing Setting with high load pressures.
Telescoping (P1) and Engine is not put under a lot of strain and cannot be
(P2) stalled.
Hoist (2) together Reduced end speed.
Hoist (1)
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E53
E54
5
Z 200 638
E61.1 1
Z 56 189 Z 200 103
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Safety Equipment 10
10.1.7.23 Assignment of Movements of Hydraulic Pumps (Quick

Menu: E 54)
(Z 200 638)
Displays the movements assigned to the hydraulic pumps
together with 10.1.7.22.
10.1.7.24 “Active Working Area Limitations” (Quick Menu: E 61)
Here the active working area limitations are displayed.
(Z 56 189)
The active limits are displayed in the top status bar (E61.1). The
valid operating range is always displayed in green.
10.1.7.25 Engine Display (Quick Menu: E 62)
(Z 200 103).
Switches to the engine display
1. Button for automotive driving. The button is green when

automotive driving is active.
2. Slide control switch for manual minimum speed.

Min. value is 800, max. value is 2100. The current value is
displayed in the centre.
3. Slide control switch for various kinds of engine information.
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Z 56 181
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Safety Equipment 10
10.1.8 Setting the Operating Mode

(Z 56 181)
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 according to the new operating
mode after the crane configuration has been changed.
The load limit device can only function automatically if it has

been set correctly by the crane operator in accordance with
the individual operating mode / crane configuration.
Risk of overturning! RISK OF BREAKAGE!

The lifting capacities outlined in the lifting capacity tables
represent 100% of the permitted maximum load for each
crane configuration. If these limit values are exceeded,
there is a risk of the crane overturning and/or crane
components and auxiliary equipment breaking.
The operating mode selection screen can be selected in the main

menu and on the quick menu of the crane operating screen.
For more information on the operation type screen see the
sub−item 10.1.7.4 on page 47 of this section.
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B
C E
D
F G
K
L
M
Z 56 182
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Safety Equipment 10
1. Select load capacity table (paper) which corresponds with

the current crane configuration.
The following example shows where you can find these
values in the load capacity table.
The following load table is only a sample.

Only the load capacity tables supplied with the crane are
valid for crane operation.
(Z 56 182)
(A) − Main boom operation (all telescopes pinned)
(B) − Permissible rotation range
(C) − Outrigger support area
(D) − Counterweight
(E) − Main boom length
(F) − Radius
(G) − Load capacity (load + hook block)
(K) − Reeving number of the hoist rope
(L) − Longitudinal code no. of extension sequence (LC)
(M) − Extension sequence of telescopes:

Tele 1 −
Tele 2 −
Tele 3 −
Tele 4 −
Tele 5 −
Tele 6 −
(N) − ID No. of the lifting capacity table, page no. within the
lifting capacity table
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Z 200 642
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Safety Equipment 10
10.1.9 Loading Operation

(Z 200 642)
When configuring, the highlighted ”Configuration” symbols in the

opposite figure appear.
In addition, the load utilization display of the load limit device is

shown in red (with 3 stars).
In configuration operation no lifting capacities are enabled!

The raising of loads is not permitted!
The crane may only be configured in an erected state
(outriggers, counterweight etc.) for which there are load
capacity tables!
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B C
E
Z 56 176
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Safety Equipment 10
10.1.10 Load Monitoring Assembly

(Z 56 176)
With the help of the computer of the load limit device, it is possible
to monitor the weight of the raised load (net load).
The load monitoring assembly may not be used to calculate

the weight but is used to check the previously calculated
weights of loads to enable the load hoist to be calculated
better and to avoid possible hazardous situations.
Before raising the load the maximum load for the operating
condition must be determined. It is shown on the display at ”B” for
”MAX (t)” (”MAX (kip)”) depending on the selected operating
mode.
Load monitoring
1. Press the button of the net display (B) when the hook block
is hanging free (no load, with load handling device). 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 now shows the net load (actual load on the
hook without load−handling device).
The gross load contains – apart from the load weight – the weight
of the main boom extension in transport position, the weight of
the hook block, the hoist rope and all load handling devices. The
net load is the actual load on the hook block without the
load−handling device. Display errors are possible due to external
factors, such as wind acting on the crane and the load.
The load may only be raised with the hoist. It is forbidden to

raise the load by extending the telescopes or luffing
cylinders.
One exception is lifting with the load lifting beam on the main
boom or on the boom point.
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111
112
113
114
115
116
Z 56 184
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Safety Equipment 10
10.1.11 Bridging Load Limit Device

(Z 56 184)
10.1.11.1 Bridging Shutdown of Movement Which Decreases

the Load Moment ”Raise Luffing Gear”
Bridging can only be initiated if the control levers are in the

neutral position and/or the initiated crane movement is
finished.
Release of this load moment reducing movement can only

occur if it does not create a dangerous situation.

the hoist has been shut down, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!
”Raise luffing gear” must never be used to raise the load!
If a prohibited overload condition has occurred, the

load−moment−reducing movement ”Raise luffing gear” is also
shut down by the load limit device.
After the overload state has been switched off by a load limit
device, the load moment reducing movement can be driven in
order to take a hanging load from the overload range into the
normal working range. The release to “raise luffing gear” is
carried out via the key button (116).
The button must be turned in the clockwise direction and held in
this position.
It is prohibited to lock the key−operated pushbutton

mechanically.
The indicator light (115) lights up in the bridged state.
Risk of overturning
If an attempt is made to set the main boom so steep that the
minimum radius of the corresponding table is not reached,
this movement is also prevented. The system switches the
movement off.
If, in this situation, the movement is released by bridging,
there is the risk of overturning backwards.
200−1−1100−286d_en
107/159
10
111
112
113
114
115
116
Z 56 184
8.1 8.2
4 8
A
B C
D
E
Z 200 644
108/159 200−1−1100−286d_en
Safety Equipment 10
10.1.11.2 Set−up Button

(only EN 13000 design)
(Z 56 184, Z 200 644)
The set−up button is only in the “EN 13000” design.
This key−operated pushbutton is used to bridge the shut−down

of all movements in the “non−EN 13000”−design.
In this case, see segment 10.1.11.3.1 (page 111).
You can check whether the crane is equipped with control

software in accordance with EN 13000 in the “Info” screen (for
“Info” screen, see segment 10.1.7.9, page 65).
Description
The setup button (112) is used to permit a slightly higher load
value (110 %) for a short period of time under special operating
conditions.
Activating the set−up button does not permit any movements
which cause component failure or stability loss.
The ”Caution” symbol (8.1) appears in the crane operating
screen.
Risk of accidents!
The set−up button may not be used to increase the
shutdown load.
Risk of accidents!
Bridging can only be initiated if the control levers are in
the neutral position and/or the initiated crane movement
is finished.
Speed of movement
When the setup button (112) is activated, the movement speed
which can be carried out is greatly reduced.
200−1−1100−286d_en
109/159
10
111
112
113
114
115
116
Z 56 184
8.1 8.2
4 8
A
B C
D
E
Z 200 644
110/159 200−1−1100−286d_en
Safety Equipment 10
Deactivation
(Z 56 184)
Crane control is switched back to standard operation by pressing
the Set−up button (112) again or by stopping the engine.
It is possible to initiate a further movement within 10 seconds
after the control levers have been placed in the neutral position.
If this time is past, the setup button (112) must be pressed again
to drive further crane movements.
10.1.11.3 Bridging the Shutdown of all Movements
10.1.11.3.1 General Instructions

(Z 200 644)
The load limit device can be bridged using a key−operated

pushbutton.

mechanically!
The load limit device may only be bridged in exceptional

cases, for example in case of repairs, fitting a rope etc.!
This may only be carried out by authorised persons who
are fully familiar with the correct operation of the crane.
The bridging of the load limit device may not be used to
increase the load moment under any circumstances!
Raising the load with the load limit device bridged is
hazardous and is prohibited.
Risk of accidents!
Bridging can only be initiated if the control levers are in
the neutral position and/or the initiated crane movement
is finished.
The ”LLD” screen (4) changes from red to black in the IC−1
display and the “Stop” symbol (8.2) appears.
200−1−1100−286d_en
111/159
10
111
112 39
38
Z 200 643
112/159 200−1−1100−286d_en
Safety Equipment 10
10.1.11.3.2 Control Elements (Shut−down of all Movements):

“EN 13000” Compared to
“Non−EN 13000”−Design
(Z 200 643)
The following table describes the different control elements for

bridging the load limit device depending on the design:
“EN 13000”−design “Non−EN 13000”−design
Control element Key−operated pushbutton Key−operated pushbutton
(39) on the outside of the rear (112) in the instrument
cab wall panel
(when key−operated
pushbutton (112) is
activated, indicator light
(111) is illuminated)
How is it activated? Turn key clockwise and Turn key clockwise and
release hold in this position
Activation time Deactivation as long as the key is held
period − press key switch (39) again in the activated position
− after 30 min
− with engine stop
In the “Non−EN 13000−design” there is a key−operated

pushbutton (39), but it is not activated.

200−1−1100−286d_en
113/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
114/159 200−1−1100−286d_en
Safety Equipment 10
10.2 Behaviour of Crane Control Depending on Load
10.2.1 General Instructions

(Z 200 644, Z 200 643)
Risk of accidents!
The behaviour of crane control in relation to load is
described in this segment.
It does not deal with the associated risks.
To ensure safe crane operation, the corresponding
warnings, notes and procedures found in some segments
of this section must be observed.
Depending on the crane’s load utilisation, crane control shows

the following displays and takes the following measures:
− Displays on the operating unit of crane control (see in 10.1.6
on page 33) change: for example
− Load utilisation display (C)
− Display “Caution” (8.1) or “Stop” (8.2) in the crane display
− Display lettering “LLD” (4)
− Acoustic and visual warning signals are given within and
outside of the crane operator’s cab:
− Warning light (38): for people within the crane’s danger
zone
− Warning buzzer in the crane operator’s cab: for the crane
operator
− Warning siren: for people within the crane’s danger zone
− Crane movements are stopped or limited.
− Overload data is saved.
Differentiation in two designs

You must differentiate between the “EN 13000”−design and the
“Non−EN 13000”−design.

200−1−1100−286d_en
115/159
10
111
112 39
38
Z 200 643
116/159 200−1−1100−286d_en
Safety Equipment 10
10.2.2 EN 13000−Design
(Z 200 643)
You must differentiate between the following operating

conditions:
− Configuration operation (10.2.2.1; page 119)
− Standard crane operation (10.2.2.2; page 121)
− Operation with activated Setup button (112) (10.2.2.3; page
123)
− Operation with bridged crane control (key (39) activated)
(10.2.2.4; page 127)
200−1−1100−286d_en
117/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 642 Z 200 643
118/159 200−1−1100−286d_en
Safety Equipment 10
10.2.2.1 Configuration Operation (EN 13000)

(Z 200 644, Z 200 642, Z 200 643)
Risk of accidents!
To ensure safe crane operation, observe the warnings,
instructions and information concerning configuration
operation in segment 10.1.9 (page 103).
If the crane is in configuration operation, crane control shows the

following displays and takes the following measures depending
on the crane’s load utilisation:
Load Signals for the crane operator Signals for Speed of
(in the crane operator’s cab) people in the moveme
crane’s danger nt
zone
Crane operating screen Warning Warning Warning
(Z 200 644, Z 200 642) buzzer light siren
(38;Z 20
0 643)
− Warning symbol at item (8)
− Maximum load displays
Normal range Load utilisation display (C) red
with configuration symbol (***);
Maximum load display and crane illuminat unlimited
status figure with configuration ed in
symbols green
Overload range
Warning symbol at item (8)
+
Load utilisation display (C) red interrupt
continuo
with configuration symbol (***); illuminat ed
us stopped
Maximum load display and crane sound ed in red warning
status figure with configuration sound
symbols
− After the crane movements have been stopped,
load−moment−reducing crane movements can be carried out again.
In an emergency, it is possible to change to “Operation with bridged
setup button” (see 10.2.2.3) or “Operation with bridged crane
control” (see 10.2.2.4).
− The overload data is recorded.
200−1−1100−286d_en
119/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
120/159 200−1−1100−286d_en
Safety Equipment 10
10.2.2.2 Standard Crane Operation (EN 13000)

(Z 200 644, Z 200 643)
Depending on the load utilisation of the crane, crane control

shows the following displays and takes the following measures:
crane’s danger nt
zone
(38;Z 20
0 643)
Normal range
(below 90%)
Load utilisation display (C) green illuminat unlimited
ed in
green
Prewarning
range Warning symbol at item (8)
(90% − 100%) interrupt
+ illuminat
ed
warning ed in unlimited
Load utilisation display (C) yellow sound yellow
Overload range
(from 100%)
interrupt
+ continuo
illuminat ed
us stopped
ed in red warning
Overload display (C) red sound
sound
In an emergency, it is possible to change to “Operation with
activated setup button” (see 10.2.2.3).
− The overload data is recorded.
All acoustic warnings listed here can be stopped / switched off in the crane operator’s cab
after 5 seconds (see ”Warning buzzer” in the crane operator’s mask).
200−1−1100−286d_en
121/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
122/159 200−1−1100−286d_en
Safety Equipment 10
10.2.2.3 Operation with Activated Set−up Button (EN 13000)

(Z 200 644, Z 200 643)
Risk of accidents!
Observe all warnings, instructions and information on the
setup button in segment 10.1.11.2 (page 109) to ensure safe
crane operation.

crane’s danger nt
zone
(38;Z 20
0 643)
Normal range Warning symbol at item (8)
(below 90%) (flashing)
+ continuo illuminat
reduced
us ed in
Load utilisation display (C) green sound to 15%
green
Prewarning Warning symbol at item (8)
range (flashing)
(90% − 100%) + continuo illuminat
reduced
us ed in
Load utilisation display (C) yellow sound to 15%
yellow
Overload range Warning symbol at item (8)
(100% − 110%) (flashing)
+ continuo
flashes reduced
us
Overload display (C) red in yellow to 15%
sound
Table continued on the next page
200−1−1100−286d_en
123/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
124/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 644, Z 200 643)

crane’s danger nt
zone
(38;Z 20
0 643)
Overload range Warning symbol at item (8)
(from 110%) (flashing)
interrupt
+ continuo
illuminat ed
us stopped
ed in red warning
Overload display (C) red sound
sound
It is possible to switch to “Operation with bridged crane control” (see
10.2.2.4) during emergencies.
Caution!
All data is recorded during crane operation with activated setup button (112).
200−1−1100−286d_en
125/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
126/159 200−1−1100−286d_en
Safety Equipment 10

(Bridging all Movements) (EN 13000)
(Z 200 644, Z 200 643)
Risk of accidents!
instructions and information concerning bridged crane
control found in segment 10.1.11.3 (page 111).
When crane control is bridged, crane control shows the following

displays and takes the following measures:
crane’s danger nt
zone
(38;Z 20
0 643)
over all load Warning symbol at item (8)
utilisation (flashing)
ranges
+ continuo continuo
flashing reduced
us us
Overload display (C) red in red to 15%
sound sound
− All crane movements are carried out without crane control
monitoring whether the executed movements can cause risks.
The acoustic warnings cannot be switched off.
Caution!
All data is recorded during crane operation with bridged crane control.
200−1−1100−286d_en
127/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 642 Z 200 643
128/159 200−1−1100−286d_en
Safety Equipment 10
10.2.3 Non−EN 13000−Design
10.2.3.1 Configuration Operation (Non−EN 13000)

(Z 200 644, Z 200 642, Z 200 643)
Risk of accidents!
instructions and information concerning configuration
operation in segment 10.1.9 (page 103).
If the crane is in configuration operation, crane control shows the

following displays and takes the following measures depending
on the crane’s load utilisation:
crane’s danger nt
zone
(38;Z 20
0 643)
− Maximum load displays
Normal range Load utilisation display (C) red
with configuration symbol (***);
Maximum load display and crane illuminat unlimited
status figure with configuration ed in
symbols green
Overload range
+
Load utilisation display (C) red
continuo continuo
with configuration symbol (***); illuminat
us us stopped
Maximum load display and crane sound ed in red sound
status figure with configuration
symbols
− The overload data is recorded with the overload recorder (optional)
activated.
200−1−1100−286d_en
129/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
130/159 200−1−1100−286d_en
Safety Equipment 10
10.2.3.2 Standard Crane Operation (Non−EN 13000)

(Z 200 644, Z 200 643)

crane’s danger nt
zone
(38;Z 20
0 643)
Normal range
(below 90%)
Load utilisation display (C) green illuminat unlimited
ed in
green
Prewarning
range Warning symbol at item (8)
(90% − 100%) interrupt interrupt
+ illuminat
ed ed
warning ed in warning unlimited
Load utilisation display (C) yellow sound yellow
sound
Overload range
(from 100%)
+ continuo continuo
illuminat
us us stopped
Overload display (C) red ed in red
sound sound
− The overload data is recorded with the overload recorder (optional)
activated.
200−1−1100−286d_en
131/159
10
8.1 8.2
4 8
A
B C
D
E
Z 200 644
111
112 39
38
Z 200 643
132/159 200−1−1100−286d_en
Safety Equipment 10

(Bridging All Movements)
(Non−EN 13000)
(Z 200 644, Z 200 643)
Risk of accidents!
instructions and information concerning bridged crane
control found in segment 10.1.11.3 (page 111).
When crane control is bridged, crane control shows the following

displays and takes the following measures:
crane’s danger nt
zone
(38;Z 20
0 643)
over all load Warning symbol at item (8)
utilisation (flashing)
ranges
+ continuo illuminat continuo
us ed in red us unlimited
Overload display (C) red sound (*) sound
− All crane movements are carried out without crane control
monitoring whether the executed movements can cause risks.
(*) = Depending on specific national regulations, the red light of warning
light (38; Z 200 643) can flash in this state as well.
The overload data is recorded with the overload recorder (optional) activated.
200−1−1100−286d_en
133/159
10
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
134/159 200−1−1100−286d_en
Safety Equipment 10
10.3 Dead man’s handle
(Z 200 667)
10.3.1 General
In order to prevent activating crane movements accidentally,
so−called dead man’s switches are used. A crane movement can
only be driven if one of these dead man’s switches are activated.
10.3.2 Arrangement of the Dead Man’s Switches

There are dead man’s switches at the following points:
− In both control levers: (36) and (32)
− Seat contact switch in the crane operator’s seat (optional)
10.3.3 Activating the Dead Man’s Switch

operator’s seat − for the optional seat contact switch) if the control
movement has been completed. The dead man’s switches can
be activated alternately during a crane movement.
Risk of accidents!
Only release the dead man’s switches or only get up from
contact switch) when the working movement has been
completed.
200−1−1100−286d_en
135/159
10
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
A
B
C
D
Z 200 035
136/159 200−1−1100−286d_en
Safety Equipment 10
10.4 Speed
10.4.1 Fine tuning of the movement speed

(Z 200 677, Z 200 035)
In order to make it possible to control crane movements more

sensitively, some of the maximum movement speeds can be set
with the control lever fully steered (within the technical limits).
The speeds of the following movements can be set:
Rotating the superstructure
Reeling in and unreeling hoist 1
Luffing down the main boom
Reeling in and unreeling hoist 2 (optional)
Procedure
This fine tuning is undertaken at control lever (24) / (16) where the
crane movement is located.
1. Press self−return rocker switch (26 / 14) briefly.

The ”Percentage setting” screen appears on the right−hand
side of the IC−1 display (Z 200 035).
As long as this screen is displayed, the indicated percentage and

thereby the speed can be modified.
If there is no adjustment of the percentages, the screen
disappears again after 5 seconds.
200−1−1100−286d_en
137/159
10
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
A
B
C
D
Z 200 035
138/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 677, Z 200 035)
2. Depending on the direction of the movement (h: horizontal;

v: vertical) in which a crane movement is moving, the
following must be done at the corresponding control lever to
finely tune the movement speed:
Movement at: Press self−return Press button (35) /
rocker switch (26) / (31)
(14)
horizontal “h”; do not push
(to the right, left)
− left: decreased;
vertical “v”; − right: increased; simultaneously with
(forward, back) self−return rocker
switch (26) / (14).
The set percentage value for the movement is displayed in the

corresponding bar diagram.
Risk of accidents!
There is a risk of accidents if crane movements are carried
out inappropriately quickly.
Observe an appropriate speed of movement.
200−1−1100−286d_en
139/159
10
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
140/159 200−1−1100−286d_en
Safety Equipment 10
10.4.2 High speed

(Z 200 677)
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 (24) /
(16). In addition, individual crane movements can be carried out
in the high−speed mode.
There is a high−speed mode for the following crane

movements:
− Luffing gear up
− Hoist 1 up / down
− Hoist 2 up / down
All crane movements listed are activated simultaneously in the

high−speed mode.
If several crane movements are carried out simultaneously in the
high−speed mode, the speed of execution is reduced.
The high−speed mode cannot be activated for the movements

“Luffing gear down”, “Slewing the superstructure” and
“Telescoping the main boom”.
Risk of accidents!
It is only permitted to carry out the crane movements in the
high−speed mode in relation to the load utilization
situation.
Observe the relevant instructions in the section in which
the crane movements are described.
Carrying out crane movements with the high−speed mode
The high−speed mode is activated by simultaneously activating

button (30) and steering the control lever (24) / (16) where the
movement is located.
200−1−1100−286d_en
141/159
10
Z 200 678
142/159 200−1−1100−286d_en
Safety Equipment 10
(Z 200 678)
The activated high speed mode is indicated in the IC−1 display

with the shown symbol.
Switching to high−speed mode is not permitted in the

following cases:
− when working with loads > 30% of the load capacity
− with fitted fly jib
− for raising and lowering the fully or partially extended
main boom
200−1−1100−286d_en
143/159
10
111
112
113
114
115
116
Z 56 184
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
144/159 200−1−1100−286d_en
Safety Equipment 10
10.5 Limit Switches
10.5.1 Hoist Limit Switch
10.5.1.1 Function
(Z 56 184, Z 57 675)
Hoist limit switches are safety devices that limit the upwards
movement of hoist ropes and hook blocks.
This avoids collisions between the hook block and boom head
and therefore possible damage to these parts and/or the hoist
rope, which could cause the load to fall.
For this reason, the crane may only be operated with fully
functional hoist limit switches that have not been triggered.
Risk of accidents!
Approach the hoist limit switch daily and check that it
functions properly.
If a hoist limit switch is triggered (and not overridden), HES (30)

(red) appears on the IC−1 display and the warning buzzer
sounds. The following crane movements are shut down:
− Raise hoists
− Extend telescopic sections
− Lower luffing gear and raise luffing gear.
Then either lower the hoist or telescope it in in order to end this

prohibited condition.
200−1−1100−286d_en
145/159
10
111
112
113
114
115
116
Z 56 184
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
146/159 200−1−1100−286d_en
Safety Equipment 10
10.5.2 Bridging the Hoist Limit Switch

(Z 56 184, Z 57 675)
Bridging can only be initiated if the control levers are in the

neutral position and/or the initiated crane movement is
finished.
The limit switches may only be bridged in exceptional cases,

e.g. when configuring the crane (fitting or changing the
equipment parts, fitting ropes etc.).
Operation of the crane with bridged limit switches is

prohibited. RISK OF ACCIDENTS!
Key−operated pushbutton (114) is used to bridge the hoist limit

switches ”raise hoists”.
The key must be turned in the clockwise direction and held in this
position.

mechanically.
On the IC−1 display HES (30) appears (black). This means that
the hoist limit switches are overridden, regardless of whether
they are triggered or not.
200−1−1100−286d_en
147/159
10
1 2 3 4 5 6 7 8
8.1
8.2
30
29 9
28
10
27
11
26
12
25 13
24 14
15
23
16
22
17
21 20 19 18
Z 57 675
148/159 200−1−1100−286d_en
Safety Equipment 10
10.5.3 Lower Limit Switch
10.5.3.1 Function
(Z 57 675)
Lower limit switches are safety devices which shut down the
unreeling function of the hoist rope when it is down to 3 remaining
turns on the drum. This prevents the rope being wound back on
in the opposite direction.
If a lower limit switch has been triggered (and not overridden), the
IC−1 Display shows SES (2) (red) and the warning buzzer
sounds. ”Lower hoist” is switched off. Only ”raise hoist” is
possible.
10.5.3.2 Bridging Lower Limit Switches
A lower limit switch must be overridden directly at the

corresponding proximity switch.
The lower limit switches may only be overridden in

exceptional cases (e.g. to change or fit ropes).
Operation of the crane with bridged limit switches is

prohibited. RISK OF ACCIDENTS!
200−1−1100−286d_en
149/159
10
61 62
”X...”
F ”X0550”
B1 A H B2
63
Z 200 441 Z 200 442
61 L: R:
63.1 63.1
”B”
”B”
”A”
61.1
63.2
3
1
Z 104 266 Z 104 166
150/159 200−1−1100−286d_en
Safety Equipment 10
10.6 Electric Safety Chain

(Z 200 441 principle illustrations, Z 200 442, Z 104 266,
Z 104 166)
On distribution box ”X0550” on the main boom head the electric

safety chain for operation of the crane is connected.
For main boom operation the sockets on the distribution box

”X0550” must be assigned on the main boom head as follows:
Socket (A, Z 200 441)
− either with the plug of the wind speed rotor (62)

− or with bridging plug (B1).
Socket (A) must in any case be fitted with one of the named
plugs.
Socket (F, Z 200 441)
− with the plug of the hazard light (61)
As shown in figure (Z 200 442), the hazard light (61) is fastened

to the main boom head using two wing nuts.
During crane operation, the hazard light (61) must be in the
swinging position (Z 200 442).
In the transport condition (Z 104 266), the hazard light (61) must
be secured against swinging using locking pin (61.1) for driving
the crane.
− or protection cap (as shown).
Socket (H, Z 200 441)
− with the plug of the connecting cable of the hoist limit switch
(63) on the right−hand side of the main boom head.
The hoist limit switch (63) is connected on the right−hand side
of the main boom head at the end of the connecting cable.
The hoist limit switch may not be blocked (bridged).

Figure (Z 104 166 figure ”R”) shows the hoist limit switch in the
functional state. The hoist limit switch shift weight must be fitted
over the slowest piece of rope (see section 17).
To prevent exceeding the permitted vehicle dimensions (vehicle

height, etc.), the hazard light (61) and the anemometer rotor (62)
must be removed for driving the crane on public roads.
200−1−1100−286d_en
151/159
10
A
B C
D
E
Z 56 185
67
Z 55 566 Z 56 192
64.11
64.12
64.13
64.14
64.10 64.15
64.16
Z 56 193 Z 200 388
152/159 200−1−1100−286d_en
Safety Equipment 10
10.7 Malfunction Procedure
10.7.1 Malfunction−free Operation

(Z 56 185)
When crane operation is free of malfunctions, the ”Menus” and
”Screens” currently configured are shown on the crane controls
display (DLOG). Crane movements can be executed with the aid
of the control lever.
In the crane operating mask (Z 56 185), the individual areas ’A’
to ’E’ are arranged on the crane control display (DLOG). For
fault−free operation the spaces between the individual fields are
separated with a grey background colour.
(Z 55 566)
In the main menu and in other submenus, the top line is displayed
in blue for malfunction−free operation.
10.7.2 Failure of the ”Touchscreen”

of the Crane Controls Display
(Z 56 192, Z 56 193, Z 200 388)
If no more entries can be made on the crane controls display
(DLOG), even though no other malfunctions are present, then the
functioning of the load limit device is ensured. The view on the
screen looks the same as the one described under
’Malfunction−free operation’ at 10.7.1.
One possible cause for the failure of the touchscreen could be the
operation of the crane controls display when ambient
temperatures are too high. The crane cab will then need to be
cooled down with the air conditioner. Direct sunlight on the crane
controls display must be avoided.
In order to be able to continue with operation of the crane, the

optional operating keys on the right−hand side of the DLOG can
be used.
If there are no operating keys on the right−hand side of the
DLOG, a commercial computer entry device with a USB port (i.e.
USB mouse, USB trackball, or similar) can be connected to the
display of the crane control system.
An optional USB connection (67, Z 56 192) can be located on the
cabin instrument panel.
If no such USB connection is available on the instrument panel,
then the crane controls display needs to be removed. Two USB
connections (64.10, Z 56 193) are located on the underside of the
device.
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153/159
10
B C
E
Z 56 185
Z 55 566
154/159 200−1−1100−286d_en
Safety Equipment 10
10.7.3 Failure of the Crane Control Display

(DLOG)
(Z 56 185, Z 55 566)
If only the display of the crane control (DLOG) fails, thenthe

function of the load limit device is safeguarded.
The display can fail in two ways:
− the background colour switches to red and/or the header is

shown in red.
The configured menus / masks continue to be displayed, but
now they are no longer being updated, either to a partial
extent or entirely.
Risk of accidents!
Please note that the load and radius display is not updated.
When the crane is switched over to carrier operation, the display

behaves in the same manner as with the above−mentioned
malfunction. The background and top line colour are displayed
in red.
− Monitor failure − the monitor turns black.
What is to be done?
Proceed with both types of monitor malfunction as follows:
1. Place load down.
2. Look for the source of the error.
3. Rectify the error.
Risk of accidents!
No crane operation is permissible when the display fails!
The error must be eliminated before crane operation is
permitted to resume!
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155/159
10
B C
E
Z 56 185
64.1
64.2
64.3
64.4
64.5
64.6
64.7
Z 55 566 Z 56 186
156/159 200−1−1100−286d_en
Safety Equipment 10
The display of the crane control (DLOG) attempts to register

automatically with the crane network.
Once this occurs, the ”Operating mode selection” screen
appears. This needs to be confirmed with Save.
All crane movements are stopped for as long as the ”Operating

mode selection” screen is displayed. The crane control reacts as
with a new start.
If the DLOG fails to register with the crane network, the CAN
mask can be selected to search for the fault. Here checks can be
carried out to see which components are in the network.
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 for example the control levers are assigned in ’Mode 1’ (see

section 10.1.7.6 on page 57), the left−hand control lever must be
moved to the rear for telescoping retraction.
If ’Mode 6’ is configured, then the right−hand control lever needs
to be moved to the left for telescoping retraction.
If telescoping retraction is not possible, then the crane

and/or the load must be put down with an auxiliary crane as
an emergency measure.
It must be observed that the load and radius display are not
updated.
In this event, please contact our customer service
department.
Monitor failure due to ambient temperatures being too high
If there is monitor failure (”black screen”) at the same time that the
”Temp” lamp (64.5, Z 56186) is illuminated, then the ambient
temperature is too high. The crane cab will then need to be
cooled down with the air conditioner. Direct sunlight on the crane
controls display must be avoided.
As soon as the ambient temperature has been reduced to a
permitted value, the crane controls display (DLOG) will once
again report to the crane network on its own.
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10
158/159 200−1−1100−286d_en
Safety Equipment 10
10.7.4 Failure of the Crane Control (CAN Stop)

In the event of crane control failure all crane movements are
stopped within one second.
No further input can be made with the control lever. Only such
inputs as affect diagnostics can be carried out via the crane
controls display (DLOG).
Before continuing operation of the crane, the fault must first

be rectified.
If necessary, the crane and load must be emergency

lowered using an auxiliary crane.
In this event, please contact our customer service
department.
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159/159
Notes on Operation 11
200−1−1110−240d_en 1/29
11
2
3
Z 53 496
Z 200 443
2/29 200−1−1110−240d_en
11 Notes on Operation
11.1 Wind Forces on the Crane

It is essential that you observe the permitted maximum wind
speeds.
11.1.1 Measuring the Wind Speed

(Z 53 496 schematic diagram, Z 200 443)
To check the wind speed, the crane is equipped with an air speed
indicator (anemometer).
This consists of two elements:

1. the rotor (1), which must be fitted to the head of the main
boom or main boom extension at the prescribed bracket (2).
To do so, insert the rotor into the bracket, screw the lock nut
(3) onto the thread of the bottom rotor component and
tighten.
If the hazard light and the anemometer rotor are fitted, the
transport height of 4 m (13.1 ft) is exceeded!
(Z 200 443)
2. the display (1) on the IC−1 screen with the corresponding
symbol.
The rotational movement of the rotor caused by the wind is
converted into an electrical signal which is displayed on the
IC−1 display in the crane operator’s cab. The crane operator
can read off the wind speed here in m/s (mph).
Before commencing work or erecting the equipment it must

be ensured that the anemometer is fully functional. This is
the case if the displayed value changes when the rotor is
rotated.
If there is no wind, this must be simulated by manual rotation
of the rotor.
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11
4/29 200−1−1110−240d_en
11.1.2 Behaviour in Relation to the Wind Speed
Erecting the boom system
For all crane configurations the boom system may only be

erected (raised from the ground) if the expected wind speeds
(weather forecast) are also permitted for operation of the crane.
Measures to be taken in accordance with the wind speed
Risk of accidents!
− When planning operation of the crane, you must obtain
information from the relevant weather station concer-
ning the expected wind forces for the period of time the
crane is to be used.
− Adhere to the maximum wind speeds listed in the load
capacity table.
− Observe the valid national regulations.
Wind speed What you have to do....

up to 9.8 m/s Crane operation does not
(35 km/h; 21.9 mph) need to be restricted.
or the maximum wind speed
listed in the load capacity
table
over 9.8 m/s Cease working with the cra-
(35 km/h; 21.9 mph) ne; place the main boom in
the high position and tele-
scope in fully;
the main boom extension can
remain in the operating
position.
If possible, place the boom
system into the wind.
15 m/s and above Main boom telescoped in and
(54 km/h; 33.6 mph) set down in the transport
position
Also observe the information in the “Instructions on crane

operation”, which are with the load capacity tables.
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11
6/29 200−1−1110−240d_en
For the wind speeds considered in the load capacity tables, a

wind surface for a load of 1.0 m2/t (4.88 ft2/kip) − however, at least
2 m2 (21.5 ft2) − and a wind resistance coefficient cw of 1.2 is
calculated.
If the relation between surface area exposed to wind and the load
or the cw value is greater than the values indicated above, there
are greater wind forces at work around the crane than used as
the basis for the calculation.
In this case the actual load on the boom system could be so large
that the LLD (LMB) switches off even though the load value in the
load table has not yet been reached nominally.
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11
8/29 200−1−1110−240d_en
11.2 Crane Operation
Before starting the engine or starting crane movements the

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

∗ the engine of the crane chassis is switched off.
∗ the cab of the crane chassis is closed.
∗ the control panels of the outriggers are locked.
Crane movements can be carried out at the same time or
independent of each other.
Before each load case, the corresponding limit switches must be

checked to make sure that they are functioning correctly.
During main boom operation, observe the segment ”Electric

safety chain” in section 10 of these operating instructions for ma-
king the electric connections correctly (applying the safety chain).
The procedures for operating the crane with additional

equipment are contained in the individual sections (e.g. main
boom extension).
Simultaneous raising of a load on the main boom extension and

on the main boom is not permitted.
Two−hook operation is not secured by the load limit
device and can lead to overloads and tilting of the crane.
For this reason, two−hook operation is prohibited.
It is not permitted to raise a load on the main boom with the main
boom extension in operating position (loaded or unloaded).
Some lifting capacity tables require that a permissible minimum

radius must be complied with. The corresponding crane
movements are then switched off.
This minimum radius must not be exceeded!

Risk of falling backwards!
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11
Z 53 410
10/29 200−1−1110−240d_en
The load capacity table in accordance with the assembly state of

the crane when raising loads must be set.
Failure to observe this will result in a RISK OF TIPPING!
Unless otherwise specified in the load capacity tables, the

number of reevings must not be lower than 2 rope lines.
If, however, single−line reeving is required, the lifting capacities
specified in the table must be reduced by 20%. This is also valid
when the lifting capacity lies below the maximum permissible
rope pull of 4.3 t / 9.7 kip per line.

If the main boom is in the high position and is completely
telescoped in, the crane movements must be carried out
carefully and at low speeds. By doing this you prevent
swinging movements of the hook block (1), which could
cause collisions with the luffing cylinder (2).
Risk of damage!
The weight of the hook blocks and lifting tackle must be taken
from the values in the load capacity tables.
If no hoist rope is reeved, the shift weight of the hoist limit

switch must be hung in the prescribed receptacle.
When raising a load on the main boom with the main boom
extension fitted in the transport position, the load capacities listed
in the load capacity tables are reduced. You must also calculate
minimum loads.
With regard to “hook block weights” and “minimum loads”

observe the “Instructions on Operating the Crane”, which
are supplied with the load capacity tables.
200−1−1110−240d_en 11/29
11
12/29 200−1−1110−240d_en
Operation of the crane is only permitted when supported on

outriggers and horizontally aligned. For the support base area,
the only values that apply are those listed in the load capacity
tables.
If no details are listed in the load capacity tables with regard to

the support base area, crane operation must be carried out in the
“normal” supported−on−outriggers state (outrigger support area:
8.2 m (26.9 ft)).
If outrigger support areas are reduced, there is increased risk of

tilting. The number of counterweight configurations permitted for
these reduced outrigger support areas can be limited. For this
reason, only the outrigger support area / counterweight
combinations described in the load capacity tables may be fitted.
If, contrary to the details in the load capacity tables, other
counterweights are fitted or if the support is with a smaller
support base area, there is a risk of tilting!
Handle 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.
Risk of crushing!
In spite of the use of automatic safety equipment, the load

cannot always be prevented from swinging out when a
movement is switched off.
This can only be prevented by braking and accelerating all
crane movements carefully and appropriately.
To allow for immediate reaction if the crane is subjected to

changing environmental conditions, it is prohibited to switch off
the drive of the crane when a load is attached and / or to leave
the crane cab.
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11
14/29 200−1−1110−240d_en
An exception is only permitted in emergency situations. To

avoid dangerous situations, as a last option the power
source (diesel engine) can be switched off using the
quick−stop switch in the crane operator’s cab. First, where
possible, any movements which have been started should
be completed using the control lever.
The erected crane without load may only be left without the
supervision of a trained crane operator if certain conditions are
met (see operating instructions for the crane chassis, section 14
”Parking”).
So−called ”dead man’s switches” are used to prevent accidental

activation of crane movements.
releasing the hand switches, sitting on / getting up from the crane
crane movement.
Risk of accidents!
the crane operator’s seat (for optional seat contact switch)
when the working movement has been completed.
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11
1/2
0 1/1
Z 63 444
16/29 200−1−1110−240d_en
(Z 63 444)
During operation of the crane observe display (4). The
temperature of the hydraulic oil must not exceed 85° C (185° F).
This applies to the oil filled ex works. For oils with a different
viscosity, observe the corresponding characteristic curves or get
in touch with the crane manufacturer.
If this value is exceeded, operation of the crane should be

stopped temporarily. Leave the diesel engine running at low revs
so that the hydraulic oil can be cooled down via the oil cooler.
200−1−1110−240d_en 17/29
11
18/29 200−1−1110−240d_en
11.3 Operation with Main Boom Extension
− During operation of the crane with the main boom extension:
∗ there must be an electric connection of the hoist limit

switch on the hoist rope to the plug of the main boom head
(see section 21).
∗ the shift weight of the hoist limit switch must be fitted to the
main boom head or refitted to the main boom extension.
If a hoist rope is not reeved, the shift weight of the hoist limit
switch must be hung in the prescribed receptacle.
− For crane operation with the main boom extension locked

inthe transport position, the loads specified in the load
tableare reduced, i.e. the proportional weight of the main
boomextension in the transport position must be added to the
loadthat is to be lifted (see Notes on crane operation).
− Operating the crane with additional equipment fitted
∗ Raising a load on the main boom extension and on the
main boom at the same time is prohibited.
∗ It is prohibited to raise a load on the main boom with an
unloaded main boom extension.
Special tables with load capacity reductions are required
for this unplanned crane configuration.
These load tables can be obtained from our spare parts
department.
− The crane may be operated with the main boom extension
only with the crane supported on outriggers.
Crane operation when not supported on outriggers is only
permitted for working with the main boom in certain cases.
The lifting capacities of the crane in relation to the main boom
length can be found in the load tables.
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11
20/29 200−1−1110−240d_en
11.4 Operation Planning / Monitoring Safety Measures
Before commencing work, i.e. before taking up a load, the

conditions described below must be fulfilled!
11.4.1 General
For every crane operation that is planned, the crane operator /

operation planner must provide a suitable crane with sufficient
lifting capacity, hoist height and working radius.
For the intended crane configuration there must exist a valid

capacity chart and it must be enabled by the crane control.
The weight of the load must be known. The crane must not be
taken for a device to determine the load weight.
Move the load as near to the ground as possible.
Avoid excessive operating speeds which could cause the load to

swing. Large loads must be guided from the ground with ropes.
Section “Safety instructions” in particular supplies additional

instructions for planning crane operation.
The capacities stated in the capacity charts are valid if all

instructions in the “Notes on crane operation” – provided together
with the capacity charts – are observed. This includes among
other things:
− Crane is set on horizontally level ground ( 0,5%)
− Ground must have sufficient bearing capacity for the resulting
ground pressures.
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11
22/29 200−1−1110−240d_en
Interpolation of capacities
The crane control comprises the capacities stated in the capacity

charts. The crane control also automatically calculates values for
differing boom positions. This is called interpolation of inter-
mediate values.
Such an interpolation may be performed:

− for intermediate radii
For operation planning these intermediate values may be

determined using a suitable Software (Cranimation). This
Software should be applied by trained personnel only.
11.4.2 Condition of the Crane
− Correctly supported on outriggers and horizontally aligned.

− All four outriggers extended to the support base area
specified in the corresponding load capacity table.
− All four outriggers safeguarded with pins to prevent them
shifting.
− All four vertical outrigger cylinders extended so that all axles
are relieved of load i.e. so that no tyres are in contact with the
ground.
− Crane control / load limit device set in accordance with the
crane assembly state and the suitable load tables.
− Support plates locked.
− Suspension system of the crane chassis switched to “raise
axles” or “hold axles”.
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11
24/29 200−1−1110−240d_en
11.4.3 Ambient Conditions
− The ground must have sufficient load−bearing capacity to

take the maximum occurring support pressures. If required,
increase the support surface by supporting the outrigger
plates with suitable materials.
Details on the maximum occurring support pressures, on

calculation of the required supporting surfaces and on safety
distances to slopes and ditches can be found in section 12
“Outriggers” of the operating instructions of the crane chassis.
− No live wires or cables in the operating area of the crane.

− No obstacles which hinder the necessary crane movements.
Maintain sufficient safety clearances in order to prevent the
risk of crushing (e. g. on the counterweight).
− Location selected so that the crane operation can be carried
out with as low a working radius as possible.
− If visibility is bad or in darkness, the immediate surrounding
area in front of the crane operator’s cab, the outriggers and
the winches must be illuminated by the spot lights which are
fitted to the machine (rear outside lighting, front outside
lighting, side outside lighting). They can be activated by the
superstructure or the chassis.
Other surrounding areas (load, load path, slewing range,
driving path, and similar) must be lit using suitable means,
independent of the crane. This is the responsibility of 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 planning operation is discussed in this
section in segment “11.1 Wind forces on the Crane“ (from
page 3).
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11
26/29 200−1−1110−240d_en
11.5 Conversion of Units
Instructions:
Multiply the known value by the conversion factor to obtain the

result in the desired units.
Example: 2 kg in lbs (US) as follows:

2 x 2.2046 = 4.4092 lbs (US)
To convert from to Multiply by

kg lbs 2.2046
lbs kg 0.45359
lbs kip 0.001
kip lbs 1000
kg kip 0.002205
kip kg 453.6
t (metric) ton (US) 1.103
ton (US) t (metric) 0.907
kip ton (US) 0.5
ton (US) kip 2.0
mm inch (in) 0.039
inch (in) mm 25.4
cm inch (in) 2.54
inch (in) cm 0.394
m ft 3.281
ft m 0.3048
km mile 0.621
mile km 1.6093
cm2 inch2 0.155
inch2 cm2 6.4516
sq.ft. (ft2) m2 9.2903 x 10−2
m2 sq.ft. (ft2) 10.746
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11
28/29 200−1−1110−240d_en
To convert from to Multiply by

m/s ft/sec 3.281
ft/sec m/s 0.3048
m/s ft/min 196.86
ft/min m/s 0.00508
m/s mph 2.236
mph m/s 0.447
km/h mph 0.621
mph km/h 1.6093
bar psi 14.513
psi bar 0.0689
psf lbs/ft2 1.0
lbs/ft2 psf 1.0
N/cm2 psi 1,478
psi N/cm2 0.677
Nm lbf−ft 0.7376
lbf−ft Nm 1.3558
kW HP 1.3410
HP kW 0.7457
ltr gal (US) 0.264
gal (US) ltr 3.7854
ltr barrel 0.0063
barrel ltr 158.99
oC oF toF= 1.8 (toC) + 32
oF oC toC= (toF−32) / 1.8
200−1−1110−240d_en 29/29
Telescoping 12
200−1−1120f_en 1/65
12
1
2
2
A A
4 4
3 B B 3
1
2
2
D D
4 4
3 C C 3
Z 200 036
2/65 200−1−1120f_en
Telescoping 12
12 Telescoping
12.1 General
(Z 200 036)
”Telescoping“ means retracting or extending the main boom.
The main boom is made up of a basic case and four telescopic

sections 6 (boom sections).
When completely telescoped in, the main boom length is 12.4 m
(40.7 ft), when completely telescoped out it is 67.8 m (222.4 ft).
The load capacity tables supplied apply only for extension
conditions where all telescopic sections are pinned.
This means that each boom section is locked to the next largest
boom section by a spring−loaded pin or bolt (3) on the left−hand
and right−hand side at the rear.
There are also load capacities in the unpinned condition. (see

section 12.8) and telescoping loads (see 12.8.2).
Telescoping all 6 telescopic sections in and out is realised by the

telescoping drive. This consists of:
− A telescoping cylinder (1), which is fastened to the back of the
basic case.
− A locking and pinning unit ”LPU” (SVE), which is connected
to the tip of the piston rod of the telescoping cylinder using a
tie frame. This is therefore moved accordingly as soon as the
telescoping cylinder is driven.
− Two hydraulic cylinders which activate the LPU (SVE).
There is a danger of crushing when the telescopic sections

are retracted and extended.
For this reason people are not permitted to be in the area
of danger.
200−1−1120f_en 3/65
12
1
2
2
A A
4 4
3 B B 3
1
2
2
D D
4 4
3 C C 3
Z 200 036
4/65 200−1−1120f_en
Telescoping 12
(Z 200 036)
All necessary steps are shown to the crane operator on the

telescoping information system (see section 12.6).
The main boom can be telescoped automatically (see section

12.6.3) or manually (see section 12.6.5) when using the length
code. The required entries and displays are carried out and
displayed on the telescoping information system (see section
12.6).
To reach an extension condition, the telescopic sections to be

extended must be telescoped out one after the other.
When telescoping out work commences with the smallest
telescopic section (the one nearest the centre).
During telescoping the telescopic section (boom section) is
locked on the LPU (locking and pinning unit).
To telescope out the next telescopic sections first the telescoping
cylinder with the fitted LPU must be moved back empty.
Before each telescoping procedure, all telescopic sections must

be pinned and unlocked. The corresponding telescopic section
is then locked and unpinned.
After each telescoping procedure, the individual telescopic
section is pinned and unlocked, before the next telescopic
section is telescoped out.
All telescopes can be pinned at 0% / 45% / 90% and 100%. There

are length codes for all extension conditions used in the load
tables (see section 12.5).
If the main boom has been extended or retracted to its final

operating length and pinned the LPU must be completely
retracted.
The load values from the load tables are only authorised and
reached when the LPU is fully retracted again.
Telescoping of the main boom without the load on the hook and
without the auxiliary equipment fitted is described in the
following.
For telescoping under load, see section 12.9.2.

Telescoping with fitted additional equipment is described in the
section where the relevant additional equipment is discussed, for
example section 18 ”Main boom extension”.
200−1−1120f_en 5/65
12
1
2
2
A A
4 4
3 B B 3
1
2
2
D D
4 4
3 C C 3
Z 200 036
6/65 200−1−1120f_en
Telescoping 12
Luffing angle:
To enable the main boom to be telescoped out with the main
boom extension fitted, the main boom must be luffed into the high
position.
If the main boom is not luffed into the high position, telescoping
out is not possible, the load limit device shuts off. The fact that the
luffing angle has fallen below the minimum permissible luffing
angle is indicated. The main boom must then be made steeper.
To drive in the transport condition, all telescopic sections must be

completely retracted and pinned. The procedure is only ended
when the LPU is in the respective position for the planned
transport condition (see section 12.2.1).
12.2 Locking and Pinning Unit (LPU)

(Z 200 036)
The locking and pinning unit is connected with the top of the
piston rod of the telescoping cylinder via a pulling frame and is
therefore moved as soon as the telescoping cylinder is moved.
The selected procedure is carried out on the locking and pinning

unit; this procedure is made up of two independent processes:
− Locking and unpinning
and vice versa

− Pinning and unlocking.
The locking and pinning unit is designed in such a way that once
the corresponding procedure has been activated, the telescopic
sections are always locked (or pinned) before the following action
of unpinning (or unlocking) can be carried out mechanically.
This ensures that the system is never in an unsafe condition
(unpinned and unlocked at the same time).
200−1−1120f_en 7/65
12
1
2
2
A A
4 4
3 B B 3
1
2
2
D D
4 4
3 C C 3
Z 200 036
8/65 200−1−1120f_en
Telescoping 12
(Z 200 036)
Locking / unpinning
Two pins (2) on both sides of the LPU are used for mechanical
locking between the locking and pinning unit and the
corresponding boom section. This is described as “locking” (A).
The LPU has now locked the boom section to be moved. This
boom section is still pinned to the next larger one.
Immediately after the locking procedure follows the “unpinning”

procedure (B). In this case, the grippers (4) draw the pins (3)
inwards to lock the corresponding boom section with the next
largest section.
You can telescope in this state. The LPU is moved at the same
time.
Pinning / unlocking
Is carried out in the same way as locking and unpinning. First the
clamshells (4) let the bolts (3) recreate the lock between the two
relevant sections (“Pinning“ (C)).
Then both horizontal locking pins (2) are retracted so that there
is no longer a connection between the locking and pinning unit
and the boom section (“Unlocking“ (D)).
200−1−1120f_en 9/65
12
Z 200 346 Z 200 306
12
Z 58 682 Z 200 288
10/65 200−1−1120f_en
Telescoping 12
12.2.1 Bringing the Main Boom in the Road Travel Condition
(Z 200 346, Z 200 306, Z 58 682, Z 200 288)
To drive in the transport condition, all telescopic sections must be

completely retracted and pinned. The procedure is only
completed when the LPU is in the position for the corresponding
transport condition and is locked.
Otherwise there is a risk of the locking and pinning unit

moving/sliding by itself in an uncontrolled manner. If the
LPU is secured in the wrong place the indicated axle loads
are incorrect.
In order to create the transport condition, the mode selection

mask must be set to the operating mode ’HA’.
After this, in the ”quick menu” of the crane operating mask the
telescopic display (E51, Z 200 346) must be selected.
By actuating the length code field (1, Z 200 306) in the telescopic
display the tele operating mode display (Z 58 682) appears.
Here the button (12, ”crane”) must be actuated.
By actuating the corresponding control lever in the retracting
direction, the extended main boom (LC >1) is first telescoped in
(LK1). The LPU on the 6th boom section is then locked (control
elements − see section 12.3).
The controls must be actuated until a symbol of the crane

appears on the screen (Z 200 288).
Only then is the main boom incl. the LPU in the road travel or
transport condition
The main boom is adjusted for crane operation as described in

section 12.6.
200−1−1120f_en 11/65
12
Z 200 346 Z 200 067
1 2 3 4 5 6 7
8
9
13 12 11 10
Z 200 306 Z 200 403
12/65 200−1−1120f_en
Telescoping 12
12.3 Telescoping Procedure
(Z 200 346, Z 200 067, Z 200 306, Z 200 403)
Procedure
1. Support the crane on outriggers in accordance with the

planned configuration (MBE, counterweights, etc.) (see load
tables for specifications).
2. With the engine running, select the desired hydraulic supply

for telescoping on the buttons “E53” and “E54” of the quick
menu (details see section 12.4).
For the condition of ”E53” shown on the figure Z 200 346 the
two hydraulic pumps are linked.
The movements “telescoping”, “luffing”, “hoist 1” and if
available “hoist 2” (button “E54”) are carried out from the
hydraulic oil of the linked hydraulic pumps.
3. If required, adapt the control lever assignment using button

“E23” (see section 12.5 and section 10).
4. Select the operating mode e.g. “HA” (= main boom

operation), to this end:
Using button “E21” (Z 200 346) on the quick menu, select the
operating mode selection mask (Z 200 067) (see also
section 10).
5. Set the length code of the desired extension condition

(automatic operation, see section 12.6.3).
to this end:
Using the button “E51” (Z 200 346) on the quick menu select
the telescoping display (Z 200 306) (see also section 12.6).
Button (1) must be selected to change to the tele mode mask
(Z 200 403). The corresponding length code must be
selected and the display exited with ”save”.
Manual telescoping, see section 12.6.5
200−1−1120f_en 13/65
12
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
14/65 200−1−1120f_en
Telescoping 12
(Z 200 677)
6. Start the telescoping procedure by activating one of the keys
of the “dead man’s switch” and carefully steering the
corresponding control lever (43) / (81) in the direction of
extension.

contact switch.
releasing the hand switches, sitting on / getting up from the crane
crane movement.
Risk of accidents!
contact switch) if the working movement has been
completed.
200−1−1120f_en 15/65
12
16/65 200−1−1120f_en
Telescoping 12
Risk of accidents!

RISK OF ACCIDENTS!
consideration.

If the hook is raised, and if the hoist limit switch has triggered, the
main boom can no longer be telescoped out. First the hoist (the
hook) must be lowered (see section 14).
200−1−1120f_en 17/65
12
Z 200 303
18/65 200−1−1120f_en
Telescoping 12
12.4 Select the hydraulic supply for telescoping
(Z 200 303)
Depending on which movements are to be carried out at the

same time, the hydraulic supply can be selected for the individual
movements. There are 4 operating modes. By tapping
repeatedly on the button “E53” the operating modes can be
selected. “E53” and “E54” then indicate which movements are
assigned to which hydraulic pump. In the upper left hand corner
of the button “E53” the number of the current operating mode can
be seen.
If “operating mode 4” is preselected, the system cannot be

telescoped. When attempting to telescope with “operating mode
4” set, a fault message appears on the display. To be able to
telescope, another operating mode must be selected.
By touching the button “E34” a switch diagram appears which

shows which hydraulic pump is assigned to which movement.
200−1−1120f_en 19/65
12
Z 200 304
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
20/65 200−1−1120f_en
Telescoping 12
12.5 Controls / Control Lever Assignment
(Z 200 304, Z 200 677)

be selected.
By actuating the button “E23” a picture of the current control lever

assignment is shown in area “E” of the crane operating mask. By
selecting a new mode (e.g. mode 4) the corresponding control
lever assignment can be displayed. The newly selected mode
becomes active when the display is exited using the ”save”
symbol (diskette). At point “A9” in field “A” the current control lever
assignment is displayed.


V = vertical)
Risk of accidents!
consideration.
200−1−1120f_en 21/65
12
Z 200 300
Z 200 327
22/65 200−1−1120f_en
Telescoping 12
12.6 Telescoping Information System
12.6.1 General
(Z 200 300, Z 200 327)
The main boom can be telescoped out both in automatic and

manual.
The remaining procedure is automatic operation (see 12.6.3).
To achieve extension conditions for which there are no length
codes (e.g. when lubricating the main boom), or in case of faults,
the main boom can be telescoped manually (see 12.6.5).
Press button (E51) to move to the telescoping information system

(Z 200 327). This serves to aid the operator when he is
telescoping the boom in and out.
The telescoping information system is an operating aid.

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.
In using the operating aid, the crane operator remains fully

responsible for the safe operation of the crane. He must
ensure that he fully understands and follows the notes and
instructions in their entirety. The system can only be
guaranteed to work correctly if it is checked daily and used
in accordance with the operating instructions.
200−1−1120f_en 23/65
12
Z 200 300
Z 200 306
24/65 200−1−1120f_en
Telescoping 12
(Z 200 300, Z 200 306)
12.6.2 Telescoping Display
After selecting the telescoping information system (E51) on the

quick menu of the crane operating mask (Z 200 300) the tele-
scoping display appears in place of the quick menu (Z 200 306).
This is where submenus can be selected and information on the
status of the telescoping system can be found:
(1) Length code selection: Tele code display appears for
selecting the length code (see
12.6.4 ”Entering length code”)
Grey: The selected length code has not
been achieved.
Green: The selected LC has been
achieved.
(2) Final length of the main boom
(3) Actual length of the main boom
200−1−1120f_en 25/65
12
Z 200 306
Z 200 307
26/65 200−1−1120f_en
Telescoping 12
(Z 200 306, Z 200 307)
(4) Changes to the display of the tele aid (Z 200 307)

Electrical limit switches are fitted on the LPU and on the drive
unit of the LPU:
B 9160 − B 9163 Used to recognise the telescopic
section (Z 200 307, ”D”). The
corresponding digit after the desig-
nation “tele” indicates which boom
section is being dealt with.
Example: 1st boom section
Description “tele 1”: The two lights
symbolising the end switch B9160
and B9161 light up as shown.
B 9164 − B 9165 Show the position of the LPU to the
telescopic section (Z 200 307).
When both light up, the LPU can
lock the affected telescopic section,
i.e. create the connection to the
telescopic section.
B 9156, B 9157, B 9158, Show the status of the LPU.
B 9168, B 9169
Z 200 307 “A”: pinned / unlocked
Z 200 307 “B”: pinned / locked
Z 200 307 “C”: unpinned / locked
(5) Display of the current tele operating condition and/or of the

LPU
/ forwards / backwards with reduced
speed
/ forwards / backwards with high
speed
/ Telescopic section pinned /
unpinned
/ LPU locked / unlocked
Black dot: tele system stop
Red dot: Error in tele system, call
up fault display 202.3
(see section 10)
200−1−1120f_en 27/65
12
Z 200 306
28/65 200−1−1120f_en
Telescoping 12
(Z 200 306)
(6) Display of the telescoping speed of the tele boom and/or

ofthe telescoping cylinder of the tele operation
Shortly before reaching the pinning position, the speed of the
telescopic procedure is reduced to enable the telescopic
sections to be pinned.
(7) Changes to display “tele manual” (see section 12.6.5)
(8) Positioning display of the tele mode
(9) Extension length of a telescopic section in percent
Telescopic section blue: These telescopic sections are al-
ready extended for the selected
length code.
Telescopic section grey: These telescopic sections are still
retracted and must be extended.
Telescopic section black: − in combination with grey back-
ground: this tele section must be
retracted for the new LC, and
subsequentlyextended again.
− in combination with white back-
ground: this tele sectionmust be
retracted for thenew LC.
Telescopic section yellow: This telescopic section extends or
retracts with the LPU
Telescopic section white: These telescopic sections are
retracted
Telescopic section The position of this telescopic
orange: section is taught (see 12.6.6)
200−1−1120f_en 29/65
12
30 14
31 15
34 32 16
35 26
36
25
24
Z 200 348
Z 200 306 Z 200 308
30/65 200−1−1120f_en
Telescoping 12
12.6.3 Automatic Operation
(Z 200 348, Z 200 306, Z 200 308)
The IC−1 enables the telescoping procedure to be carried out

automatically by actuating the corresponding control lever once
the desired final length has been selected (input of the
lengthcode LC, see 12.6.4; Length codes see 12.7). This means,
if the boom is to be telescoped out to a new final length, the
corresponding control lever must be pressed exclusively in the
extension direction and held (when selecting an operating mode
at which the crane can be telescoped).
The current telescoping speed varies during the procedure.
Shortly before reaching the pinning position, the speed of the

telescopic procedure is reduced to enable the telescopic
sections to be pinned.
The telescoping procedure can be observed on the telescoping

display (Z 200 306). As soon as the selected final length has
been reached the colour of the button background ”LC” changes
from grey to green (Z 200 306).
From the actual values supplied by the length transducers by

comparing the stored extension programs and additional factors,
the system calculates the best extension sequence and displays
this by means of the colour−marked telescopic sections in figure
(Z 200 306). Each step required is shown until the telescoping
procedure is completed.
The display of the movement of the individual tele sections and

the locking and pinning unit (LPU) as well as the condition of the
locking and pinning elements is continually adapted to the
ongoing changes.
When work is interrupted, the system automatically stores the

values last displayed so that the work can be resumed at this
point.
Fault routines monitor correct locking and pinning of the boom.

System errors are shown using a red dot at (5, Z 200 306) and
can be called up using the error buttons.
If an error occurs, the fault display “202.3” (Z 200 308) appears.

This must first be actuated before work can be continued.
200−1−1120f_en 31/65
12
Z 200 306
1 2 3 4 5 6 7
13 12 11 10
Z 200 403
32/65 200−1−1120f_en
Telescoping 12
12.6.4 Input of the Length Code − Selection of the Main

Boom Length
(Z 200 306, Z 200 403)

By selecting the button of the length code ”LC” (1) the tele
operating display is shown (Z 200 403).
By pressing on the desired length code, this is selected. By
actuating button (9) the display is exited with saving of the length
code.
Further information is contained on the tele operating display:
Dialogue tele code

(Z 200 403)
Dialogue for selection of a boom configuration.
1 Length code number. By pressing on the LC (LK).
2 Length main boom.
3 Tele extension sequence 1 to 6 (from left to right)
0 % extended 90 % extended
45 % extended 100 % extended
4 Load in high position.

5 Radius in high position.
6 Load in low position.
7 Radius in low position.
8 Opens the length code selection list for lubrication of the
main boom (dependent on the control software) (see
part 3: maintenance and lubrication instructions of the
superstructure, section 10 ”Main boom”).
9 Can be scrolled for leafing through length code.
10 Exit dialogue. The settings are saved.
11 Scrolling function: > one page down; < one page up
12 Length code selection for driving position (only for operating
type main boom).
13 Exit dialogue without saving. The settings are not saved.
200−1−1120f_en 33/65
12
Z 200 652
34/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
12.6.5 Manual Telescoping
For faults on the telescoping system (e.g. limit switch failure) or

in order to achieve the main boom extension conditions without
length code (LC) e.g. for lubricating the slideways, the main boom
can also be telescoped ”manually”.
Risk of accidents! Risk of overturning!

During manual operation crane surveillance by crane
control / is not possible! This creates a risk of the crane
tilting to the front and possibly to the rear.
The crane operator is responsible for any damage or

accidents caused by this situation.
Under certain circumstances (no monitoring of the crane

control during manual telescoping) the telescopic drive can
be extended so much that it slides off the inner guide rails.
For this reason, there is a table with the approximate locking
and pinning positions of the LPU (SVE) under subpoint
12.6.7 ’Locking and pinning positions positions of the LPU’
(on page 51).
The table values correspond with the LPU position (1) in the
’TeleManual’ screen.
The corresponding locking and pinning positions may be
exceeded by approx. 0.05 m (approx. 2 in) at the most.
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.
200−1−1120f_en 35/65
12
Z 200 652
36/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
If the telescopic drive has come off the inner guiding slides,
telescoping is no longer possible. Locking and pinning (or
unpinning) the telescopic sections of the main boom is then no
longer possible either. The telescopic drive can be extended but
will always stick at the same place when being extended.
The information required for manual telescoping concerning the

telescopic drive or the LPU can be seen in the ”Tele manual”
display. After selecting the telescoping information system (E51)
on the quick menu of the crane operating mask, the telescoping
display appears in place of the quick menu.
By selecting button (E51.7) the display changes to the ”tele
manual” display.
The procedure for manual telescoping is described under
12.6.5.2. By selecting the telescoping display (13) the tele
manual display can be exited without switching to manual
telescoping.
Below (section 12.6.5.1) the contents of the tele manual display
are explained.
12.6.5.1 Content: ”TeleManual” screen

1 Position of the LPU in m (or ft)
2 Speed of the LPU in mm/s (or ft/min)
3 Hydraulic supply LPU
Depending on the design of your machine, the hydraulic
supply of the LPU is fed through the telescoping cylinder
with an inner oil supply. In the tele manual display the
current pressure is then displayed at (3). The desired
range of the hydraulic pressure is 65 bar (943 psi) to
85 bar (1233 psi).
If the pressure in the accumulator falls under 76 bar
(1100 psi), the loading procedure is automatically
started.
The loading procedure is not carried out if:
1. the telescopic cylinder is retracted;
2. the LPU is in the state ”locked / unpinned” and the
telescopic cylinder is not telescoped (unpinned
loads);
3. the LPU is in the state ”unlocked / pinned”, the
telescopic cylinder is not telescoped and the entire
telescoping drive is telescoped out less than 1.5 m
(4.9 ft);
200−1−1120f_en 37/65
12
Z 200 652
38/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
4. the LPU is in the approach position, fine position or

follow−up position during the locking and pinning
procedure;
If the pressure sensor (E:325) fails the receiver pressure

can be manually charged by actuating the button. At a
pressure within the nominal range the button is
displayed in green, outside the range it is displayed in
red. During the charging procedure, max. 15 sec., the
button is shown in yellow.
If the pressure is larger than 86 bar (1247 psi), the
loading procedure cannot be started manually with the
pressure sensor intact.
4 Number of telescope connected to the LPU.
5 Preselection locking
6 Status display telescoping system (see 12.6.2 in (5))
7 Pinning
8 Unpinning
9 Locking
10 Unlocking
11 Back to the telescoping display, is blocked following
manual activation.
12 Teaching (setting and storing) the position of the
telescopic section.
13 Switching between automatic (hand symbol crossed
through) and manual (hand symbol not crossed through)
telescoping operation.
200−1−1120f_en 39/65
12
Z 200 652
40/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
14 Proximity switches for the state of the LPU (triggered

proximity switches with red background).
The following states are indicated by letters in German, in all

other languages they are represented by the number in brackets:
ES / VB Unlocked / pinned (1)

? / VB Intermediate position (12)
GS / VB Locked / pinned (2)
GS / ? Intermediate position (23)
GS / EB Locked / unpinned (3)
15 Proximity switches for identification of telescopes. The

telescopic section currently identified by the LPU is
specified in position 4 (activated proximity switches with
red background).
16 Proximity switches for pre− and follow−up position for

locking (activated proximity switches with red
background).
17 Proximity switches for pre− and follow−up position for
pinning (activated proximity switches with red
background).
200−1−1120f_en 41/65
12
Z 200 652
42/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
12.6.5.2 Procedure for “Manual Telescoping”
Observe the instructions on using manual telescoping in section

12.6.5.
Manual telescoping is activated with button (13).
It is not possible to monitor the crane with the LLD during

manual operation. Great risk of accidents!
For this reason, in manual operation the key switch (112) must be
actuated to bridge the load limit device. The indicator light (111)
lights up.
Following manual telescoping of the main boom, the tele system

must be informed which extension condition the main boom is in
(select button 12). For this ”Teaching” procedure, see 12.6.6. You
cannot exit the ”Telemanual” display without ”teaching”.
If the tele system is activated before a valid length code is

reached without bridging the load limit device, the crane display
shows the symbol displayed at ”L”.
In principle, when telescoping out the main boom, work should

always commence with the smallest boom section to be tele-
scoped (the one nearest the centre).
When telescoping in, work should commence with the largest
(the boom section nearest the outside).
The procedure of manual telescoping is explained using the

following example:
The 1st boom section should be moved from the 100% pinning
hole into the 0% pinning hole.
Check whether the LPU is in the condition unlocked /pinned

(condition 1, see 12.6.5.1). In the tele manual display this is the
right−hand entry at (14). The LPU can be moved forwards and
backwards in this condition using the control lever, without a
boom section moving. This can be seen in the display at (2): A
speed greater than 0 mm/s (ft/min) must be displayed without the
main boom moving.
200−1−1120f_en 43/65
12
Z 200 652
44/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
By moving the tele control lever forwards, the LPU is moved to

the 1st boom section.
(4) shows when telescopic section 1 has been reached, 1 (stands
for 1st boom section) must appear.
Then the telescopic drive is telescoped out approx. 9.342 m
(30.650 ft) (1st boom section, 100% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.6.7 on page 51).
Once the LPU has reached the desired boom

section, the locking procedure is activated by
selecting the button (5) ”select” and the key (9)
”lock”.
The sequence in which both buttons are ac-
tivated is important: first Pre−selection, then
Lock! Now the locking procedure is automati-
cally started when the fine position has been
activated. Both proximity switches VPS and
NPS are active (16) in the fine position.
The locking procedure is completed when
’GS/VB’ (locked / pinned)
or the number ’2’ appears at (14, at the end of
the line).
If automatic activation of the locking procedure
does not work, the boom section must be
locked manually. This is carried out by
pressing the button (9):
This button may only be activated in the fine
position (VPS and NPS active).
After locking the precise position for pinning
must be reached, i.e. both proximity switches
NPV and VPV must have a green background
(17), only then can the unpinning procedure
be started by pressing button (8).
If the LPU is moved forwards with the tele
control lever approx. 1 to 2 cm (0.5 to 1 in),
the system is unpinned. The unpinning
procedure is completed when at (14) “GS/EB”
or the number ’3’ appears at the end of the
line.
The inner section hangs in this condition on
the LPU and can be retracted with the tele
control lever.
The boom section is retracted by pulling back
on the tele control lever.
200−1−1120f_en 45/65
12
Z 200 652
46/65 200−1−1120f_en
Telescoping 12
(Z 200 652)
During telescoping of the tele drive the pinning position of the

90%− and 45% pinning holes is also passed. The electric limit
switches for pinning then indicate that a possible pinning position
is being passed. The two proximity switch fields “VPV” and “NPV”
are then given a green background. When the 0% pinning
position is reached the green background of the two proximity
switch fields “VPV” and “NPV” also indicates the pinning position.
Then the telescopic drive is telescoped out approx. 0.060 m
(0.197 ft) (1st boom section, 0% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.6.7 on page 51).
The button (7) ”pin” should then be actuated.
When pinning has been completed the display

at (14) shows “GS/VB” (locked / pinned)
and/or the number ’2’ at the end of the line.
To unlock the LPU the button ”preselect” (5)
and subsequently the button ”unlock” (10) is
pressed.
The unlocking procedure is then automatically initiated when the

fine position is activated. The unlocking procedure can be
initiated manually using the button ”Unlock” if it does not happen
automatically. In this case, the ”preselect” button may not be
activated.
After unlocking the display (14, at the end of

the line) shows “ES/VB” (unlocked / pinned)
and the number ’1’.
To change back to the tele−automatic mode, the position of the

individual telescopic sections must be ”taught” (set and saved).
The following text (section 12.6.6) describes how the extension

sequence of the telescopic sections is taught.
200−1−1120f_en 47/65
12
Z 58 683
48/65 200−1−1120f_en
Telescoping 12
12.6.6 Teaching the extension sequence of the telescopic

sections
(Z 58 683)
Following manual telescoping of the main boom, the tele system

must be informed which extension condition the main boom is in.
This procedure is described as ”teaching”.
Teaching of the telescopic sections is only possible in an

extension condition for which there is a length code (LC).
− Selection of the button (12) for teaching:
The teleteach display appears.
− Setting the pinning condition of the telescopic sections in the
display. In this case the pinning condition of each boom
section must be set by pressing the corresponding button as
often as required.
− By selecting the button (LC) the tele operating mode mask
can be selected in order to enter the length code of the
current extension condition.
− Exiting the display with ”Teach”.
If the tele system is activated before a valid length code is

reached without bridging the load limit device, the symbol ”L”
appears in the crane display.
200−1−1120f_en 49/65
12
Z 200 652
50/65 200−1−1120f_en
Telescoping 12
12.6.7 Locking and Pinning Positions of the

Telescopic Drive
The locking and pinning positions are required during manual
telescoping.
The indicated extension lengths may be exceeded by

approx. 0.05 m (approx. 2 in) at the most during manual
telescoping so that the telescopic drive does not come off
the inner guide rails.
The table values correspond to the ’SVE_Pos’ (1) in the

TeleManuell display (Z 200 652 below).
Locking and pinning position

Boom section Pinning LPU LPU
hole (%) position position (ft)
(m)
0 0.060 0.197
45 4.284 14.055
1
90 8.531 27.989
100 9.342 30.650
0 0.262 0.860
45 4.487 14.721
2
90 8.737 28.665
100 9.506 31.188
0 0.461 1.512
45 4.690 15.387
3
90 8.938 29.324
100 9.728 31.916
0 0.664 2.178
45 7.889 16.040
4
90 9.139 29.984
100 9.930 32.579
0 0.851 2.792
45 5.091 16.703
5
90 9.344 30.656
100 10.093 33.113
0 1.041 3.415
45 5.281 17.326
6
90 9.532 31.273
100 10.093 33.113
200−1−1120f_en 51/65
12
1 2 3 4 5 6 7
13 12 11 10
Z 200 403
Z 58 686
52/65 200−1−1120f_en
Telescoping 12
12.7 Extension Lengths of the Telescopic Sections
12.7.1 Overview Length Code − Main Boom Length
In order to have an overview of the available length codes and

main boom lengths, it is possible to call up the display of the main
boom’s pinning state which is assigned to one length code on the
dialogue unit of crane control.
12.7.1.1 Display via the Telescopic Operating Mode Mask
(Z 200 403)
For selection of the telescopic operating mode mask, see 12.6.4

(page 33).
If the extension state is not to be changed, the display can exited

using the Exit key (13).
12.7.1.2 Display via the Operating Mode Preselection Mask

(Z 58 686)
This possibility depends on the crane control’s software level.
For selection of the operating mode preselection mask, see

section 10 ’Safety devices’.
You can observe the main boom’s pinning state which is assigned
to one length code by selecting the ’Registers LK’ in the operating
mode preselection mask.
200−1−1120f_en 53/65
12
Z 200 300
Z 200 327 Z 200 328
54/65 200−1−1120f_en
Telescoping 12
12.7.2 Monitoring the Extension Lengths During the

Telescoping Procedure
(Z 200 300, Z 200 327, Z 200 328)
During the telescoping procedure the current length of the boom

as well as additional geometric data are displayed in field ”D” on
a crane symbol.
The current extension condition of the individual telescopic

sections can be read off the telescoping information system
(E51).
In addition, using switch (E51.4) the condition of the sensors and

pins of the LPU can be followed during the telescoping procedure
(Z 200 327).
12.7.3 Extension Sequence of the Telescopic Sections
The extension sequence of the telescopic sections is the

sequence in which the individual telescopic stages are brought
to their final lengths.
When the main boom is fully extended, the extension sequence

is (6−5−4−3−2−1), i.e. first telescopic section 6, then telescopic
section 5, etc. and finally telescopic section 1 is fully extended
and pinned.
If all the telescopic stages are not required for the extension
length selected, the extension sequence for the telescopic
stages required is analogous.
When the telescopic sections are retracted the sequence is

followed in reverse.
200−1−1120f_en 55/65
12
Z 200 329
56/65 200−1−1120f_en
Telescoping 12
12.8 Load capacities in the pinned condition

(Z 200 329)
The lifting capacities that are specified in the load capacity tables
in relation to the radius (see marked area in the display) only
apply when all telescopic sections are pinned.
The following load table is only a specimen. Only the load

tables supplied with the crane may be used for operating the
crane.
12.9 Lifting Capacities in the Unpinned Condition

In addition to the load capacities in the pinned condition of the
main boom there are also load capacities for the case in which
the largest extended boom section is unpinned:
− Unpinned lifting capacities for which the main boom length
remain unchanged, so−called “lifting capacities in inter-
mediate positions”. See section 12.9.1.
− Unpinned load capacities, for which the main boom length is
changed under load, so−called “telescoping load capa-
cities“. See section 12.9.2.
200−1−1120f_en 57/65
12
Z 200 330
58/65 200−1−1120f_en
Telescoping 12
12.9.1 Lifting Capacities in Intermediate Positions

(Z 200 330)
The lifting capacities that are specified in the load capacity tables
in relation to the radius only apply when all telescopic sections
are pinned.
Example:
In straight main boom operation (operating mode HA),
with a main boom length (A) of 20.9 m (68.6 ft), an extension
state (E) of the individual telescopic sections of (0/45/45/0/0/0)
(LK9) and a radius (B1) of 5 m (16.4 ft), the corresponding pinned
lifting capacity (C1) would be 104 t (229 kip).
There are however also lifting capacities for the unpinned

condition of the main boom. These enable load cases for the
case that the crane cannot be operated with pinned lengths due
to particular restricted space conditions. The bottom extended
boom section is then connected to the telescoping cylinder via
the LPU.
When attaching loads in the unpinned intermediate positions the

attachable loads are limited additionally by the load capacity of
the telescoping cylinder and the bend of the main boom.
These influences are contained in an additional table.
With the above example:

With a main boom length (A) of 20.9 m (68.6 ft), an extension
state (E) of the individual telescopic sections of (0/45/45/0/0/0)
(LK9) and a radius (B1) of 5 m (16.4 ft), the corresponding
unpinned lifting capacity (D1) would be 30.7 t (67.7 kip).
The specification in this additional table is a maximum value,

which is not absolutely applicable. This maximum value
“unpinned” is − related to the resulting radius − balanced
against the value “pinned” of the load limit device.
If − as in this case − the value “pinned” of 104 t (229 kip) (C1)
is larger than the value “unpinned” of 30.7 t (67.7 kip) (D1),
the permitted load is reduced to 30.7 t (67.7 kip).
If the radius were 16 m (52.5 ft) (B2), the value “pinned” 29 t
(63.9 kip) (C2) would be smaller than the value “unpinned”,
in this case also 30.7 t (67.7 kip) (D2). The permitted load is
reduced to the pinned value of 29 t (63.9 kip).
200−1−1120f_en 59/65
12
B2 E21
D20
Z 200 331
Z 200 332
60/65 200−1−1120f_en
Telescoping 12
(Z 200 331, Z 200 332)
This comparison of the pinned load with the table value is

automatically carried out by the load limit device. The crane
operating mask then always shows the actual attachable load at
(B2).
For (D20) the length code relevant to the load limit device and the
resulting radius for this extension condition and luffing angle is
displayed in ”red”. With the LLD−relevant LC and the radius, the
additional table can be consulted to find the corresponding
unpinned maximum value.
In the first case the red spec. would be (LC9/5) (= length code 9
/ radius step 5 m / 16.4 ft).
In the second case the red spec. would be (LC9/16) (= length

code 9 / radius step 16 m / 52.5 ft).
Intermediate values are interpolated.
The additional table “unpinned loads” can be displayed on the

screen.
Procedure:
− Select the button (E21) in the crane operating mask

(Z 200 331)
− The operating mode selection mask appears (Z 200 332)
− Select the button (T, table symbol) in the operating mode
selection mask:
The table “pinned load capacity” for the set operating mode
appears. On the button (7) a symbol of a crane boom is
displayed (without arrow).
− Select button (7): switch to additional table “unpinned load
capacities”. The table “Unpinned load capacities” appears.
On the button (7) a symbol of a crane boom is shown with a
double arrow. This state is shown in figure (Z 200 332).
200−1−1120f_en 61/65
12
Z 200 333
62/65 200−1−1120f_en
Telescoping 12
Example
(Z 200 333)
Operational planning has shown that due to lack of space, when

there is a radius of 5 m (16.4 ft), a main boom length of approx.
18 m (59.1 ft) is needed. The mass of the load to be raised is 30 t
(66.1 kip).
Proceed then as follows:

− Select the locked main boom length above the one actually
required (here: 20.9 m / 68.6 ft).
− Search for the length combination that offers the best
valuesin the unpinned intermediate positions for the desired
radius(here: LC 12, extension condition: 0/0/0/0/45/45).
For 30 t (66.1 kip) of load to be raised LK 9/10/11 could also be

relevant.
− Enter the corresponding length code (here: LC 12) and

telescope out the main boom in accordance with the
information in the tele control system without load until
telescopic section 6 is pinned at 45% and telescopic
section 5 is extended out in the locked and unpinned
condition to the point where the required main boom total
length of approx. 18 m (59.1 ft) has been reached.
At this point calculate the telescoping procedure using the
information of the tele control system.
The permitted unpinned load capacity corresponds with the

tablevalue of the additional table “unpinned” (here: 38.1 t /
84 kip), as it islower than the pined value (here: 53.5 t / 118 kip).
The load of 30 t (66.1 kip) can then be raised with the telescopic
boom in the unpinned condition.
At the current point in time, the max. authorised load capacities

in the intermediate position for operation with main boom
extension are 2 t (4.4 kip).
200−1−1120f_en 63/65
12
Tabelle auf Anfrage
64/65 200−1−1120f_en
Telescoping 12
12.9.2 Telescoping Lifting Capacities
The lifting capacities in intermediate positions described in

section 12.8.1 are also authorised during a telescoping
procedure.
However, the lifting capacities that are actually achievable

during telescoping under load are only given as approximate
values due to the large number of variable external influences.
The telescopable load capacities (on request) are achieved

under the following conditions:
− Sliding surfaces well lubricated
− Normal ambient temperature
− The systematics of the tele control system when carrying out
the extension sequences are predetermined and do not need
to be determined by the crane operator.
− The main boom angle may not be changed by the luffing gear
during the telescoping procedure.
200−1−1120f_en 65/65
Luffing 13
200−1−1130e_en 1/15
13
Z 200 300
2/15 200−1−1130e_en
Luffing 13
13 Luffing
13.1 Luffing Operation

(Z 200 300)
The main boom is luffed (raised and lowered) by extending and

retracting the luffing cylinder.
On devices with dolly preparation, the ball tap terminating the

luffing cylinder during road driving must be open (see section
13.3 and section 6 in the carrier operating instructions).
Proceed as follows to luff the main boom:
1. Stabilize crane according to planned working position (MBE,

CWT etc.) (for specifications, see load capacity chart).
2. With the engine running, select the desired hydraulic supply

for the luffing gear using buttons “E53” and “E54” on the
quick menu (see section 13.4).
With the ”E53” status shown in fig. Z 200 300, both hydraulic
pumps are connected. Telescoping, luffing, HW1 and, if
available, HW2 movements (“E54” button) are performed by
means of the hydraulic oil of the connected gear oil pumps.
3. If necessary, use the “E23” button to change the control lever

function (see section 13.5 or section 10).
200−1−1130e_en 3/15
13
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
4/15 200−1−1130e_en
Luffing 13
(Z 160 635)
4. Initiate the luffing movement by activating one of the buttons

of the “dead man’s switch” and carefully steering the control
lever (24) / (16) in the corresponding direction.

contact switch.
The dead man’s switch must only be activated (pressing and
crane movement.
Risk of accidents!
contact switch) if the working movement been completed.
Risk of accidents!
To prevent the load or hook block from swinging out and

creating a crushing / impact hazard when a movement is
switched off, it is critical to ensure that the speed and
acceleration of all crane movements are carefully set and
modulated.
200−1−1130e_en 5/15
13
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
6/15 200−1−1130e_en
Luffing 13
(Z 200 677)
RISK OF ACCIDENTS!
consideration.

When released, the control lever automatically returns to neutral

position. The current crane movement is stopped.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the
hook) must be lowered (see section 14).
The drive of the luffing gear has 2 speed ranges:

Stage 1: Normal Operation
Stage 2: High speed
Buttons (30) are used to select speed levels (see section 13.6.1).
In addition, it is possible to fine−tune the speed of crane
movement “Luffing gear down” (see section 13.6.2).
If a prohibited overload condition has occurred, the load−mo-

ment−reducing movement ”raise main boom” is also shut down
by the load limit device. For information on what to do in this case,
see section 13.7.
13.2 Lifting loads using luffing gear
Risk of accidents!
Lifting loads using the luffing gear is prohibited in all
cases.
200−1−1130e_en 7/15
13
220
Z 200 334
Z 200 335
8/15 200−1−1130e_en
Luffing 13
13.3 Bring the luffing gear into function
(Z 200 334)
On devices with dolly preparation, the ball tap terminating the

luffing cylinder during road driving must be open.
13.4 Selecting hydraulic supply for luffing gear
(Z 200 335)
You can select the hydraulic supply for individual movements

depending on which movements are to be performed
simultaneously. There are four operating modes that can be
used.
By tapping repeatedly on the button “E53” the operating modes

can be selected. On “E53” and “E54” you can see the movements
and the pumps that have been assigned to them. In the upper
left−hand corner of the “E53” button, you can see the number of
the current operating mode.
Operating modes 2 and 4 are best used for delicate,

simultaneous movement of the luffing gear and hoist.
Operating mode 3 can only be selected if hoist 2 is among the

assigned control lever functions.
200−1−1130e_en 9/15
13
Z 200 304
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
10/15 200−1−1130e_en
Luffing 13
(Z 200 304, Z 200 677)

be selected. By actuating the button “E23” a picture of the current
control lever assignment is shown in area “E” of the crane
operating mask. By selecting a new mode (e.g. mode 4), you can
display the corresponding control lever function. The newly
selected mode becomes active after you select the ”Save”
symbol (disk) to quit the display. The current control lever function
is shown at position “A9” in field “A”.



V = vertical)
Risk of accidents!
consideration.
200−1−1130e_en 11/15
13
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
Z 200 678
A
B
C
D
Z 200 035
12/15 200−1−1130e_en
Luffing 13
13.6 Luffing speeds
13.6.1 Luffing up main boom in high speed mode

(Z 160 635, Z 200 678)
The high−speed mode for luffing up is activated by simul-

taneously activating button (30) and steering the control lever
(24/16) where the luffing movement is located.

High range may only be used with up to a maximum of 30%

of the corresponding load value.
Switching to high−speed mode is not permitted in the

following cases:
− − with suspended loads
− with attached main boom extension
− to lift or lower a boom, which has been either fully or
partially extended, out of a flat position.
13.6.2 Fine−tuning downward luffing (”luffing gear down”)

(Z 200 035)
The luffing gear is electrically pre−controlled. The speed when

lifting the main boom is determined by the rotation speed of the
hydraulic pump and movement of the control lever.
The speed of the crane movement ”Luffing gear down” can be
additionally fine−tuned. The movements that are carried out via
the x−axle (horizontal movement of pilot control lever) of the
individual pilot control lever can be regulated via the
corresponding self−return rocker switch (26/14) (button actuated
to the right − fast; button actuated to the left − slow). The
movements that are carried out via the y−axle (vertical movement
of the pilot control lever) of the individual pilot control lever can
be regulated via the corresponding self−return rocker switch
(26/14) and by pressing the keys (35/31); on the front side of the
pilot control lever in the direction of travel, always left) at the same
time.
While the speed is being adjusted using the buttons, a corres-
ponding percentage value will appear on the LMB display (C)
(Z 200 035) (see section 10).
200−1−1130e_en 13/15
13
111
112
113
114
115
116
Z 200 648
14/15 200−1−1130e_en
Luffing 13
13.7 Bridging Load Limit Device
(Z 200 648)
If the load has exceeded the limit, movements which increase the
load moment are switched off by the load limit device. Lowering
the load on the hook is the only movement still permitted (Unless
the movement has also been switched off by the lowering limit
switch. For information on what to do in this case, see section 10).
13.7.1 Overriding shutdown of movement ”Raise luffing

gear”
To move a suspended load from the overload area into the

permitted operating area, it is possible to raise the main boom.
The release to “raise luffing gear” is carried out via the key button
(116). To do this, turn the key clockwise and hold in this position.
This movement is only permitted if it is clear that no

dangerous situations can arise as a result.

the hoist has been shut down, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!
”Raise luffing gear” must never be used to raise the load!
Using the key−operated push button (116), it is possible to move

the load out of the shutdown area without switching off the entire
LMB (including all monitoring functions).
200−1−1130e_en 15/15
”Hoist 1” Hook Operation 14
200−1−1140d_en 1/9
14
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
B C
E
Z 56 174
2/9 200−1−1140d_en
14 ”Hoist 1” Hook Operation
14.1 Raising and Lowering the Load with Hoist 1

(Z 200 677)

be selected.



V = vertical)

contact switch.
crane movement.
200−1−1140d_en 3/9
14
v h v h
26 25 16 14 15
34 30
35 24 31
36 32
Z 200 677
B C
E
Z 56 174
4/9 200−1−1140d_en
(Z 200 677)
Risk of accidents!
completed.
Risk of accidents!

RISK OF ACCIDENTS!
consideration.

− The movement ”raise load” is automatically shut down when:

∗ The load limit device has shut down. Lifting capacity of
100% is reached
(bar display C, Z 56 174)
∗ The hook block has tripped the hoist limit switch.
Lowering load is possible.
200−1−1140d_en 5/9
14
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
Z 200 678
A
B
C
D
Z 200 035
6/9 200−1−1140d_en
(Z 160 635, Z 200 678)
− The movement ”lower load” is automatically shut down, when

the lower limit switch for hoist 1 has tripped.
Raising of the load is possible.
− When activating control lever (24/16), touch the cone of the
hoist rotation indicator (25/15).
As soon as the hoist rotates, you will feel a definite vibration
there.
Raising the Load in High Range
The high−speed made for hoist 1 is activated by simultaneously

activating button (30) and steering the control lever (24/16)
where the hoist movement is located.
High−speed mode may only be used for up to a maximum of

30% of the corresponding load capacity.
High speed may not be used for one−rope crane operation
with main boom extension.
14.2 Hoist Speeds

(Z 200 035)
The hoist is pilot controlled electrically. The hoist speed depends

on the speed of the hydraulic pump and the position of control
lever.
The speed of the crane movement „Hoist 1“ can also be precision
controlled. The movements that are carried out via the X−axle
(horizontal movement of pilot control lever) of the individual pilot
control lever can be regulated via the corresponding self−return
rocker switch (26/14) (button actuated to the right − fast; button
actuated to the left − slow). The movements that are carried out
via the Y−axle (vertical movement of the pilot control lever) of the
corresponding self−return rocker switch (26/14) and by pressing
the keys (35/31; on the front side of the pilot control lever in the
direction of travel, always left) at the same time.
As long as the speed is being regulated via button (26/14), the
corresponding percentage is shown in the display of the load limit
device (B, Z 200 035) (see also Sect. 10).
200−1−1140d_en 7/9
14
27
27.1 27.2 27.3 27.4 27.5
Z 57 676
8/9 200−1−1140d_en
14.3 Camera Surveillance of the Hoist (Optional)
(Z 57 676)
A camera is fitted to the hoist in order to monitor the reeling

behaviour of the hoist rope from display (27) in the crane
operator’s cab. It is in a protective case.
The entire unit must be slid up and clamped in place for operation
When the crane is in the transportation state the entire unit must
be slid down and clamped in place.
The display (27) is on the top of the instrument panel in the

superstructure cab.
The following settings can be made on display (27):

Button Meaning
27.1 LED: display readiness for operation
27.2 Manual switch−over camera 1 / camera 2
27.3 Switch−over brightness between 2 levels of
brightness
27.4 Switch−over camera or AV input for the screen
27.5 On / Off switch
Changing the setting Colour (contrast) and brightness is only

possible for hoist 1. The selected setting remains for hoist 2
(optional).
When the display is switched on hoist 1 is automatically shown

as soon as the ignition is activated. As soon as the control lever
for hoist 2 is activated, hoist 2 (optional) is displayed instead of
hoist 1.
200−1−1140d_en 9/9
Hoist 2 (Optional) 15
200−1−1150−240_en 1/29
15
1a
1b
Z 200 624
2/29 200−1−1150−240_en
15 Hoist 2 (Optional)
You can use the second hoist when working with the main boom
extension and when utilising an auxiliary head sheave and/or a
runner.
15.1 Information on Transport and Attachment Points

(Z 200 624)
15.1.1 Attachment Points

In transport configuration, the actual hoist 2 (1a) is mounted
together with the assembly aid (1b). Figure (Z 200 624) shows
the transport condition.
The connecting bolts must be fitted and secured against falling
out.
Use the attachment points (A) as shown in figure (Z 200 624).
Risk of accidents!
claws must be used.
15.1.2 Transport Dimensions / Weights
Transport dimensions Approx.

Length Width Height weight
mm mm mm kg
(in) (in) (in) (lbs)
Hoist 2 with mounting 1730 mm 795 mm 710 mm 1800 kg
device (68.1 in) (31.3 in) (28.0 in) (3968 lbs)
Additional top roller 953 mm 61 mm 242 mm 15 kg
(37.5 in) (2.4 in) (9.5 in) (33.1 lbs)
200−1−1150−240_en 3/29
15
1a
1b
2
Z 200 163
4/29 200−1−1150−240_en
15.2 Fitting and Removing Hoist 2

(Z 200 163)
Equipment may only be fitted and removed by trained

and qualified personnel!
The hoist 2 (1) can be assembled with the help of an auxiliary

crane, or mounting aid (1b) in combination with counterweight (2)
as support.
In transport configuration, the actual hoist 2 (1a) is mounted
together with the assembly aid (1b). Z 200 163 shows the
transport conditions.
RISK OF TIPPING!
Hoist 2 needs to be secured against falling when
transported separately.
A risk of crushing exists during attachment of hoist 2

between the hoist housing and the superstructure frame
and the counterweight that has been set down.
The outrigger span needs to be selected in accordance
with subsequent crane operation.
200−1−1150−240_en 5/29
15
G A G 7
1a
10
10
F 1a
F
6 B 7
5 C
1b
4 3 2 Z 200 682
F BO E
ST
C A L
Z 200 680
6/29 200−1−1150−240_en
15.2.1 Fitting and Removing Hoist 2 with the Auxiliary Crane
15.2.1.1 Fitting
(Z 200 682, Z 200 680)
1. Stabilise the crane and make it level.
2. Hitch the entirety of hoist 2 to the slinging points (A) provided

on the auxiliary crane and raise slightly.
Persons must not stand or walk beneath suspended loads

or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until the
bolting at all locking points has been completed.
3. Separate the hoist 2 (1a) from the mounting aid (1b):

To do this, loosen bolts (3) and (4), push the connecting rod
(5) up and lock.
The rod of the hydraulic cylinder (10) can not be locked with
the pins (3) at point (B) until after connection with the
superstructure hydraulic system.
4. Hoist 2 using the upper securing forks, place Hoist 2 on the

guide rail on thesuperstructure frame and push towards the
superstructure. Fasten hoist 2 using the 4 biconical pins (7)
into points (F) and (G), and secure (4x each).
Risk of crushing!
Risk of crushing exists between hoist 2 and the respective
fastening points on the superstructure frame.
5. Release the auxiliary crane.
6. Switch off the superstructure engine.
200−1−1150−240_en 7/29
15
F BO E
ST
C A L
Z 200 680
8
9B
9A
Z 200 113
10
12
3
C Z 200 683
8/29 200−1−1150−240_en
(Z 200 680, Z 200 113, Z 200 683)

7. Connect up the hydraulics connections (C, A, L, ST, BO, X)
and electric connection (E) between hoist and super-
structure frame.
The hydraulic lines are equipped with signs which indicate
which belongs where.
All hydraulic couplings are fitted with protective caps which must
be removed before fitting.
Make sure in each case that the hydraulic connections have

been joined correctly, i.e. that the couplings open properly.
Joining and releasing of hydraulic connections is always
permitted only in depressurised condition, in other words,
the superstructure engine must not be running
8. Connect the mobile control panel (Z 200 113) to the

connection (F).
Depending on the design, connection (F; X0029) is fitted firmly

to the assembly plate or it is fastened to the cable harness behind
it.
The position of the rotary switch (8, Z 200 113) is irrelevant for
this procedure.
9. Using the mobile control panel (Z 200 113), retract the

hydraulic cylinder (10) via button (9B) until the rod can be
connected and secured with bolt (3) in point (C).
10. Place the mounting aid on the counterweight and secure.
11. Pull up the counterweight (2) using the counterweight

cylinder and bolt.
12. Reeve the hoist rope of hoist 2.
13. Remove the mobile control panel (Z 200 113) and store it
safely.
200−1−1150−240_en 9/29
15
10/29 200−1−1150−240_en
15.2.1.2 Removal
Proceed in reverse sequence when dismounting Hoist 2 with the

aid of an auxiliary crane.
The protective caps must be screwed back in place after
disconnecting the hydraulic and electric connections.
Risk of injury!
Wind the hoist rope onto the drum completely prior to
dismantling the hoist and fasten the rope end to the frame
of hoist 2.
No personnel are permitted in areas where loads /

equipment could fall while the biconical pins are being
released.
200−1−1150−240_en 11/29
15
P 1b
Z 200 167
12/29 200−1−1150−240_en
15.2.2 Fitting and Removing Hoist 2 with Your Own Crane
15.2.2.1 Fitting
(Z 200 167)
Assembling and dismantling hoist 2 with your own crane is

carried out using mounting aid (1b) and the 43.5 t (96 kip)
counterweight.
A risk of crushing exists when fitting and removing hoist 2
between the individual elements and the superstructure
frame and the crane chassis!
To avoid dangerous situations, pay particular attention to
the safety instructions in section 1.2.4 ”When Assembling
and Dismantling Crane Components”.
In particular, make sure that you allow sufficient safety
clearance.

or in areas where loads / equipment could fall.
The auxiliary crane must be able to hold the load until the
bolting at all locking points has been completed.
1. Stabilise the crane and make it level.
2. Adjust crane controls in accordance with the rigging

situation.
3. Place minimum counterweight combination of 43.5 t (96 kip)

on the counterweight support on the superstructure frame.
4. Attach hoist 2 with assembled mounting aid (1b) onto

designated suspension points (A), place on counterweight
stack and secure.
For positioning aid, the counterweight has cams, which
catch in the corresponding grooves in the mounting aid.
According to design: secure mounting aid in point (P).
200−1−1150−240_en 13/29
15
F BO E
ST
C A L
Z 200 680
8
9B
9A
Z 200 113
14/29 200−1−1150−240_en
(Z 200 680, Z 200 113)
5. Rotate superstructure to the rear and pin (superstructure) to

the undercarriage.
6. Switch off the superstructure engine.
7. Connect up hydraulic connections (C, A, L, ST, BO, X) and

electronic connection (E) between hoist and superstructure
frame (Z 200 680).
The hydraulic lines are equipped with signs which indicate
which belongs where.
All hydraulic couplings are fitted with protective caps which must
be removed before fitting.

been joined correctly, i.e. that the couplings open properly.
Joining and releasing of hydraulic connections is always
permitted only in depressurised condition, in other words,
the superstructure engine must not be running.
8. Connect the mobile control panel (Z 200 113) to the

connection (F).
Depending on the design, connection (F; X0029) is fitted firmly

to the assembly plate or it is fastened to the cable harness behind
it.
The position of the rotary switch (8, Z 200 113) is irrelevant for
this procedure.
200−1−1150−240_en 15/29
15
1 A H
”a” ”b”
10 10
1 2
7 10
”c” 7 ”d”
C
6
F 3
5
3 4
8
9B
”e” 9A ”f”
Z 200 684
16/29 200−1−1150−240_en
(Z 200 684 “a”, “b”, “c”)

9. On the mobile control panel (Z 200 684 ”f”), extend the
hydraulic cylinder (10) via button (9A).
Hoist 2 (1) performs a movement thereby by which the
securing forks (H) are guided along the guide rails of the
superstructure frame. Carry out the adjusting movement of
the hydraulic cylinder (10) until the biconical pins (7) can be
rigged in point (G).
(Z 200 684 “c”)
10. Pin and secure hoist 2 (1) with the biconical pins (7) in point
(G) (2 x).
(Z 200 684 “c”)
11. Remove bolts (4), push connecting rod (5) up, and secure
using bolts (6).
(Z 200 684 “c”, “d”, “f”)
12. Using the mobile control panel (Z 200 684 ”f”), run in the
hydraulic cylinder (10) via button (9B) until the pins (7) can
be mounted in point (F).
(Z 200 684 “d”)
13. Pin and secure hoist 2 (1) with the biconical pin (7) in point
(F) (2 x).
(Z 200 684 “d”, “f”)
14. Using the mobile control panel (Z 200 684) run in the
hydraulic cylinder (10) via button (9B) until the eye of the rod
can be fastened with bolt (3) in point (C) − secure bolts.
15. Remove the mobile control panel (Z 200 684 “f”) and store
it safely.
16. Reeve the hoist rope of hoist 2 (1).
200−1−1150−240_en 17/29
15
21 12 11
43 6
5
13
14
Z 200 407
2 12 11
43 6
13
14
Z 200 408
18/29 200−1−1150−240_en
15.2.2.2 Removal
Proceed in reverse sequence when dismounting hoist 2.

The protective caps must be screwed back in place after
disconnecting the hydraulic and electric connections.
Risk of injury!
Wind the hoist rope onto the drum completely prior to
dismantling the hoist and fasten the rope end to the frame
of hoist 2.
No personnel are permitted in areas where loads /

equipment could fall while the biconical pins are being
released.
15.3 Fitting and Removing the Additional Top Rollers
(Z 200 407, Z 200 408)
In order to stop the hoist ropes from rubbing against each other,
they must be separated by additional top rollers.
The additional top rollers must be removed in order to

maintain the vehicle height of 4.0 m (13.1 ft) (transport state).
Risk of ripping off!
You must use the supplied folding / sliding ladder or

another suitable aid, e.g. operating hoist stage, in order to
carry out the work described in the following.
Depending on the design of the crane there are 5 additional top

rollers (1 to 5; Z 200 407) or 3 additional top rollers (2 to 4;
Z 200 408) on the main boom.
In order to have an advantageous run of the rope, we recommend

that you only use 3 additional top rollers (2 to 4; Z 200 408) in the
crane with 5 additional top rollers.
The additional top rollers must each be fastened using screw (6)
(4 x each).
The additional top rollers are removed in the same way in the
opposite sequence.
200−1−1150−240_en 19/29
15
21 12 11
43 6
5
13
14
Z 200 407
2 12 11
43 6
13
14
Z 200 408
20/29 200−1−1150−240_en
15.4 Rope Guide
(Z 200 407, Z 200 408)
When reeving both hoists together, the hoist rope (11) of hoist 1
is fed through the rope guides of the standard top roller or the
additional top roller and laid on the main boom head over the
sheave (14).
The hoist rope (12) for hoist 2 is to be placed over the respective
upper rope guide of the auxiliary carrying roller, and over the rope
sheave (13) on the main boom head (centre of the main boom
head).
Now the hoist limit switches must be fitted in accordance with the
equipment used.
200−1−1150−240_en 21/29
15
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
22/29 200−1−1150−240_en
15.5 Hook Operation with Hoist 2
15.5.1 Control Lever Assignment
(Z 160 635)
Depending on the crane equipment, different control lever

assignments can be selected.
See section 10 (Safety equipment) ”Pilot Control Assign-

ment”.

contact switch.
crane movement.
Risk of accidents!
Only release a dead man’s switch while a working move-
ment is being carried out if another one is activated.
completed.
200−1−1150−240_en 23/29
15
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
B C
E
Z 56 174
24/29 200−1−1150−240_en
(Z 160 635, Z 56 174)
Risk of accidents!
To prevent the load or hook block from swinging out and

creating a crushing / impact hazard when a movement is
switched off, it is critical to ensure that the speed and
acceleration of all crane movements are carefully set and
modulated.
RISK OF ACCIDENTS!
consideration.

− The movement ”raise load” is automatically shut down when:

∗ The load limit device (LLD) has shut down. Lifting capacity
of 100 % is reached
(bar display C, Z 56 174)
∗ The hook block in the hoist limit switch is activated.
Lowering load is possible.
The movement ”Lower load” is automatically shut down if the

lower limit switch for hoist 2 has been activated.
Raising of the load is possible.
200−1−1150−240_en 25/29
15
14
30
15
31
26 16
32
34 25
35 24
36
Z 160 635
A
B
C
D
Z 200 035
Z 200 678
26/29 200−1−1150−240_en
(Z 160 635)
− When activating control lever (24/16), touch the cone of the

hoist rotation indicator (25/15).
As soon as the hoist rotates, you will feel a definite vibration
there.
15.5.2 Hoist Speeds
The hoist is pilot controlled electrically. The hoist speed is

influenced by the engine speed, steering of the control lever as
well as the number of movements carried out at the same time.
Fine tuning:
(Z 160 635, Z 200 035)
The speed of the crane movement ”Hoist 2” can be additionally

fine tuned. The movements that are carried out via the x−axle
(horizontal movement of pilot control lever) of the individual pilot
control lever can be regulated via the corresponding self−return
rocker switch (26/14) (button actuated to the right − fast; button
actuated to the left − slow). The movements that are carried out
via the y−axle (vertical movement of the pilot control lever) of the
corresponding self−return rocker switch (26/14) and by pressing
the keys (35/31); on the front side of the pilot control lever in the
direction of travel, always left) at the same time.
As long as the speed is adjusted via key (26/14), the
corresponding percentage appears in the display of the LLD (D,
Z 200 035) (see also section 10).
High range:
(Z 160 635, Z 200 678)
The high−speed mode for hoist 2 is activated by simultaneously

activating button (30) and steering the control lever (24/16)
where the hoist movement is located.

High−speed mode may only be used for up to a maximum of

30% of the corresponding load capacity.
High speed may not be used for one−rope crane operation
with main boom extension.
200−1−1150−240_en 27/29
15
27
27.1 27.2 27.3 27.4 27.5
Z 57 676
28/29 200−1−1150−240_en
15.6 Camera Surveillance of the Hoist (Optional)
(Z 57 676)
A camera is fitted to the hoist in order to monitor the reeling

behaviour of the hoist rope from display (27) in the crane
operator’s cab. It is in a protective case.
The entire unit must be slid up and clamped in place for operation
When the crane is in the transportation state the entire unit must
be slid down and clamped in place.
The display (27) is on the top of the instrument panel in the

superstructure cab.
The following settings can be made on display (27):

Key Meaning
27.1 LED: display readiness for operation
27.2 Manual switch−over camera 1 / camera 2
27.3 Switch−over brightness between 2 levels of
brightness
27.4 Switch−over camera or AV input for the screen
27.5 On / Off switch
Changing the setting Colour (contrast) and brightness is only

possible for hoist 1. The selected setting remains for hoist 2
(optional).
When the display is switched on hoist 1 is automatically shown

as soon as the ignition is activated. As soon as the control lever
for hoist 2 is activated, hoist 2 (optional) is displayed instead of
hoist 1.
200−1−1150−240_en 29/29
Heating and Ventilation 16
200−1−1160−063b_en 1/27
16
7 8 9 10
2
1 3
0 4
11
Z 54 356
12a 12b
to the engine
to the heat exchanger

Heating
Engine
from the heat exchanger

Inlet
12c
12d 12e
Z 53 495
2/27 200−1−1160−063b_en
16 Heating and Ventilation

(Z 54 356, Z 53 495)
16.1 Engine−Dependent Heating
This heating is dependent on the coolant temperature of the en-

gine. The heating temperature in the cab is regulated using rotary
switch (9).
The fan can be switched to 4 different settings using rotary switch

(8) or switched off (setting “0”). The air exchange in the can be
accelerated accordingly by using the fan.
Using luminous switch (10), you can select between fresh air and
surround air operation:
− Luminous switch (10) not activated; the indicator light in the
switch does not light up: fresh air operation.
− Luminous switch (10) activated; the indicator light in the
switch lights up: surround air operation.
There are several air nozzles (12) in the cab. The air nozzles
(12b−e) can be opened or closed individually as required.
In order for the defroster nozzles (12a) to have as great an effect
as possible, the other air nozzles (12b−e) should be closed.
200−1−1160−063b_en 3/27
16
7 8 9 10
2
1 3
0 4
11
Z 54 356
4/27 200−1−1160−063b_en
16.2 Engine−Independent Heating with Coolant Preheating

System
In addition, observe the operating instructions of the manu-

facturer in part 5 of this documentation.
These are much more detailed and contain additional areas
(for example fitting, safety devices etc.).
16.2.1 General
(Z 54 356)
The mobile crane is equipped with an engine−independent coo-

lant preheating system for the superstructure engine. At low out-
side temperatures of up to −20°C ( −4 °F) it facilitates starting the
engine.
Below −20°C ( −4 °F) the coolant must be preheated. There is a
timer (7) in the crane cab for operation of the system.
Coolant preheating without preheating the cab: set the rotary
switch (9) to minimum.
Coolant preheating with preheating the cab: set rotary switch (9)
to maximum. The fan automatically starts up after a certain coo-
lant temperature which has been set that switch (8).
The heater may only be used for the purpose specified by the
manufacturer, and all operating instructions supplied must
be observed.
Operation is not permitted:
− where flammable fumes or dust can be produced
(i.e. near fuel, coal dust, wood dust, wheat depots, or
similar places)
− in enclosed spaces (e.g. garages) due to the risk of
poisoning.
− when refuelling.
When carrying out electric welding work on the vehicle, the

positive terminal must be disconnected from the battery to
protect the control unit and connected to ground.
200−1−1160−063b_en 5/27
16
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
6/27 200−1−1160−063b_en
If the coolant has been replaced, or if large quantities of coo-

lant have been added, before switching on the engine−inde-
pendent heater − the engine must be set to an operating tem-
perature of approx. 80 C (176F) ( = opening point coolant
thermostat). The coolant circuit and the circuit for the en-
gine−independent heater assembly can then be vented auto-
matically.
16.2.2 Operating elements

(Z 36 772)
(1) − Time
(2) − Preselection
(3) − Heater
(4) − Backwards
(5) − Forwards
Display of the timer
(6) − Memory
(7) − Symbol for radio remote control
(8) − Week day / selected day
(9) − Current time / selected time
(10) − Temperature
(11) − Service indicator light
The heater should be switched on briefly (approx. 10 s) out-

side of the normal heating periods at least once a month.
This prevents the water pump and burner motor from seizing
up.
Before the heating period, a test run should be carried out

using the heater assembly. If strong smoke develops or if un-
usual burner noises or the smell of burning fuel occurs, the
heater must be switched off and placed out of operation by
removing the fuse. The equipment should only be restarted
once it has been tested by an authorised service outlet.
200−1−1160−063b_en 7/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
8/27 200−1−1160−063b_en
16.2.3 Setting
(Z 36 739)
After connecting the power supply the display shows all signals
flashing − the timer must be completely set. In this condition, the
heater assembly cannot be switched on.
16.2.3.1 Setting the time and week day for the first time
Press briefly; time display flashes 12:00.

Set the current time.
Note: If two keys are shown next to each other, one or the
other must be pressed.
As soon as this stops flashing, it is saved. After this, the
weekday flashes.
Set the current week day.
As soon as this stops flashing, it is saved.
With the ignition “ON” the display remains set, with the igni-
tion “OFF” it goes out after 10 s.
16.2.3.2 Adjusting the time and day of week
Press longer until the time flashes. Then proceed as descri-

bed above in section 16.2.3.1.
By pressing 2 x after setting the clock the adjustment op-
tion for the weekday can be skipped.
By pressing after setting the weekday the flashing of the
weekday can be shortened.
With the ignition switched on the time and week day are con-
stantly displayed. When the ignition is switched off the dis-
play goes out after 15 s.
Voltage interruptions are bridged by the heater timer.
After voltage interruptions, all signals on the display are
flashing. The system must be completely reset!
200−1−1160−063b_en 9/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
10/27 200−1−1160−063b_en
16.2.4 Heating operation without pre−set times

(Z 36 739)
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
80 C (176 F ) engine temperature so that the heating system
can be vented 100 %.
16.2.4.1 ... with the ignition ”OFF”
Switch on the heater

Heating symbol = observe the service indicator light.
Press briefly.
Display: Operation, heating time.
The heating time is set at a default of 120 minutes. It be changed

as a one−off or permanently.
Changing the heating time as a one off

Switch on the heating.
Press − shorten (min. 1 minutes) or lengthen (max. 120 mi-
nutes) heating time
Changing the heating time permanently

Do not switch on the heating
Press and hold approx. 3 s until the display appears and flas-
hes. Release briefly.
Press − shorten (min. 10 minutes) or lengthen (max. 120 mi-
nutes) heating time
When the display goes out, the new heating time is saved.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
200−1−1160−063b_en 11/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
12/27 200−1−1160−063b_en
16.2.4.2 ... with ignition ”ON”

(Z 36 739)
Switch on the heater

Press briefly.
Display: Operation, time, day of week.
The heater remains in operation as long as the ignition is swit-

ched on. After switching off the ignition, 15 minutes residual hea-
ting time remains.
Changing the residual heating time

Switch on the heating.
Press − shorten (min. 1 minute) or lengthen (max. 120 minu-
tes) residual heating time.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
16.2.5 Heating operation with preselection

(Z 36 739)
Starting point: Neutral position, as long as the display is visible.

No memory activated.
Three starting times can be set within the next 24 hours or 1 star-
ting time within up to 7 days.
Only 1 starting time can be activated at once.
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
80C (176 F ) engine temperature so that the heating system
can be vented 100 %.
200−1−1160−063b_en 13/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
14/27 200−1−1160−063b_en
16.2.5.1 Heating start within 24 hours
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The selected time is shown flas-

hing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Press to select a memory again.
Set the preselected day

The preselected day is set automatically. It is therefore not
necessary to set it.
The selected time and day are stored as soon as the time
display goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for 5 s)
200−1−1160−063b_en 15/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
16/27 200−1−1160−063b_en
16.2.5.2 Heating start after 24 hours (max. 7 days)

(Z 36 739)
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The selected time is shown flas-

hing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Set the preselected day

Approx. 5 s after setting the selected time the selected day is
shown flashing.
Press to set the preselected day for the heater.
The selected time and day are stored as soon as the time
display goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for 5 s)
200−1−1160−063b_en 17/27
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
18/27 200−1−1160−063b_en
16.2.6 Rectifying faults

In case of faults or damage to the heater, an authorised service
outlet must be contacted to repair the damage using original
spare parts.
Repairs in house are therefore not permitted.
Proceed as follows:
− switch off and on (not more than twice)
− check main fuses
− check that the air flow is not blocked
− go to a workshop.
If a fault occurs when the heating is switched on and the diagno-

sis line is connected, the service indicator light flashes and
the code no. of the fault is displayed (contact garage).
200−1−1160−063b_en 19/27
16
7 8 9 10
2
1 3
0 4
11
Z 54 356
20/27 200−1−1160−063b_en
16.3 Air Conditioning Equipment (Standard, Optional)

(Z 54 356)
The air conditioning unit only works when the engine is running
and the fan is switched on. Proceed as follows in order to operate
the air conditioning unit:
1. Set switch (8) to the desired fan setting.
2. Press luminous switch (11); the indicator light in the switch

lights up.
The air conditioning unit works permanently with maximum per-

formance. The actual cooling performance is determined by the
selection of the fan setting.
In order achieve maximum cooling in the cab:

− Set fan to highest setting using switch (8).
− Turn switch (9) fully to the left (anti−clockwise) up to the stop.
− Fully open the ventilation nozzles.
− Activate luminous switch (10) for surround operation.
− Close windows and doors of the cab.
Instructions on operating the air conditioning unit
If the cooling performance of the air conditioning unit decreases

noticeably even though the switch settings have not been chan-
ged, it is possible that the vaporiser has become iced up.
In this case, switch the air conditioning unit off for approx. 3 minu-
tes with the vaporiser fan still running. The ice on the vaporiser
will melt.
On damp days the air conditioning unit can dehumidify the cab
air. Cooling is compensated by the heating. This then achieves
a pleasant cab climate and prevents windows fogging up.
Cold air coming out of the ventilation nozzles must not be allowed
to flow directly over unprotected skin.
The air conditioning unit must be switched on at least once

a month for a short period of time (compressor lubrication).
200−1−1160−063b_en 21/27
16
7 8 9 10
2
1 3
0 4
11
Z 54 356
205.1
205
Z 56 153
22/27 200−1−1160−063b_en
16.4 Auxiliary AC system (optional)

(Z 54 356, Z 56 153)
For special climate situations the cab can be equipped with an

additional AC system.
The housing (205) is then fitted in the cab.
The air conditioning equipment works like the standard AC only
when the engine is running and the fan switched on. The air con-
ditioning works permanently with maximum power.
Proceed as follows in order to operate the air conditioning unit:
1. Set switch (205.1) to the desired fan level.
2. Press luminous switch (11); the indicator light in the switch

lights up.
The auxiliary AC is then switched on with the same switch (11) as

the standard AC.
Whether and how the standard and auxiliary AC systems provide
cool air depends on the position of the fan switch.
When the fan is switched off, the corresponding AC does not pro-
vide a cooling function.
In order achieve maximum cooling in the cab:

− Set the fan to the highest level using switch 8 and (205.1)
− Turn switch (9) fully to the left (anti−clockwise) up to the stop.
− Open the vent nozzles in the cab and housing (205) of the au-
xiliary AC system completely
− Activate luminous switch (10) for surround operation.
− Close windows and doors of the cab.
The instructions for operating the AC system in section 16.3 ap-

ply in the same way.
200−1−1160−063b_en 23/27
16
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
24/27 200−1−1160−063b_en
16.5 Petrol gas heating (engine−independent), optional

There is an operating panel for operating the liquid gas heating
system in the cab.
Depending on the design of the crane, operating panels with sli-
ding switches or a combined rotary switch are used.
Operating panel with sliding switches
(Z 56 140, principle drawing)
Set the desired room temperature at the control knob (1) of the
operating panel.
Using sliding switch (3), either operating modes “Heat” (C) and
“Ventilation” (E) can be set or the system can be switched off
(switch in middle position ’D’).
Using sliding switch (2), the heating performance can be set in
two stages.
Operating panel with combined rotary switch
(Z 56 138)
The upper part of the rotary switch is designed as a rotating knob

(1.1) and is used as a temperature selection switch.
The lower part (1.2) of the rotary switch is used to switch the sy-
stem on and off (d) and is used to set the two operating modes
“Heat” (c) and “Ventilation” (e).
The heater setting and ventilation output can be set in two sta-
ges.
Heating
Proceed as follows to switch on the heating:
1. If fitted, remove the flue cap.
2. Open the bottle valve and quick−closing valve in the gas.
3. Set the desired room temperature using the control knob (1,
Z 56 140 or 1.1, Z 56 138) of the operating panel.
4. Depending on the operating panel, set heating using the sli-

ding switch (2, Z 56 140) or, if the operating panel has a com-
bined rotary switch, set heating (”FULL, large flame” or ”1/2,
small flame”) using the lower part of the rotary switch (1.2).
At low ambient temperatures leave the heating running on
”FULL”.
200−1−1160−063b_en 25/27
16
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
26/27 200−1−1160−063b_en
Ventilation
If the operating panel has sliding switches, slide sliding switch (3)
to position (E) in order to activate the fan.
If the operating panel has a combined rotary switch, the lower

part of the rotary switch (1.2, Z 56 138) is set to the desired venti-
lation degree (”FULL” or ”1/2”) in order to activate the fan.
Notes on heating operation

(Z 56 140, Z 56 138)
If the system is activated, the green indicator light under the con-
trol knob must be illuminated. The fan is in operation.
If the control lamp is not illuminated, the fuse in the electronic con-
trol unit must be replaced (see maintenance and lubrication in-
structions).
If the heating is switched off after a heating phase, the green light
means that the fan is still running to use up the residual heat. The
ignition switch may therefore only be switched off once the fan
has come to a standstill.
When refuelling and in enclosed spaces (garage etc.) the heating

may not be operated.
Uninterrupted display of the red control lamp can, amongst other

things, point to a lack of gas, air in the gas line, heavily clogged
blower or malfunction in one of the safety units.
The fault can be deactivated by switching the heating off and
back on again.
Flashing of the red indicator lamp points to low operating voltage

for the heater.
Make sure that the exhaust flue and combustion air intake is al-
ways clear of clogging (slush, foliage etc.).
The cap for the flue must always be fitted when the heating is not
in operation.
For operation and servicing of your heater, see also the operating
instructions of the manufacturer in part 3.
Before carrying out any welding work, the corresponding fuse

breaker must be removed, switched off.
200−1−1160−063b_en 27/27
Reeving 17
200−1−1170−240e_en 1/41
17
Z 53 401
2/41 200−1−1170−240e_en
Reeving 17
17 Reeving
17.1 General Notes

(Z 53 401, similar depiction)
The safety of the crane is endangered by incorrect reeving.
Every configuration is assigned a corresponding reeving

number that is shown in the load capacity tables supplied.
Work only in accordance with the reeving numbers listed!
The corresponding reeving number must be set on the load
limit device (IC−1).

If, however, single−line reeving is required, the lifting
capacities specified in the table must be reduced by 20%.
This also applies when the lifting capacity is less than the
maximum permitted cable tension per strand (see Notes on
Crane Operation).
When fitting a new hoist rope, which has never been placed
under load, twisting problems can occur. For this reason, we
recommend that a spin stabiliser be used (1, Z 53 401,
similar depiction)).
Transport dimensions spin Approx.

stabilizer weight
Length Width Height
mm mm mm kg (lbs)
(in) (in) (in)
350 mm 80 mm 80 mm 8.0 kg
(13.8 in) (3.2 in) (3.2 in) (17.6 lbs)
200−1−1170−240e_en 3/41
17
Z 55 762
“a” “b”
ca. 1250
ca. 1500
Z 55 732
4/41 200−1−1170−240e_en
Reeving 17
(Z 55 762, Z 55 732)
If a spin stabiliser (1) is fitted to the rope attachment point of

the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to the bottom edge of the
hoist limit switch) must be AT LEAST approx. 1500 mm
(59 in) (see ”a” in figure Z 55 732). Only then is it ensured
that the switch−off of ”Raise hoist” is carried out by the hoist
limit switch within a sufficient distance of the lowest point of
the main boom head. Otherwise there is risk of damage!
If the chain is not long enough for this, the additional chain
which is supplied with the spin stabiliser must be fitted as an
extension.
If a spin stabiliser is not fitted to the rope attachment point

of the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to bottom edge of the
hoist limit switch) must be AT LEAST approx. 1250 mm
(49 in) (see ”b” in figure Z 55 732).
In order to achieve maximum hoist heights, a longer chain
could be used once it is shortened. However, the length must
always be at least 1250 mm (49 in). RISK OF DAMAGE!
200−1−1170−240e_en 5/41
17
3
2
Z 52 210
6/41 200−1−1170−240e_en
Reeving 17
17.2 Load Lifting Equipment

(Z 52 210)
If a load is to be raised with the crane, so−called load lifting

devices are required to raise the said load. These are:
− Carrying Equipment
Carrying equipment is permanently connected to the crane.
This includes:
− hoist ropes (1, see section 17.2.1)
− hook blocks (3, see section 17.2.2).
− Load−handling devices
Load−handling devices are equipment, for example lifting
beams, that are not part of the crane. They are connected to
the carrying equipment and take up the load.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
− Lifting tackle
Lifting tackle is equipment, e.g. sling ropes, which does not
belong to the crane. They connect the carrying equipment
and load or carrying equipment and lifting devices.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
To ensure that the load−handling equipment is used

correctly the individual national regulations, for example the
accident prevention regulations ”Load handling equipment
in hoist operations” (GUV−V9a)” must be observed.
200−1−1170−240e_en 7/41
17
8/41 200−1−1170−240e_en
Reeving 17
17.2.1 Hoist Ropes
17.2.1.1 General Notes
Information on how to handle ropes safely and correctly is

contained in section 11 of the lubrication and maintenance
instructions for the chassis.
When reeving there is a risk of becoming caught and

entangled in the head− and deflection rollers as well as in
the hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
Risk of overloading and accidents!

If a rope has to be replaced, the new rope must satisfy the
technical parameters of the original rope, for example with
regard to rope diameter, nominal tensile strength,
calculated breakage force, minimum breakage force, type
of lay etc. in accordance with the rope certificate in the
crane logbook.
If this is not the case, the operational reliability of the crane
in the normally permitted lifting capacity range is no longer
guaranteed!
The length of the ropes of hoist 1 and hoist 2 is 345 m (1132 ft)
each.
200−1−1170−240e_en 9/41
17
2
2
Z 52 212
3
4
4
Z 52 211 Z 52 213
10/41 200−1−1170−240e_en
Reeving 17
17.2.1.2 Rope End Connections
Risk of accidents!
If the rope connection is not made correctly as described
below, the hook block / load could fall!
Rope end connection with press fitting

(Z 52 211, Z 52 212, Z 52 213)
The rope end connection with press fitting is made up of the

following elements:
(1) − Locking pin and mushroom handle
(2) − Protect trap
(3) − Press fitting on the end of the hoist rope
(4) − Rope pocket
Proceed as follows to make the rope end connection as

described below.
(Z 52 212, Z 52 213)
1. Release the locking pin (1) from the lock at the
corresponding bore hole of the rope pocket (4) by pulling its
domed head handle against the spring resistance, and fold
out the safety flap (2).
200−1−1170−240e_en 11/41
17
Z 52 211
12/41 200−1−1170−240e_en
Reeving 17
(Z 52 211)
2. Attach hoist rope with press fitting (3) to rope pocket (4).
3. Fold over the safety flap (2) on the mushroom handle of

locking pin (1) into position ”lock” and allow the locking pin
(1) to lock in the corresponding hole of rope pocket (4).
Safety flap (2) prevents the press fitting being released from
the rope pocket when the hoist rope is not under load (e.g.
when the hook block is set down suddenly on the ground).
Risk of accidents!
The hoist rope may only be placed under load later when
the press fitting (3) is secured with safety flap (2) and the
locking pin (1) is locked in place.
In the design that is described and shown, the rope pocket

may only be used for low−twisting / non−twisting ropes.
Before reeving a hoist rope with press fitting all rope

protection arrangements such as rollers or bolts on the
deflection rollers or idlers to be reeved must be removed or
opened.
If this is not done the hoist rope cannot be drawn through
with the press fitting or may cause damages.
200−1−1170−240e_en 13/41
17
1
2
Z 41 377
1
1
5
4a 4b
4a
Z 200 177 Z 41 379
14/41 200−1−1170−240e_en
Reeving 17
Rope end connection without press fitting

(Z 41 377, Z 200 177, Z 41 379)
The illustrations of the rope socket (1) and the cable clip (3)
are principle drawings and do not correspond exactly with
the components supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.
In order to fit the rope socket (1), first the free rope end is pulled
through the conical rope pocket, laid in a loop and then pulled out
of the rope pocket again. The rope key (2) is laid into the rope loop
and the hoist rope is pulled through the rope socket (1), so that
the free end juts out by approx. 8 times the width of the rope
diameter.
Danger of the load and / or the hook block falling down!
200−1−1170−240e_en 15/41
17
Z 200 342 Z 200 343
1
1
5
4a 4b
4a
Z 200 177 Z 41 379
16/41 200−1−1170−240e_en
Reeving 17
Using a cable clip (3), the ”unloaded“ rope end (4a; Z 200 177)
is now secured where it comes out of the rope socket at a
distance of approx. 3 times the width of the rope, so that the hoist
rope is not pulled through.
The free end is connected with Litz wire (5) ø1.5 mm (0.06 in) from
the rope clamp to prevent the hoist rope from being pulled
through.
(Z 41 379)
Risk of damage to the rope!
The cable clip may not be attached in such a way that it
connects the ”loaded” (4b) and ”unloaded” ropes (4a) with
each other.
(Z 200 342)
When fitting the rope socket you must make sure that the
”loaded” rope (4b) runs through the rope socket in such a way that
the tension force’s line of action runs exactly through the
fastening pin without bending the cable when the end connection
is loaded.
(Z 200 343)
When fitted incorrectly, the end connection will align itself
whenever loaded so that the tension force’s line of action
runs through the fastening pin, bending the highly loaded
”loaded” rope of the cable at the rope pocket exit every time.
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 creates 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.
200−1−1170−240e_en 17/41
17
E1
11 3−TOP
12
13
K
Z 52 200 Z 53 402
18/41 200−1−1170−240e_en
Reeving 17
17.2.1.3 Reeving / Unreeving the Hoist Rope

(Z 52 200) (Z 53 402, similar depiction)
Stepping onto the main boom
Risk of accidents!
There is a risk of accidents when stepping onto the main
boom due to slipping / stumbling.
For this reason, it is prohibited to step onto the main boom.
Reeving
Before reeving and before starting crane work, check the

status of all accessible ropes (including the end
connections), winches and sheaves.
1. Position the hook block beneath the main boom head so that
it is stable.
Work may only be carried out on the hook block (reeving
and unreeving) when it is set down and stable on solid
ground.
2. Remove bolts for rope guard (11) from the hook block and
fold out the rope protection plate (12).
3. Remove the bolt for the rope guard (13) from the main boom
head.
4. Guide the hoist rope from the hoist via the main boom to the
guide sheave (E1) on the main boom head.
Guide sheave (E2) is optional.
While the crane operator is using the hoist, the hoist rope
must be guided by a helper to prevent slack rope from
forming.
200−1−1170−240e_en 19/41
17
E1
11 3−TOP
12
13
K
Z 52 200 Z 53 402
20/41 200−1−1170−240e_en
Reeving 17
(Z 52 200) (Z 53 402, similar depiction)
5. Guide the hoist rope via guide sheave (E1) to the sheaves
(K) in the main boom head and reeve in accordance with the
corresponding reeving diagram (see section 17.3).
6. Fit the bolt for rope guard (11) on the hook block and (13)
reattach on the main boom head and secure. To this end the
rope protection plate (12) must be folded in again on the
hook block.
7. Fit rope end into rope socket (if this has not already
beendone). Follow the instructions in section 17.2.1.2 ”Rope
End Connections”.
200−1−1170−240e_en 21/41
17
”A”
FKr
F Kl
Z 53 409
2 1
Fu
3
2
2a 2b
Z 52 214 Z 52 209
22/41 200−1−1170−240e_en
Reeving 17
(Z 53 409, Z 52 214, Z 52 209)
8. Bolt the rope socket or rope pocket to the corresponding

fixing point:
− with uneven number of rope strands fixing point on the
hook block (FU, Z 52 209)
− with even number of rope strands fixing point on the main
boom head, here: right side − (Z 53 409)
9. Release the shift weight of the hoist limit switch from the
transport position (”A”, Z 53 409), remove both clip pins and
pull the two halves (2a) and (2b) of the shift weight apart.
10. Guide the separated halves of the shift weight around the
hoist rope and secure again with clip pins.
The condition shown in picture (Z 52 209) must be shown.
The shift weight should be fitted on the ”resting” rope. This

avoids wearing of the hoist rope and shift weight.
The ”resting” rope is the rope line that goes to the fixing
point:
Make sure that the shift weight is hanging free. Only then is
it guaranteed to function properly.
RISK OF DAMAGE!
If the shift weight of the hoist limit switch is not − as
described − fitted on the hoist rope, the hoist stroke
limitation does not work.
There is a risk of damage to the rope, sheave and shift
weight.
200−1−1170−240e_en 23/41
17
24/41 200−1−1170−240e_en
Reeving 17
Unreeving
In principle, unreeving is carried out in the same as reeving, only

in the reverse order.
In particular pay attention to the following points:
− Tipping over of the stationary hook block
Work may only be carried out on the hook block (reeving
and unreeving) when it is set down and stable on solid
ground.
− Sudden release of the hoist rope end from the hook block
Risk of accidents!
When unreeving, the hoist must be operated carefully and
the hoist rope wound slowly.
The area around the hook block must be kept clear at all
times.
− Watch the winding pattern of the hoist rope when reeling in

the rope. There must be no slack rope.
200−1−1170−240e_en 25/41
17
Z 50 696
26/41 200−1−1170−240e_en
Reeving 17
17.2.2 Hook Blocks

(Z 50 696)
17.2.2.1 Definition
In DIN 15002 the hook block is defined as the ”multiple line

suspension of carrying equipment with a hook”.
A single−line suspension would be referred to as a hook

suspension gear. As this differentiation is not relevant for the
following general contexts, only the description ”hook block” is
used.
Only hook blocks may be used which have been obtained

from the crane manufacturer.
The use of other hook blocks is only permitted following
consultation with the crane manufacturer.
17.2.2.2 Markings
The following details must be permanently and legibly marked on

hook blocks:
− Warning marking
− Manufacturer or supplier
− Year of construction
− Type, if type designation applies
− Factory or serial number
− Permitted load
− Rope diameter
− Drive group
− Dead weight.
200−1−1170−240e_en 27/41
17
Z 42 980
28/41 200−1−1170−240e_en
Reeving 17
17.2.2.3 Operation
(Z 42 980)
When reevingthere is a risk of persons becoming caught

and dragged into equipment and crushing near rotating
and moving components on the hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
In particular the following points must be observed:

− The personnel (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

should be taken as a result of swinging loads or hook
blocks.
Once the load has been attached or released, the fitter must
leave the slewing or hazardous area immediately.
The fitter must be easily recognisable to the crane operator.

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These items of recognition must be of a distinctive colour
and preferably all in the same design and must be
worn/carried exclusively by the person connecting up the
load.
Before starting movements of the winches (raising or

lowering) all persons must leave the danger zone 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.
200−1−1170−240e_en 29/41
17
Z 42 975
Z 50 697 Z 42 976
30/41 200−1−1170−240e_en
Reeving 17
(Z 50 697, Z 42 975, Z 42 976)
− Touch the hook block only using the handrails provided. The
hands must be KEPT CLEAR of the following areas:
∗ between the sheaves, side plates and covers.
∗ in the area of the fixing points (sometimes of a folding
design), the hook, the hook nut, the lifting beam or the
protecting cages.
− Make sure that items of clothing do not get caught in rotating
parts.
− Work on the hook block may only be carried out (i.e. reeving),
when it is set down in a stable position on firm ground.
Be aware that the hook block could still tip over however!
− Only use the hook block for lifting in the vertical direction.
Pulling sideways is not permitted.
− Place the hook block under load slowly and evenly.
No sudden loads! No one−sided loads!
− 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 twin hook.
Welding on the hook block is prohibited.
200−1−1170−240e_en 31/41
17
32/41 200−1−1170−240e_en
Reeving 17
17.2.2.4 Hook Block Types / Transport Dimensions / Weights
Hook block Description Hook Transport dimensions

type size * Length Width Height
mm mm mm
(in) (in) (in)
200−9/21−D 9−sheaves, twin hook, weight 2100 mm 680 mm 1000 mm
1900 kg (4190 lbs), (82.7 in) (26.8 in) (39.4 in)
with double−sided HD attachment 40
or with one−sided HD attachment
(max.16 falls)
1500 kg (3307 lbs) , (74.8 in) (26.8 in) (29.5 in)
with one−sided HD attachment
max. 15 falls 32
without HD attachment
max. 12 falls
32
1125 kg (2480 lbs) max. 11 falls, (74.8 in) (26.8 in) (21.7 in)
80−3/21−E 3−sheaves, single hook, weight 1800 mm 680 mm 350 mm
20
850 kg (1874 lbs) max. 7 falls (70.9 in) (26.8 in) (13.8 in)
20
850 kg (1874 lbs) max. 7 falls, (68.9 in) (26.8 in) (17.7 in)
3−sheaves, twin hook, weight 1750 mm 680 mm 350 mm
1150 kg (2535 lbs) with removable 20 (68.9 in) (26.8 in) (13.8 in)
weight elements**, max. 7 falls
32−1/21−E 1−sheave, single hook, weight 1650 mm 680 mm 300 mm
10
600 kg (1323 lbs), max. 3 falls (65.0 in) (26.8 in) (11.8 in)
32−1/21−D 1−sheave, twin hook, weight 1550 mm 680 mm 300 mm
10
600 kg (1323 lbs), max. 3 falls (61.0 in) (26.8 in) (11.8 in)
12.5−0/21−E Hook suspension gear, weight 950 mm 350 mm 350 mm
5
350 kg (772 lbs) (37.4 in) (13.8 in) (13.8 in)
12.5−0/21−E Hook suspension gear, weight 950 mm 400 mm 400 mm
350 kg (772 lbs) with removable 5 (37.4 in) (15.8 in) (15.8 in)
weight elements**
* Hook size in accordance with DIN 15401 (single hook) or DIN 15402 (twin hook)
** If there are removable weight elements on a hook block and they are fitted, they
must be screwed or bolted on tightly, depending on the design, and secured
against falling off.
200−1−1170−240e_en 33/41
17
1x 2x 3x 3x 4x
3 3
1 1 1 3
2 1
1
2 2 4
2
5x 6x 7x 7x 8x
5 7 5 8 7
3 5 3 3 1 6 5 3 1
1 1 4
7 5 2
4 2 6 6 4 3 6
4 2 1 4
2 2
12x 13x
9x 10x 11x
11 9 13 11 9 7 5
10 7 5 3 3 1
9 9 7 5 11 9 7 5 1
7 5 3 1 12
3 1 3 1 10 12 10 8 6
10 8 8 6 8 4 2
8 6 4 6 4
6 4 2 4 2 2
2
14x 15x 16x 17x
14 6
13 5
11 9 7 5
3 1
8 7 5 8 3 10 9
10 5
10 1 12 12
6 7 4 14 7
12 10 8 3 21 12 14 8 6 3
6 4 9 11 4 11 4 14 16
2 9 2 11 13 2
13 15 13 15 1 15 17
16
Z 200 660
34/41 200−1−1170−240e_en
Reeving 17
The weights of the hook blocks, hook suspension gear, lifting

devices, etc. must be deducted from the working loads in the
tables.
17.3 Reeving the Hoist Rope on the Main Boom Head
The safety of the crane is impaired by incorrect reeving!

This is why you must follow the reeving examples in figure
Z 200 660.
(Z 200 660)
Other reeving configurations would disrupt the function of the

load limit device.
The following hook blocks can be used:
The weights of the hook blocks, hook suspension gear, lifting

devices, etc. must be deducted from the working loads in the
tables.
Only use original hook blocks suitable for this crane. If you
wish to use other hook blocks, you must first contact our
customer service departments.
200−1−1170−240e_en 35/41
17
36/41 200−1−1170−240e_en
Reeving 17
17.4 Reeving the Hoist Rope on the Main Boom Headwith

Auxiliary Sheaves (HD attachment, optional)
Risk of accidents!
Only the original HD attachment of the crane manufacturer
for this crane type may be used!
For the use of other additional equipment the crane
operator carries sole responsibility.
17.4.1 Information on Transport and Attachment Points
17.4.1.1 Attachment Points
Risk of accidents!
There are no attachment points welded to the HD
attachment. For this reason, it must be attached with a
looping tackle.
The actual attachment procedure must be undertaken
with the utmost care.
RISK OF ACCIDENTS!
claws must be used.
17.4.1.2 Transport Dimensions / Weights

mm mm mm kg (lbs)
(in) (in) (in)
HD attachment 1125 mm 243 mm 613 mm 91.0 kg
2−sheave (44.3 in) (9.6 in) (24.1 in) (200.6 lbs)
Sheave for 524 mm 524 mm 80 mm 15.7 kg
double−sided HD (20.6 in) (20.6 in) (3.2 in) (34.6 lbs)
attachment
200−1−1170−240e_en 37/41
17
2
1
5
3
4
4
Z 200 345
38/41 200−1−1170−240e_en
Reeving 17
17.4.2 Fitting and Removal of One−Sided Fitted HD

Attachment
(Z 200 345)
In the standard design there are 6 sheaves on the axle (2) of the
main boom.
For reevings above 12 falls, it is possible to attach
additionalsheaves (3, HD attachment).
Stand the main boom axis (2) on its end, push on HD attachment
(3) and secure with bolt (1) as shown.
Secure the bolts (1) on both sides with locking pins (5).
To reeve the hoist rope on the HD attachment (3) the three rope
locking pins (4) can be removed.
Immediately after fitting the hoist rope all 3 rope locking pins (4)
must be fitted again and locked.
The HD attachment is removed in the same way, in the reverse

order.
When using the heavy duty device, you must move the hoist limit
switch from the head and hang it onto the heavy duty equipment.
The existing forelock must be used for locking.
Only the heavy duty equipment supplied by the crane

manufacturer may be used.
The crane manufacturer is not responsible for possible
accidents or damage caused by the use of incorrect
optional equipment.
200−1−1170−240e_en 39/41
17
61 62
”X...”
”X0550” F
B1 A H B2
63
Z 200 442 Z 200 441
40/41 200−1−1170−240e_en
Reeving 17
17.4.3 Fitting and Removal of Double−sided Fitted HD

attachment
In the standard design there are 6 sheaves on the axle (2) of the
main boom.
For the heavy duty equipment mounted at both sides, there are
additional sheaves mounted to the left and right side of the main
boom head. The hook block is reeved with the hoist rope of
thehoist 1 and the hoist rope of the hoist 2. This means that
17−foldreeving is possible with the hook block ”Type 200”.
Only the heavy duty equipment supplied by the crane
manufacturer may be used.
The crane manufacturer is not responsible for possible
accidents or damage caused by the use of incorrect
optional equipment.
Risk of rope damage!

The fact that two hoist ropes are reeved at the same time for
this reeving can cause slight crooked positions of the hook
block. This is not permitted.
For this reason an additional person must observe the
behaviour of the hook block from the outside and, if the
hook block is in a crooked position, he must instruct the
crane operator to straighten the hook block again by
driving the corresponding movement!
Connecting the hoist limit switches / Electrical safety chain

(Z 200 442, Z 200 441 principle illustrations)
In the event of a reeving in which two hoist ropes are participating,

two hoist limit switches on the ”X0550” junction box on the
left−hand side of the main boom head must also be connected.
To connect the first hoist limit switch, see description of the
”Electrical safety chain” in section 10 (”Safety devices”).
An adapter cable is connected for the purpose of connecting the
second hoist limit switch to Connection ”A” (Z 200 441). The
second hoist limit switch is connected to the free end of the
adapter cable.
200−1−1170−240e_en 41/41
Main Boom Extension (MBE) (Optional) 18
18 Main Boom Extension (MBE) (Optional)
18.1 GeneralInformation
The tension bars of the main boom extension (”MBE” in the

following) must be checked at least once a year by a
technical expert (in accordance with the accident prevention
regulations ”Load receptacle devices in lifting devices
operation”, VBG 9a).
They should also be checked by a specialist in the meantime
depending on the applications of use and the operating
conditions. The inspection intervals are generally
determined by the operating and site conditions. This means
that inspections are carried out more frequently as the crane
equipment is used more.
This inspection must be documented once it has been

carried out (e.g. in the examination log book for the crane).
The following checks should be made:

* Check for cracks
* Check the length
* Check for wear
* Check the paintwork
* Check for plastic deformation.
Instructions on carrying out the checks can be found in the
”Maintenance and lubrication instructions for the
superstructure”, part 3, section 11 ”Equipment”).
The inspection of the tension bars must be documented, along

with the results, in the crane log book under ”Inspection reports”.
The MBE is marked with the construction number of the

crane. It may only be fitted on the crane with this
construction number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).
200−1−1180−240c_en 1/129
18
72
73
2−EXPLICIT
3−EXPLICIT
Z 200 484 Z 55 536
72
Z 104 192
71 72
Z 54 839
2/129 200−1−1180−240c_en
(Z 200 484, Z 55 536, Z 104 192, Z 54 839)
Risk of falling!
A folding / sliding ladder (72) is supplied with the machine
so that it is possible to carry out all assembly procedures
with as little risk as possible. It is not permitted to climb or
walk on the main boom extension.
The supplied folding / sliding ladder (72) can be fastened under

the basic boom for transportation.
− If the folding/sliding ladder (72) is fitted on the basic boom

MBE the 4 plugs (71, tensioning straps) must be undamaged
and hooked in place.
There are brackets on the folding / sliding ladder (72) for

fastening the actuating rod (73). This actuating rod (73) can be
used as an aid when fitting the hoist rope.
There are plates on the main boom head and on parts of the main
boom extension for safe attachment of the ladders (72) during the
corresponding operating procedure (Z 104 192).
In addition make sure that there are no signs of damage to

the tubular construction of the lattice mast components. If
damaged tubes are discovered during visual checks,
further work with the MBE is prohibited!
200−1−1180−240c_en 3/129
18
4 3
4 3 2
4 3 2 1
Z 200 444
4/129 200−1−1180−240c_en
18.2 Components
(Z 200 444)
Depending on the state of assembly, the MBE consists of the

following components:
− 9 m MBE (29.5 ft) parts 3
− 17 m MBE (55.8 ft) parts 3, 4
− 25 m MBE (82 ft) parts 2, 3, 4
− 33 m MBE (108.3 ft) parts 1, 2, 3, 4
The components of the MBE 9 m (29.5 ft) and 17 m (55.8 ft) can
be carried along on the side of the main boom for transportation,
if the relevant devices for this procedure have been fitted. The
permissible axle loads must be observed.
When raising loads with the MBE 9/17 m (29.5 ft / 55.8 ft)
folded alongside, the load values in the tables are reduced.
See ’instructions for crane operation’ enclosed with the
supplied set of tables.
The procedure for folding the MBE from the transport position to
the operating position is described in section 18.4 from page 17.
Parts 3 and 4 CAN, parts 1 and 2 MUST be transported

separately.
Information on fitting the parts for separate transportation can be

found in section 18.5 from page 61.
The MBE is folded over and raised onto the rollway and pinned
at the pivotal point by means of a hydraulic cylinder.
These are marked with number plates which correspond to the
item numbers in the following description and the positions of the
selector switch on the mobile control panel.
Actual swivelling from the transport position into the working

position is done manually using an auxiliary rope.
200−1−1180−240c_en 5/129
18
4 3
4 3 2
4 3 2 1
Z 200 444
32A 32B A
31 31
Z 200 459
6/129 200−1−1180−240c_en
(Z 200 444, Z 200 459 schematic diagram)
Connection between the individual components:
The connections between:

− the intermediate section 1 (1) and the main boom head,
− the basic boom 2 (2) and the main boom head or the
intermediate section (1),
− the basic boom (3) and the main boom head or the
intermediate section 2 (2),
− tip section (4) with the basic boom (3),
are all made using 4 biconical pins (31).

Each biconical pin must be secured against falling out using two
functioning safety elements.
Locking springs of the “type (32A)” and “type (32B)” are used.
Risk of accidents!
Only the supplied pins may be used to assemble the main
boom extension and for the transport position. (They have
a cylindrical design at one end (see detail A).)
Each pin must be secured against falling out using 2
functioning locking elements (32A) or (32B).
Only locking elements which were fitted in the first delivery
of the crane may be used.
All different types of securing elements (32) can be seen or

referred to in the graphics illustrations or in the associated text of
this section.
The only securing elements which may be used are those which
were installed in the corresponding position at the time of the
original delivery of the crane.
If pins are sluggish, the biconical pin (31) must be greased before
the pinning procedure.
200−1−1180−240c_en 7/129
18
4 3
4 3 2
4 3 2 1
Z 200 444
C 1 D B
Z 200 448
8/129 200−1−1180−240c_en
(Z 200 444)
Part Description Nominal Transport dimensions Approx.

no. length Length Width Height weight
(m / ft) mm mm mm (kg / lbs)

(in) (in) (in)
1 Intermediate 8,0 m / 8100 mm 1985 mm 865 mm 640 kg /
section 26.2 ft (318.9 in) (78.2 in) (34.1 in) 1411 lbs
2 Intermediate 8,0 m / 8270 mm 2025 mm 870 mm 925 kg /
section 26.2 ft (325.6 in) (79.7 in) (34.3 in) 2039 lbs
3 Basic boom 9,0 m / 9500 mm 1060 mm 1670 mm 1250 kg /
29.5 ft (374.0 in) (41.7 in) (65.7 in) 2756 lbs
4 tip section 8,0 m / 7970 mm 990 mm 500 mm 570 kg /
26.2 ft (313.8 in) (39.0 in) (19.7 in) 1257 lbs
18.3 Transport Instructions
18.3.1 Transport Instructions for the MBE in the Transport

Position
The following must be observed when driving the crane with the
MBE folded
in the transport position:
(Z 200 448)
− Observe the permitted axle loads.
− The folding cylinder (1) must be attached to the basic boom
of the MBE and retracted.
− The locking cylinder (3) must be fully extended (display plate
raised).
− The MBE must be pinned at the rear fixing point ”C” .
− The connecting pins between the basic boom MBE and tip
section (if fitted) must be pinned and locked.
− The tension bars of the basic boom MBE must be locked (D).
− The rollway must be folded up and pinned.
− All pins must be in a transport position which is secured
against falling out.
200−1−1180−240c_en 9/129
18
23
24
Z 200 360
71 72
Z 54 839
10/129 200−1−1180−240c_en
(Z 200 360)
− The shift weight (23) of the hoist limit switch must (depending
on its design) be inserted on the top piece of the MBE or on
the main boom and must be secured in place with locking
spring (24).
− The optional rotaflare light on the right−hand side of the
chassis cab must be dismantled (risk of collisions).
(Z 54 839)
− If the folding/sliding ladder (72) is fitted on the basic boom
MBE the 4 plugs (71, tensioning straps) must be undamaged
and hooked in place.
200−1−1180−240c_en 11/129
18
24
24 ”b”
24
”a”
Z 54 212
12/129 200−1−1180−240c_en
18.3.2 Transport Instructions for Separate Transportation
Observe the attachment points for the individual parts as

described in section18.5.2 on page 65.
Risk of crushing!
If the parts of the 17 m (55.8 ft) MBE (part 3 and 4) are
transported separately, folded together, there is a risk of
tipping over!
The components must be placed on the outrigger feet
supplied or on another suitable support (e.g. squared
timber) in order to ensure that they rest on the ground in a
stable way.
The components are not permitted to be suspended until
after lashing is completed, in order to ensure that the they
will not tip over.
The basic boom (3) is equipped with retractable support feet for
safe transportation of the basic boom (3) and / or of the basic
boom (3) with folded tip section (4).
(Z 54 212, schematic diagram)
Unlock the support feet (24) and slide down from position ’b’
(when raising loads) to position ’a’ (for support on the ground).
Secure both support feet with forelocks.
200−1−1180−240c_en 13/129
18
Z 200 264
Z 200 361 Z 200 118
14/129 200−1−1180−240c_en
(Z 200 264)
It must be ensured that the catch between the basic boom

MBE and tip section locks in place and that the retaining
rope is attached between the basic boom and tip section.
(Z 200 361)
The folding cylinder (1) on the main boom and the rollway must
be moved over and locked.
(Z 200 118)
Depending on the design of the crane the rollway is locked by

inserting pins (6, Z 200 118) (as shown) or by a catch pin locking
in place.
200−1−1180−240c_en 15/129
18
9B
9A
Z 200 119 Z 200 113
14
30
15
31
16
32
26
34 25
35 24
36
Z 160 649 Z 200 288
16/129 200−1−1180−240c_en
18.4 Folding up and down Procedure
When the MBE is not required, the 9 m (29.5ft) and 17 m (55.8

ft) MBE can be stored alongside the main boom − folded into the
transport position and pinned.
When driving in this condition, observe the applicable axle

loads!
18.4.1 General Instructions for Folding over the Equipment

The conditions listed below must be observed both for folding out
of the operating into the transport position (MBE 9 m; 29,5 ft:
section 18.4.2 from page 21 and MBE 17 m; 55.8 ft: section
18.4.3 from page 51) as well as in the opposite direction.
∗ Support the crane and MBE in accordance with the planned
configuration (MBE, counterweight, etc.) and fit the
counterweight (for details, see load tables).
∗ Slew gear brake applied.
∗ Main boom in the transport position (travel position: fully
telescoped in, pinned and horizontal) (see section 12,
Telescoping information system ”Length code selection for
travel positions”). View on display see Z 200 288).
∗ The anti−torsion catches must be fitted in place (on the right
and left−hand side of the main boom) (Z 200 119, area A).
To enable the folding procedure to be carried out without any

problems, the main boom must be completely retracted. The
stops between the telescopic sections must be flush. Some of the
stops have been fitted so that they are covered. It is not always
possible at a casual glance to recognise whether the stops are
fitted correctly.
The boom sections of the teleboom are pulled to the stops

hydraulically during pinning / unpinning (with cylinder 3) and
when pulling the MBE out or pushing it in (with cylinder 1)
sideways into the transport position. While the rocker switch
(9A/9B) on the remote control is being used, it is not possible to
carry out movements using the control levers in the crane
operator’s cab.
200−1−1180−240c_en 17/129
18
14
30
15
31
16
32
8
9B
26
9A
34 25
35 24
36
Z 200 113 Z 160 649
Z 200 288
18/129 200−1−1180−240c_en
(Z 200 113, Z 160 649, Z 200 288)
There is a mobile control panel with which the individual

movements can be monitored during the folding procedure (from
transport to operating position and vice versa). The procedure
description of the folding procedure depicts the use of the control
panel.
No other movements may be controlled with control levers (24)
and (16) at the same time.
Risk of crushing and collision on the front supports of the

telescoping sections. When the hydraulic cylinders 1 and
3 are actuated the boom sections automatically begin to
move in the retracting direction. Persons must therefore
stay well clear of hazardous zones and must not hold on to
the front bearings when hydraulic cylinders 1 and 3 are
actuated.
Depending on the design of your machine, the main boom must

be somewhat extended and the transport condition (Z 200 288:
display) must be recreated using the telescoping information
system (refer to section 12.2.1: LPU in the position ”Driving on the
road”) or additionally, the tele drive secured to the last boom
section must be retracted manually (see section 12 Telescoping
information system ”Manual telescoping”).
Before each pinning and unpinning procedure, the upper

and lower pins of the slewing point cylinder and the
biconical locking pins must be well greased.
When the MBE is folded from the transport− into the

operating position or vice versa or when working with the
MBE folded against the main boom, the mirror on the
superstructure must be folded away to the right.
The area in which the equipment is to be folded must be clear
of all obstacles.
When carrying out assembly work on the MBE use the

foldaway sliding ladders. Walking on the MBE or on the
top of the main boom is prohibited.
Risk of collision!
When folding over the MBE, the pins for connecting the
tension bars with the main boom head (for setting the
operating angles 20 and 40) may not be in the tension bars.
200−1−1180−240c_en 19/129
18
C 1 D B
Z 200 452
9B
9A
Z 54 840 Z 200 113
20/129 200−1−1180−240c_en
18.4.2 Folding the 9 m MBE (29.5 ft)
When folding and during pinning and unpinning there must

be no−one in the slewing range or beneath the MBE or in
areas at risk of falling equipment etc.
The order of the operating steps during the folding

procedure must be followed.
With 18.4.2.1 (from page 21) only the 9 m MBE (29.5 ft) is fitted
in the transport position on the main boom.
With 18.4.2.2 (from page 47) the 17 m MBE (55.8 ft) is fitted in the
transport position. However, only the 9 m MBE (29.5 ft) should be
folded into the operating position. The tip section remains fitted
on the basic case of the main boom in the transport position.
18.4.2.1 9 m (29.5 ft) MBE fitted in the transport position
18.4.2.1.1 Folding from the Transport into the Operating

Position
1. Observe all the instructions contained in section 18.4.1,

which contains general instructions for folding over the
equipment (from page 17).
2. Secure the draw and guide rope on the head of the basic
boom MBE.
You pull as well as brake the MBE using the draw and guide
rope.
3. Fold out the rollway; fit pins (1, Z 54 840) from the bottom up
and secure with fore locks.
4. Insert the mobile control panel (Z 200 113) in the socket of

the junction box on the right−hand page of the basic main
boom section at the front.
200−1−1180−240c_en 21/129
18
C 1 D B
Z 200 452
1 12
11
2
3.1
Z 200 364 Z 200 120
22/129 200−1−1180−240c_en
5. Start the engine of the superstructure.
Before releasing the connecting pins, make sure that the

MBE is pinned with the main boom at the pivotal point ”B”
(cylinder 3, Z 200 452). In addition, checks must be made to
ensure that the connecting piece of the swing cylinder (1)
has ”gripped” the MBE.
In addition, checks must be made to ensure that the
connecting piece (11) of the folding cylinder (1) has
”gripped” the MBE (Z 200 364).
6. Remove the pin (2) from point (C) with the help of the lever
drive (3) (Z 200 120, shown without MBE).
200−1−1180−240c_en 23/129
18
F
1 b
G
1 H(I)
c
Q G
F(G)
1
B d
3
1
Z 200 363 Z 200 127
31 32
8
9B
F
G 9A
32
31
Z 104 212 Z 200 113
24/129 200−1−1180−240c_en
When the MBE is subsequently folded, it must be ensured that

the lower head axis is turned as shown (Z 200 363).
(Z 200 363)
7. Extend the folding cylinder (1) carefully until the holes of the
fork ends are flush with the corresponding holes in the head
axis (F, G).
(Z 200 113)
To this end, switch the selector switch (8) on the mobile control
panel to position (1) and press the rocker switch (9B) until the
position is reached.
The MBE then rotates around pivotal point (B, Z 200 127 “d”).
When folding the lattice mast top section from the transport−
into the operating position there are risks of crushing,
shearing or falling objects (e.g. forgotten tools).
There must therefore be no−one in the endangered area
during the folding procedure. It is prohibited to step between
the lattice mast top sections and the main boom!
Risk of crushing and collisions on the front bearings of the

telescopic sections as a result of boom sections moving in
the retracting direction (see also section 18.4.1 from page
17).
RISK OF DAMAGE!
If the hoist limit switch is fitted on the right−hand side of the
main boom head, it must be removed before the following
insertion of the lower biconical pins (3) in fixing point (G).
8. Lock the MBE at the boom head axes at fixing points (F) and
(G) with pins (31) and secure the pin with locking springs (32)
(Z 104 212).
The pins (31) and the locking springs (32) can be found in point
(Q) (Z 104 212, Z 200 363).
The telescopic sections must, when folding the MBE into the
operating position, be completely telescoped in.
200−1−1180−240c_en 25/129
18
8
B
3 9B
9A
Z 200 113
15
35
3
Z 200 123 Z 200 470
F
1
Q G
Z 200 121
26/129 200−1−1180−240c_en
Risk of collision!
When folding over the main boom extension during one of
the following steps, the pins (35) for connecting the tension
bars with the main boom head (operating angles 20° and 40°)
may not be in the tension bars.
9. Check whether pins (35) are in the ”resting position” as

shown in figure (Z 200 470).
RISK OF ACCIDENTS!
During the following unpinning procedure in point (B),
no−one may be under the main boom extension or in the
area where there is a risk of objects falling.
If the MBE is not held by the draw and guide rope, it can fold
away to the side during unpinning.
(Z 200 123, depicted without MBE)
10. Disconnect the MBE from the basic boom section of the main
boom by retracting the cylinder (3) in point (B).
To do, first remove rope (15) from the holding device. Pull this
rope, pulling back the safety catch of the locking cylinder (3).
This unlocks it. The safety catch must be held in this position
until the locking cylinder (3) is retracted, as described in the
following.
(Z 200 113)
To do so, switch the selector switch (8) on the mobile control
panel to position ”3”. Press the rocker switch (9A) down, until
the cylinder (3) is completely retracted.
It is only permitted to unpin the locking cylinder (3) when

the MBE is unpinned at the front of the main boom head.
(Z 200 121)
The locking cylinder (3) and the pins on the main boom
head (F) and (G) may never be unpinned at the same
time.
RISK OF ACCIDENTS!
200−1−1180−240c_en 27/129
18
1 12
11
15
Z 200 471 Z 200 364
9B
9A
37
Z 200 113 Z 200 460
28/129 200−1−1180−240c_en
(Z 200 471)
RISK OF ACCIDENTS!
After use, wind the rope (15) for releasing mechanical
retraction lock from cylinder (3) back onto the
corresponding device. It must not, under any
circumstances, hang loose, as pulling on this rope could
release the mechanical retraction lock of the cylinder (3).

the retracting direction (see also section18.4.1 from page
17).
(Z 200 364)
11. Extend the folding cylinder (1) carefully until the main boom
extension has moved down from the rollway.
(Z 200 113)
To this end, switch the selector switch (8) on the mobile control
panel to position (1) and press the rocker switch (9B) until the end
position is reached.
The MBE then rotates around the slewing point (F/G).
(Z 200 364)
12. Detach the folding cylinder (1) as follows:
Using the rod supplied, raise safety piece (11) and, if
necessary, at the same time retract the folding cylinder
slightly (usingthe remote control).
When swinging the MBE and during pinning and unpinning

there must be no−one in the folding range or beneath the
MBE or in areas a risk of falling equipment etc.
13. Fold the MBE in front of the main boom using the draw and
guide rope.
Make sure that the locking pin (37) locks into the cross axle on
the left (Z 200 460).
200−1−1180−240c_en 29/129
18
32 31 H
24
I 63
31
32
Z 200 473 Z 200 472
”X...”
HR
B1 A H B2 Z 200 441 Z 200 454
”X0550”
Z 200 457
30/129 200−1−1180−240c_en
(Z 200 473)
14. Using the pin (31), pin at points (H) and (I) and secure with
the locking springs (32) (Z 200 473).
The pins (31) are inserted at the top and bottom.

Both pins are driven in deeper alternatively until the locking
springs for securing the pin can be inserted.
(Z 200 472, Z 200 441, Z 200 454)

15. Fit the hoist limit switch (63, Z 200 472) with attached shift
weight to the head of the basic boom MBE and secure
If a second hoist limit switch is not used and the hoist limit switch
from the main boom head is used: connect the bridging plug (’B2’,
Z 200 441) on the right−hand side of the main boom head to the
usual connection for the hoist limit switch (HR; Z 200 454).
The bridging plug “B2” is marked with the letter “W”.
Risk of malfunctions!
The bridging plug (B2) supplied with the crane must be used.
(Z 200 457, Z 200 441)

16. Connect the plug of the basic boom harness to the junction
box “X0550” on the main boom head (connection ’A’,
Z 200 441).
200−1−1180−240c_en 31/129
18
L: R:
63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 104 165
32/129 200−1−1180−240c_en
(Z 104 165)
17. If a second hoist limit switch is used:
To prevent risk to persons or damage to equipment, attach
the shift weight or the hoist limit switch, which is fitted to the
head of the main boom, in the transport position (left−hand
side of the main boom head) and secure against falling out.
If a second hoist limit switch is fitted and the hoist limit switch shift
weight of the hoist limit switch of the main boom head is fitted in
the transport position (on the left−hand side of the main boom
head), the switch must be locked mechanically in the open
position (bridged). Figure (Z 104 165 figure ’R’) shows the hoist
limit switch in the bridged state. In order to bridge the hoist limit
switch, the restrainer (63.2) must first be fitted onto the actual
hoist limit switch (63.1) 1 . Then the jumper wire is pulled away
to the side 2 , then rotated in the longitudinal direction of the
restrainer (63.2), 3 and finally relaxed. This procedure jams the
restrainer (63.2) by the jumper wire’s spring resistance.
200−1−1180−240c_en 33/129
18
61
61
62
”X0560”
5 61.1
a: b:
Z 200 477
”X...”
23
63 S1
Z 200 453 B1 A H B2 Z 200 441
Z 200 361
34/129 200−1−1180−240c_en
(Z 200 453, Z 200 477, Z 200 441)

18. Fit the hazard light (61) and the rotor of the anemometer (62)
to the head of the basic boom (3) of the MBE.
The hazard light (61) must be in the swinging position (Z 200 477
”b”) during crane operation.
The locking pin (61.1; Z 200 477) may not be locked in place.
Figure (Z 200 477 “a”) shows the locking pin (61.1) locked in
place for the transport condition.
19. Connect the plug of the hoist limit switch (63) to connection
“H”, the plug of the hazard light (61) to connection “F” and the
plug of the anemometer rotor (62) to the connection “A” of the
junction box “X0560”.
Risk of accidents!
Observe all information from the segment “Applying the
electric safety chain for operation of the main boom
extension (MBE)” (18.5.3, from page 67).
20. Fold the folding cylinder (1, Z 200 361) to the side and lock.
21. Depending on the desired operating angle, angle the MBE

to the 20° or 40° position, see section18.7 from page115.
22. Reeve in the hook block. To do so, fit the shift weight of the
hoist limit switch over the “slowest” piece of hoist rope! (see
section 17).
Check that all pins and locking elements are seated

correctly.
23. For information on erecting the main boom with the MBE
fitted, see section 18.8 from page 127.
200−1−1180−240c_en 35/129
18
3.1
Z 200 120 Z 54 840
11 1 3 A
8
9B
9A
15
Z 200 113 Z 54 841
36/129 200−1−1180−240c_en
18.4.2.1.2 Folding from the Operating into the Transport

Position
1. Unreeve the hook block (see section 17).
2. If the MBE was angled: fit the MBE on the main boom headin
the 0° position (see section18.7 from page 115 in the reverse
order).
3. Fasten the draw and guide rope (15) to the head of the basic
boom MBE.
4. Fold the mirror on the superstructure on the right−hand side

so that it is not within the slewing range.
5. Remove the pins (2) from point (C) using the lever drive (3)
(Z 200 120).
7. Insert the mobile control panel into the socket on the front
right−hand side of the basic boom section of the main boom
(Z 200 113).
8. Place the folding cylinder (1) in the operating position and

extend completely. (Z 200 366)
(Z 200 113)
To do so, switch the selector switch (8) on the mobile control

panel to position ”1” and press the rocker switch (9B) until the
position has been reached.

the retracting direction (see also section18.4.1).
9. If required:
Retract the pinning cylinder (3), so that the pins are pulled
into the top and bottom guide at points (A) and (B).
(Z 200 125)
To do this, first remove rope (15) from the holding device. Pull this
rope, pulling back the safety catch of the locking cylinder (3). This
unlocks it. The safety catch must be held in this position until the
locking cylinder (3) is retracted. (Z 54 841)
200−1−1180−240c_en 37/129
18
8 61
9B 62
”X0560”
9A
5
Z 200 113
23
63 S1
HR
Z 200 454 Z 200 453
L: R:
23 63.1 63.1
”B”
24 ”B”
”A”
63.2
3
1
Z 200 360 2 Z 104 166
38/129 200−1−1180−240c_en
(Z 200 113)
Switch the selector switch (8) on the mobile control panel to
position ”3”. Press the rocker switch (9A) until the cylinder (3) is
completely retracted.

the retracting direction (see also section 18.4.1).
10. Pull the plug of the harness of the MBE from the main boom
head.
11. If only one hoist limit switch is in use:
Remove the hoist limit switch (63) and the shift weight from
the head of the basic boom (3) (Z 200 453).
If a second hoist limit switch is fitted on the main boom head:
Fit the shift weight (23, Z 200 360) of the hoist limit switch to
the head of the basic boom (3) in the transport position
(Z 200 360).
If a second hoist limit switch is in use and the hoist limit switch of
the main boom head is locked mechanically in the open position
(bridged), this bridging position must be deactivated.
To deactivate the bridging of the hoist limit switch, the equipment
wire must be pulled down 1 and then to the side 2 and out of
the way. The holding device (63.2) can then be removed 3 .
Figure (Z 104 166 figure ’R’) shows the hoist limit switch in the
functional state.
12. Remove the hazard light (61) and the rotor (62) of the
anemometer and store in the storage compartment
(Z 200 453).
200−1−1180−240c_en 39/129
18
Z 155 157
1 12
11
37
Z 200 460 Z 200 364
40/129 200−1−1180−240c_en
For the following unpinning procedure at points (H) and (I) (Z

155 157), make sure that the locking pins (37, Z 200 460) are
locked into the main boom on the bottom left.
13. Remove the pins (31) from points (H) and (I).
RISK OF FALLING
For subsequent unlocking of the lock catch (37, Z 200 460):
Do not lean the ladder against the MBE.
14. Unlock the locking pin (37) by a 180°−turn.
If the MBE is not held on the pulling and guidance rope, it can
fold away to the side when the locking bar (37) is unlocked.
15. Fold the MBE around by the pulling and guidance rope until
the retaining component (11) of the folding cylinder on the
basic boom MBE is linked (Z 200 364).
200−1−1180−240c_en 41/129
18
8 1 H(I)
c
9B
F(G)
9A 1
B d
3
1
Z 200 113 Z 200 127
Z 200 269 Z 200 128
42/129 200−1−1180−240c_en
(Z 200 127 “d”)
16. Using cylinder (1), pull the MBE carefully past the until the
pinning position at point (B) has been reached.
The drilled holes in the shackles of the basic boom are then flush
with the corresponding drilled holes of the retainer (Z 200 269).
To do so, switch the selector switch (8) (Z 200 113) on the mobile
control panel to position ”1” and press rocker switch (9A)
(Z 200 113) until the position has been reached.
The MBE then rotates around the centre of motion (F/G,
Z 200 127, figure ”c”).

17. Connect the MBE to the basic boom section of the main
boom by extending the cylinder (3) at point (B) (Z 200 127,
figure ”c”).
The unlocking rope of the safety catch does not need to be

pulled.
To do so, switch the selector switch (8, Z 200 113) on the mobile
control panel to position ”3” and press rocker switch (9B,
Z 200 113) until the pinning cylinder (3, Z 200 127) is completely
extended.
(Z 200 128)
The pins then protrude from the steel construction. The top pin
then presses a flap upwards which indicates that pinning is
complete. The lower pin protrudes from the steel construction of
the retainer.
Check that the top pin presses the flap upwards and that
the lower pin protrudes from the steel construction of the
retainer.

200−1−1180−240c_en 43/129
18
C
b
1 H(I) 2
c
F(G)
1 3
B d
3
1 3.1
Z 200 127 Z 200 120
HR
Z 200 454
44/129 200−1−1180−240c_en
RISK OF DAMAGE!
If the hoist limit switch is fitted to the right−hand side of the
main boom head, it must be removed before the following
removal of the lower biconical pin from fixing point (G).
18. Remove the biconical pins from the fixing points (F/G,
Z 200 127, figure ”c”) on the boom head axle and insert into
the transport retainer (on the inside of the basic boom MBE)
and secure.

Fit the hoist limit switch (63) on the right−hand side of the
main boom head and connect to connection (’HR’,
Z 200 454).
20. Pull MBE with the folding cylinder (1, Z 200 127, figure ”b”)
completely into the transport position past the main boom.
21. Pin the MBE at point (C) by rotating the lever (3.1) clockwise
(Z 200 120, depicted without MBE ).
The actuating lever of the lever drive must lock into the
depression of the housing.
If only the basic boom (MBE 9 m; 29.5 ft) is being fitted in the
transport position, an adapter must be fitted between the basic
boom MBE and the pinning point on the main boom at point
(C, Z 200 120).
22. Fold guide rail back, pin and secure, remove mobile control
panel, remove pulling and guidance rope.
200−1−1180−240c_en 45/129
18
3.1
Z 170 612 Z 200 120
9B
9A
Z 54 840 Z 200 113
46/129 200−1−1180−240c_en
18.4.2.2 17 m (55.8 ft) MBE Fitted in the Transport Position
18.4.2.2.1 Folding over the 9 m (29.5 ft) MBE from the Transport
into the Working Position
Before the basic boom MBE can be folded over, the connection
between the basic boom MBE and the tip section must be
removed.
Procedure:
1. Follow all the instructions contained in the section 18.4.1
”General instructions for folding over the equipment” from
page 17.
2. Create the front connection between the tip section and the
basic case of the main boom and lock (if not already
occurred).
To do so, slide the pin in using a power stretcher (Z 170 612).
3. Pin the MBE in point (C) by rotating the lever (3.1) clockwise
(if this has not already been done) (Z 200 120, depicted
without MBE).
4. Secure the draw and guide rope on the head of the basic
boom MBE.
You pull as well as brake the MBE using the draw and guide
rope.
6. Insert the mobile control panel into the socket on the front
right−hand side of the basic boom section of the main boom
(Z 200 113).
200−1−1180−240c_en 47/129
18
1 12 11
Z 200 364 Z 200 270
Z 200 285 Z 200 264
48/129 200−1−1180−240c_en
Before releasing the connecting pins, make sure that the

MBE is pinned with the main boom at the pivotal point ”B”
(cylinder 3). In addition, checks must be made to ensure
that the connecting piece of the swing cylinder (1) has
”gripped” the MBE.
In addition, checks must be made to ensure that the
connecting piece of the folding cylinder (1) has ”gripped”
the
MBE. Otherwise the basic boom MBE could swing away
unchecked after separation.
7. Disconnect the connection between the basic boom MBE

and the tip section. To do so, rotate locking bar by 180° and
unhook retaining rope between the basic boom and the tip
section (Z 200 270).
8. Knock out the biconical connecting pins between the tip

section and basic boom MBE (Z 200 285).
9. Start the engine of the superstructure.
10. For the further procedure, see from page 25, section
18.4.2.1.1 from points “7.” to “23.”.
18.4.2.2.2 Folding the 9 m MBE from the Operating to the

Transport Position
1. Carry out points “1.” to ”20.” in section 18.4.2.1.2 from page

37.
Then the basic boom MBE and the tip section must be connected
again:
2. Knock out the rear connecting pins (2x) between the basic
boom MBE and the tip section and secure (Z 200 285).
3. Connect the basic boom MBE to the tip section. To do so,

check the locking function of the locking bar, if necessary,
rotate the pins by 180° (Z 200 264). Attach the retaining rope
between the basic boom MBE and the tip section.
4. Fold guide rail back, pin and secure, remove mobile control
panel, remove pulling and guidance rope.
200−1−1180−240c_en 49/129
18
Z 200 285 Z 200 264
Z 200 131 Z 200 270
31
32
32 3
31
52 Z 200 461
50/129 200−1−1180−240c_en
18.4.3 Folding over the 17 m MBE (55.8 ft)
When folding and during pinning and unpinning there must

be no−one in the slewing range or beneath the MBE or in
areas at risk of falling equipment etc.
The prescribed sequence for the slewing procedure must
be followed at all times!
18.4.3.1 Folding the 17 m (55.8 ft) MBE from the Transport to

the Operating Position
Before folding the MBE 17 m (55,8 ft), you must check that
connecting pins between the basic boom MBE and tip section
have been knocked out and are secured (Z 200 285), that the
locking bar between the basic boom MBE and the tip section has
clicked in place and that the retaining rope is attached
(Z 200 264).
1. Observe all information contained in section 18.4.1 ”General
instructions for folding over the equipment” from page 17.
2. Release the connection between the tip section and the
basic case of the main boom; to do so: pull out the pin with
the lever tensioner (Z 200 131).
3. Carry out steps “2.” to “14.“ in section 18.4.2.1.1 ”Folding
over from the transport to the operating position” from page
21.
Fasten the pulling and guidance rope onto the tip section.
The tip section can be pulled as well as braked with that.
Fold the tip section on the basic boom MBE into the
operating position:
4. Disconnect the connection between the basic boom MBE

and the tip section. To do so, turn the locking catch (52) by
180°. Detach the retaining rope between the basic boom and
the tip section (Z 200 270).
5. Fold the tip section (4) over both pins (31).

Make sure that the locking pin (52) then locks into place in
the front on the basic boom MBE (depiction similar to
Z 200 461).
200−1−1180−240c_en 51/129
18
3
”X0560”
”X...”
K
31
F
4 31
B1 A H B2
Z 200 456 Z 200 441
”X0550” L: R:
63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 200 457 Z 104 165
52/129 200−1−1180−240c_en
(Z 200 456)
6. Fix tip section (4) in points (K) and (L) using pin (31; 2x).
Secure the pins (Z 200 456) against falling out.
Both pins (31) are inserted at the top and bottom.

Both pins are driven in deeper alternatively until the locking
springs for securing the pin can be inserted.
(Z 200 456, Z 200 441)

7. Connect the plug of the cable harness of the tip section (4)
in junction box (”X0560”) on the head of the basic boom MBE
(3) with connection “A” (Z 200 441).
(Z 200 457, Z 200 441)

8. Connect the plug of the basic boom harness to the junction
Z 200 441).
head), the switch must be locked mechanically in the open state
(bridged). Figure (Z 104 165 figure ’R’) shows the hoist limit
switch in the bridged state. In order to bridge the hoist limit switch,
the restrainer (63.2) must first be fitted onto the actual hoist limit
switch (63.1) 1 . Then the jumper wire is pulled away to the side
2 , then rotated in the longitudinal direction of the restrainer
(63.2), 3 and finally relaxed. This procedure jams the restrainer
(63.2) by the jumper wire’s spring resistance.
200−1−1180−240c_en 53/129
18
62
54
4 ”X0580” ”X...”
61
F
63 S2
Z 200 455 B1 A H B2 Z 200 441
61
HR
61.1
a: b:
Z 200 454 Z 200 477
Z 200 361
54/129 200−1−1180−240c_en
(Z 200 455, Z 200 441, Z 200 454)

weight to the head of the tip section (4) and secure against
falling out.
(Z 200 455, Z 200 477, Z 200 441)
11. Fit the hazard light (61) and the rotor (62) of the anemometer
to the head of the tip section.
“H”, the plug of the hazard light (61) to connection “F” and the
plug of the anemometer rotor (62) to the connection “A” of the
junction box “X0560”.
Risk of accidents!
extension (MBE)” (18.5.3, from page 67).
(Z 200 361)
13. Fold the folding cylinder (1, Z 200 361) to the side and lock.
200−1−1180−240c_en 55/129
18
62 23
54
4 ”X0580”
24
61
63 S2
Z 200 455 Z 200 360
56/129 200−1−1180−240c_en
14. Depending on the desired operating angle, angle the MBE

to the 20° or 40° position, see section18.7 from page 115.
15. Reeve in the hook block. To do so, fit the shift weight of the
hoist limit switch over the “slowest” piece of hoist rope (see
section 17).

correctly.
16. Erect the MBE in accordance with section 18.8 from page 127.
18.4.3.2 Folding the 17 m (55.8 ft) MBE from the Operating to

the Transport Position
Configuring from the operating to the transport position is done
in several steps.
(Z 200 445, Z 104 165)
1. Unreeve the hook block (see section 17).
2. If the MBE was angled: fit the MBE on the main boom headin
the 0° position (see section18.7 from page115 in the reverse
order).
3. Remove the hazard light (61) and the rotor (62) of the
anemometer and store in the storage compartment
(Z 200 455).

Remove the hoist limit switch (63) and the shift weight from
the head of the tip section (4) (Z 200 455).
If a second hoist limit switch is fitted on the main boom head:
Bring the shift weight (23, Z 200 360) of the hoist limit switch
on the head of the basic boom (3, Z 200 366) or of the tip
section (4, Z 200 455) into the transport position.
200−1−1180−240c_en 57/129
18
L: R:
63.1 63.1 62
54
4 ”X0580”
”B”
”B”
”A” 61
63.2
3
1
63 S2
2 Z 104 166 Z 200 455
”X0560” 3 31
32
K
31
L 4
32 3
31 31
4 Z 200 478 52 Z 200 462
Z 200 264
58/129 200−1−1180−240c_en
If a second hoist limit switch is in use and the hoist limit switch of
the main boom head is locked mechanically in the open position
(bridged), this bridging position must be deactivated.
To deactivate the bridging of the hoist limit switch, the equipment
wire must be pulled down 1 and then to the side 2 and out of
the way. The holding device (63.2) can then be removed 3 .
Figure (Z 104 166 figure ’R’) shows the hoist limit switch in the
functional state.
5. Remove the plug of the cable harness of the tip section (4)
on junction box (”X0560”) on the head of the basic boom
MBE (3) (Z 200 478).
6. Remove pins (31; 2x) in points (K) and (L) from the
connection between the basic boom and the tip section
(Z 200 478).
7. Fold the tip section (4) over both pins (31).

To do so, turn the locking catch (52) by 180° (depiction similar
to Z 200 462).
8. Connect the basic boom MBE to the tip section. Allow the
locking catch (52) to snap in place, attach the retaining rope
between the basic boom and tip section (Z 200 264).
It must be ensured that the locking bar between the basic

boom MBE and tip section is inserted correctly and that the
retaining rope between the basic boom and tip section is
correctly attached (Z 200 264).
9. Carry out steps “3.” to “10.“ in section 18.4.2.1.2 (from page

37).
10. Carry out steps “13.” to “22.“ in section 18.4.2.1.2 (from page
41).
200−1−1180−240c_en 59/129
18
IV ”a”
3
I IV ”b”
4 3
I II IV ”c”
4 3 2
I II III IV ”d”
4 3 2 1
Z 200 463
60/129 200−1−1180−240c_en
18.5 Fitting and Removing for Separate Transportation

The 9 / 17 m MBE (29.5 / 55.8 ft) can be transported separately.
The additional components for achieving the MBE lengths 25 m
(82 ft) or 33 m (108.3 ft) must be transported separately.
The components for the individual desired MBE length can be
fitted using an auxiliary crane.
The components must be attached at the prescribed attachment
points (see 18.5.2 from page 65).
200−1−1180−240c_en 61/129
18
IV ”a”
3
I IV ”b”
4 3
I II IV ”c”
4 3 2
I II III IV ”d”
4 3 2 1
Z 200 463
32A 32B A
31 31
Z 200 459 Z 200 264
62/129 200−1−1180−240c_en
18.5.1 General Instructions for Fitting

(Z 200 463)
Rotate the superstructure when supported on outriggers by 0°
back and luff the main boom into the horizontal (0°).
For the planned configuration, the counterweight with the
corresponding support base as specified in the load tables must
be fitted.
(Z 200 459)
To fit the MBE only the pins (31) may be used that are
cylindrical (A) at one end. The pins are secured using
locking spring, type (32A) or (32B).
For pinning and securing the MBE, use the supplied

foldaway sliding ladder or an appropriate step−up aid
(ladder, scaffolding). Make sure that the climbing aid is on
firm / secure ground. It is not permitted to walk on the top
of the MBE.
If the supplied folding/sliding ladder is not used, it must be

removed before the basic boom is fitted.

or in areas where loads/equipment could fall.
The auxiliary crane must hold the parts to be fitted until all
pinning points have been pinned and locked correctly.
The intermediate sections (1, 2) of the MBE may only be

fitted individually (Z 200 444).
The basic boom MBE (3) and the tip section (4) can be
transported individually or folded together.
For safety reasons, it must be ensured that the biconical

pins and the locking bar between the basic boom MBE (3)
and tip section are inserted correctly and that the retaining
rope between the basic boom and tip section is correctly
attached (Z 200 264).
200−1−1180−240c_en 63/129
18
Z 200 449
6 5 4 3 2 1
8 7
Z 200 450
3+4
6 5 4 3 2 1
8 7
Z 200 451
64/129 200−1−1180−240c_en
Observe the adjacent depictions for attaching the individual

elements of the main boom extension. They show which
attachment points must be used so that the elements are
attached symmetrically to the centre of gravity.
The attachment points on the basic boom (3) are marked with
number signs. Only the indicated − and depicted −
attachment points may be used for each configuration.
The elements must not swing out or hang crookedly when
raised. If required, a suspension gear equipped with
shortening claws must be used.
The lifting tackle must be supplied by the customer.
(Z 200 449)
(1) − Intermediate section ”1”
(2) − Intermediate section ”2”
(Z 200 450)
(3) − Basic boom

Suspension points: “3” + “8”
(Z 200 451)
(3) + (4) − Basic boom and tip section (folded together)

Suspension points: “4” + “6”+ “8”
(Z 200 449)
(4) − tip section
200−1−1180−240c_en 65/129
18
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
66/129 200−1−1180−240c_en
18.5.3 Closing the Electric Safety Chain for

Operation with Main Boom Extension (MBE)
(Z 200 458)
Figure (Z 200 458) shows which electric element can or must be

connected to which electric connection (electric safety chain).
The rotor of the anemometer and the hazard light do not

necessarily have to be fitted and connected electrically (for
example for indoor crane operation).
Risk of accidents!
− If the rotor of the wind measuring device is not fitted, no
wind speed is indicated at the entry machine of crane
control. This means that one cannot recognise if the
wind speed is within the permitted limits of the load
capacity table.
− If the hazard light has not been fitted, people and
machines in the vicinity (for example, cranes working
simultaneously) are not warned of impending collisions.
Always seal off all unused plugs and sockets with protective
caps.
200−1−1180−240c_en 67/129
18
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
”X0550”
”X...”
Z 200 457 B1 A H B2 Z 200 441
68/129 200−1−1180−240c_en
18.5.3.1 Electric Connections on the Main Boom Head
Figure (Z 200 458) shows the principle connection diagram for

the installations or connections on the main boom head.
Junction box “X0550”
(Z 200 457)
Socket (A, Z 200 441)
Depending on the fitted length of the main boom extension:

− with the plug of the basic boom cable harness;
− or with the plug of the intermediate section.
Socket (A) must in any case be fitted with one of the named
plugs.
Socket (F, Z 200 441)
− with the protective cap (as shown).
If required, the hazard light (61) and the anemometer (62) of the
wind measuring device are fitted to the top piece of the fitted main
boom extension and connected electrically.
Socket (H, Z 200 441)
− with the plug of the connecting cable of the hoist limit switch
(63) on the right−hand side of the main boom head.
200−1−1180−240c_en 69/129
18
”X...”
HR
Z 200 454 B1 A H B2 Z 200 441
L: R:
63.1 63.1
”B”
”A”
63.2 63.2
1 2
3
Z 104 165
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
70/129 200−1−1180−240c_en
Connection “HR” (right−hand side of the main boom head,

Z 200 454)
If the hoist limit switch of the main boom head is also to be used
on the main boom extension:
− with the bridging plug (’B2’, Z 200 441) on the right−hand
side of the main boom head with the usual connection for the
hoist limit switch (HR; Z 200 454).
If a second hoist limit switch is used on the main boom extension

and the hoist limit switch of the main boom head is also to remain
on the main boom head:
− with the plug of the hoist limit switch (63) from the main boom
head;
head), the switch must be locked mechanically in the open state
(bridged). Figure (Z 104 165 figure ’R’) shows the hoist limit
switch in the bridged state. In order to bridge the hoist limit switch,
the restrainer (63.2) must first be fitted onto the actual hoist limit
switch (63.1) 1 . Then the jumper wire is pulled away to the side
2 , then rotated in the longitudinal direction of the restrainer
(63.2), 3 and finally relaxed. This procedure jams the restrainer
(63.2) by the jumper wire’s spring resistance.
18.5.3.2 Electric Connections on the Intermediate Sections (1)

or Intermediate Section 2
(Z 200 458)
For the MBE 25 m (82 ft) and the MBE 33 m (108.3 ft) and
depending on the assembly length of the main boom extension,
the cable harnesses of the intermediate sections are either fitted
directly on the main boom head (see 18.5.3.1) or on the next
intermediate section.
200−1−1180−240c_en 71/129
18
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
61
62
”X0560”
5 ”X...”
F
23
63 S1
Z 200 453 B1 A H B2 Z 200 441
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
HR
3
1
2 Z 104 166 Z 200 454
72/129 200−1−1180−240c_en
18.5.3.3 Electric Connections on the Basic Boom
(Z 200 458, Z 200 453, Z 200 441, Z 104 166, Z 200 454)
Depending on the assembly length of the main boom extension,

the end of the basic boom’s (3) cable harness is fitted either
directly on the main boom head (see 18.5.3.1) or on the next
intermediate section.
Junction box “X0560” (Z 200 458, Z 200 453)
Socket (A, Z 200 441)
Depending on the fitted length of the main boom extension:

− with the plug of the rotor of the anemometer;
− or with the plug of the harness of the tip section (4,
Z 200 458);
− with the protection cap.
Socket (F, Z 200 441)

Socket (H, Z 200 441)
− with the plug of the hoist limit switch (63).

200−1−1180−240c_en 73/129
18
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
3
”X0560”
”X...”
K
31
4 31 Z 200 456 B1 A H B2 Z 200 441
62
54
4 ”X0580”
61
63 S2
Z 200 455
74/129 200−1−1180−240c_en
(Z 200 458, Z 200 441, Z 200 454)
18.5.3.4 Electric Connections in the Tip Section
(Z 200 458, Z 200 456, Z 200 441)
The end of the tip section’s (4) cable harness is connected to the
basic boom to junction box “X0560” to connection “A”.
Junction box “X0580” (Z 200 441, Z 200 455)
Socket (A, Z 200 441)
− with the plug of the rotor of the anemometer;

− with the protection cap.
Socket (F, Z 200 441)

200−1−1180−240c_en 75/129
18
4 3 2 1
X0580 X0560
X0550
HES HES HES
Z 200 458
62
54
4 ”X0580” ”X...”
61
F
63 S2
Z 200 455 B1 A H B2 Z 200 441
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
HR
3
1
2 Z 104 166 Z 200 454
76/129 200−1−1180−240c_en
(Z 200 458, Z 200 455, Z 200 441, Z 104 166, Z 200 454)
Socket (H, Z 200 441)
− with the plug of the hoist limit switch (63).

200−1−1180−240c_en 77/129
18
IV
3
Z 200 465
32A 32B A
24
31 31 Z 200 459 Z 200 464
61
61 62
”X0560”
5
3
61.1
23
a: b:
63 S1
Z 200 477 Z 200 453
78/129 200−1−1180−240c_en
18.5.4 Fitting the 9 m MBE (29.5 ft)

(Z 200 465, Z 200 459, Z 200 464, Z 200 477, Z 200 453)
1. Using the auxiliary crane, hang the basic boom MBE (3) from
the prescribed attachment points (see 18.5.2 on page 65) in
front of the main boom head, so that the biconical pins (31)
can be knocked in.
2. Knock in the biconical pins (31, 4x) in the fastening point (IV)
between the basic boom (rear) and the main boom head.
Secure the pins against falling out using locking springs (32).
3. If not already occurred:

Slide the support feet (24) into the basic boom MBE (3) and
secure with fore locks.
Figure (Z 200 464) shows this state.
4. On the head of the basic boom:
4.1 Fit the hoist limit switch (63, Z 200 453) with the
attached shift weight and secure against falling out
using fore locks.
4.2 Fasten the hazard light (61) using two wing nuts.
4.3 Screw anemometer (62) rotor in tightly.
5. Apply the electric safety chain (connect the hoist limit switch,
the hazard light and the anemometer to junction box “X0560”
and to the cable harness, see 18.5.3 from page 67).
Risk of accidents!
extension (MBE)” (18.5.3 from page 67), especially the
notes on the hoist limit switch.
6. Set the operating angle (see 18.7, from page 115).
200−1−1180−240c_en 79/129
18
I IV
4 3
Z 200 466
32A 32B A
31 31 Z 200 459
80/129 200−1−1180−240c_en
7. Reeve the hoist rope and the hook block (see section 18.6,
from page 107).

correctly.
Removal is the same, but in the opposite sequence.
No persons may be in the area where there is a risk of falling

items when loosening the biconical bolts.
18.5.5 Fitting the 17 m MBE (55,8 ft)

(Z 200 466, Z 200 459)
When fitting the 17 m MBE (55.8 ft), the basic boom (3) and the
tip section (4) can be fitted individually or folded together.
Risk of falling! Risk of tipping! Risk of crushing!

Fitting in the outstretched and assembled condition:
If the basic boom (3) and the tip section (4) are to be fitted
in the outstretched and assembled state, there is a risk of
falling, tipping and crushing when removed and fitted and
during the pinning procedure.
It is therefore prohibited to fit both components (3 and 4) in
the outstretched and assembled state.
First, either the steps listed in 18.5.5.1 “Fitting the basic boom
MBE (3) and the tip section (4) individually” or the steps listed in
“18.5.5.2 Fitting the basic boom MBE (3) and the tip section (4)
in the folded state“ must be carried out and then the steps in
“18.5.5.3 Preparation for raising loads”.
200−1−1180−240c_en 81/129
18
I IV
4 3
Z 200 466
32A 32B A
24
31 31 Z 200 459 Z 200 464
82/129 200−1−1180−240c_en

Tip Section (4) Individually
1. Using the auxiliary crane, hang the basic boom MBE (3) from
front of the main boom head, so that the biconical pins (31)
can be knocked in.
3. Using the auxiliary crane, hang the tip section (4) at the
prescribed attachment points (see 18.5.2 on page 65) in
front of the basic boom MBE, so that the biconical pins (31)
can be knocked in.
4. Knock in the biconical pins (31, 4x) in the fastening point (I)
between the tip section (rear) and the basic boom MBE.

For the further procedure on fitting the 17 m MBE (55.8 ft), see
18.5.5.3 from page 85.

Tip Section (4) Folded Together
Risk of falling, risk of crushing!

The MBE package must first be attached to the auxiliary
crane and the lifting tackle must be tightened before the
lashing device is released with the transportation
equipment.
1. Using the auxiliary crane, hang the basic boom MBE (3) with
folded tip section (4) from the prescribed attachment points
(see 18.5.2 on page 65) in front of the main boom head, so
that the biconical pins (31) can be knocked in.
200−1−1180−240c_en 83/129
18
I IV
4 3
Z 200 466
32A 32B A
24
Z 200 464 31 31 Z 200 459
62 61
54
4 ”X0580”
61
61.1
63 S2 a: b:
Z 200 455 Z 200 477
84/129 200−1−1180−240c_en
3. Fold over the tip section to the front in the operating position,
in accordance with section 18.4.3.1 from page 51 from step
“4.” to “6.”.

18.5.5.3 from page 85.
18.5.5.3 Preparation for Raising Loads

(Z 200 466, Z 200 459, Z 200 455, Z 104 477)
Initial situation:
− Basic boom MBE (3) and tip section (4) are pinned to the main
boom head, one after the other, in the load raising position.
The biconical pins (31) are secured against falling out using
locking springs (32).
Procedure:
1. On the head of the tip section:
using fore locks.
and to the cable harnesses, see 18.5.3 from page 67).
Risk of accidents!
200−1−1180−240c_en 85/129
18
86/129 200−1−1180−240c_en
from page 107).

correctly.

200−1−1180−240c_en 87/129
18
I II IV
4 3 2
Z 200 467
32A 32B A
31 31 Z 200 459
88/129 200−1−1180−240c_en
18.5.6 Fitting the 25 m MBE (82 ft)

(Z 200 467, Z 200 459)
When fitting the 25 m MBE (82 ft), the basic boom (3) and the tip
section (4) can be fitted individually or folded together.

After the intermediate section 2 (2) has been fitted to the head of
the main boom (18.5.6.1), first either the steps in “18.5.6.2 Fitting
the basic boom MBE (3) and the tip section (4) individually” or the
steps in “18.5.6.3 Fitting the basic boom MBE (3) and tip section
(4) in the folded state“ must be carried out and then the steps in
18.5.6.1 Fitting the Intermediate Section 2 (2)

1. Using the auxiliary crane, hang the intermediate section 2
(2) (with angle possibilities) from the prescribed attachment
points (see 18.5.2 on page 65) in front of the main boom
head, so that the biconical pins (31) can be knocked in.
between the intermediate section 2 (2) (rear) and the main
boom head. Secure the pins against falling out using locking
springs (32).
For the further procedure on fitting the 25 m MBE (82 ft), see
18.5.6.2 (from page 91) or 18.5.6.3 (from page 91).
200−1−1180−240c_en 89/129
18
I II IV
4 3 2
Z 200 467
32A 32B A
24
31 31 Z 200 459 Z 200 464
90/129 200−1−1180−240c_en

1. Using an auxiliary crane, hang the basic boom MBE (3) from
front of the intermediate section 2 (2), so that the biconical
pins (31) can be knocked in.
2. Knock in the pins (31, 4x) in the fastening point (II) between
the basic boom (rear) and the intermediate section 2 (2).
can be knocked in.

18.5.6.4 from page 93.


equipment.
(see 18.5.2 on page 65) in front of the intermediate section 2
(2) so that the biconical pins (31) can be knocked in.
200−1−1180−240c_en 91/129
18
I II IV
4 3 2
Z 200 467
32A 32B A
24
Z 200 464 31 31 Z 200 459
62 61
54
4 ”X0580”
61
61.1
63 S2 a: b:
Z 200 455 Z 200 477
92/129 200−1−1180−240c_en
“4.” to “6.“.

For the further procedure on fitting the 25 m MBE (82 ft), see
18.5.6.4 from page 93.

(Z 200 467, Z 200 459, Z 200 455, Z 104 477)
Initial situation:
− The intermediate section 2 (2), basic boom MBE (3) and the
tip section (4) are pinned to the main boom head, one after
the other, in the load raising position. The biconical pins (31)
are secured against falling out using locking springs (32).
Procedure:
using fore locks.
Risk of accidents!
200−1−1180−240c_en 93/129
18
94/129 200−1−1180−240c_en
from page 107).

correctly.

200−1−1180−240c_en 95/129
18
I II III IV
4 3 2 1
Z 200 468
32A 32B A
31 31 Z 200 459
96/129 200−1−1180−240c_en
18.5.7 Fitting the 33 m MBE (108.3 ft)

(Z 200 468, Z 200 459)
When fitting the 33 m MBE (108.3 ft), the basic boom (3) and the
tip section (4) can be fitted individually or folded together.

After the intermediate sections have been fitted to the head of the
main boom (18.5.7.1), first either the steps in “18.5.7.2 Fitting the
basic boom MBE (3) and the tip section (4) individually” or the
steps in “18.5.7.3 Fitting the basic boom MBE (3) and tip section
(4) in the folded state“ must be carried out and then the steps in
18.5.7.1 Fitting the Intermediate Sections

1. Using an auxiliary crane, hang the intermediate section 1 (1)
(without angle possibility) from the prescribed attachment
points (see 18.5.2 on page 65) in front of the main boom
head so that the biconical pins (31) can be knocked in.
2. Knock in the biconical pins(31, 4x) in the fastening point (IV)

between the intermediate section 1 (1) (rear) and the main
boom head. Secure the pins against falling out using locking
springs (32).
200−1−1180−240c_en 97/129
18
I II III IV
4 3 2 1
Z 200 468
32A 32B A
31 31 Z 200 459
98/129 200−1−1180−240c_en
3. Using the auxiliary crane, hang the intermediate section 2

(2) (with angle possibility) from the prescribed attachment
points (see 18.5.2 on page 65) in front of the intermediate
section 1 (1) so that the biconical pins (31) can be knocked
in.
between the intermediate section 2 (2) (rear) and the
intermediate section 1 (1). Secure the pins against falling out
using locking springs (32).
18.5.7.2 (from page 99) or 18.5.7.3 (from page 101).

1. Using an auxiliary crane, hang the basic boom MBE (3) from
front of the intermediate section 2 (2), so that the biconical
pins (31) can be knocked in.
can be knocked in.
200−1−1180−240c_en 99/129
18
I II III IV
4 3 2 1
Z 200 468
32A 32B A
24
31 31 Z 200 459 Z 200 464
100/129 200−1−1180−240c_en

18.5.7.4 from page 103.


equipment.
(see 18.5.2 on page 65) in front of the intermediate section 2
(2) so that the biconical pins (31) can be knocked in.
“4.” to “6.”.

18.5.7.4 from page 103.
200−1−1180−240c_en 101/129
18
I II III IV
4 3 2 1
Z 200 468
32A 32B A
62
54
4 ”X0580”
61
63 S2
31 31 Z 200 459 Z 200 455
61
24
61.1
a: b:
Z 200 477 Z 200 464
102/129 200−1−1180−240c_en

(Z 200 , Z 200 459, Z 200 453, Z 104 477)
Initial situation:
− The intermediate sections (1) and (2), the basic boom MBE
(3) and the tip section (4) are pinned to the main boom head,
one after the other, in the load raising position. The biconical
pins (31) are secured against falling out using locking springs
(32).
Procedure:
using fore locks.
Risk of accidents!
200−1−1180−240c_en 103/129
18
104/129 200−1−1180−240c_en
from page 107).

correctly.

18.5.8 Converting from One Length to Another

In order to convert the MBE from one length to another, it might
be necessary to first remove the MBE components of the ”original
length” in accordance with the corresponding section; or already
assembled components can be fitted.
Then the ”desired length” is created in accordance with the
corresponding section.
200−1−1180−240c_en 105/129
18
U
U
F S
W
Z 200 685 Z 200 688
6 15
Z 54 203
106/129 200−1−1180−240c_en
18.6 Reeving the Hoist Rope
18.6.1 ... for Setting the Operating Angle
Starting position
− MBE pinned in operating position (0°).
To do so, follow the procedure described in the
corresponding section.

18.6.1.1 Reeving the Rear Deflection Roller on the

Basic Boom MBE
(Z 200 685, Z 200 688, Z 54 203)
1. Remove locking pins (S) from the support rods.
Note:
The pin (F) in the hinge point on the support rod always remains
fitted.
2. Release stop bolt (15, Z 54 203).
DANGER!
During the procedures for setting up or setting down the
deflection roller (U) which are described in the following
segments, there is a risk of crushing between the
deflection roller (U), the support rods and the main boom
extension.
No−one must be in the corresponding area at risk when the
deflection roller (U) is moving.
Design with winch
3. Release the winch (W, Z 200 688) somewhat so that the

deflection roller (U) luffs up slightly.
4. Continue with step 6. (page 109).
200−1−1180−240c_en 107/129
18
US U
US U
F S
Z 200 687 Z 200 690
1.1
1.2
1
2
Z 200 689
108/129 200−1−1180−240c_en
Design with hydraulic cylinder (optional)
(Z 200 687, Z 200 689)
With this option the deflection roller is erected on the basic boom
of the MBE with the help of a hydraulic pump.
5. Luff up the deflection roller (U) slightly:
5.1 Fit the actuating lever (1.1) of the pump (1) from the
transport position on the corresponding connection of
the pump.
5.2 Place the hand valve integrated in the pump (1.2) in the
’erecting position’;
5.3 Luff the deflection roller (U) up slightly by actuating the

pump.
(Z 200 690)
6. Lay the hoist rope over the rear deflection roller (U) on the
basic boom MBE and the remaining sheaves or carrier
rollers depending on the relevant state of assembly.
7. Secure the hoist rope to prevent it coming off using

corresponding rope guidance pins (US) on the rear
deflection roller of the basic boom MBE and on the other
sheaves.
Fit the (safety) locks of the rope retaining pin.
200−1−1180−240c_en 109/129
18
US
S S
Z 200 691 Z 200 686
1.1
1.2
1
Z 200 692
110/129 200−1−1180−240c_en
(Z 200 691)
8. Proceed as follows to continue to erect the deflection roller

until the final position has been achieved:
− Design with winch: Continue to release the winch (see
work step 3.). If necessary, press up the deflection roller
using the supplied rod.
− Design with hydraulic cylinder: Actuate the pump (see
work step 5.).
9. Insert locking pins (S) on the support rods and secure.
10. Set the operating angle (see section 18.7 from page 115).
(Z 200 686, Z 200 692)
Removing the hoist rope / the deflection roller
The hoist rope and / or the deflection roller (U) are removed in the
same manner in the opposite sequence.
If the basic boom MBE is fitted with the equipment for

hydraulically erecting the deflection roller, the deflection roller (U)
must also be set down hydraulically.
The lever (1.2) on the hand pump (1) must be folded over
accordingly (Z 200 692). The deflection roller can then be folded
over by pumping on the hand lever (1.1).
200−1−1180−240c_en 111/129
18
“X”
8
10 8
11
9 11 “Y”
10
10
1−(2)
Z 52 780
61
62 62
”X0560” 54
5 4 ”X0580”
61
3
23
S1 63 S2
63
Z 200 453 Z 200 455
112/129 200−1−1180−240c_en
(Z 52 780, Z 200 453, Z 200 455)
18.6.1.2 Feeding the Hoist Rope through the Sheaves on the

Intermediate Sections
Sheaves are attached to the intermediate sections. At a length

of the main boom extension of 25 m (82 ft) or 33 m (108.3 ft),
during the reeving process the hoist rope must be threaded
through a top roller (8) attached to an intermediate section (2) or
intermediate connections (1) and (2) (Z 52 780).
To make sure that the hoist rope can be pulled through, the
corresponding top roller must be released.
To do this, unlock pin (9) and pull out, release lock catch (10) (see
detail “X”) and fold rocker arm (11) upwards (see detail “Y”).
The hoist rope is dismantled in the same way, in the reverse

order.
18.6.2 ...for Raising Loads

1. Lay hoist rope on the MBE and erect the deflection roller on
the basic boom MBE in accordance with section 18.6.1.
2. Reeve in the hook block in accordance with section 17.
For two−fold reeving, the hoist rope end is pinned to the basic
boom MBE in point “S1” (MBE 9 m / 29.5 ft) or to the tip section
in point “S2” (remaining MBE lengths).
200−1−1180−240c_en 113/129
18
IV ”a”
3
I IV ”b”
4 3
I II IV ”c”
4 3 2
I II III IV ”d”
4 3 2 1
Z 200 463
S Z2
D Z3 Z0 Z1
F(H)
31
31
Z 200 474
114/129 200−1−1180−240c_en
18.7 Setting the Operating Angle

(Z 200 463, Z 200 474)
Crane operation with the main boom extension can be carried out
at an angle of 0°, 20° or 40° to the main boom.
However, it is only permitted to fit the MBE using the auxiliary
crane or to fold the MBE 9 / 17 m (29.5 ft / 55.8 ft) in the 0° position.
The 9 / 17 m MBE (29.5 ft / 55.8 ft) is folded directly at the main

boom head (point ”IV”). For the 25 / 33 m MBE (82 ft / 108.3 ft),
the two front MBE components (point ”II”) are folded.
The steps for folding are the same in both cases.
In the ”0”° position, the basic boom is pinned directly to the main
boom head (MBE 9/17 m; 29.5 ft / 55.8 ft) or to the intermediate
section 2 (2) (MBE 25/33 m; 82 ft / 108.3 ft) using 4 pins.
When setting the operating angle 20° or 40°, the tension bars are
mounted and the top biconical pins (31) are removed from points
(F, H).
In sections 18.7.1 and 18.7.2 the hoist rope is used as an aid for
setting the operating angle.
After setting, make sure that all pins are there.
200−1−1180−240c_en 115/129
18
US U
a:
W
S Z2 Z1
D Z3 Z0
45 F(H)
33
31
b:
G(I)
S1 31
Z1
Z3 35
45
c:
Z1
35
Z2
45
d:
e: IV
4 S1 3 Z 200 447
116/129 200−1−1180−240c_en
18.7.1 Switching from the 0 − Degree to the 20 − Degree

Position
(Z 200 447)
Starting position
− MBE pinned in the operating position (0°) (biconical pins (31,
4x) pinned at the individual points F, G, H, I. Pins secured
against falling out.).
− Hoist rope reeved in accordance with 18.6.1 (from page 107).
Deflection roller set high and pinned.
− Hook block unreeved.
− Pin (45) in each tension bar is fitted in point (Z3).

Procedure
Steps 1 to 3 are carried out, one after the other, on each side of
the basic boom MBE to prevent unnecessary ladder adjustment.
1. Loosen the transport locking pins (33; 2x) at point (D).

Push the inner parts of the tension bar slightly forward so that
the pin (33) can be pushed back into the same holes on the
basic boom MBE in the “resting position”.
2. Pull the inner part of the tension bar forward out of the
”resting position” and, using pins (35), pin to the main boom
head or intermediate section 2 in pinning point (Z1) with the
corresponding counterpiece. Secure pins (35) against falling
out.
3. Check whether both pins(45) are inserted in points (Z3) and

that pins (45) are secured against falling out.
200−1−1180−240c_en 117/129
18
US U
a:
W
S Z2 Z1
D Z3 Z0
45 F(H)
33
31
b:
G(I)
S1 31
Z1
Z3 35
45
c:
Z1
35
Z2
45
d:
e: IV
4 S1 3 Z 200 447
118/129 200−1−1180−240c_en
4. Fasten hoist rope at point (S1).

− If only the basic boom MBE (3) must be angled, the hoist
rope is laid over the front deflection rollers of the basic
boom MBE,
(Z 200 447 ”b”).
− If the basic boom MBE (3) and the tip section have to be
angled, the hoist rope is also laid over the sheave of the
tip section (Z 200 447, figure ”e”).
5. Tighten the hoist rope by reeling in the hoist rope winch.
RISK OF ACCIDENTS!
No−one may be under the MBE during the following pulling
of pins (31)!
The pins (31) of the lower pinning points (G) and (I) must
always remain pinned.
6. With the hoist rope taut, pull pins (31) out of points (F) and
(H).
7. Carefully unreel the hoist rope . Let the MBE tilt downwards
until the MBE is lying on the ground.
8. Luff up the main boom until the MBE is angled 20° and the
hook block can be reeved.
9. Reeve the hook block in (see section 17).
10. Move main boom into steep position.
11. Telescope the main boom out to the desired length.
The equipment is converted from the 20° position to the 0°

position in the same way, only in the reverse order.
200−1−1180−240c_en 119/129
18
US U
a:
W
S Z2 Z1
D Z3 Z0
45 F(H)
33
31
b:
G(I)
S1 31
Z1
Z3 35
45
c:
Z1
35
Z2
45
d:
e: IV
4 S1 3 Z 200 447
120/129 200−1−1180−240c_en
18.7.2 Switching from the 0 − Degree to the 40 − Degree

Position
(Z 200 133)
The procedure is similar to the one described under 18.7.1.

However,before the two top biconical pins (31) can be removed,
pins (45) must be removed from points (Z3) and inserted in points
(Z2).
Figure (Z 200 133 “d”) shows this state.
200−1−1180−240c_en 121/129
18
5
a:
II
4 S1 3 2 1
Z3 S Z2 Z1
D Z0 F(H)
45
33 31
b:
G(I)
31
Z1
Z3 35
45
c:
Z1
35
Z2
45
d:
Z 200 446
122/129 200−1−1180−240c_en
18.7.3 33 m (108.3 ft) MBE Supported on the Ground

(Setting the Operating Angles 20 Degree and 40
Degree)
(Z 200 446)
Minimum counterweight for:

* Outrigger support area 8.2 m (27.7 ft): 13 t (28.7 kip)
* Outrigger support area 6.85 m (22.5 ft): 22,1 t (48.7 kip)
* Outrigger support area 5.7 m (18.7 ft): 25,3 t (55.8 kip)

Starting position
-- Extension state of the main boom
(0/0/0/0/0/100 = LK14 for machines with 80 longitudinal
codes)
-- 33 m MBE (108.3 ft) pinned in the operating position (0°)
(biconical pins (31, 4x) pinned in the individual points F, G, H,
I. Pins secured against falling out.
-- Hoist rope reeved in accordance with 18.6.1 (from page 107).
Deflection roller of the basic boom MBE set high and pinned.
-- Hook block unreeved.
-- Pin (45) at each tension bar is inserted in point (Z3) and
secured against falling out.
Procedure
1. Luff down the main boom until the MBE is lying on the
ground.
The steps 2. to 4. are carried out at each tension bar or on each

side of the basic boom MBE to prevent unnecessary ladder
adjustment.
2. Loosen the transport locking pins (33; 2x) at point (D).

Push the inner parts of the tension bar slightly forward so that
the pin (33) can be pushed back into the same holes on the
basic boom MBE in the “resting position”.
3. Pull the inner part of the tension bars forward out of the
”resting position” and using pins (35), pin to the intermediate
section 2 (2) in pinning point (Z1) with the corresponding
counterpiece. Secure pins (35) against falling out.
200--1--1180--240c_en 123/129
18
5
a:
II
4 S1 3 2 1
Z3 S Z2 Z1
D Z0 F(H)
45
33 31
b:
G(I)
31
Z1
Z3 35
45
c:
Z1
35
Z2
45
d:
Z 200 446
124/129 200−1−1180−240c_en
for operating angle 20°:
4. Check whether both pins(45) are inserted in points (Z3) and

that pins (45) are secured against falling out.
for operating angle 40°:
5. Insert both pins (45) in points (Z2). Secure the pins (45)
6. Pull both biconical pins(31) out of points (F) and (H).
RISK OF ACCIDENTS!
The pins (31) of the lower pinning points (G) and (I) must
always remain pinned.
7. Luff up the main boom until the MBE is angled in the set
operating angle and the hook block can be reeved.
8. Reeve the hook block in (see section 17).
9. Move main boom into steep position.
10. Telescope the main boom out to the desired length.
The equipment is repositioned from the angled position to the 0°
position in the reverse order.
200−1−1180−240c_en 125/129
18
126/129 200−1−1180−240c_en
18.8 Telescoping the Main Boom with the MBE

Fitted in the Load−raising Position
Before telescoping, check that all the required

pins have been fitted and that there are no loose objects
(for example, hammers) on the main boom or on the MBE.
After fitting or folding the MBE into the operating position the
desired operating position can be selected as follows:
1. Bring the main boom into the high position by extending the
luffing cylinder.
The further procedure is identical to the telescoping

procedure as described in section 12.
Make sure that the details of each valid load capacity table
correspond with the current crane configuration (for
example, main boom length, fitted counterweight, etc.).
18.9 Raising Loads with the

9/17 m (29.5 ft / 55.8 ft) MBE Folded in the Transport
Position
When raising loads with the MBE 9/17 m (29.5 ft / 55.8 ft)
folded alongside, the load values in the tables are reduced.
See the ’instructions for operating the crane’, contained in
the supplied load table set.
200−1−1180−240c_en 127/129
18
128/129 200−1−1180−240c_en
18.10 Operation with Main Boom Extension

1. Fit the main boom extension in the desired operating position
(load raising position) and reeve the hoist rope 2−fold (for
rope path, see 18.6.2, page 113).
Depending on the starting situation, see the corresponding

segment in this section.
2. Setting the crane configuration in the operating mode

preselection screen (section 15 Safety equipment)
Type: MBE
other settings in accordance with the fitting state
When selecting the MBE operating mode when the equipment is

already telescoped out, it must be remembered that the selected
and currently relevant length code (LC) must also be available as
an extension sequence with MBE. Otherwise the change in
operating mode is not possible.

If, however, single−line reeving is required, the lifting
capacities specified in the table must be reduced by 20%.
This is also valid when the lifting capacity lies below the
maximum permissible rope pull of 9.9 t (19.8 kip) per line.
Use of the high speed range is than prohibited.
18.11 Emergency Removal 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.
200−1−1180−240c_en 129/129
Head Roller (Optional) 21
200−1−1210−240a_en 1/23
21
61 62 E2 E1
101 101a
101b
R
63
64
105
Z 200 479
2/23 200−1−1210−240a_en
21 Head Roller (Optional)

(Z 200 479)
21.1 General
The head sheave (101) is for raising loads with single strand
reeving. If the crane is equipped with a second hoist, the hook
block can remain reeved on the main boom head.
The head sheave (101) consists of a basic body (101a) and the
hinged rocker arm (101b).
The head sheave can be folded to the side of the main boom for
transportation (if the permitted axle loads allow for it).
Figure (Z 200 479) shows the head sheave in the operating

position (with rocker arm (101b) folded down).
Main boom operation with the head sheave fitted in the transport
position results in the crane having a reduced load capacity.
The optional “runner” (see section 41) can also be folded to the
side of the main boom head in the transport position at the same
point.
However, only the runner or the head sheave can be folded to the
left of the main boom head at the same time.
21.2 Important Notes
The head roller is marked with the factory number of the

crane. It can only be fitted onto a crane with this
Exceptions are only permitted if this is clearly indicated in
the crane documents (e.g. the crane passport).
Only trained and instructed personnel may fit and remove

the head sheave!
200−1−1210−240a_en 3/23
21
72
73
2−EXPLICIT
3−EXPLICIT
Z 200 484 Z 55 536
72
Z 104 254 Z 200 483
4/23 200−1−1210−240a_en
When fitting and removing the head sheave there is a risk

of crushing between the main boom head and head sheave.
Especially take the notes on risks in section 1.4.8
”Assembling and dismantling crane components” into
consideration as well as the procedure described in the
following.
It is prohibited to walk on the boom!
(Z 200 484, Z 55 536, Z 104 254, Z 200 483)
- Supplied folding / sliding ladder (72):
Risk of falling!
In order to carry out all assembly work with as little risk as
possible, a ladder is supplied with the machine.
If the supplied ladder is not used, the assembly work must
be carried out using other suitable aids (ladders, hoist
platforms, scaffolding, auxiliary crane).
It is not permitted to climb or walk on the main boom.

main boom extension for transportation, for example.
There are brackets on the folding / sliding ladder (72) for

fastening the actuating rod (73). This actuating rod (73) can be
used as an aid when fitting the hoist rope.
There are metal plates on the main boom for attaching the
ladders (72) safely during the corresponding working procedures
(Z 104 254 principle depiction).
There are also metal plates on the head sheave for hanging up
the ladders (72). However, these can only be used if the head
sheave is pinned firmly in the transport position or when the head
sheave is not to be folded over in the load raising position
(Z 200 483).
Risk of falling!
The ladders’ (72) attachment facilities on the head sheave
may only be used if the head sheave is pinned firmly in the
transport position or when the head sheave is not to be
folded over in the load raising position.
200−1−1210−240a_en 5/23
21
”a”
107 101
101a
”F”
108 101b
”A” 106
”b” ”c”
108
”B” ”E”,”F” ”B” ”E” ”F”
106 107
”e”
”d”
106
101
101a
”A”
101b
106
105
”B”
”D”
101a 105
”D”
101b
101
Z 200 485
6/23 200−1−1210−240a_en
Risk of unchecked head sheave movement!

Generally, the main boom must be aligned horizontally
during fitting or folding the head sheave. Any exceptions to
this rule are clearly listed.
21.3 Folding from the Transport Position to the Operating

Position
(Z 200 485)
When folding the head sheave there is a risk of crushing

between the main boom head and head sheave. Proceed
with appropriate caution!
Risk of falling!
During the folding procedure, the head sheave is only held
in place by pin (107) in point “F” on the left−hand side of the
head.
Pin (107) may not be removed during the folding procedure.
No−one may be in the area at risk of objects falling!
1. Remove pins (106) (2x) from their pinning positions in the

head sheave (101).
2. Loosen pin (108, Z 200 485 “a”) and insert in the “resting
position” on the head sheave (Z 200 485 “b”); secure
3. Fold the head sheave (101) forwards, over the fitted pin
(107) (point (F)), until pin (106) can be inserted at point (B)
(Z 200 485 “b”).
4. Insert pin (106) in point (B) and secure against falling out.
5. Remove pin (107) from point (F).
6. Continue to fold head sheave (101) over the fitted pin (106)
(point (B)), until the holes of the mounting shackles of the
head sheave are flush with the corresponding holes of the
retainer welded to the main boom head in point (A).
7. Insert pin (107) in point (E) in the resting position and secure
8. Insert pin (106) in point (A) and secure against falling out
(Z 200 485 “c”).
200−1−1210−240a_en 7/23
21
”a”
107 101
101a
”F”
108 101b
”A” 106
”b” ”c”
108
”B” ”E”,”F” ”B” ”E” ”F”
106 107
”e”
”d”
106
101
101a
”A”
101b
106
105
”B”
”D”
101a 105
”D”
101b
101
Z 200 485
8/23 200−1−1210−240a_en
(Z 200 485)
9. Raise the hinged rocker arm (101b) slightly to relieve pin

(105) of load and to remove pin (105) from position (D)
(Z 200 485 “d”)
Risk of crushing!
There is a risk of crushing between the rocker arm and the
frame of the head sheave as soon as the rocker arm moves
or is moved.
10. Fold the rocker arm (101b) down, until the corresponding
rocker arm (101b) hole is flush with the hole in the frame
(101a) of the head sheave.
Then insert pin (105) in position (D) and secure
(Z 200 485 “e”) .
Risk of accidents!
Operation with the head sheave may not be carried out
under any circumstances in the raised position (transport
position)!
200−1−1210−240a_en 9/23
21
61 62 E2 E1
101 101a
101b
R
63
64
105
Z 200 479
61
61.1
a: b:
Z 200 477
10/23 200−1−1210−240a_en
(Z 200 479)
11. Feed the hoist rope from the hoist drum to the intake sheaves
on the main boom head.
Observe for this the detailed specifications contained in
section 17 ”Reevings” in the subpoint ”Reeving the hoist
rope in and out”.
12. Feed the hoist rope over the intake sheave (E2) on the main
boom head to the head sheave’s sheave (R) and pin on
suitable hook suspension gear (105).
Risk of accidents!
The head sheave is only permitted to be operated with
single−strand lines!
The rope may not be fed via intake sheave (E1) as this
would make the deviation angle of the hoist rope too large.
Risk of damage to the rope!
During reeving, there is a risk that all involved sheaves

become wrapped and wound up. Proceed with appropriate
caution!
(Z 200 479, Z 200 477)

13. Fit the hazard light (61) and the anemometer (62) rotor to the
main boom head.
200−1−1210−240a_en 11/23
21
61 62
X0566 X0550
101 101a
101b
HES HES
Z 200 476
63
”X...”
64
105
Z 200 487 B1 A H B2 Z 200 441
”X0550”
HR
Z 200 454 Z 200 457
12/23 200−1−1210−240a_en
(Z 200 487, Z 200 476, Z 200 441, Z 200 454)
weight (64) to the head sheave and secure against falling
out.
You must make sure that the shift weight is fitted over the
hoist rope and is hanging freely.
Only then is it guaranteed to function properly.
Observe the details in section 17 “Reevings”.
(Z 200 457, Z 200 441)

15. Connect the plug of the head sheave’s cable harness to the
junction box “X0550” on the main boom head (connection ’A’,
Z 200 441).
200−1−1210−240a_en 13/23
21
61 62
X0566 X0550
101 101a
101b
HES HES
Z 200 476
63
”X...”
64
105
Z 200 487 B1 A H B2 Z 200 441
L: R:
63.1 63.1
”X0566”
”B”
”A”
63.2 63.2 F
1 2
3 A H
Z 104 165 Z 200 488
14/23 200−1−1210−240a_en
(Z 200 487, Z 200 476, Z 200 441, Z 104 165, Z 200 488)

17. Connect the plug of the hazard light (61) to the connection
“F” (Z 200 441) of the junction box “X0550” on the main
boom head.
18. Connect the plug of the hoist limit switch (63) to the
connection “H” and the plug of the anemometer (62) rotor to
the connection “A” of the junction box “X0566” (Z 200 488)
on the head sheave.
Risk of accidents!
If the rotor of the anemometer is not fitted or not connected,
the wind speed is not displayed on the IC−1. A prohibited
high wind speed might not be recognised.
200−1−1210−240a_en 15/23
21
”a” ”b”
106
101
101a ”A”
101b 106
105
”B”
101a ”D”
105
”D” 101b
101
”A” 106
”c” ”d”
108
”B” ”E” ”F” ”B” ”E”,”F”
106 107
”e”
101
107 101a
”F”
108 101b
Z 200 482
16/23 200−1−1210−240a_en
21.4 Folding from the Operating Position to the Transport

Position
(Z 200 482)
If the head sheave is not required, it can be folded laterally

backwards to the main boom head.
When folding the head sheave there is a risk of crushing

between the main boom head and head sheave. Proceed
with appropriate caution!
No−one may be in the area at risk of falling equipment
during the folding procedure!
The head sheave is folded from the operating position into the
transport position as described in 21.3 (’Folding from the
transport position into the operating position’), just in the opposite
sequence.
Hoist limit switches must be removed or hung in the
corresponding transport position.
The hoist rope must be reeled in.
Risk of falling!
During the folding procedure, the head sheave is only held
in place by pin (107) in point “F” on the left−hand side of the
head.
Pin (107) may not be removed during the folding procedure.
No−one may be in the area at risk of objects falling!
200−1−1210−240a_en 17/23
21
18/23 200−1−1210−240a_en
21.5 Separate Transport
Risk of accidents!
There are no attachment points welded to the head
sheave. For this reason, it must be attached with a
looping tackle.
The actual attachment procedure must be undertaken
with the utmost care.
RISK OF ACCIDENTS!
When being raised, the head sheave may not sing out or
hang crookedly. If necessary, lifting chains fitted with
shortening claws must be used.

mm mm mm kg
1170 mm 880 mm 810 mm 155 kg
(46.1 in) (34.6 in) (31.9 in) (342 lbs)
200−1−1210−240a_en 19/23
21
106
”A”
101
101a 106
101b
”B”
105
”D”
Z 200 480
20/23 200−1−1210−240a_en
21.6 Assembly and Removal of the Head Roller during

Separate Transport
(Z 200 480)
1. Move head roller against auxiliary crane.

When raising, the head sheave must be straight and must
not swing.
The head roller is in transport position, i.e. the hinged rocker arm
(101b) is connected in point (D) with pins (105), and secured with
a forelock.
2. Bring the head roller (101) into assembly position

usingauxiliary crane on the main boom head. To do so, the
relevant holes of the head sheave’s mounting shackles must
be flush with those on the corresponding mounting shackles
on the main boom head on the right (points ”A”) and left
(points ”B”).
Rig both points with pins (106), and secure these
usingforelocks.
As long as the head sheave is being attached to the

auxiliary crane or is not yet completely pinned, there must
be no−one in the area at risk of falling!
The head roller is now fastened on the main boom head.

No loads may be raised in this state!
3. In order to fit the head sheave in the operating position:

Carry out steps “9.“ to “18.” from section 21.3 (from page 9).
4. In order to fit the head sheave in the transport position on the
side of the main boom head, see segment 21.4.
200−1−1210−240a_en 21/23
21
22/23 200−1−1210−240a_en
21.7 Operation
1. Fit the head sheave in the operating position, fit the hoist limit
switch with the accompanying shift weight, connect the head
sheave electrically, reeve the hoist rope, pin the hook
suspension gear in place and then fit the shift weight to the
hoist rope.
This is described in detail in section 21.3 ’Folding from the
transport to the operating position’ (from page 7).
2. The operating mode “HA” (“Main boom”) must be selected on

the LLD.
3. Set the reeving to “1”.
Risk of accidents!
The head sheave is only permitted to be operated with
single−strand lines!
4. Select all other parameters in accordance with the actual

crane configuration, which must correspond to the relevant
load capacity table.
You will find details on operating mode selection in section 10

”Safety devices”.
200−1−1210−240a_en 23/23
Dismantling and Assembly of the Main Boom (Optional) 31
31 Dismantling and Assembly of the Main Boom (Optio-

nal)
In the course of assembling and dismantling the main

boom there is the danger of being crushed:
− between the main boom base and bearings.
− between the main boom and superstructure frame.
This is why no person is permitted in the danger zone!
Pay special attention to the notes on dangers in section
1.4.7 ”In the course of assembling and dismantling crane
components” as well as the procedure described in the fol-
lowing.
All assembly work is to be carried out with the help of suita-
ble equipment (ladders, lifting platforms, frames, auxiliary
crane).
Should it not be possible to carry out work either using
such equipment or from the ground, then the assembling
personnel must protect themselves with suitable means
(e.g. safety belt) against the RISK OF FALLING !
It is especially prohibited to spend any time in the area
where there is the risk of the attached load (main boom) fal-
ling in the course of assembling (dismantling)!
31.1 General
The main boom can be removed from the superstructure with the
auxiliary crane for repair purposes or in order to reach certain axle
loads.
The transport configuration without the main boom is describedin

the operating instructions for the crane chassis, section 2,section
6.4 and following pages “Driving on the road”.
Before starting to dismantle or assemble, pay special attentionto

the following:
− Before the main boom is dismantled or assembled, the cra-
ne’s counter weight must be removed. The crane must be sta-
bilised in the course of this procedure, in accordance with the
configuration for the counter weights.
− Before the main boom is dismantled, the telescopic units
must be retracted completely and pinned.
− The crane must always be supported on outriggers (outrig-
ger span at least 8.2 m x 2.8 m (26.9 ft x 9.2 ft)) for the actual
dismantling and assembly of the main boom.
200−1−1310g_en 1/25
31
74
Z 200 653 Z 200 188
2/25 200−1−1310g_en
31.2 Dismantling the Main Boom

The dismantling of the main boom can be divided into 3 steps:
preparations for dismantling (see 31.2.1), pulling the luffingcylin-
der head pin (see 31.2.2, page 9) and extracting the boom foot
pin /taking off the main boom (see 31.2.3, page 15). These wor-
king steps must be carried out in the sequence listed.
Notes on assembling the main boom, see section 31.3, page 25.
31.2.1 Preparation for dismantling

1. Stabilise crane and align horizontally (counterweight remo-
ved).
2. Unreeve bottom hook block or hook suspension gear and

wind hoist cable on to cable drum, secure hoist rope end.
(Picture Z 200 653, similar format)
3. Lift main boom over luffing gear. Rotate superstructure so
that the main boom faces the rear and insert the mechanical
superstructure locking device. Operate switch (74) to do so.
For further information on pinning and fixing the superstruc-
ture to the carrier see section ”Rotating” in ”Preparations for
rotating”.
(Z 200 188)
4. Use open lashing strap to mount luffing cylinder support
mount to the designated attachment devices at the rear end
of the chassis frame.
5. Fully lower the main boom so that the luffing cylinder is lying
on the luffing cylinder support.
6. Close the safety stop valve on the side of the luffing cylinder.
200−1−1310g_en 3/25
31
8
9B
9A
Z 54 804 Z 200 113
9
100
10
11
12
Z 58 689 Z 200 191
4/25 200−1−1310g_en
7. Insert remote control from figure (Z 54 804) or (Z 200 113)

into plug (100, Z 58 689) in the hydraulic carrier on the right−
hand side of the machine.
In order to be able to operate the mobile hydraulic cylinder

(Z 200 191), a remote control must be inserted in the correspon-
ding connection in the hydraulic carrier.
If a movement is to be carried out with the mobile hydraulic
cylinder (Z 200 191), an assistant must activate the switch in
the relevant remote control.
Depending on the design of the crane, either the remote control

in figure (Z 54 804) or the remote control in figure (Z 200 113)
must be activated.
200−1−1310g_en 5/25
31
90
15 t 21 t 16 t
6380 5970
Z 200 243
6/25 200−1−1310g_en
(Z 200 243)
8. Using an auxiliary crane, hang the main boom with 4 auxiliary
reeving ropes onto the top head axles on the boom head and
onto the attachment shackles on the boom foot.
The weight of the main boom is approx. 21 t (46.3 kip). Select

the auxiliarycrane and the auxiliary ropes in accordance
with the ropeforces that occur (see below).
The centre of gravity of the main boom is about 5970 mm

(19.6 ft) from the main boom base bearing in the direction of
the pulley head.
The length of the lifting gear (provision of material for custo-
mers) can be taken from the diagram opposite. If necessary,
adjust the length to fit a minimally differing centre of gravity.
The ropes must be arranged in such a way that, in the extreme

case, the total load can also be held securely by just 2 ropes.
There are − for the specified angles of the sling ropes − the follo-
wing maximum rope forces per rope:
front : approx. 15 t (33 kip) (according to head weight of ap-
prox. 10 t (22 kip))
rear : approx. 16 t (35.3 kip) (according to foot weight of ap-

prox. 11 t (24.3 kip)).
9. Pull auxiliary ropes tight with auxiliary crane.
200−1−1310g_en 7/25
31
B1 ST P L T B2 9
10
11
12
Z 200 190 Z 200 191
7 21 20
Z 200 192
8/25 200−1−1310g_en
(Z 200 190)
10. Release hydraulic connections B1, ST, P, L, T and B2 and

electric connections of the main boom on the back of the su-
perstructure frame (Z 200 190).
Please make sure that the designation signs for the hydrau-
lic connections are attached to the hose and connection.
Otherwise, mark the hydraulic connections before discon-
necting.
Connecting and disconnecting hydraulic connections is
only ever permitted in the depressurised condition, in other
words,the superstructure engine must not be running.
31.2.2 Retracting the Luffing Cylinder Head Pin

(Z 200 191, Z 200 192)
1. In order to extract the connecting bolt main boom / luffing cy-
linder, you must use a mobile hydraulic cylinder (Z 200 191).
In the following, this connecting pin is called the luffing cylin-
der head pin.
To do so, insert the mobile cylinder into the receptacle on the
connecting bolt so that the support elements (10, Z 200 191)
of the mobile cylinder lie in the inner bearing points (7,
Z 200 192).
Danger of tipping!
When relieving the mobile cylinder there is the danger of
itoverturning in the course of all of the working procedures-
described as follows: the mobile cylinder could tip over to
the rear out of the locating shell.
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the mounting plate. Please act carefully.
The weight of the mobile cylinder is approx. 20 kg (44 lbs)
200−1−1310g_en 9/25
31
B1 ST P L T B2 9
10
11
12
Z 200 190 Z 200 191
19
20
62 22
21
9
Z 200 193
10/25 200−1−1310g_en
(Z 200 190, Z 200 191)

2. Connect the mobile cylinder hydraulically. To do so, first con-
nect both supplied hydraulic hoses (L = 11 m (36.1 ft)) with
the connections P, T (12, Z 200 191) of the mobile cylinder.
Then connect the free hose ends to the corresponding con-
nections P and T on the back of the superstructure frame
(Z 200 190). These are the same connections with which
normally also P and T of the main boom are connected.
Connect the identically marked connections.

been connected correctly, i.e. that the couplings open pro-
perly.
3. Start superstructure engine.

(Z 200 191, Z 200 193)
4. By activating the control lever (11, Z 200 191), drive the
clamshell in the piston rod of the mobile cylinder (9,
Z 200 193) into the corresponding groove of the luffing cylin-
der head pin (62, Z 200 193). Extend the mobile cylinder until
the groove of the clamshell (9, Z 200 193) and the most exte-
rior hole (22, Z 200 193) of the luffing cylinder head pin (62,
Z 200 193) correspond with each other.
(Z 200 193)
5. Guide the pin (21) that has been pulled out of the vertical lok-
king position (19) through the slots of the mounting plates so
that it passes through the outermost bore hole (22) of the luf-
fing cylinder head pin (62) main boom / luffing cylinder and
through the groove of the clamshell. Secure pin (21) again
with the fore lock.
200−1−1310g_en 11/25
31
62 21 61
I
62 21 61
II
62 21 9 7 8 61
III
62
IV
Z 200 194
3 4
Z 200 196
12/25 200−1−1310g_en
(Z 200 194, I+II)

6. Fully retract the cylinder rods by activating the control lever
on the mobile cylinder (61) accordingly, pulling out the luffing
cylinder head pin (62).
(Z 200 194, II)
7. Remove pin (21), thereby disconnecting luffing cylinder
head pin (62) and mobile cylinder (61).
(Z 200 194, III)
8. Move mobile cylinder (61) on to the outer bearing points (8)
of the mounting plate. Extend mobile cylinder until the
groove of the clamshell (9) and the inner bore of the luffing
cylinder head pin (62) correspond.
9. Stick pin (21) through the slots of the mounting plate, the in-
ner bores of the luffing cylinder head pin (62) and the groove
of the clamshell (9) and secure.
(Z 200 194, IV)
10. Extract the whole luffing cylinder head pin (62).
11. Switch off superstructure engine and disconnect hydraulic

hoses from mobile cylinder. Remove mobile cylinder and
have it ready for further use in order to extract the boom foot
pin (see section 31.2.3, page 15).
(Z 200 196)
12. Lash luffing cylinder (4) on to luffing cylinder support (5) with
lash strap (3).
After dismantling the main boom, bring the luffing cylinder head
pin into the transport position (see step 18. in section 31.2.3 page
23).
200−1−1310g_en 13/25
31
10
11
12
Z 200 191
”D” ”C” ”B” I

1
62
”A”
2 3 5 4
6 7 8
Z 200 197
14/25 200−1−1310g_en
31.2.3 Extracting the Boom Foot Pin / Lifting the Main Boom
Especially the operations listed in the following that are ne-

cessary to draw out the main boom foot pin must be carried
out with special care and in accordance with all necessary
safety measures because there is a repeated risk of stum-
bling and falling.
(Z 200 191, Z 200 197)
1. The connecting pin main boom / superstructure is also ex-

tracted using the mobile hydraulic cylinder (Z 200 191). In the
following, this connecting
pin is called boom foot pin.
To do so, insert the mobile cylinder (62, Z 200 197) in the pin
extracting device on the left−hand page of the superstruc-
ture frame (crane cab side) so that the support elements (10,
Z 200 191) of the mobile cylinder are inserted in the inner
bearing points (B, Z 200 197,). The pin extractoris extracta-
ble.
With this step, the pin extracting device is used in theretrac-
ted condition: the extractable part (4, Z 200 197) isinserted
in the basic carrier which is fitted on thesuperstructure frame
(3, Z 200 197) and is inserted throughthe bolt (2, Z 200 197)
in point (D, Z 200 197).
Risk of crushing!
In the course of inserting the mobile cylinder there is the
danger of being crushed between the mobile cylinder and
the mounting plate. Please act carefully.
The weight of the mobile cylinder is approx. 20 kg (44 lbs)
200−1−1310g_en 15/25
31
B1 ST P L T B2 9
10
11
12
Z 200 190 Z 200 191
”D” ”C” ”B” I

1
62
”A”
2 3 5 4
6 7 8
Z 200 197
16/25 200−1−1310g_en
2. Connect the mobile cylinder hydraulically. To do so, first con-

nect both supplied hydraulic hoses (L = 11 m (36.1 ft)) with
the connections P, T (12, Z 200 191) of the mobile cylinder.
Then connect the free hose ends to the corresponding con-
nections P and T on the back of the superstructure frame.
(Z 200 190). These are the same connections with which
normally also P and T of the main boom are connected. Con-
nectthe identically marked connections.

been connected correctly, i.e. that the couplings open pro-
perly.
(Z 200 197)
3. Remove lock nuts (7) from the axle holder (8). The fixing
nuts (6) remain fitted. These nuts (6) serve to secure the
entire pin extracting device.
The axle stirrup (8) remains screwed fast to the boom foot pin
(1) and is designed in such a way that the mobile cylinder can
later be attached in order to pull.
4. Start superstructure engine.
(Z 200 191, Z 200 197)
5. Extend the mobile cylinder by operating the control lever (11,
Z 200 191). The mobile cylinder is raised out of the bearing
points (B, Z 200 197) of the pin extracting device. To ensure
that the groove of the clamshell (9, Z 200 191) can be latched
into the axle stirrup (8, Z 200 197), the mobile cylinder must
be held at an angle. Now the mobile cylinder must be exten-
ded until the support elements (10, Z 200 191) can be put
back on to the bearing points (B, Z 200 197) of the pin extrac-
tor . Set down mobile cylinder on to the bearing points (B,
Z 200 197) of the pin extractor
200−1−1310g_en 17/25
31
1 ”B” 10 61
II
8 ”A” 10 61
III
14 61
2
IV
3 ”D” 4 61
2
V
3 ”D” 4
”C” 61
2
VI
3 4 8
”D” ”C”
VII
VIII
4
”D” 15 5
Z 200 244
18/25 200−1−1310g_en
(Z 200 244, II)

6. By operating the control lever of the mobile cylinder (61) ac-
cordingly, retract cylinder rods completely thereby extracting
the boom foot pin (1).
7. Fit retaining rope (14) between the pin extracting device and
the boom foot pin (1) (on the axle stirrup (8)).
(Z 200 244, III)
8. Move mobile cylinder (61) on to the outer bearing points (A)
of the pin extractor. To do so extend the mobile cylinder until
the support elements (10) fit on to the bearing points (A). The
changed length lifts the mobile cylinder diagonally out of the
pin extractor. The groove of the clamshell (9) thereby re-
mains attached to the axle holder (8).
(Z 200 244, IV)
9. Retract the cylinder rods completely by operating the control
lever on the mobile cylinder (61) accordingly thereby further
extracting the boom foot pin (1).
(Z 200 244, IV)
10. The connecting pin (2) that is between the fixed part (3) and
the extractable part (4) of the pin extractor is now pulled out
of the locking point (D) and set down.
(Z 200 244, V)
11. By operating the control lever on the mobile cylinder (61) ac-
cordingly, extend cylinder rod, thereby extending the extrac-
table part (4) of the dismantling device until the connecting
pin (2) can be connected to the locking point (C). Insert con-
necting pin (2) in pinning point (C). To do so, the extractable
part (4) of the pin extractor might have to be raised a little.
(Z 200 244, VI)
12. Retract the cylinder rods completely by operating the control
lever on the mobile cylinder (61) accordingly thereby further
extracting the boom foot pin (1).
200−1−1310g_en 19/25
31
1 ”B” 10 61
II
8 ”A” 10 61
III
14 61
2
IV
3 ”D” 4 61
2
V
3 ”D” 4
”C” 61
2
VI
3 4 8
”D” ”C”
VII
VIII
4
”D” 15 5
Z 200 244
20/25 200−1−1310g_en
13. Switch off superstructure engine and disconnect hydraulic

hoses from mobile cylinder. Remove the mobile cylinder.
(Z 200 244, VII)
14. Fit retaining rope (14) between the pin extracting device and
the boom foot pin (1) (on the axle stirrup (8)).
Push the basic bolt manually over the guide rollers until the
retaining rope is tensioned. The basic bolt is then lying on the
pin extracting device and in the hole of the superstructure
frame. The main boom can now be lifted out.
Danger of tipping
If the guide rope is not seated in the pin extracting devi-
ceand the basic bolt, the basic bolt can slip backwards
out ofthe pin extracting device.
15. Use the auxiliary crane to move main boom vertically out of
the bearings of the main boom base and of the luffing cylin-
der and if required set it down on the transport vehicle.
Risk of crushing!
When the main boom is raised there is the danger of being
crushed between the main boom and the superstructure
frame or between the main boom and the rack on the
ground or the rack of the transport vehicle.
Make sure that tilting of the main boom on the bearing points
is avoided.
16. Remove lifting gear from main boom.
200−1−1310g_en 21/25
31
2 61
VI
3 4 8
”D” ”C”
VII
VIII
4
”D” 15 5
Z 200 245
62
40
21
Z 200 236 Z 57 664
22/25 200−1−1310g_en
(Z 200 245, VIII)

17. Bring boom foot pin in transport condition. To do so insert ex-
tractable part (4) of the dismounting device and fix connec-
ting pin (2) to the locking point (D).
To do so the extractable part (4) of the pin extractor might
have to be raised a little. Push boom foot pin by hand into the
superstructure frame until the locking pin (5) can be inserted
and secured.
Lash boom foot pin together with the dismounting device
with lashing strap (15).
(Z 200 236)
18. Bring luffing cylinder head pin in transport condition.
To do so reinsert luffing cylinder head pin (62) completely. Fix
pin (21) vertically.
19. Insert warning light (40) in the luffing cylinder head hole and
secure. Plug in the electric supply lead on the rear of the ve-
hicle in the corresponding socket.
To prevent the electric supply lead of the warning light being des-
troyed, it must be fastened to the luffing cylinder so that it does
not fall onto the road surface.
200−1−1310g_en 23/25
31
B1 ST P L T B2
Z 200 190 Z 200 199
”D”
6 7 8
7 21 20
Z 200 192 Z 200 200
24/25 200−1−1310g_en
31.3 Assembly of the Main Boom

The assembly of the main boom is done in the same way but in
the opposite sequence as dismantling (for dismantling, see sec-
tion 31.2, page 3).
Make sure that:

− main boom base and luffing cylinder set up on their bearing
correctly.
− the electric connections and hydraulic connections B1, ST, P,
L, T and B2 of the main boom are connected properly at the
rear of the superstructure frame (plug and plug connections
with the same designation, the hydraulic couplings must
open correctly).
The diagram (Z 200 190) shows the connections on the su-
perstructure framewith hydraulic hoses not connected to the
main boom.
The mobile cylinder is used again for pushing in the bolts.
(Z 200 199)
As soon as the main boom is assembled, the unloaded rok-
ker cylinder frame (5) must be removed again and transpor-
ted separately.
(Z 200 192, Z 200 200)

After reattaching of the main boom foot pin and the connec-
ting pin main boom/luffing cylinder these pins must be secu-
red unconditionally. (Z 200 192) shows the fixed locking pin
(21, Z 200 192) of the luffing cylinder head pin. Figure
(Z 200 200) shows the axle stirrup bolted on the boom foot
pin (6, Z 200 200) with mounted lock nut (7, Z 200 200).
200−1−1310g_en 25/25
Radio Remote Control (Optional) 34
200−1−1340−286a_en 1/35
34
201
Z 200 423
202
Z 200 424
2/35 200−1−1340−286a_en
34 Radio Remote Control (Optional)

(Z 200 423, Z 200 424)
Your crane is equipped with a radio remote control, which

basically consists of 2 components:
− mobile radio transmitter with control panel (201, Z 200 423)
− radio receiver (202, Z 200 424)
All crane movements can be controlled ”remotely”, from outside

the cab, using this radio remote control.
34.1 General
Before using the radio remote control you must read and
observe the operating instructions from the radio remote
control’s manufacturers!
If instructions are unclear, please contact our customer

service department before operating the remote control
system.
Every crane movement activated by the radio remote

corresponds exactly with a crane movement activated from
the crane operator’s cab.
All instructions and descriptions of the corresponding
sections of the crane operating manual must therefore be
observed.
The minimum command period and the crane’s reaction time

increase minimally due to the radio remote control.
All movements of the crane and the load must be in the field
of view of the crane operator. If necessary a spotter must be
used
You, too, as the operator of the radio control must remain

clear of the hazardous area of the crane during crane
operations!
200−1−1340−286a_en 3/35
34
24
24 1 2
21 3 4
20 5
LC
0
19
B C
6
A D
1 SCANNER 2 2 2
2
1
18
10 10
17 16 26 25 15 14 12 11 10 26 25 9 8
13 7
Z 60 232
4/35 200−1−1340−286a_en
34.2 Safety Regulations

(Z 60 232)
Applicable regulations on work safety and accident prevention
for operations using radio remote control must be observed!
The radio remote control may only be placed in operation upon
receipt of a special radio permit.
34.3 Important Information before Using the Radio Remote

Control
Only operate the radio transmitter with the transportation belt
in the DBM−supplied delivery (risk of confusing the operating
elements)!
Before working with the radio remote control, make sure that
you are fully conversant with how the system works! Only
authorised and suitably trained personnel may therefore
work with the radio remote control!
Check function of the STOP switch (7) every time before

commencing work!
If one procedure with radio remote control has been

completed, the slew gear brake (retaining brake) must be
applied for safety reasons!
Never leave the activated transmitter unattended!
Stop operation immediately if there is a defect, an emergency

or any other malfunction in the operating range of the radio
remote control in order to rectify the cause, i.e.:
− Switch off the radio transmitter using the STOP switch (7)
− Pull out key (13) from the radio transmitter
− Pull out connection cable from the radio receiver.
Take even small faults in the radio remote control into
consideration! They can lead to serious malfunctions!
Do not continue to work with a defective radio remote

control!
Defective radio remote controls may only be repaired by a

specialist! Only use original spare parts of the
manufacturer!
Depending on country specifications or as an optional extra there

could be a green lamp, which flashes during operation with radio
remote control.
200−1−1340−286a_en 5/35
34
202
202.1 202.2 202.3 202.4
Z 200 426
6/35 200−1−1340−286a_en
34.4 Radio Receiver

(Z 200 426)
The radio receiver is on the left−hand side of the superstructure.
Make sure that the radio receiver and the antenna do not come
into contact with other objects
There are 4 indicator lights (LEDs) in the lid of the radio receiver,
which indicate the operating condition of the radio remote control:
(202.1) − “On”
The yellow LED is illuminated as soon as the receiver is under
operating voltage. The connection to the crane electrical system
has been made, the internal operating voltage is live.
(202.2) − “HF”
The red LED is illuminated when the transmitter is switched off
and goes out as soon as the transmitter is switched on, i.e. when
the receiver receives a signal on its radio frequency.
If the LED ”HF” goes out when the transmitter is switched off, this
indicates that the radio channel is also being used by another
transmitter.
In the event of the system being shut down as a result of radio
faults, you should switch off your transmitter and watch to see if
the LED “HF” goes out anyway.
(202.3) − “SI 1”
The green LED flashes briefly approx. 2 x per second when the
transmitter is switched off. In this time the safety circuit is
checked. After switching on the transmitter, the LED lights up
permanently, i.e. the receiver has recognised its transmitter at the
same system address (code). Safety circuit ”SI 1” is enabled.
(202.4) − “SI 2”
The green LED is assigned to the internal safety circuit “SI 2”,
which switches the driving commands off twice when the
command sensor is in the ”Off” position, i.e. “SI 2” is not
illuminated.
Only when one or more drive commands (e.g. slew, hoist, etc.)
are output should the display ”SI 2” light up!
200−1−1340−286a_en 7/35
34
24
24 1 2
21 3 4
20 5
LC
0
19
B C
6
A D
1 SCANNER 2 2 2
2
1
18
10 10
17 16 26 25 15 14 12 11 10 26 25 9 8
13 7
Z 60 232
8/35 200−1−1340−286a_en
34.5 Control Elements of the Radio Transmitter

(Z 60 232)
Item Designation Function

1 Left control lever Telescopic section / slew gear
2 Display Details on load, utilisation, hoist
limit switch and telescoping system
(see page 15)
3 Indicator light Load state battery
4 Right control lever Hoist / luffing gear
5 Button Horn
6 Button Power unit hydraulic main boom
extension ON / OFF
7 Switch Emergency stop
8 Rotary switch Assignment of the control lever
(see page 13)
9 M.C. tumbler switch “ + ” = increase engine speed
“ − ” = lower engine speed
10 Rotary switch Radio channel: A, B, C or D
Scanner − radio frequency
11 M.C. tumbler switch Engine start = top
Engine stop = bottom
12 Push button Display switch−over (see page 15)
13 Key switch M2 Transmitter on/off Function
The keys for both key switches are marked with “M1” or “M2” and only
fit in accordance with their designation.
200−1−1340−286a_en 9/35
34
24
24 1 2
21 3 4
20 5
LC
0
19
B C
6
A D
1 SCANNER 2 2 2
2
1
18
10 10
17 16 26 25 15 14 12 11 10 26 25 9 8
13 7
Z 60 232
10/35 200−1−1340−286a_en
(Z 60 232)
Item Designation Function

14 M.C. tumbler switch Fine tuning of crane movements:
slew gear left / right, luffing gear,
hoists
15 Rotary switch LC input “+” = upwards
LC input “−” = downwards
1st step each = 1 step
2nd step = 10 steps
16 Rotary switch Selection of the crane movement
for fine tuning with item 14
17 Toggle switch Slew gear brake:
top − closed
bottom − open
18 Key switch M1 Bridging ”Raise luffing gear”
Risk of accidents!
This switch may only be pressed
briefly and only when it does not
cause a dangerous situation!
You must observe the instructions
in section 10 “Safety equipment”,
subpoint “Bridging the load limit
device”.
19 Button Lighting equipment for the display
20 Button High speed
21 Buzzer Acoustic warning signals
24 Handle
25 Attachment eyelets for
transportation belt
26 Transportation belt
200−1−1340−286a_en 11/35
34
LC
0
AB CD
1 SCANNER 2 2 2
2
1
0
10 10
2
2 2
8
Z 60 233
40.4 t 10
0.0°
Z 56 924
12/35 200−1−1340−286a_en

(Z 60 233, Z 56 924 principle diagram)
As soon as the radio remote control is switched on, the position

of rotary switch (8) determines the control lever assignment. In
this case it does not matter which mode of control lever
assignment is selected via IC−1.
(Z 56 924 principle depiction)

The display of the selected mode in the top line of the IC−1
display adapts accordingly.
For detailed instructions on the modes of the control lever
assignment, see section 10 “Safety equipment” under “Mask
control lever assignment”.
Switch Right control lever

Mode Left control lever
position
Slewing Luffing
SLH = SRH =
gear gear
“o” “1”
SLV = Tele SRV = Hoist 1
Slewing
2 SLH = SRH = Hoist 2
gear
“3”
SLV = Tele SRV = Hoist 1
Slewing Luffing
SLH = SRH =
2 gear gear
“2”
SLV = Hoist 2 SRV = Hoist 1
2 Slewing
SLH = SRH = Hoist 2
“3” with gear
HAVHY* Luffing
SLV = SRV = Hoist 1
HAVHY*
Slewing Luffing
SLH = SRH =
“1” with gear gear
HAVHY* Luffing
SLV = SRV = Hoist 1
HAVHY*
∗ Main boom extension which can be luffed down hydraulically
S = control lever, R = right, L = left, H = horizontal, V = vertical
Risk of accidents!
Observe the selected pilot control assignment in order to
avoid unintentional movements.
200−1−1340−286a_en 13/35
34
2.1
2.2
”A” 2.3
2.6 2.5 2.4
2.7 2.8
%
”B” LK
2.9
2.12 2.11 2.10
12
Z 200 428
14/35 200−1−1340−286a_en
34.7 Display
(Z 200 428)
Using push button (12), you can select between two different
displays during operation of the crane.
Operating display (“A”)
(2.1) − Bar display of load utilisation (also appears at the same

place in the telescoping display “B”)
(2.2) − Percentage display of load utilisation
(2.3) − Radius
(2.4) − Hoist limit symbol
When the hoist limit symbol lights up (HE) the hoist limit
switch has been triggered.
(2.5) − Current gross load
The gross load includes the weight of the hook block, the
hoist rope and all load lifting attachments.
(2.6) − Max. load capacity in accordance with the load capacity
table
Telescoping display (“B”)
(2.9) − Selected LC
(2.10) − Display appears when selected LC has been achieved.
(2.11) − Position indicator of the locking and pinning unit (LPU)
(2.12) − Bar display of the selected LC
The following symbols are shown in the bottom right−hand corner

for both displays as required:
(2.7) − Prewarning symbol
Prewarning range (90 − 100 % of the load moment)
Prewarning symbol flashes.
(2.8) − Overload symbol
Overload range (from 100 % of the load moment)
Overload symbol flashes up.
The LLD switches off the movement ”Raise load”,
”telescope out” and ”lower luffing gear”.
200−1−1340−286a_en 15/35
34
62
53 54
Z 115 153 Z 200 654
40.4 t 2
40.4
7.0
2
Z 60 237
40.4 t 2
40.4
7.0
2
Z 60 239
16/35 200−1−1340−286a_en
34.8 Starting Operation of the Radio Remote Control

(Z 115 153 principle diagram, Z 200 654, Z 60 237 principle
diagram, Z 60 239 principle diagram)
The sequence described below for starting operations must be

followed (for finishing operation, in the reverse order).
(Z 115 153 principle diagram)

1. Insert charged battery with the decals facing outwards in the
corresponding compartment on the bottom of the control
panel. Observe correct polarity of the battery.

2. Switch on the ignition(62) in the cab (see section 5 “Engine”).
The IC−1 ramps up and mask (Z 60 237 principle diagram)
“Selection of the operating mode” appears.

3. Switch over the key switch (54) to radio remote control (and
pull out key). Indicator light “53” lights up. In mask “Selection
of the operating mode”, key .
200−1−1340−286a_en 17/35
34
40.4 t 2
HA
0.0
0.0
40.4
7.0
2
40.4
7.0
Z 60 240
40.4 t 2
27
0.0°
Z 60 241
18/35 200−1−1340−286a_en

4. Taste in the display of the IC−1 (Z 60 240 principle
diagram). In addition, an ”Information” mask appears, in
which the parameters for the currently set configuration are
indicated. Either activate the correct configuration with the
“Continue” key or return to the ”Configuration” mask using
the ”Return” key and adapt setting to the actual crane state.
Risk of accidents!
All parameters must be selected by the crane operator so
that they correspond with the actual state of the crane. This
is the sole responsibility of the crane operator. Only when
this entry is correct can the load limit device reliably
monitor crane operation.
After activating the configuration, the “Operation of the crane”

mask appears with symbol (27, Z 60 241 principle
diagram).
As soon as crane operation with ”Radio remote control“ has been

activated, it is not possible to change the crane configuration on
the IC−1.
In order to prevent unwanted crane movements or

disruptions, pull out the key switch “Operational readiness
of radio remote control”, close the crane operator’s cab and
take both keys with you.
200−1−1340−286a_en 19/35
34
21 3
LC
0 B C
A D
1 SCANNER 2 2 2
2
1
0
10 10
11
13 7
Z 60 242
202
202.1 202.2 202.3 202.4
Z 200 426
20/35 200−1−1340−286a_en
(Z 60 242, Z 200 426)
5. Make sure that the STOP switch (7) is unlocked. If required,

unlock the STOP switch by turning it.
6. Switch the radio transmitter on. To do so, turn the key

switch M2 (13) in the direction of the arrow. The state display
(202.3) flashes green, the transmitter is ready for operation.
If the red LED of the state display (202.3) is illuminated and / or

an acoustic signal goes off via buzzer signal (21), it means that
the battery is almost empty. Then you must immediately proceed
as follows:
− Replace the empty battery with a charged one.
− Charge empty battery again (see section 34.10 “Battery”,
from page 29).
If the empty rechargeable battery is not replaced with a fully

charged one, the transmitter will switch itself off in a few minutes.
The radio connection to the receiver (Z 200 426) has been

created if the red LED ”HF” (202.2) goes out after the transmitter
has been switched on, and the green LED ”Si1” (202.3) is
illuminated.
Control commands can then be entered using the radio
transmitter’s control panel.
7. Start the crane engine using the radio remote control;

(engine start; flip switch ”11” − top)
Every time before starting work you must:
Press button (5) ”Horn”. This warns your colleagues that

crane or hook movements must be taken into consideration
at this point in time.
Check function of the STOP switch (7).
200−1−1340−286a_en 21/35
34
21 3
LC
0 B C
A D
1 SCANNER 2 2 2
2
1
0
10 10
11
13 7
Z 60 242
22/35 200−1−1340−286a_en
(Z 60 242)
If the transmitter has been switched off using the STOP switch
(7), the following steps must be carried out for further
transmission operation:
1. Switch off the radio transmitter. To do so, turn the key

switch M2 (13) against the direction of the arrow.
2. Unlock the STOP switch (7) by turning it.
3. Switch the radio transmitter again. To do so, turn the key

switch M2 (13) in the direction of the arrow.
Switch the transmitter on and off using the key switch M2

(13). Only use the STOP switch (7) in case of emergency and
if there are malfunctions in the area of operation.
200−1−1340−286a_en 23/35
34
21 3
LC
0 B C
A D
1 SCANNER 2 2 2
2
1
0
10 10
11
13 7
Z 60 242
24/35 200−1−1340−286a_en
(Z 60 242)
The control command is also transmitted outside the

visible range to the crane. Therefore, if out of use, remove
the key (13) from the transmitter and store in a safe place.
Automatic transmitter shutdown
The transmitter is equipped with an automatic transmitter

shutdown and switches itself off approx. 15 minutes after
entering the last control command.
The automatic transmitter shutdown is for safety purposes and
increases the battery’s standstill time.
Always be very careful and observant when using the radio

remote control!
Select a safe operating location where you can see the
workplace fully.
During operational breaks or when operation is finished,

switch the transmitter off using key switch (13) or stop
switch (7) and pull out the connection plug from the
receiver!
The automatic transmitter shutdown never absolves the
operator from his responsibility to switch off the radio
transmitter if it is no longer needed!
Operation may not be continued with a defective radio

system!
Unintended or improper use of the radio remote control will lead

to its manufacturer’s warranty being invalidated!
200−1−1340−286a_en 25/35
34
41
Z 60 243
26/35 200−1−1340−286a_en
34.9 Battery
(Z 60 243)
The battery (41) must be in the corresponding compartment on the

bottom of the radio transmitter’s control panel − as depicted.
The length of the battery’s operating period depends on the age of the
battery and the surrounding temperature. Older batteries lose their
functioning capacity with age. If temperatures are below 0° C / 32° F,
the battery does not achieve full capacity.
If treated correctly, the battery can have 500 charging cycles. For this
reason:
− Only charge the battery when it is empty, i.e. if the red display
flashes on the transmitter and / or the acoustic signal goes off.
Charge the batteries before using them for the first time!
Batteries that have been stored for a longer period of time must be
charged before use.
− Do not keep the battery in the toolbox or in trouser pockets (risk of

short circuiting).
− Always use the supplied protection caps for storage.
− Store the batteries at room temperature (approx. 20° C / 68° F).
200−1−1340−286a_en 27/35
34
51
56
55
54
53
52
Z 60 382
28/35 200−1−1340−286a_en
34.10 Battery Charging Set

(Z 60 382)
Only HBC batteries of the type FuB 10 AA and FuB 10 XL

may be charged with the charging set FLG 110D!
Only use original HBC batteries. Not using original HBC

batteries can cause performance and safety problems
during charging (from overheating to explosion of the
battery)!
Do not operate the charging set in areas at risk of

explosions!
Only use the charging set with the network voltage

indicated on the bottom!
Only use the charging set in vehicles!
Only operate the charging set within the indicated

temperature range and protect it from overheating, dust
and damp!
Disconnect the charging set from the power supply before

opening the unit!
Do not cover the charging set during operation!
Disconnect the charging set from the power supply if it is

not being used!
Stop operation of the unit immediately if there is a fault in

the unit or the cable!
Do not make any technical changes to the charging set or

the cables!
Only have repairs carried out by a specialist!
200−1−1340−286a_en 29/35
34
51
56
55
54
53
52
Z 60 382
30/35 200−1−1340−286a_en
Charging the battery

(Z 60 382)
1. Connect the charging set to a vehicle socket.
2. Insert the battery in the charging compartment (52) with the

decals facing outward. Make sure that the polarity of the
battery is correct.
The charging state of an inserted battery is displayed via 4 LEDs:
LED (56), red − Battery defective or exhausted

LED (55), yellow − battery is charged.
LED (54), green − Battery is charged
LED (53), yellow − Battery is discharged
Technical data
Operating voltage 10 − 30 V DC
Loading time approx. 3 hours
Operating +10° C − +40° C
temperature (+50° F − +104° F)
Unit protection class II
Function “Discharging”
The battery’s capacity can decrease with increasing service life.

In this case, the battery charging set enables an improvement of
the available battery capacity using a function “Discharging”. All
that is needed is to briefly press the button (51) “Discharging“.
The battery is completely discharged and recharged
automatically.
200−1−1340−286a_en 31/35
34
32/35 200−1−1340−286a_en
34.11 Troubleshooting
First please check the functions using the cab or cable control.
Fault Possible cause Measures

No reaction when No operating voltage Check the battery contacts for damage or
switching on the contamination.
transmitter
Insert a charged battery into the battery
compartment.
Fully charge the battery.

Undervoltage after a The battery contacts Check the battery contacts for damage or
short operating time, are clogged or contamination.
i.e. the state display damaged.
in the transmitter Fully charge the battery.
flashes red The battery is not
charged. Check that the charging procedure is being
carried out correctly.
The battery is
defective. Check the transmitter function with a fully
charged or substitute battery.
The transmitter The receiver does Check the connection cable to the receiver.
indicates a normal not have any
operating display, but operating voltage. Check the fuses in the transmitter.
does not allow any
control commands to There is no radio Check the functions using the LEDs in
be carried out. connection. receiver’s lid.
Individual commands The receiver is Make sure the connection cable is fitted
are not being carried defective. correctly.
out.
The connecting line If required, contact a service technician.
to the crane is
disrupted.
200−1−1340−286a_en 33/35
34
34/35 200−1−1340−286a_en
34.12 Servicing
The radio system is largely maintenance−free. However, the

following points should be observed:
− Make sure that the STOP switch moves easily. Mortar
remnants and dirt can hinder activation of the switch or render
it impossible.
− Check the control lever’s bellows regularly to make sure they
are sealed. Change bellows early enough if cracks start to
appear as invading damp and dirt hinder the function of the
control lever.
− Charge and discharge the transmitter batteries regularly.
− Never “clean” the radio system with high−pressure cleaners
or with steam cleaners. If required, use a paintbrush of a
cloth.
− If electrical welding work is to be carried out on the crane:
− switch off the radio system
− remove the plug on the receiver.
Failure to carry out these safeguards will result in the
receiver electronics being destroyed.
If problems occur with the radio remote control, please contact

our service department.
Take even small faults in the radio remote control into

consideration! They can lead to serious malfunctions!
Only have defective radio systems repaired by a specialist!

Only use original spare parts of the manufacturer!
200−1−1340−286a_en 35/35
Emergency Operation (Optional) 36
200−1−1360b_en 1/11
36
6
5 P
T
L UW
T UW 4
P
UW
Z 200 171
2/11 200−1−1360b_en
36 Emergency Operation (Optional)
Follow all safety instructions which are also valid fornor-

mal operation!
The emergency operation procedures described in the following

are only for when the superstructure engine or a pump fail so that
small loads (load pressures < 210 bar (< 3046 psi)) can be reco-
vered safely.
Emergency operation is not equipped or suitable for maintaining
normal crane operation.
36.1 General
The required connections (hydraulic interfaces) arestandardi-

sed. The required auxiliary power unit is a hydraulic transfor-
mer,which basically consists of a pump and an engine. Such a
transformer can be ordered from the cranemanufacturer.
(Z 200 171)
The transformer has the following connections:
TUW − Tank connection crane chassis
PUW − Pressure connection crane chassis
LUW − Leakage oil connection crane chassis
T − Tank connection superstructure
P − Pressure connection superstructure.
The shut−off lever (6, Z 200 171) of the hydraulic transformer is
set to open throughfeed and is only closed when a movement is
to be driven immediately afterwards.
The engine of the transformer (4) is driven by an external hydrau-

lic system (e.g. from the crane chassis, a second crane or a spe-
cial unit) and it then drives the transformer pump (5), which sup-
plies the superstructure hydraulic system.
The following movements can then be driven by activating the

control lever in the superstructure:
− Luffing
− Raising / lowering hoists
− Rotating (in connection with a stop valve on the superstruc-
ture)
The required hydraulic transformer and all requiredhoses must
be supplied by the customer or can be delivered as optional
equipment.
200−1−1360b_en 3/11
36
6
5 P
T
L UW
T UW 4
P
UW
Z 200 171
4/11 200−1−1360b_en
36.2 Connecting the Transformer

(Z 200 171)
Initial situation:
− Crane in relevant operating configuration (outrigger support

area, counterweight and similar) with hanging small load.
− Superstructure:
∗ Failure of diesel engine or pump
∗ Hydraulics and electrics functioning
∗ Engine and ignition off
− Crane chassis:
∗ Hydraulic external supply from the crane chassis or exter-
nal machine with connections for driving the transformer
∗ Engine and ignition off
− Use of a standard transformer In the following, an example
of the transformer (Z 200 171) supplied by the crane manu-
facturer is described.
1. Unfold protection caps on the relevant couplings of the trans-

former and unscrew hydraulic hoses.
200−1−1360b_en 5/11
36
6
5 P
T
L UW
T UW 4
PUW
Z 200 171
H 2.1 1.1 P(1) D T
TUW
4
6
5
M P
PUW
LUW
L
PUW
TUW
Z 200 172
6/11 200−1−1360b_en
(Z 200 171, Z 200 172)
2. Connect transformer engine (4) to the corresponding hy-

draulic couplings on the crane chassis using hoses.
hese hydraulic couplings (x 3) are on the left−hand side of the

chassis between the wheels of axles 2 and 3 on the bottom of the
covering. There are protection caps on the hydraulic couplings
which must be removed.
The corresponding coupling sleeves and plugs are marked

with plates as follows:
TUW − tank connection crane chassis
LUW − Leak oil crane chassis
PUW − pressure connection crane chassis.
There is no risk of them being confused as the connections of the

different hoses have different sizes.
For transformers without a leak oil connection, coupling “LUW” re-

mains free on the crane chassis.
The shut−off lever (6, Z 200 171) of the hydraulic transformer is

set to ”open throughfeed”. Figure (Z 200 171) shows the stop
valve (6) in the closed position.
3. Connect pump (5) of the transformer to the corresponding

hydraulic couplings of the superstructure using hoses. To do
so, unscrew each protection cap and screw on the hydraulic
hose.
The coupling sleeves and plugs which belong together can
be marked with plates as follows:
P − Pressure connection superstructure
T − Tank connection superstructure
There is no risk of them being confused as the connections of the

different hoses have different sizes.
4. Connect bridging hose ”S” on the superstructure between

the connections 1.1 and 2.1 (rotate for function Superstruc-
ture).
200−1−1360b_en 7/11
36
Z 200 173
103
Z 200 174
8/11 200−1−1360b_en
36.3 Recovering a Small Load

(Z 200 173, Z 200 174)
1. Connect the transformer in accordance with section 36.2.
2. Switch on the ignition of the superstructure.
3. Activate the function Emergency lowering (optional) (203.3,

Z 200 173) in the service line in the main menu of the crane
control system.
The function surface then displays “ON”.
When the crane operating mask is switched on, a red cross
with ”ON” written on it is displayed at (25, Z 200 173) in the
crane display (A, Z 200 173).
4. Open stop valve (6) of the hydraulic transformer (= pres-

sure−free circuit from pump side), if this has not already been
done!
The stop valve is only closed shortly before a movement is execu-

ted.
5. Start up the engine of the crane chassis.
6. Press switch (103, S 2430) (Z 200 174) in the chassis cab.

To do so, the hand brake must be applied and the transmis-
sion must be in ”neutral position”.
The engine of the hydraulic transformer is supplied with oil.
7. Close stop valve (6) of the hydraulic transformer: The super-

structure hydraulic system is supplied with oil.
The further procedure depends on the movement to be carried:
Hoist and luffing
8. The crane movements ”Hoist and luffing” can be carried out

as before using the joystick.
200−1−1360b_en 9/11
36
H 2.1 1.1 P(1) D T
TUW
4
6
5
M P
PUW
LUW
L
PUW
TUW
Z 200 172
103
Z 200 174
10/11 200−1−1360b_en
(Z 200 172, Z 200 174)
Rotating the superstructure
9. In order to rotate the superstructure, the position of the stop

valve (H) must be modified:During normal crane operation,
the stop valve (H) is in the middle position. In order to rotate
the superstructure clockwise, the lever of the stop valve
must be pressed inwards. In order to rotate the super-
structure anti−clockwise the lever of the stop valve must
be pulled outward. The lever of the stop valve is moved in
the final position each time (locks in place!)
The speed of the slewing movement is set using the knob of

the throttle (D). You will have a slewing speed that is easily mana-
geable when you turn the rotating knob half a turn from the com-
pletely screwed−in position (closed). Further opening of the
throttle results in an increase of the slewing speed.
The actual slewing movement is introduced by pressing the
corresponding joystick to the right or the left.
(Steering direction immaterial!)
Risk of crushing and pushing!

The slewing direction of the superstructure is determined
by the position of the hand stop valve (H) and not by
steering the joystick.
10. Open stop valve (6) of the hydraulic transformer after the mo-
vement has been carried out (= pressure−free circuit from
pump side).
Only operate the transformer as long as is required for reco-

vering the load and do not let it run at idle speeds for longer
periods of time.If the transformer is operated for a longer pe-
riod of time, the oil can overheat.
11. After the load has been recovered, switch off the ignition in
the superstructure and with there was a slewing movement
previously: return hand stop valve (H) to the middle position
(locks in place).
12. Switch off switch (103, S 2430) in the crane chassis and turn
off the engine.
13. Disconnect all connections of the transformer again and refit

the protective caps on the couplings.
200−1−1360b_en 11/11
Runner (Optional) 41
200−1−1410−312_en 1/31
41
”a” ”b”
80
Z 200 661
2/31 200−1−1410−312_en
41 Runner (Optional)
41.1 General
(Z 200 661)
The hoist rope can be reeved up to four times using the runner
(80). Figure (Z 200 661, ”a”) shows the runner (80) in the load
raising position.
The hook block can remain reeved on the main boom head.
The runner can be folded and it can be folded away to the side
of the main boom head in accordance with the permitted axle
loads (Z 200 661, “b”).
Main boom operation with the runner fitted in the transport

position results in a reduced load capacity of the crane.
The optional “head sheave” (see section 21) can be folded to the
side of the main boom head in the transport position in the same
place.
However, only the runner or the head sheave can be folded to the
left of the main boom head at the same time.
If the runner is fitted to the main boom head in the transport

position, the main boom extension (see section 18) cannot be
fitted in the load raising position.
41.2 Important Notes
The runner is marked with the construction number of the

crane. It can only be fitted onto a crane with this
Exceptions are only permitted if this is clearly indicated in
the crane documents (e.g. the crane passport).
Only trained and instructed personnel may fit and remove

the runner!
Check that there is no damage to the tubes on the runner

components. If you find damaged tubes during a visual
check, it is prohibited to continue working with the runner.
200−1−1410−312_en 3/31
41
4/31 200−1−1410−312_en
Risk of accidents!
When fitting or removing the runner, there is risk of
crushing between the main boom head and the runner.
Observe in particular the danger instructions in chapter
1.4.8 ”On assembling and disassembling crane
components” and the procedures described in the
following.
All assembly work must be carried out using suitable
equipment (ladders, lifting stages, scaffolding, auxiliary
crane).
Stepping onto the boom is strictly forbidden!
RISK OF BREAKAGE!
The runner’s draw bars must be checked at least once a
year by a specialist (in accordance with the accident
prevention regulations ”Load receptacle devices in hoist
operation (VBG 9a / BGV D6)”. In addition, depending on
the operating conditions and environment, they should be
checked between these intervals by an expert.
The inspection intervals are generally determined by the
operating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals
should be.
This inspection must be documented once it has been

carried out (e.g. in the examination log book for the crane).
The following checks should be made:

− Check for cracks
− Check of length
− Checking for Wear
− Checking the paint
− Check for plastic deformation
Information on carrying out the inspection can be found in
the ”Lubrication and Maintenance Instructions of the
Superstructure”, (part 3).
200−1−1410−312_en 5/31
41
72
73
2−EXPLICIT
3−EXPLICIT
Z 200 484 Z 55 536
72
Z 104 254
6/31 200−1−1410−312_en
- Supplied folding / sliding ladder (72):
(Z 200 484, Z 55 536, Z 104 254)
Risk of falling!
In order to carry out all assembly work with as little risk as
possible, a ladder is supplied with the machine.
If the supplied ladder is not used, the assembly work must
be carried out using other suitable aids (ladders, hoist
platforms, scaffolding, auxiliary crane).
It is not permitted to climb or walk on the main boom.

main boom extension for transportation, for example.
There are brackets on the folding / sliding ladder for fastening the
actuating rod (73). This actuating rod (73) can be used as an aid
when fitting the hoist rope.
There are metal plates on the main boom for attaching the
ladders (72) safely during the corresponding working procedures
(Z 104 254 principle depiction).
Risk of unchecked runner movement!

Generally, the main boom must be aligned horizontally
when fitting or folding the runner. Any exceptions to this
rule are clearly listed.
200−1−1410−312_en 7/31
41
32
31
Z 200 490
”a” ”b” ”c”

”X”
”Y”
81
80
Z 200 662
8/31 200−1−1410−312_en
(Z 200 490 Principle drawing)
The runner is always connected to the main boom head using 4

biconical bolts (31).
Each biconical bolt must be secured against falling out with two
functioning locking springs (32).
Risk of accidents!
Only the supplied bolts may be used for fitting the runner.
(They have a cylindrical design at one end (see detail A).)
Each bolt must be secured against falling out using 2
functioning locking elements (32).
Only the locking elements may be used which are fitted on
the crane in the first delivery.
(Z 200 662)
The runner can be folded and it can be folded away to the side
of the main boom head in accordance with the permitted axle
loads (Z 200 662, “c”).
In this case, the runner must be converted from the operating

position (Z 200 662 “a”) into the “folded position” (Z 200 662 “b”).
To do so, pull the runner head up using the rope winch until hole
“Y” is flush with hole “X”. Then pin the rods in point “X” with pins
(81). Only then may the runner be folded into the transport
position (Z 200 662 “c”).
The conversion from the transport position (Z 200 662 “c”) into
the operating position (Z 200 662 “a”) is similar, but in the
opposite sequence.
If the runner is transported separately, the runner is fitted and

removed in the folded position (Z 200 662 “b”) on the main boom
head. Then the runner must be converted into the transport
position (Z 200 662 “c”) or into the operating position (Z 200 662
“a”).
Depending on the initial situation, carry the working procedures

described in the following.
200−1−1410−312_en 9/31
41
86
”a”
80b
80a
E 80
”b”
31
32
”c”
31
32
Z 200 663
10/31 200−1−1410−312_en
41.3 Separate Transport

Use the 4 attachment points (E) as they can be seen in figure
(Z 200 663 “a”, “b”).
RISK OF ACCIDENTS!
When being raised, the runner may not swing out or hang
crookedly. If necessary, lifting chains fitted with shortening
claws must be used.

mm mm mm kg
1650 mm 1450 mm 980 mm 500 kg
(65.0 in) (57.1 in) (38.6 in) (1102 lbs)
200−1−1410−312_en 11/31
41
86
”a”
80b
80a
E 80
”b”
31
32
”c”
31
32
Z 200 663
12/31 200−1−1410−312_en
41.4 Fitting and Removing the Runner for Separate

Transportation (in the Folded Position)
(Z 200 663)
The runner is in the folded position for fitting, i.e. the runner frame
(80a) is pulled up to the adapter (80b) using the adjustment rope
(86) of the auxiliary winch. The entire component group is on the
ground on the fork ends and the standing pipes of the runner
frame (80a).
1. Attach the runner (80) to the prescribed attachment points

”E” (x 4)in the fitting position on the main boom head using
the auxiliary crane.
To do so, each drilled hole in the fork ends of the runner
adapter (80b) must correspond with the ones on the right−
and left−hand head axle, top and bottom.
No−one may be in the area at risk of falling equipment, etc.

as long as the runner is attached to the auxiliary crane or
has not yet been completely pinned!
2. Knock in the biconical bolts (31) at the pinning points (4

times). Secure the biconical bolts (31) against falling out
using 2 locking springs (32).
The then achieved ”folded” fitting position (Z 200 663, “c”) only
serves as an intermediate state when fitting and removing or
folding in and out of the transport position.
Risk of accidents!
This “folded” fitting position may NEVER be used for
raising loads. To do so, the runner must first be brought in
the operating position.
200−1−1410−312_en 13/31
41
14/31 200−1−1410−312_en
For the further procedure for

∗ Raising loads:
see ”Converting from the folded position to the load raising
position (and vice versa)” (see 41.5, from page 17)
∗ Converting to transport position:
see “Folding from the folded position to the transport position
(and vice versa)” (see section 41.6, from page 27)
The runner must also be removed in the ”folded” position. To do

so, proceed in the same manner just in the opposite sequence.
200−1−1410−312_en 15/31
41
80a 80b
80
Z 200 664
85
81, 82
”c”
80b 80
”a” 80a
85.1
84 86
”b”
83
88
88
Z 200 491
16/31 200−1−1410−312_en
41.5 Converting from the Folded Position to the Load

Raising Position (and Vice Versa)
41.5.1 Converting to Load Raising Position

(Z 200 664, Z 200 491)
The condition for this procedure is that the runner (80) is fitted to
the main boom head in the folded position.
Procedure:
1. Lower runner frame (80a).

To do so:
1.1 (Z 200 491, “c”): Fit the crank (84) to the attachment
eyelet (85.1) of the auxiliary winch (85) and unreel the
adjustment rope (86) of the auxiliary winch, until the
bracing rods (81, 82) are straight on both sides
(Z 200 491, “a”).
1.2 With the runner in the operating position (bracing rods

straight), loosen the adjustment rope (86) by slightly
unreeling it, so that it is never under load during runner
operation.
2. For even reevings (Z 200 491, “b”):

Bring the rope attachment point (88) into the operating
position. To do so, loosen the trigger snab (83) of the
fastening chain of the rope attachment point: rope
attachment point (88) swings down.
During reeving, there is a risk that all involved sheaves

become wrapped and wound up.
3. Feed the hoist rope from the hoist drum to the intake sheaves
on the main boom head.
Observe for this the detailed specifications contained in
section 17 ”Reevings” in the subpoint ”Reeving the hoist
rope in and out”.
200−1−1410−312_en 17/31
41
E2 E1
61 62
61
”X0566” 80b 80
80a
R2 R1 61.1
FU
63 a: b:
105
FR L
64
Z 200 494 Z 200 477
4 3 2 1
E2 E2 E2 E2
E1 E1 E1 E1
R2 R2 R2 R2
R1 R1 R1 R1
FR FR
3 1 3
1 1 1
4 2
2 2
U3 U2 FU U3 U2 U3 U2 FU
U1 U1 U1
Z 200 495
18/31 200−1−1410−312_en
(Z 200 494, Z 200 495)

4. Feed hoist rope to the sheave (R1) of the runner via intake
sheave (E2).
Risk of rope damage!

The rope may not be fed via intake sheave (E1) as this would
make the deviation angle of the hoist rope too large.
5. Reeve the hoist rope in accordance with the desired reeving.

Reeving of thehoist rope can be up to 4−fold over the runner
(Z 200 495).
E − Intake sheaves on the main boom head
R − Sheaves on the runner
U − Hook block pulleys
FR − Fixing point on the runner
FU − Fixing point on the hook block
(Z 200 494, Z 200 477)

6. Fit the hazard light (61) to the runner frame (80b) as well as
the rotor of the anemometer (62) to the head of the main
boom.
200−1−1410−312_en 19/31
41
E2 E1
61 62 X0566 X0550
”X0566” 80b 80 HES HES
Z 200 475
80a
R2 R1
FU
”X...”
63
105
FR L
64
Z 200 494 B1 A H B2 Z 200 441
”X0550”
HR
Z 200 454 Z 200 457
20/31 200−1−1410−312_en
(Z 200 494, Z 200 475, Z 200 441, Z 200 454)
weight (64) in point “L” and secure against falling out.
You must make sure that the shift weight is fitted over the
hoist rope and is hanging freely.
Only then is it guaranteed to function properly.
Observe the details in section 17 “Reevings”.
(Z 200 457, Z 200 441)

8. Connect the plug of the runner cable harness to the junction
Z 200 441).
200−1−1410−312_en 21/31
41
E2 E1
61 62 X0566 X0550
”X0566” 80b 80 HES HES
Z 200 475
80a
R2 R1
FU
”X...”
63
105
FR L
64
Z 200 494 B1 A H B2 Z 200 441
L: R:
63.1 63.1
”X0566”
”B”
”A”
63.2 63.2 F
1 2
3 A H
Z 104 165 Z 200 488
22/31 200−1−1410−312_en
(Z 200 494, Z 200 475, Z 200 441, Z 200 454)

(Z 200 494, Z 200 488)
“H”, connect the plug of the hazard light (61) to the
connection “F” and connect rotor plug of the anemometer
(62) to connection “A” of the junction box “X0566” on the
runner.
Risk of accidents!
If the rotor of the anemometer is not fitted or not connected,
the wind speed is not displayed on the IC−1. A prohibited
high wind speed might not be recognised.
200−1−1410−312_en 23/31
41
E2 E1
61 62
”X0566” 80b 80
80a
R2 R1
FU
63 80a 80b
105 80
FR L
64
Z 200 494 Z 200 664
L: R:
63.1 63.1
”B”
”B”
”A”
63.2
3
1
Z 104 166
24/31 200−1−1410−312_en
41.5.2 Converting to the Folded Position
(Z 200 494, Z 200 664)
“Conversion from the load raising position (Z 200 494) to the

folded position” (Z 200 664) is done in the same manner as
“Conversion from the folded position to the load raising position”
(see 41.5.1, from page 17), just in the opposite sequence.
(Z 104 166)
If a second hoist limit switch was used:

After removing the runner from the load raising position, the hoist
limit switch (63) on the main boom head must be reset to a
functioning state. The restrainer (63.2) of the hoist limit switch
(63) must be removed again.
Figure (Z 104 166 “R”) shows the hoist limit switch in a
functioning state.
If only one hoist limit switch is used:

After removing the runner from the load raising position, the hoist
limit switch (63) must be fitted to the main boom head again and
connected.
Risk of collision!
If the hoist limit switch is not put back into a functioning
state, there is risk of collision between the hook block and
the head of the main boom during main boom operation.

∗ Converting to transport position:
see “Folding from the folded position to the transport position
(and vice versa)” (see section 41.6 from page 27).
∗ Removing the runner for separate transport:
see ”Fitting and removing the runner for separate transport
(in the folded position)” (see 41.4, from page 13).
200−1−1410−312_en 25/31
41
”a” ”b”
H F
G
I
”c” ”d”
F(G) 31, 32
5
6
H(I)
31, 32 4
31, 32
7
Z 200 665
26/31 200−1−1410−312_en
41.6 Folding from the Folded Position to the Transport

Position (and Vice Versa)
41.6.1 General
(Z 200 665)
If the runner is not needed, it can be folded onto the side of the
main boom head while in the folded position (Z 200 665 “b”).
When folding the runner, there is risk of crushing between

the main boom head and the runner. Proceed with
appropriate caution!
During the folding process, no person is permitted in the
crash range!
Before folding on the main boom side, the runner has to be

folded out of the working position into the transport position
(Z 200 665, “a”)!
If the runner is fitted in the transport position on the

left−hand head side, the head sheave (see section 21) cannot
be fitted in the operating position or in the transport position.
If the runner is then fitted to the left−hand side of the head in the
transport position, neither the main boom extension in the
load−raising position (see section 18) nor the head sheave (see
section 21) in the transport position can be fitted.
You need a pulling and guidance rope for the actual slewing. The
pulling and guidance rope for slewing the main boom extension
can be used.
200−1−1410−312_en 27/31
41
”a” ”b”
H F
G
I
”c” ”d”
F(G) 31, 32
5
6
H(I)
31, 32 4
31, 32
7
Z 200 665
28/31 200−1−1410−312_en
41.6.2 Folding into the Transport Position

Conditions for the procedure:
∗ The runner is fitted to the front of the main boom head in the
folded position (Z 200 665 ”a”).
∗ The mounting adapter (4) is fitted to the left−hand side of the
main boom head, using the drilled holes (5) and (6) in the
prescribed welding components (Z 200 665 ”c”).
Procedure:
Risk of falling
For the following removal of the bolts (31) from points (F)
and (G): do not lean the ladder onto the runner.
If the runner is not held by the pulling and guidance rope, it

can swing away to the side when unpinning the pins (31).
1. Attach the pulling and guiding rope to the attachment eyelet

on the runner frame.
2. Remove bolts (31, Z 200 665 ”a”) from points (F) and (G).
3. Slew the runner on the pulling and guidance rope until the
runner dips into the mounting adapter.
4. Insert pins (7, Z 200 665 ”c”) and secure.
Bolts (31) incl. each of both locking springs (32) remain

pinned in points (H) and (I).
Bolts (31) incl. each of both locking springs (32) remain pinned
in points (H) and (I).
200−1−1410−312_en 29/31
41
”a” ”b”
H F
G
I
”c” ”d”
F(G) 31, 32
5
6
H(I)
31, 32 4
31, 32
7
Z 200 665
30/31 200−1−1410−312_en
41.6.3 Folding into the Folded Position
Folding from the transport position into the folded position is done
in the same manner as folding from the folded position into the
transport position (see 41.6.2, from page 29).
Risk of accidents! Risk of falling!

For pinning and unpinning procedures: do not lean the
ladder onto the runner.

∗ Raising loads:
see ”Converting from the folded position to the load raising
position (and vice versa)” (see 41.5, from page 17)
41.7 Operation
1. Fit the runner in the operating position (load−raising position)

and reeve hoist rope.
2. Setting the crane configuration in the operating mode

preselection mask (section 10 ”Safety equipment”)
Operating mode: “MS” “Boom point / runner’
other settings in accordance with the fitting state.
The load capacity tables also have the designation “ MS ”.
200−1−1410−312_en 31/31
Central lubricating system (optional) 46
200−1−1460c_en 1/15
46
Z 42 271
7
8
6 9
10
Z 29 548
2/15 200−1−1460c_en
46 Central lubricating system (optional)
(Z 29 548, Z 42 271)
46.1 Components
(1) Lubricating nipple for manual lubrication
(2) Grease containers
(3) Safety valve
(4) Filling nipple
(5) Sealing plug
After the sealing plug (5) has been removed, the control board
with the following details is visible:
(6) LED ”Battery voltage applied”

(7) Rotary switch ”Setting the interval times”
(8) Rotary switch ”Setting the operating time”
(9) LED ”Display of a lubrication procedure”
(10) Button for additional lubrication impulse
200−1−1460c_en 3/15
46
Z 42 271
7
8
6 9
10
Z 29 548
4/15 200−1−1460c_en
46.2 Function
(Z 42 271, Z 29 548)
The central lubricating system automatically supplies the

connected lubricating points with grease via a local
sub−distributor.
It then operates in prescribed cycles, i.e. there areinterval and

operating times. They start to run as soon as the ignition in the
chassis is switched on.
Pause time: Period in which no lubrication procedure occurs

(exceptions are possible with the additional
lubrication impulse)
Operating time: Time period in which there is a lubrication

procedure.
You will find an exact description of the interval and operating

times in section 46.3.
If there is a blockage in the system, lubricant will come out of the

pump safety valve (3).
You will find an exact description of the procedures to be followed

in the case of malfunctions in section 46.7.
A test run is possible for a functions check of system and

controls.
1. Switch on the ignition:Light−emitting diode (6) must light up.
2. Press key (10) for additional lubrication for approx. seconds.

The pause time is then shorter and is followed by theusual
lubrication procedure;light−emitting diode (9) is lit up.
200−1−1460c_en 5/15
46
7
8
6 9
10
Z 29 548
6/15 200−1−1460c_en
46.3 Setting the interval and operating times

(Z 29 548)
46.3.1 Generalinformation
The interval and operating times are controlled electronically.

As soon as the ignition is switched on, the interval timebegins.
When the interval time has expired, the operating time starts,
which is the actual lubrication procedure.
If, for example, an interval time of 6 hours was set, the interval
time that has passed up to that point is saved when the ignition
is switched off (e.g. 4 hours). When it is switched on again, there
are only two hours interval time remaining.
If the battery voltage is interrupted − for more than 4 days− a

complete interval time (6 hours) will first pass.
As long as the ignition is switched on, the operating time will

continue once it has been started.
If the operating time is interrupted by the ignition being switched
off, it will continue from the point it was interrupted at, when the
ignition is switched on again.
Each period is saved electronically.
Example: Expired operating time 3 min. −
remaining operating time 3 min.
The length of a lubrication cycle depends on the lubrication

requirements of the system. The interval / operating times of the
chassis are set ex works as follows:
− Pause time: 6 hours
Position of the rotary switch (7) = 6
− Operating time: 6 min.
Position of the rotary switch (8) = 3
This means that there is a lubrication procedure lasting 6 minutes

every 6 hours.
200−1−1460c_en 7/15
46
7
8
6 9
10
Z 29 548
8/15 200−1−1460c_en
46.3.2 Setting the interval time

(Z 29 548)
The pause time can be set at rotary switch (7) in 15 steps.

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
The pause time set ex works is 6 hours.
This setting should be maintained in normal operating conditions.
46.3.3 Setting the operating time

(Z 29 548)
The operating time can be set at rotary switch (8) in 15 steps.

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Minutes 2 3 6 8 10 12 14 16 18 20 22 24 26 28 30
The operating time set ex works is 6 minutes.
This setting should be maintained in normal operating conditions.
200−1−1460c_en 9/15
46
7
8
6 9
10
Z 29 548
Z 42 271
10/15 200−1−1460c_en
(Z 29 548, Z 42 271)
46.4 Additional lubrication impulses

When you are not within an automatic lubrication cycle, it is
possible to end the interval time prematurely and to introduce
additional lubrication procedures. They are released bypressing
the button (10) on the control board of the lube pump(for approx.
2 seconds).This makes the light−emitting diode (9) on the control
board light up.
The ignition must be switched on!
After the additional lubrication procedure is finished, the usual

pause time starts again.
46.5 Manual lubrication in the case of an emergency

If the lube pump fails, the lubricating pointscan also be lubricated
manually using grease.
To do so, grease is fed into the system via the lubricating nipple
(1) using a grease gun.
46.6 Filling the grease container

The grease container (2) is filled up to the “Max.” mark using the
filling nipple (4). This is done using a commercialgrease pump or
a lever type hand gun.
During filling, the pump must be set in motion (by first activating
the additional lubricating pulse).
The grease that is filled in must be free of any contamination

and must not lose its consistency with time.
Observe the instructions regarding the prescribed lubricants in

the corresponding lubrication and maintenance instructions!
200−1−1460c_en 11/15
46
12/15 200−1−1460c_en
46.7 Troubleshooting
Malfunction: Pump engine not running

Cause Remedy
Electricity supply interrupted. Check electricity supply / (safety) fuses.
Rectify malfunction / if required replace
(safety) fuses.
Malfunction: Pump is not pumping

Cause Remedy
Container is empty. Fill up container with clean grease, let pump
run (additional lubrication), until lubricant
emerges at all lubricating points.
Note: Depending on the ambient temperature
and / or the lubricant, the pump elements can
require up to 10 minutes in order to achieve
the full pumping capacity.
Air trapped in the lubricant. Release additional lubrication impulse.
Remove exhaust screw from the safety valve.
The lubricant must emerge without any
bubbles.
Unsuitable lubricant used. Replace the lubricant, see lubricants table
(lubricating and maintenance instructions of
the superstructure“, part 3).
Suction bore hole of the pump element Remove pump element, check suction bore
blocked. hole impurities and remove.
Pump piston worn. Exchange pump element.
Non−return valve in the pump element Exchange pump element.
defective or blocked.
Malfunction: Different lubricant quantity at the lubricating point

Cause Remedy
Corresponding valve body was fitted without a Remove valve body and check if there is a
clamping ring. clamping ring. If not, fit a clamping ring.
200−1−1460c_en 13/15
46
Z 29 549
14/15 200−1−1460c_en
Malfunction: Blockage in the progressive system, connected in series (Z 29 549)

Cause Remedy
Bearing, lines or distributor Find and remove cause of blockage − as described in the
blocked. following example.
The malfunction can be 1. Let the pump run (additional lubrication impulse).
identified by the following 2. At the main distributor (B), remove all main lines (G) to
characteristics: the subdistributors one after the other. If, for example,
a) Grease coming out at the grease emerges when there is pressure on the exhaust
safety valve. (1) of the main distributor (B) you must search for the
blockage in the lubrication circuit of the subdistributor (D).
b) Check pins at the distributor 3. Let the pump continue to run.
pistons (if they exist) are not 4. Remove all lubricating point leads (E) of the subdistributor
moving. (D) one after the other. If, for example, grease escapes at
the exhaust (3) of the distributor (D) when pressure is
applied, you must search for the blockage in the line of
the exhaust (3) or in the connected bearing.
5. Replace safety valve A.
Note: In order to check the individual exhausts leave each
exhaust released for a longer period of time, as there is
only one stroke per pump rotation. However, several
strokes are required for a complete run of all distributors.
c) If a distributor is blocked, no Pump through blocked line / bearing using a hand pump.
lubricant emerges at any Exchange distributor or clean as describedin the following:
exhaust. 1. Remove all hose connecting screws.
2. Unscrew piston sealing screws.
3. If possible, drive the piston out using a soft mandrel
(∅ smaller than 6 mm (0,24 in)).
Caution: The pistons are fitted into the drilled distributor
holes. After they have been removed, mark the fitting
position and direction of the pistons for refitting. They
must not be confused during fitting.
4. Clean distributor bodies thoroughly in a fat−dissolving
cleaner and blow out using compressed air.
5. Using a pin, press the sloped channels (ø 1,5 mm (ø
0.06 in)) through at the thread ends of the piston bore
holes.
6. Clean and blow out distributors again.
7. Assemble distributors.
8. Renew copper washers.
9. If possible, pump oil through the distributor several times
using a hand pump before screwing the hose connecting
screws in place. The pressure in the distributor must not
exceed 25 bar (362.8 psi).
If this happens, replace the distributor.
200−1−1460c_en 15/15

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Translation

of the Original Operating Instructions

2 Structure of the Mobile Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7 Supporting the crane on outriggers from the

8 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10.1.11.1 Bridging Shutdown of Movement Which Decreases

14 ”Hoist 1” Hook Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

18 Main Boom Extension (MBE) (Optional) . . . . . . . . . . . . . . . . . . . 1

18.5.3.1 Electric Connections on the Main Boom Head . . . . . . . . . . . . . . . . 69

21 Head Roller (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

31 Dismantling and Assembly of the Main Boom (Optional) . . . 1

34 Radio Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3

36 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

46 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . . 3

The operating, lubricating and maintenance instructions included

Crane classification (as Mobile Crane

Crane Type AC 200−1

Construction number ___________________

Manufacturer Terex Demag GmbH

as owner of a crane manufactured by us, we have produced this

The complete manual comprises 5 parts:

Please note that the information contained in this manual corres-

In such cases we make every effort to bring your documentation

Pass this manual on to your crane operator and driver and to

You will appreciate that we can accept no claims for damage or

Should you discover any mistakes when reading this manual or

Terex Demag GmbH

Handover of the crane

If the crane is delivered from the works with a protective coating

The protective coating can be removed using:

Washing thinners, e.g. Conrad thinners RV 5339 E 45430

”Instructions on using the catalogue”

Please contact our customer services team with any questions

or contact your nearest TEREX−Demag dealership.

Modifications to the crane

After modifications or repairs to parts which affect the safety of

For this reason, please notify us without delay of any modifica-

WHAT do I want to know ?

WHERE do I find the information required above ?

The complete manual comprises 5 parts:

2. I glance over the bold headings of the sections until I come

3. In this Section11 I then find ”Wind speeds” as item 11.1.

HOW do I find the page in Section 11 ?

1. I take the pages of Part 1 and flick through the pages as

Please note that this option of fast and accurate access to

The headings and corresponding symbols ”Danger”, ”Caution”

”Danger” is used for operation procedures, mounting se-

”Caution” is used for operating procedures, mounting se-

”Note” is used to indicate an important operation or mounting pro-

Information such as “left” and “right” of the crane must always be

This section ”Safety Instructions” provides a compact and

The safety instructions for lubrication, maintenance and service

1.2 Intended Use

The crane is designed for lifting loads.

Risk to life and limb!

The crane is not intended for lifting people. It is prohibited to

The crane may only be used to lift people in a so−called ”man

Such an exceptional use is only permitted if the requirements

− The use of mobile cranes for lifting persons is permitted by

Requirements concerning the equipment

Requirements concerning tests before use