AC 665-39005, 665-1180-038 - en (Main Boom Extension)

Main Boom Extension 18
18 Main Boom Extension
18.1 General
The draw bars for the main boom extension must be checked
at least once a year by a ”Sachkundiger” (specialist) (in ac-
cordance with the German accident prevention regulations
for load suspension devices in load handling operation
(VBG 9). If necessary, depending on the operating condi-
tions and the applications for which they are used, the draw
bars should be additionally inspected by a specialist be-
tween these prescribed checks.
The inspection intervals generally depend on the operating
conditions and the applications for which the equipment is
used. This means that if the equipment is used more often,
the inspection intervals should be shortened accordingly.
These inspections must be recorded (e.g. in the crane log

book).
The following inspections should be performed:
* Check for cracks

* Check the length
* Check for wear
* Check the paintwork
* Check for plastic deformation
Instructions for carrying out the inspections can be found in

the ”Lubrication and Maintenance Instructions for the Su-
perstructure”, Part 3, Sect. 11 ”Equipment”.
The main boom extension is marked with the crane

construction number. It may only be fitted to the crane of this
construction number.
Exceptions are only allowed when this is expressly stated in
the crane documentation (e.g. crane log book).
A ladder is supplied with the crane as standard equipment,

to enable fitting and assembly to be carried out as safely as
possible. Do not walk along the main boom extension.
Ensure that the tubing on the lattice mast sections has not
been damaged. If damaged tubing is discovered during
visual inspections, further operation of the main boom ex-
tension is prohibited.
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7 17
Z 31 319
Z 31 364
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18.2 Components
(Z 31 319, Z 31 364)
The main boom extension (10.7 m) is made up of the actual lattice

mast point (7) and adapter (17).
The main boom extension described in this Section always refers

to the lattice mast point (7) with adapter (17).
The lattice mast point (7) is also used in certain boom lengths for
the luffing and fixed fly jib. This is described in Sections 19 and
20 respectively.
The main boom extension is extended, secured to the base sec-

tion of the main boom, pin locked in the pivot and pin locked in
the operating position all via hydraulic cylinders.
These are marked with number plates, which correspond to the
number positions in the following description and the positions of
the selector switch on the mobile control panel.
The crane may only be operated if both axles (Z 31 364) in the

main boom head are installed.
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4
2
4
Z 31 820 Z 35 824
10
8
12 Z 32 806 Z 31 323
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18.3 Fitting and Removing Using an Auxiliary Crane
If the main boom extension was transported separately, it can be

fitted using an auxiliary crane.
18.3.1 Before Fitting
The following conditions must be met before the main boom ex-
tension can be fitted:
The crane supported on outriggers and horizontally aligned.
Slew gear brake applied and mechanical superstructure locking

device engaged.
Main boom in transport position (completely telescoped in, pin

locked and horizontal).
(Z 31 820)
The catch on the adapter must be folded in the horizontal posi-
tion.
(Z 35 824)
The pins of the 3 locking cylinders (2) and (4) on the adapter must
be retracted.
(Z 32 806)
Bring both three--way directional control valves (12) on the base
section of the main boom into the position shown. This position
is marked II. Especially pay attention that the marker notches at
the square are positioned correctly.
If the crane is not equipped with the Superlift these three--way

directional control valves do not apply. This applies whenever
these three--way directional control valves are mentioned in this
Section.
(Z 31 323)
Both draw bars (10) on the adapter must be in the position shown
(0°angle to the main boom, with pin ”8” fastened).
The upper and lower pins of all locking cylinders must be

well greased before each pin locking and locking off opera-
tion.
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Z 31 829
”A”
”B”
Z 32 807
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18.3.2 Fitting
When fitting the main boom extension, there are several

areas where persons may be crushed.
Observe, in particular, the notes regarding dangerous
situations given in Section 1.4.8 ”When Mounting and
Dismounting Crane Components” and the procedures
described in the following.
Especially prohibited:
-- to stand underneath the main boom extension (or any
of its components) or in the area endangered in case a
fall--down should occur while it is being fitted
(including pin locking and unlocking).
-- to walk between adapter and lattice mast point or
between main boom extension and main
boom.
(Z 32 807)
1. Attach the lattice mast point to the fixing points (”A”) provided
on the auxiliary crane, raise the mast and set it down on the
ground.
2. Fit the adapter to the lattice mast point.
If the main boom extension is already assembled (lattice mast

point + adapter ), go straight to point 3.
2.1 Attach the adapter (weight approx. 400 kg) to the auxil-
iary crane and position it so that the holes of the
adapter draw bars line up with the upper holes on the
lattice mast point and the respective lower holes.
(Z 31 829)
2.2 Using four pins connect lattice mast point with adapter.
Guard the pins with the corresponding pin locks.
The main boom extension is now ready to be fitted.
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Z 31 348
”A”
”B”
Z 32 807
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(Z 32 807)
3. Attach the main boom extension to the designated fixing
points (”B”) on the auxiliary crane.
4. Raise the main boom extension and position it on the main

boom head for fitting.
(Z 31 348)
5. Connect up the hydraulics and electrics.
A ladder is supplied with the main boom extension for carry-

ing out mounting work at a certain operating height. Please
use it. Walking along the main boom extension is prohibited.
Ensure that the hydraulic lines are connected properly, i.e.

that the quick couplings release properly.
The connection must be made when there is no pressure in
the hydraulics (engine and ignition OFF).
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4 4 2
Z 29 181 Z 32 894
11
12
4
11
Z 31 356
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6. Start the superstructure engine and set the engine speed to

approx. 1000 to 1200 rpm.
7. Connect the mobile control panel to distribution box ”X564”

(on the adapter), socket ”Q560A”.
(Z 29 181, Z 32 894)
8. When the pin locking holes on the main boom head and on
the adapter of the main boom extension are aligned and the
catch of the adapter on the main boom head has locked into
place, move selector switch (8) on the mobile control panel
to position ”4”. Press self--return rocker switch (9) upwards
until both locking cylinders (4) are fully extended.
(Z 31 356)
9. When both locking cylinders (4) are fully extended, they are
guarded automatically by spring--loaded catch (11) engag-
ing.
Check that these safety devices have locked into place.
10. Pin lock swing cylinder (2) likewise.

To do this, move selector switch (8) on the mobile control
panel to position ”2”. Press self--return rocker switch (9) up-
wards until locking cylinder ”2” is fully extended.
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Z 31 348
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11. Remove the mobile control panel from socket ”Q 560A” of

distribution box ”X 564” on the adapter and close it with the
protection cover.
(Z 31 348)
12. Release the quick coupling for both hydraulic connections
(when depressurised) and the electrical connection on the
main boom head.
13. Disconnect the auxiliary crane from the main boom exten-
sion.
The procedure is subsequently identical to that described in Sec-

tion 18.4.2 from point 20. onwards.
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4 4 2
Z 32 894
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18.3.3 Removal
The procedure for removing the main boom extension is analo-

gously the reverse of the fitting procedure. It should only be re-
moved when in the operating position (main boom extension pin
locked on the main boom head).
If the main boom extension is to remain fitted, it can be folded

from the operating position into the transport position.
See Sect. 18.4.3.
(Z 32 894)
If the main boom extension has been folded into transport posi-
tion and cannot -- for lack of space -- be folded into the operating
position, you can proceed as follows for this exceptional situa-
tion.
Swing the main boom extension out of the transport position so
far that swing cylinder (2) can be pinned to the head of the main
boom.
Proceed as described in Sect. 18.4.1 “Before folding”, page 21,
and Sect. 18.4.2 “Folding out of Transport Position into Operating
Position“ up to and including point 12., pages 23 -- 31..
The main boom extension is then hooked up to the auxiliary
crane and the swing cylinder (2) unpinned analogously to the re-
moval of the main boom extension from the operating position.
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”A”
”B”
Z 32 807
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(Z 32 807)
Before unlocking the main boom extension on the main
boom head, it must be ensured that the auxiliary crane is
properly attached at the centre of gravity of the main boom
extension (”B”).
After unlocking the main boom extension, it must not swing
to and fro or swing away from the crane.
Before removing the main boom extension using the auxil-
iary crane:
-- Disengage the two hydraulic hoses and the electrical
connection on the main boom head.
-- disconnect the mobile control panel from the distribution
box.
Observe in particular the notes on hazardous situations

given in Sect. 1.4.8 ”Mounting and Dismounting Crane
Components”.
Standing underneath the main boom extension, or in the
area endangered in case a fall--down should occur, is
prohibited.
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4 4 2
3
Z 32 894 Z 32 112
Z 36 725
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(Z 32 894, Z 32 112)
For removing the main boom extension, swing cylinder (2) and
locking cylinder (3) must be retracted simultaneously. However,
for safety reasons, this is prevented from happening by electric
switchgear.
Therefore, when removing the main boom extension, the limit
switch for retracted locking cylinder (3) must be bridged, so that
the remaining swing cylinder (2) can also be retracted.
This limit switch may only be bridged exclusively for the

purpose described here.
Accidents may otherwise occur.
(Z 36 725)
This limit switch can then be bridged by pulling cable (2) of pull
switch (1). This pull switch (1) is located on the left--hand side of
the base section on the corresponding distribution box.
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10
8
12 Z 32 806 Z 31 323
Z 31 827
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18.4 Folding Procedure
As long as the main boom extension is not needed, it can be

folded and pin locked in the transport position on the main boom
while the crane is driven.
When driving in this condition, observe the relevant axle

loads in each case.
When operating the crane in this condition observe Sect.
18.4.4.
18.4.1 Before Folding
The conditions listed below must be observed both when folding

from the transport into the operating position (Sect. 18.4.2) and
vice versa (Sect. 18.4.3).
∗ Crane supported on outriggers and aligned horizontally.
∗ Slew gear brake applied and mechanical superstructure lock-
ing device engaged.
∗ Main boom in transport position (completely retracted, pin
locked and horizontal).
(Z 32 806)
∗ Both three--way directional control valves (12) on the base
section of the main boom in the position II shown.
(Z 31 323)
∗ Both draw bars (10) on the adapter must be in the position
shown (0° angle to the main boom, fastened using pin ”8”).
(Z 31 827)
∗ If the 5.8 t counterweight base plate is set down on the crane
chassis, the draw bar must be folded down in the transport
position.
Before each pin locking and unlocking procedure the upper

and lower pins of all the locking cylinders are to be greased
thoroughly.
Each time before folding, the contact surfaces of the catch
on the adapter and on the main boom head are to be greased.
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Z 31 348
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18.4.2 Folding out of Transport Position into Operating Posi-

tion
During the folding procedure and when pin locking or un-

locking there must be no persons standing in the slewing
range or under the main boom extension or in the area
endangered in case a fall--down should occur.
The order of steps to be carried out during the folding

procedure must be strictly adhered to.
(Z 31 348)
1. Connect the hydraulic and electric lines.

use it. It is not permitted to walk along the main boom exten-
sion.

2. Connect mobile control panel to distribution box ”X564” (on

the adapter), socket ”Q560A”.
3. Start the engine for the superstructure and set the engine
speed to approx. 1000 to 1200 rpm.
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12 11
Z 31 826 Z 29 178
12
12
Z 31 824 Z 31 825
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(Z 31 826, Z 29 178)
4. Extend cylinder (1) completely.
To do this move selector switch (8) on the mobile control
panel to position ”1”. Press self--return rocker switch ”9” up-
wards until the cylinder is fully extended.
The cylinder can alternatively also be retracted and extended

from the crane operator’s cab, using illuminated pushbuttons
(75) and (76) . See Sect. 18.4.4 ”Operating the Main Boom with
the Main Boom Extension Folded Alongside”.
(Z 31 824, Z 31 825)
5. Release the rail from the transport position (withdraw spring--
loaded pin ”12”), fold it out and guard it in the operating posi-
tion using pin (12).
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2 ”C”
12 11
”B”
13 1
Z 31 826
Z 31 330 Z 31 329
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6. Check that all three locking cylinders (2) and (4) on the
adapter are completely retracted.
Before releasing the main boom extension from the rail, al-
ways ensure that at pivotal point ”B”, the main boom and
main boom extension are correctly pin locked together and
guarded.
When folding the main boom extension from the transport

position to the working position there is a danger of crush-
ing, shearing or falling objects (e.g. forgotten tools).
There must therefore be nobody standing in the hazardous
area during the folding procedure.
It is prohibited to step between the main boom extension

and the main boom.
(Z 31 826)
7. Release the main boom extension from cylinder (1).
To do this release clip pin (11), then move lever (12) first up-
wards and then to the right.
The locking mechanism is then in position unlocked. Re--
mount the clip pin to the same place as it had been before.
8. Secure the rope (provided by the customer) to the tubular

construction of the main boom extension and allow it to hang
down.
This rope can then later be used to pull the main boom exten-
sion down for folding, without the assembly personnel hav-
ing to go underneath the main boom extension.
(Z 31 329, Z 31 330)
9. Fold the main boom extension at pivotal point ”B” by pulling
on the rope, until the stop (Z 31 329) is lying flat against the
main boom head and the pins of swing cylinder (2) are flush
with the outer holes on the brackets on the main boom head
(”C”).
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Z 31 331
Z 31 332 Z 31 820
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(Z 31 331, Z 31 332)
10. Pin lock main boom extension to main boom head.
panel to position ”2”. Press self--return rocker switch ”9” up-
A limit switch on the upper pin locking point monitors the
completion of the pin locking procedure.
The main boom extension may only be disconnected from
the base section of the main boom (via locking cylinder ”3”)
when this limit switch has been tripped.
The main boom extension must not be disconnected

from the base section of the main boom (locking cylinder
”3”) until locking cylinder (2) is fully extended.
ACCIDENTS MAY OTHERWISE OCCUR.
(Z 31 820)
11. Move the catch on the adapter to horizontal position.
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2 ”C”
”B”
3
3
1
Z 31 355
Z 31 330 Z 31 348
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When carrying out the unlocking procedure described in

the following, there must be no persons standing under-
neath the main boom extension or in the area endan-
gered in case a fall--down should occur.
(Z 31 330, Z 31 355, Z 31 348)

12. Release the main boom extension from the base section of
the main boom by retracting cylinder (3) at point ”B”.
For this, first detach rope (1) from the bracket (Z 31 348). Pull
this rope, thus drawing back the safety catch for locking cylin-
der (3). The cylinder is now released. The safety catch must
be held in this position, until locking cylinder (3) -- as de-
scribed below -- is retracted.
To do this move the selector switch on the mobile control
panel to position ”3”. Press self--return rocker switch down-
wards until cylinder (3) is fully retracted.
Locking cylinder (3) may only be unpinned if locking cyl-

inder (2) on the main boom head is pin locked.
Locking cylinders (2) and (3) must never be retracted si-
multaneously. ACCIDENTS MAY OTHERWISE OCCUR.
(Z 31 330)
13. On the rope (provided by the customer), which was fastened
earlier, slew the main boom extension from locking cylinder
(2) at point ””C”” into the operating position, until the catch on
the main boom head locks into place.
During the folding procedure and when pin locking and

unlocking, no persons must be standing in the range of
slewing or underneath the main boom extension or in the
area endangered in case a fall--down should occur.
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4 4 2
Z 32 894
Z 29 181 Z 31 348
32/93 665--1180--038_en
(Z 32 894, Z 29 181)
14. Pin lock the main boom extension on the main boom head
in the operating position.
panel to position ”4” and press self--return rocker switch (9)
upwards until both pins of the locking cylinders (4) are ex-
tended to the limit.
(Z 31 348)
15. Attach the rope to its bracket again. It must not be hanging
down loose.
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11
12
4
11
Z 31 356
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(Z 31 356)
16. When both locking cylinders (4) are completely extended,
they are guarded automatically by flicking the spring--loaded
catch (11).
The main boom extension is now in operating position (0°) and

the pin locking procedure is complete. The superstructure engine
can now be switched off.
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12
Z 31 348 Z 31 824
19
21
19 20
21 20
Z 34 312 Z 34 313
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17. Disconnect the mobile control panel from socket ”Q 560A” of

the distribution box ”X 564” on the adapter and close it with
the protection cover.
(Z 31 348)
(when depressurised) and the electrical connection on the
main boom head.
(Z 31 824)
19. Disguard rail, fold it in the transport position and guard.
When driving on the construction site and when operating the

crane the rail can remain folded out and pin locked.
(Z 34 312, Z 34 313)
20. Release the deflection roller (19) on the base of the main
boom extension from the transport position (Z 34 313).
To do this, disguard and withdraw pin (20), lift up the deflec-
tion roller around pin (21) -- use handle --, pin and guard it
again in the operating position (Z 34 312) using pin (20).
Danger of crushing between deflection roller and main

boom extension. DO handle the deflection roller using
the handle.
If operation with the Superlift is planned, at a main boom ex-

tension angle of 0°, the deflection roller (19) can remain se-
cured in the transport position.
The hoist rope is fed via the deflection roller on the Superlift
bracing support, directly to the head of the main boom exten-
sion.
Deflection roller (19) must not be reeved.
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19
Z 31 823 Z 31 336
Z 33 473
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(Z 31 823)
21. Release the shift weight for the hoist limit switch on the head
of the main boom extension from the transport position.
To guarantee proper functioning of hoist limit switch “S2D”

the shift weight must then hang free.
(Z 33 473)
22. Pin and guard the rotor of the anemometer to pipe (4) in the
head of the main boom extension.
If the crane is equipped with aircraft warning light (optional) it is

also fixed at the mounting tube of the anemometer.
(Z 31 336)
23. Feed the hoist rope via deflection roller (19) to the head of
the main boom extension and reeve the hook block or hook
suspension gear.
If operation with the Superlift is planned at a main boom ex-

tension angle of 0° the hoist rope must be guided via the
deflection sheave at the Superlift mast directly to the head
of the main boom extension.
In this case deflection roller (19) must not be reeved.
See Section 17 of these operating instructions for notes on reev-

ing the hoist rope on the head of the main boom extension.
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Z 31 338
Z 29 165 Z 29 166
40/93 665--1180--038_en
(Z 31 338)
24. Connect the electric lines to the main boom extension.
24.1 To prevent any risks to people or damage to equip-

ment, fit and guard the shift weight for the hoist limit
switch (S1) on the head of the main boom in transport
position and bridge the hoist limit switch using the flag.
To do this, proceed as follows:
Putting the hoist limit switch retainer in the blocked position

(bridged)
(Z 29 165, Z 29 166)
∗ Pull the rope of the hoist limit switch down, then bend it back
parallel to the boom and hold in position¡.
∗ Slide the retainer from the left side with its slot over the rope
between the crimped stop and the switch ©. Then push it up-
wards against the guide of hoist limit switch¢.
∗ Pull the rope down again, inserting it into the slot of the re-
tainer, turn the flag of the retainer so that it can be seen easily
by the crane operator ¤ and then release £.
If the main boom is also equipped with a hoist rope when operat-
ing the crane with additional equipment such as the main boom
extension, the shift weight of the hoist limit switch must hang
freely on the main boom and the hoist limit switch may not be
bridged (see Sect. 10.4).
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Z 31 338
42/93 665--1180--038_en
(Z 31 338)
24.2 Insert plug ”Q 5C” from cable ”M” of the distribution box
”X 570” in the head of the main boom extension, into
socket ”Q 5” of the distribution box ”X 550” on the main
boom head.
Sockets ”Q 3” and ”Q 2” at ”X 552” and socket ”Q 4” at ”X 550”

are supplied simply with a protection cap.
Socket ”Q 6, X 550” is fitted with bridging plug ”Q 6A”.
24.3 Connect aircraft warning light and anemometer to the

corresponding sockets of distribution box ”X 570” in
the head of the main boom extension:
− plug ”Q 4A” for the aircraft warning light to socket ”Q
4D”.
− plug ”Q 5B” for the anemometer to socket ”Q 5D”.
The shift weight of the hoist limit switch ”S2D” must hang free.
25. Set the load limit device in accordance with the actual config-
uration of the crane (see corresponding load tables).
A crane with main boom extension is depicted on the ECIS
display.
The crane is now ready for ”operation with main boom extension”.
Owing to the risk of the crane tipping, it should be re--

checked in the appropriate load table that the code num-
ber (DS) is correct, and the fitted counterweight likewise.
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Z 31 320 Z 31 348
12
Z 31 850
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18.4.3 Folding from Operating Position into Transport Posi-

tion
1. Observe all the conditions in Sect. 18.4.1 ”Before Folding”.
During the folding procedure and when removing pins

there must be no persons standing in the slewing range
or under the main boom extension or in the area endan-
gered in case a fall--down should occur.
The order of steps to be carried out during the folding
procedure must be strictly adhered to.
2. Carry out points 24. to 19. in Sect. 18.4.2 analogously in the

reverse order.
(Z 31 320)
3. Lift up the catch on the adapter.
(Z 31 850)
4. Push lever (12) of the locking device downwards. This en-
sures that the locking device can later click into position on
the cylinder automatically.
(Z 31 348)
5. Connect up the hydraulic and electric lines.

use it. It is prohibited to walk along the main boom exten-
sion.

that the quick couplings release correctly.
6. Connect the mobile control panel to distribution box ”X564”

(on the adapter), socket ”Q560A”.
7. Check now that the pin for locking cylinder (3) on the main
boom base section is completely retracted.
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11
12 4
11
Z 31 356 Z 31 348
4 4 2
Z 29 181 Z 32 894
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8. Switch on the superstructure engine.
(Z 31 356, Z 31 348)
9. Release rope (12) from the bracket (Z 31 348) and by pulling
this rope, draw back safety catch (11) for the locking cylin-
ders (4). The locking cylinders are now disguarded. The
safety catches (11) must be held in this position until the lock-
ing cylinders (4) -- see next point -- are retracted.
During the following unlocking procedure there must be

no persons standing underneath the main boom exten-
sion or in the area endangered in case a fall--down
should occur.
The locking cylinders (4) may only be drawn when the

main boom extension and main boom have been suc-
cessfully connected via the pin locked swing cylinder (2,
Z 32 894).
(Z 29 181)
10. Unlock the main boom extension from the operating position
on the main boom.
panel to position ”4” and press self--return rocker switch (9)
downwards, until both locking cylinders (4) are retracted.
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2 ”C”
”B”
Z 31 329
Z 31 330
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(Z 31 330, Z 31 329)
11. Slew the main boom extension on the rope (provided by the
customer) around locking cylinder (2) at point ”C” to the
adapter stop on the main boom head. The main boom exten-
sion runs against the rail.
No persons must be standing in the area through which

the main boom extension swings during the folding pro-
cess or underneath the main boom extension or in the
area endangered in case a fall--down should occur as
ACCIDENTS MAY OCCUR.
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2 ”C”
”B”
Z 31 330 Z 31 355
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(Z 31 330, Z 31 355)
12. Pin lock the main boom extension at point ”B” on the base
section of the main boom by extending cylinder (3).
wards, until cylinder (3) is fully extended.
A limit switch on the upper pin locking point monitors the comple-
tion of the pin locking procedure. Locking cylinder (2) may only
be retracted when this limit switch has tripped.
When extended, cylinder (3) is automatically guarded via a

safety catch.
Check that this safety device has locked into place.
13. When the unlocking is complete, the rope must be re--fas-

tened to its bracket to disguard the safety catch for the lock-
ing cylinders (4).
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2 ”C”
”B”
Z 31 332
12 11
13 1
Z 31 330 Z 31 826
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(Z 31 330, Z 31 332)
14. Retract locking cylinder (2) at point ”C”.
panel to position ”2”. Press self--return rocker switch (9)
downwards, until locking cylinder (2) is fully retracted.
This may only be done when locking cylinder (3) at point

”B” is pin locked.
Locking cylinders ”2” and ”3” must never be retracted
simultaneously. OTHERWISE ACCIDENTS MAY OCCUR.
(Z 31 826)
15. Pull the main boom extension using the rope (provided by
the customer) on to the rail until the locking device slots auto-
matically into the groove of the fully extended cylinder (1).
Then guard lever (12) on the locking device in the transport
position, using clip pin (11).
Danger of persons being crushed
When the main boom extension is pulled onto the rail

there must be nobody standing underneath it or between
the main boom and main boom extension.
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18
12
Z 31 824
54/93 665--1180--038_en
(Z 31 824)
16. Disguard the rail, fold it into transport position and guard it
again.
17. Switch off the superstructure engine.
18. Disconnect the mobile control panel from socket ”Q560A” of

the distribution box ”X564” on the adapter and close the
socket with the protection cap.
The hydraulic connection via the quick disconnect couplings and

the electric connection between distribution box ”X564” on the
adapter and ”X510” on the base section of the main boom do not
need to be disconnected.
The main boom extension is now in the transport position.

When driving the crane in this condition, observe the permissible
axle loads for each case.
When operating the main boom with the main boom exten-
sion folded alongside, the main boom extension must NOT
remain in this transport position.
See Sect. 18.4.4 ”Operating the Main Boom with the Main
Boom Extension Folded Alongside
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18
7 7
8 8
”B”
Z 33 411 Z 33 412
56/93 665--1180--038_en
18.4.4 Operating the Main Boom with the Main Boom Exten-
sion Folded Alongside
(Z 33 411, Z 33 412)
The main boom can also be operated when the main boom ex-
tension is folded alongside.
In this case the loads stipulated in the load capacity tables are
smaller.
For telescoping the boom however the main boom extension

must not remain in the transport position (Z 33 411), as this
would cause the cantilever plates of the main boom to collide
with the foot section/adapter on the main boom extension.
If your crane is equipped with runner (option) there is a pin-

ning device (8) at the adapter. BEFORE telescoping this de-
vice has to be dismounted and removed by unscrewing the
4 bolts (7, tightening torque 265 Nm).
Danger of collision with main boom cantilever plates!
In this instance, therefore, the main boom extension must first

-- i. e. already before raising the main boom -- be brought into
the telescoping position (Z 33 412) (Starting point: main boom ex-
tension in transport position) before telescoping may be started.
The rail remains in transport position.
Proceed as follows:
1. Actuate luminous pushbutton (75) in the crane operator’s

cab until cylinder (1) is fully retracted.
The proximity switch S563 is then not actuated, allowing the
telescoping to proceed. The indicator light on the switch
comes on.
For safety reasons the proximity switch must be checked

regularly to see that it is functioning correctly and is not
damaged.
In addition, when telescoping the boom out with the main
boom extension folded alongside, the crane operator must
always ensure that there is sufficient space between the
main boom head, or the cantilever plates on the head, and
the main boom extension.
For proceeding further observe sect. 18.6 “Telescoping the
Main Boom with the Main Boom Extension Attached”.
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Z 31 348 12 Z 32 806
58/93 665--1180--038_en
Oil must continue to be supplied to the cylinder when the main

boom extension is folded into the transport condition.
Consequently:
(Z 31 348)
∗ Leave the two hydraulic lines and the electric cable con-
nected to the main boom head.
(Z 32 806)
∗ Leave the 3--way directional control valves on the main
boom base section in the position II shown.
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Z 33 474
Z 31 342
60/93 665--1180--038_en
18.5 Setting the Operating Angle
The crane can be operated with the main boom extension at an

angle of 0° and 20° to the main boom.
Both the fitting of the main boom extension using the auxiliary
crane and folding the main boom extension may only be carried
out in 0° position.
The angle is adjusted using draw bars (Z 31 342).
Starting point: main boom extension pin locked in operating posi-

tion (0°) as described in the previous Sections.
18.5.1 Adjusting from 0 to 20 Degrees Position

(Z 33 474)
1. Unreeve hoist rope on the hook block and fasten it at fixing

point ”C”.
This fixing point ”C” must only be used for adjusting the
angle.
The fixing point for when operating the crane is located be-
hind the top piece of the main boom extension.
2. Tighten the hoist rope by reeling in the winch of hoist 1.
665--1180--038_en 61/93
18
5 0° 9 0°
8
7
6
5 10 9
”A”
Z 31 344 Z 31 345
20° 20°
5 9
10
6 7 8
5 10 9
”A”
Z 31 346 Z 31 347
62/93 665--1180--038_en
(Z 31 344, Z 31 345)
The draw bars (10) between lattice mast point (5) and adapter (9)
are at 0° position. They are fixed at 0° position to the lattice mast
point (5) with pin (6) and to the adapter (9) with pin (8). Pins (7)
are simply inserted but do not perform any function.
All these pins must always be guarded with pin locks.
3. When the hoist rope is taut withdraw pin (8).
When the pin is to be withdrawn there must be no per-

sons standing underneath the main boom extension. AC-
CIDENTS MAY OCCUR.
The lower pin locking points ”A” must always remain pin
locked. ACCIDENTS MAY OTHERWISE OCCUR.

(Z 31 346, Z 31 347)
4. Carefully unwind the winch of hoist 1. The main boom exten-
sion tilts until draw bars (10) come to rest on pin (7).
5. Insert and guard pins (8) in the same place again. They now
have no function.
6. Relieve the hoist rope, release it from the fixing point and
reeve the hook block again.
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18
20° 20°
5 9
10
6 7 8
5 10 9
”A”
Z 31 346 Z 31 347
5 0° 9 0°
8
7
6
5 10 9
”A”
Z 31 344 Z 31 345
64/93 665--1180--038_en
18.5.2 Adjusting from 20 to 0 Degrees Position
(Z 31 346, Z 31 347)
The draw bars (10) between lattice mast point (5) and adapter (9)
are at 20° position. They are fixed in this position with pin (6) to
the lattice mast point (5) and pin (7) to the adapter (9). Pins (8)
are simply inserted but have no function.
All these pins must always be guarded with a pin lock.
1. Remove pin (8).
When removing the pin there must be no persons stand-

ing underneath the main boom extension. ACCIDENTS
MAY OCCUR.
The lower pin locking points ”A” must always remain pin
locked. ACCIDENTS MAY OCCUR.
2. Repeat points 1. -- 2. from Sect. 18.5.1.

(Z 31 344, Z 31 345)
3. Reel in the winch of hoist 1 carefully. The main boom exten-
sion is raised until it can be locked in the 0° position using pin
(8).
4. Relieve the hoist rope, release it from the fixing point and
reeve the hook block again.
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18
66/93 665--1180--038_en
18.6 Telescoping the Main Boom with the Main Boom Ex-
tension Attached
18.6.1 Telescoping Procedure
After fitting or folding the main boom extension into the operating
condition, the desired operating position can be reached as fol-
lows:
1. Bring the main boom into high position (82°) by extending the
luffing cylinder.
The procedure then is exactly as for the telescoping procedure,

an example of which is given in Section 12.6 ”Telescoping Proce-
dure”.
Observe the prescriptions of the valid duty chart, especially

concerning the permitted main boom length.
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68/93 665--1180--038_en
18.6.2 Emergency Lowering
The procedure described below is permitted only with the

main boom extension not under load. i. e. no load at the hook
(Superlift is possible, but bracing rods and bracing rope
must not be tensioned then).
If the stripping procedure for the retraction of telescopic sections

3 and 4 is no longer possible due to a defect in the securing or
pin locking system, the main boom with the main boom extension
unladen, can be lowered by derricking regardless of the data of
the telescoping information system, under the conditions given
below.
The maximum main boom length with the maximum possible ex-
tension sequence 0%/0%/100%/100% must not exceed approx.
36 m. In this instance:
∗ telescopic section 4 is 100 % telescoped out and pin
locked.
∗ telescopic section 3 is 100 % telescoped out and pin
locked.
∗ telescopic section 2 must be fully telescoped in and pin
locked.
∗ telescopic section 1 must be fully telescoped in and pin
locked.
Regardless of the extension lengths of telescopic sections

3 and 4, sections 2 and 1 must be completely retracted be-
fore the main boom is lowered.
The main boom must be in the high position (82°) for this pur-
pose.
The reeved hook block must be set down on the ground before
the main boom is lowered.
The fitted counterweight must be at least 31 t.
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”B”
3
12
Z 31 824
Z 31 327 Z 31 823
70/93 665--1180--038_en
18.7 Main Boom Extension with Superlift
For operating the Superlift with the main boom extension refer to
Sect. 30.7.4.1 ”Operating the Superlift with the Main Boom Ex-
tension”.
18.8 Notes on Transport

(Z 31 327)
When driving the crane with the main boom extension folded into
the transport position (Z 31 327) the following applies:
-- Observe the permissible axle loads.
-- The main boom must not be telescoped when the main boom
extension is in this position.
-- Cylinder (1) must be guarded on the main boom extension
and fully extended.
-- Locking cylinder (3) at point ”B” must be completely ex-
tended.
(Z 31 824)
− The rail (12) must be folded into the transport position and
guarded.
(Z 31 823)
− The shift weight of the hoist limit switch must be locked in the
top piece of the main boom extension.
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18
19
21
19 20
21 20
Z 34 312 Z 34 313
Z 31 348
72/93 665--1180--038_en
(Z 34 312, Z 34 313)
− The deflection roller (19) must be folded into transport posi-
tion, locked and guarded (Z 34 313).
(Z 31 348)
− The hydraulic connection via the quick disconnect couplings
and the electric connection between distribution box ”X564”
on the adapter and ”X510” on the base section, of the main
boom do not need to be disconnected.
The transport weight of the main boom extension is approx.

1500 kg.
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7 6 17
Z 32 168
74/93 665--1180--038_en
18.9 Main Boom Extension with Intermediate Section

(21.7 m), optional
18.9.1 General
See Section 18.1.
18.9.2 Components
(Z 32 168)
The 10.7 m main boom extension is made up of the lattice mast

point (7) and adapter (17).
For the 21.7 m main boom extension the intermediate section
1207--5--11 (L = 11000 mm) is also required.
18.9.3 Fitting and Removal
The 21.7 m main boom extension must be fitted using an auxiliary

crane.
18.9.3.1 Before Fitting
See Section 18.3.1.
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4
2
4
Z 35 824 Z 31 348
76/93 665--1180--038_en
18.9.3.2 Fitting
When fitting the main boom extension, there are several

areas where crushing may occur.
Observe, in particular, the notes regarding dangerous
situations given in Section 1.4.8” When Mounting and
Dismounting Crane Components” and the procedures
described in the following.
Especially prohibited:
-- to stand underneath the main boom extension (or any
of its components) or in the area endangered in case a
fall--down should occur while it is being fitted (includ-
ing during pin locking and unlocking).
-- to walk between the main boom head and adapter, the
adapter and intermediate section or the intermediate
section and lattice mast point.
All assembly work is to be carried out using suitable aids
(ladders, lifting stages, scaffolding, auxiliary crane).
(Z 35 824)
1. Attach the adapter (weight approx. 400 kg) to the auxiliary
crane, raise and position it so that the mountings above and
below pin locking cylinders (2) and (4) align with the mount-
ings on the main boom head.
(Z 31 348)
2. Connect up the hydraulics and electrics.

ing out such mounting work at a certain operating height.
Please use it. Do not walk along the main boom extension.

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4 4 2
Z 29 181 Z 32 894
11
12
4
11
Z 31 356
78/93 665--1180--038_en
3. Start the superstructure engine and set the speed to approx.

1000 to 1200 rpm.
(Z 29 181)
4. Connect the mobile control panel at distribution box ”X 564”
(on the adapter), socket ”Q 560A”.
(Z 29 181, Z 32 894)
5. When the pin locking holes on the main boom head and on
the adapter of the main boom extension line up and the catch
of the adapter on the main boom head locks into place, move
selector switch (8) on the mobile control panel to position ”4”.
Press self--return rocker switch (9) upwards until both locking
cylinders (4) are fully extended.
(Z 31 356)
6. When both locking cylinders (4) are fully extended, they are
guarded automatically by spring--loaded catch (11) engag-
ing.
7. Pin lock swing cylinder (2) likewise.

665--1180--038_en 79/93
18
Z 31 348 Z 32 171
Z 32 172
80/93 665--1180--038_en
8. Disconnect the mobile control panel from socket ”Q 560A” of

distribution box ”X 564” on the adapter and close it with the
protection cap.
(Z 31 348)
(when depressurised) and the electric connection on the
main boom head.
10. Unhook the adapter from the auxiliary crane.
(Z 32 171)
11. Attach guide sheave (3) to the support provided, lock using
2 pins and guard.
(Z 32 172)
12. Attach intermediate section 1207--5--11 (weight approx.
920 kg) at the fixing points provided on the auxiliary crane,
raise and fit it to the adapter.
To do this, position the intermediate section on the adapter
so that the bores of the adapter draw bars align with the up-
per bores on the intermediate section and the lower bores of
the fork ends. Then lock them with 4 double conical pins and
guard using 2 pin locks on each.
13. Unlock the intermediate section from the auxiliary crane.
665--1180--038_en 81/93
18
Z 32 173
”A”
Z 32 823
82/93 665--1180--038_en
(Z 32 823, Z 32 173)
14. Attach the lattice mast point (weight approx. 1350 kg) at the
fixing points (”A”) provided on the auxiliary crane, raise it and
pin it to the intermediate section using 4 pins. Guard the pins
using pin locks.
665--1180--038_en 83/93
18
19
7 6 17
Z 32 176
19
21
19 20
21 20
Z 34 313 Z 34 312
84/93 665--1180--038_en
(Z 32 176, Z 34 312, Z 34 313)

15. Release the deflection roller (19) on the foot section of the
lattice mast point from the transport position (Z 34 313).
To do this, disguard and withdraw pin (20), lift up the deflec-
tion roller around pin (21) -- use handle --, pin and guard it
again in the operating position (Z 34 312) using pin (20).
Danger of crushing between deflection roller and main

boom extension. DO handle the deflection roller using
the handle.
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18
Z 31 823
Z 33 473
86/93 665--1180--038_en
(Z 31 823)
16. Release the shift weight of the hoist limit switch on the head
of the main boom extension out of transport position.
The shift weight must hang freely in order to guarantee the

function of the hoist limit switch ”S2D”.
(Z 33 473)
17. Lock the rotor of the air speed indicator to pipe (4) in the head
of the main boom extension using pins, and guard the pins.
If the crane is equipped with aircraft warning light (optional) it is

also fixed at the mounting tube of the anemometer.
18. Reeve the hoist rope. Observe here the following specifica-
tions.
665--1180--038_en 87/93
18
0°
20 °
7 7
3 3
Z 32 170
88/93 665--1180--038_en
(Z 32 170)
The hoist rope is fed from the hoist drum to the head of the main
boom extension as follows:
∗ Main boom extension at 0°position, operation without Su-
perlift -- rope is fed (broken line) from hoist (1) over deflection
roller (3) and deflection roller (7) to the head of the main boom
extension.
∗ Main boom extension at 0°position, operation with Superlift
-- rope is fed (dot--dash line) from hoist (1) over deflection
roller (5) on the superlift bracing support and deflection roller
(7) to the head of the main boom extension. Deflection roller
(3) must not be reeved.
∗ Main boom extension at 20°position, operation without Su-
perlift -- rope is fed (broken line) from hoist (1) over deflection
roller (3) and deflection roller (7) to the head of the main boom
extension.
∗ Main boom extension at 20°position, operation with Super-
lift -- rope is fed (dot--dash line) from hoist (1) over deflection
roller (5) on the Superlift bracing support, deflection roller (3)
and deflection roller (7) to the head of the main boom exten-
sion.
The hook block is reeved (2 fold) as described in Sect. 17.2.2

“Reeving the Hook block”.
The subsequent procedure is exactly as in Sect. 18.4.2 “Folding

out of Transport Position into Operating Position”, from point 24.
onwards “Connect the electric lines to the main boom extension”.
665--1180--038_en 89/93
18
4 4 2
3
Z 32 894 Z 32 112
Z 36 725
90/93 665--1180--038_en
18.9.3.3 Removal
The procedure for removing the main boom extension is analo-

gously the reverse of the fitting procedure.
Before unlocking the various components of the main boom

extension, it must be ensured that the auxiliary crane is
properly attached at the centre of gravity on each compo-
nent.
After unlocking the main boom extension it must not swing
to and fro or swing away from the crane.
Before removing the adapter using the auxiliary crane:
-- disengage the two hydraulic hoses and the electrical con-
nection on the main boom head.
-- disconnect the mobile control panel from the distribution
box.
Observe in particular the notes on hazardous situations

given in Sect. 1.4.8 ”When Mounting and Dismounting
Crane Components”.
Standing underneath the main boom extension or in the
area endangered in case a fall--down should occur is pro-
hibited.
(Z 32 894, Z 32 112)
For removing the main boom extension, swing cylinder (2) and
locking cylinder (3) must be retracted simultaneously. However,
for safety reasons, this is prevented from happening by electric
switchgear.
Therefore, when removing the main boom extension, the limit
switch for the retracted locking cylinder (3) must be bridged, so
that swing cylinder (2), which remains extended, can also be re-
tracted.
This limit switch is to be bridged exclusively for the pur-

pose described here.
Accidents may otherwise occur.
(Z 36 725)
This limit switch can then be bridged by pulling cable (2) of pull
switch (1). This pull switch (1) is located on the left--hand side of
the base section on the corresponding distribution box.
665--1180--038_en 91/93
18
92/93 665--1180--038_en
18.9.4 Folding Procedure
The 21.7 m main boom extension is not to be folded.
18.9.5 Adjusting the Operating Angle
See Sect. 18.5.
18.9.6 Telescoping the Main Boom with the Main Boom Ex-
tension Fitted
See Sect. 18.6.
18.9.7 Main Boom Extension with Superlift
See Sect. 18.7.
18.9.8 Notes on Transport
See Sect. 18.8 and Sect. 19.4.
665--1180--038_en 93/93

AC 665-39005, 665-1180-038 - en (Main Boom Extension)

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AC 665-39005, 665-1180-038 - en (Main Boom Extension)

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Main Boom Extension 18

18 Main Boom Extension

These inspections must be recorded (e.g. in the crane log

The following inspections should be performed:

* Check for cracks

Instructions for carrying out the inspections can be found in

The main boom extension is marked with the crane

A ladder is supplied with the crane as standard equipment,

The main boom extension (10.7 m) is made up of the actual lattice

The main boom extension described in this Section always refers

The main boom extension is extended, secured to the base sec-

The crane may only be operated if both axles (Z 31 364) in the

18.3 Fitting and Removing Using an Auxiliary Crane

If the main boom extension was transported separately, it can be

18.3.1 Before Fitting

The crane supported on outriggers and horizontally aligned.

Slew gear brake applied and mechanical superstructure locking

Main boom in transport position (completely telescoped in, pin

If the crane is not equipped with the Superlift these three--way

The upper and lower pins of all locking cylinders must be

When fitting the main boom extension, there are several

2. Fit the adapter to the lattice mast point.

If the main boom extension is already assembled (lattice mast

The main boom extension is now ready to be fitted.

4. Raise the main boom extension and position it on the main

A ladder is supplied with the main boom extension for carry-

Ensure that the hydraulic lines are connected properly, i.e.

6. Start the superstructure engine and set the engine speed to

7. Connect the mobile control panel to distribution box ”X564”

Check that these safety devices have locked into place.

10. Pin lock swing cylinder (2) likewise.

11. Remove the mobile control panel from socket ”Q 560A” of

The procedure is subsequently identical to that described in Sec-

The procedure for removing the main boom extension is analo-

If the main boom extension is to remain fitted, it can be folded

Observe in particular the notes on hazardous situations

This limit switch may only be bridged exclusively for the

18.4 Folding Procedure

As long as the main boom extension is not needed, it can be

When driving in this condition, observe the relevant axle

18.4.1 Before Folding

The conditions listed below must be observed both when folding

Before each pin locking and unlocking procedure the upper

18.4.2 Folding out of Transport Position into Operating Posi-

During the folding procedure and when pin locking or un-

The order of steps to be carried out during the folding

A ladder is supplied with the main boom extension for carry-

Ensure that the hydraulic lines are connected properly, i.e.

2. Connect mobile control panel to distribution box ”X564” (on

The cylinder can alternatively also be retracted and extended

When folding the main boom extension from the transport

It is prohibited to step between the main boom extension

8. Secure the rope (provided by the customer) to the tubular

The main boom extension must not be disconnected

When carrying out the unlocking procedure described in

(Z 31 330, Z 31 355, Z 31 348)

Locking cylinder (3) may only be unpinned if locking cyl-

During the folding procedure and when pin locking and

Check that these safety devices have locked into place.

The main boom extension is now in operating position (0°) and

17. Disconnect the mobile control panel from socket ”Q 560A” of

When driving on the construction site and when operating the

Danger of crushing between deflection roller and main