Superlift 30

30 Superlift

30.1 General

All components which hold or brace the main boom, must be

inspected at least once a year by a specialist (in accordance
with the local accident prevention regulations for load han-
dling equipment). If necessary, depending on the operating
conditions and applications for which they are used, they
should also be inspected by a specialist between these pre-
scribed checks.
The inspection intervals generally depend on the operating
conditions and applications for which the equipment is
used. Thus, when the equipment is being operated more fre-
quently, the time between inspection intervals should be
correspondingly shorter.

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

book).

Checks for the following should be made:

* Check for cracks

* Check the length
* Check for wear
* Check the paintwork
* Check for plastic deformation

Details on how the checks should be made can be found in

the ”Lubrication and Maintenance Instructions for the Su-
perstructure”, Part 3 of this document.

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6
7

Z 30 428

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30.2 Components
(Z 30 428)

In addition to the standard crane configuration, the DEMAG AC

665 hydraulic crane can be fitted with a Superlift (main boom
bracing). This can be used when the main boom, main boom ex-
tension, rigid and luffing fly jib are in operation.

This Superlift equipment comprises the following parts:

(1) -- Deflection roller for the bracing rope

(2) -- Bracing rope

(3) -- Drop--back retaining rope

(4) -- Bracing support

(5) -- Deflection roller on bracing support (for bracing rope)

(6) -- Deflection roller on bracing support (for hoist rope)

(7) -- Bracing winch

(8) -- Erection cylinder

(9) -- Bracing rod strand (left and right hand side)

The weight of the complete Superlift is approximately 5000 kg.

The Superlift is marked with the construction number of the

crane. It may only be fitted to a crane bearing this construc-
tion number.
Only if expressly stated in the crane’s documents (e.g. crane
logbook), can an exception to this rule be made.

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1S
1

Z 30 429

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 Superlift 30

30.3 Transport Proposal

(Z 30 429)

Since the crane may not be driven on public roads with the Super-
lift attached, the Superlift must be transported separately on a
low--loader.

Depending on the transport possibilities available, the deflection

roller (1) can either
-- be folded on to the bracing support, which means that it must
then be supported by a square timber (as shown in the above
figure), or
-- be removed from the bracing support. In this case it must then
be appropriately supported on and securely tied to the boom
(see figure below).

The Superlift must be supported in such a way, e.g. with

square timbers, symmetrical to the centre of gravity ”S”, that
the brake band holders on bracing winch (2) of the bracing
support do not come into contact with the chassis.
RISK OF DAMAGE.

After lowering the Superlift onto the low loader, it must be

tied securely to the transport vehicle.

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Z 26 185

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30.4 Before Fitting

(Z 26 185)

The Superlift may only be fitted and removed by trained

and experienced personnel.

Before the Superlift equipment is fitted, the brake lever bearings

and the rope drum bearings of the bracing winch must be
greased. If the bracing support remains attached for a prolonged
period, the lubrication procedure must be repeated every 50 op-
erating hours. Use lubricating grease KP2K for lubricating the
bracing winch.

Close the front window of the superstructure cab, for other-

wise damage may occur when lowering and setting down the
bracing support on the main boom.

There is a risk of personnel being crushed when both erect-

ing and dismounting the Superlift. In both cases it is placed
on the base section of the main boom, which means that
personnel may become trapped between the bracing sup-
port and the base section.
With the exception of experienced personnel, it is forbid-
den to remain in this area when the equipment is being as-
sembled and erected.
Pay particular attention to the notes on dangerous situa-
tions in Section 1.4.8 ”When Mounting and Dismantling
Crane Components” and the procedure described below.
All stages of the assembly work are to be carried out using
suitable accessories (ladders, lifting platforms, scaffold-
ing, auxiliary crane).
However, should work need to be carried out from the base
section of the main boom, then the assembly personnel are
to guard against the RISK OF FALLING by wearing a safety
harness.

1. Support the crane correctly so that it is level (see operating

instructions for the crane chassis, Part 2, Section 12).

2. Install the required counterweight for the desired operating

mode (crane configuration) see Section 9.

3. Raise the main boom with the luffing gear to approximately

5° .

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Z 30 430

9a

Z 30 431

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 Superlift 30

30.5 Attachment
(Z 30 430, Z 30 431)

1. Insert 2 (9a, L = 6000 mm) and 2 (9b, L = 2510 mm) bracing

rods on the left and right hand sides of the base section of
the main boom in the corresponding mounts. The bracing
rods (9a) must rest in the direction of the boom foot.

The weight of the individual bracing rods is approximately 71 kg

(9a) and approximately 33 kg (9b).

The complete strand of the bracing rods comprises on both sides

an additional 2 shackles and one bracing rod (L = 4500 mm). The
weight of this rod is approximately 54 kg.
These bracing rods are secured on the bracing support and are
later fitted on the main boom, along with the support.

(Z 30 431)
2. Fasten bracing rods (9a) with pins onto the foot section of the
main boom base section, and secure with fore locks.

3. Connect bracing rods (9a) and (9b) to each other in a similar

fashion using pins with fore locks.

In both cases, insert pins from the outside inwards, and se-
cure with fore locks so that the bracing support does not
damage the pin head when being lowered.

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19

Z 30 449 Z 30 450

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(Z 30 449, Z 30 450)

If the two assembly components of the whole bracing rod strand

are already in safety locks on the main boom, then the pin lock
(19) must simply be removed.

The pins which have been removed can be inserted on the

foot of the Superlift trestle on a retaining plate (Z 30 450).
Pins must be secured with fore locks to stop them from fal-
ling. Accident risk.

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”D”
”E”

1
13

”C”
3
”B”
”A”

Z 30 457

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 Superlift 30

(Z 30 457)

4. Prepare the Superlift for connection to the main boom.

Before lowering the Superlift on to the main boom, the follow-
ing points are to be observed:
− The lock pins must be removed from the foot bearing (”A”).
− The deflection rollers (5) must be in transport position (”B”).
− The drop--back retaining rope (3) must be disconnected at
point ”D” on bracing support (transport position) and
pinned at point ”C” of deflection roller (1).
− The shackles on deflection roller (1) must be in transport
position and pin (13) inserted and guarded(”E”).
− The erection cylinder on the main boom base section must
be fully retracted.

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Z 30 432

Z 30 433

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(Z 30 432, Z 30 433)
5. Attach auxiliary ropes to the 3 eyes provided on bracing sup-
port (4) and hook the ropes to the auxiliary crane.

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11
Z 30 434

Z 30 458

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 Superlift 30

(Z 30 434, Z 30 458)
6. Raise the Superlift using auxiliary crane, position the bracing
support in the basic bolts (11) on the main boom base section
and insert and guard locking pins (Z 30 458).

When the bracing support is lowered onto its foot section

bearings on the main boom base section, utmost care
must be taken since there is a danger of crushing be-
tween the bracing support and the base section.
It is prohibited to work on the boom during assembly
work.

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Z 30 460

”C”

Z 30 435

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 Superlift 30

7. Lower bracing support onto the base section using the auxil-
iary crane.

During this procedure, ensure that the head of the erection

cylinder (8) slides into the ram mounting of the bracing sup-
port (Z 30 460).

8. Disconnect the auxiliary ropes from the bracing support and

attach the auxiliary crane to the deflection roller.

(Z 30 435)
9. Disconnect drop--back retaining rope (3) at point ”C” on
deflection roller (1) and lower the latter onto the main boom.

Risk of falling
The drop--back retaining rope is to be disconnected from
the side using a ladder and/or lifting platform.
However, should this be carried out from the base sec-
tion, then the crane operator is to guard against falling
by wearing a safety harness, before the rope is discon-
nected from the deflection roller. Furthermore, there is
also a risk of stumbling on the thimble of the discon-
nected drop--back retaining rope.

Risk of crushing.
When lowering the deflection roller there is a risk that
people may be crushed between the deflection roller and
the base section. It is prohibited to remain in the danger
zone.

10. Disconnect the auxiliary crane from deflection roller (1).

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13

Z 30 461

1 1

2 2

3
3

Z 30 436

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 Superlift 30

(Z 30 461)
11. Disconnect the connecting brackets from their transport
position of deflection roller (1) by removing pins (13).

(Z 30 436)
12. Fasten connecting brackets (3) of the deflection roller to
shackles (2) of the third boom section using the pins which
have already been removed, and guard.

The pin locking points of the deflection roller described here

only apply when operating the Superlift on the main boom.

When operating the Superlift with additional equipment (e.g.

fly jib) attached to the main boom, the deflection roller is pin
locked to shackles (1) of the main boom head.

Pins (13) are inserted from the outside inwards, and secured
with fore locks.

Risk of falling.
The deflection rollers are to be pinned to shackles on the
3rd and/or 4th boom sections (main boom head). This is
to be carried out from the side using ladders and/or lift-
ing platforms.

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Z 30 437

Z 30 447

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 Superlift 30

(Z 30 437, Z 30 447)
13. Disconnect the bracing support from deflection roller
(Z 30 437) and the main boom from deflection roller
(Z 30 447) by removing the pins.

The removed pins can be inserted on the foot of the bracing

support on a retaining plate. Pins must be secured with fore
locks to guard against them falling. Accidents may other-
wise occur.

The main boom and deflection roller (Z 30 447) are only con-
nected if the deflection roller has already been lowered onto the
main boom in the transport position.

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Q 38

S38

Z 30 438

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 Superlift 30

Hydraulic Connections
(Z 30 438)

Four hydraulic connections must be made between superstruc-

ture and bracing support:
∗ Connection ”Hydraulic engine of the bracing winch -- unreel”
∗ Connection ”Bracing winch hydraulic motor -- reel in”
∗ Connection ”Bracing winch brake”
∗ Connection ”Leakage oil”
When connecting, ensure that the hydraulic hose number corre-
sponds to the connection number.

Electrical Connection
(Z 30 438)

The distribution box (”X 38”) on the bracing support must be con-
nected to the distribution box (”X 510”) on the base section of the
main boom Insert plug (”Q 38”) into socket (”Q 38A”) on distribu-
tion box (”X 38”).

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12
Z 32 812

AUF

ZU

Z 36 744

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 Superlift 30

(Z 32 812)
14. Extend erection cylinder (8). For this to happen, there must
first be a supply of hydraulic oil. Position the two three--way
directional control valves (12) on the main boom base sec-
tion as shown. This position is marked I. Especially pay
attention that the marker notches at the square are posi-
tioned correctly.

If the crane is not equipped with a main boom extension, then

these three--way directional control valves are not necessary.
This is to be taken into account whenever the three--way direc-
tional control valves are mentioned in this Section.

15. Press button (79) in the crane operator’s cab when the su-
perstructure engine is running. The erection cylinder ex-
tends and thus raises the bracing support.

Raise the bracing support until the deflection roller(s) of the hoist
rope and/or the deflection roller for the rope of the Superlift brac-
ing winch on the head of the bracing support is at operating
height.

It is forbidden for personnel to remain under the raised

bracing support.
Accidents may otherwise occur.
If, for certain erection work, this cannot be avoided, then
the bracing support is to be attached to the auxiliary
crane in such a way, that a possible accident caused by
the bracing support falling is prevented.

16. Reeve the rope of the bracing winch.

The rope must only be reeved when the Superlift is erected for
the first time. This rope then remains reeved. As a rule, this rope
is already reeved when delivered to the customer.
If the rope is reeved, then proceed with point ”17.”.

(Z 36 744)
16.1 Move shut--off valve (30) on the upper right rim of the
superstructure hydraulic block (behind the cap cover)
to the ”ZU” position, as shown. This results in the wind-
ing speed of the bracing winch being reduced, which
is only permissible for reeving the rope of the bracing
winch.

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12
1
7
13
11

14

2 10

5
Z 30 442

Z 36 745

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16.2 Press luminous pushbutton (81) ”Unreel bracing rope”

in the crane operator’s cab and keep it pressed down.
The bracing winch unreels the rope.

”Unreel Bracing Rope” should only be used when reeving

the bracing winch rope.

(Z 30 442)
16.3 Reeve the bracing winch rope. The rope is unwound
from bracing winch (7) -- on the left hand side on the
foot of the bracing support -- and fed through to the fix-
ing point on the right hand side of the head of the brac-
ing winch, via deflection roller (5) in the head of the
bracing support and deflection roller (1) which is
mounted on the main boom.
Rope socket (11) is attached to the shackle there with
pin (12), using 2 supporting discs (13). It is then se-
cured using pin lock (14), which consists of a pipe with
screw and nut (countered or secured using Loctite).

When reeving there is a risk of being caught and dragged

in at the deflection rollers. Thus, proceed with caution.

(Z 36 745)
16.4 Once the rope of the bracing winch is reeved and se-
cured, move shut--off valve (30) to the position ”AUF”
as shown.

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12 ”B” ”C” 12
11 14
13 11

C
D
13

Z 30 445

13

12

16
15
Z 30 446

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(Z 30 445, Z 30 446)
17. Connect bracing rods (15), which have already been se-
cured to the main boom (L = 6000 mm and L = 2510 mm) and
bracing rods (13, L = 4500 mm) and shackles (12), which are
in the transport position on the bracing support.

This connection must be made for the left and right hand bracing
rod strand.

(Z 30 445)
17.1 Release bracing rods (13) from their transport position,
by removing forelocks (11) and then the corresponding
shackle (12) and bracing rod (13) from pin (14).
Pins which are released are to be placed on the ap-
propriate plate at point ”D” and secured with fore locks.

One bracing rod (13, L = 4500 mm) weighs approximately 54 kg.

(Z 30 446)
17.2 Fasten the free end of shackle (12) with the free end
of bracing rod (15) onto the main boom using pin (16)
and guard with fore locks.

If this is carried out on the left and right hand side, then both brac-
ing rod strands are closed.

Insert pins from the outside inwards and secure with fore
locks so that the bracing support does not damage the pin
cone when being lowered.

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5.2 5.1

5.1
29

28
Z 30 439 Z 30 440

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(Z 30 439)
18. Fold deflection roller (5.1) and/or (5.2) into operating position
in order to reeve the hoist rope.
Pull out pin (28), fold deflection roller(s) up through 90° and
secure in this position again using pin (28). Secure pin with
fore lock.

Should the rope from hoist 1 ever be reeved, then only deflection
roller 5.1 need be used.

(Z 30 440)
19. Release rope run--off safety (29) from deflection roller (5.1).

20. Feed the hoist rope over deflection roller (5.1) to the main
boom head section, and reeve the hook block.

When the hoist rope is being drawn in and also when the
hook block is being reeved, there is a danger of items
being caught and dragged in at the deflection rollers and
at the hook block.
Proceed in an appropriately cautious manner and ensure
that safety guards, such as a run--in protection, are fitted.

21. Attach rope run--off safety (29) once again.

22. Fully extend the erection cylinder. The angle of the bracing
support to the main boom is approximately 10°.

23. Now check that the proximity switch S 39.1 (bracing support
rests on erection cylinder) is correctly activated.
Press luminous pushbutton (82) ”Reel in bracing rope”. The
light in the button must illuminate and the bracing winch
draws the bracing rope taut.
Briefly press luminous pushbutton (81) , and thus activate
”Reel out bracing rope”.
Both movements must function correctly.

If this is not the case then the Superlift may not start to
be fitted. The error must first be amended.

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Z 30 437 Z 30 447

”B” ”D”

Z 30 455

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30.6 Erecting the Bracing Support

30.6.1 Before Erecting the Bracing Support

Before erecting the bracing support you should double

check that the following items in particular are in good
condition.
Accidents may otherwise occur.

-- The crane should be properly supported on outriggers and

the necessary counterweight fitted.
-- All connecting bolts are to be guarded according to the speci-
fications.
-- The function of the proximity switch S 39.1 ”Bracing support
rests on erection cylinder” is to be checked.
-- The safety locks of deflection roller (1) on bracing support (4),
2 x (Z 30 437), and on the main boom base section, 1 x (Z 30
447), are to be removed.
-- Bracing rod strands on the left and right hand side are to be
completely removed, and possibly also all transport safety
locks of the rods.
-- No cracks should be present either on the bracing rod or on
the mountings of the deflection roller on the main boom.

Should fractures be discovered during the visual check,

then it is forbidden to continue work using the Superlift. The
rods or shackles must be replaced. Repairs are not per-
mitted.

-- Drop--back retaining rope (3) pin locked at point ”B” on the

bracing support -- and released at point ”D” (Z 30 455).
-- Bracing and drop--back retaining rope should not be dam-
aged (see lubrication-- and maintenance instructions of the
superstructure, ”Part 3, Section 11.4 ”Ropes”).
-- The brake on the bracing winch is to release correctly.
When luminous pushbutton (81, ”Unreel bracing rope”) is ac-
tuated, the brakes of the bracing winch must open. When the
brake is released, the bracing winch’s rope drum must rotate.

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12
Z 30 462

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30.6.2 Erection Procedure

1. Set the load limit device (including length coding) according

to the current crane configuration (see Section 10).

2. Tighten the bracing rope by pressing luminous pushbutton

(82) ”Reel in bracing rope”.

If the bracing rope is sagging (and hence also the deflection

roller) then pretensioning is necessary, so that the deflection
roller does not get caught on the upper cantilever plates of the
telescopic sections when the main boom is subsequently ex-
tended.

The Superlift bracing support is to be erected simply by telescop-

ing the main boom.

(Z 30 462)
3. By pressing button (109) in the crane operator’s cab, unpin
telescopic section 2 and extend it using control lever (26) un-
til the bracing support just starts to lift away from erection cyl-
inder (8) (maximum 20 mm).

When the boom is being telescoped, the information in the

info screen of the telescoping--information system in the
ECIS display must be observed at all times.

4. Now check that proximity switch S 39.1 (bracing support is

resting on erection cylinder) is no longer activated.
First press luminous pushbutton (82) and then luminous
pushbutton (81). Neither of the functions ”reel in and/or un-
reel bracing rope” should be able to be activated, and neither
of the pushbuttons should illuminate.

Should this not be the case, the erection procedure

should not be continued. The fault must first be rectified.

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5. Further extend telescopic section 2 with control lever (26),

thereby raising bracing support.
At the same time, bracing rods are raised from the main
boom.

The length of the main boom and the extent to which the tele-
scopic section has been extended are indicated on the ECIS con-
sole.

When the bracing support has reached an angle of approx. 90°

the proximity switch indicating the high position of the bracing
support ”extend telescope” switches off. The main boom length
is then approx. 19.3 m (actual value of telescope 2 indicated is
42%). When telescoping out, check the bracing rods. If they are
clearly subject to strain, and shutdown does not occur, there is a
fault. First identify the fault, and then rectify it.

It is only by telescoping in and/or out the main boom that the

bracing support may be erected and/or lowered.
When erecting and lowering the bracing support, luminous
pushbuttons (81, ”Unreel bracing rope”) and (82, ”Reel in
bracing rope”) must not be activated, as otherwise the brac-
ing support may sag backwards.

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”K”

Z 30 451

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6. Switch the bracing winch to ”wind in rope” by pressing lumi-

nous pushbutton (82), thus moving the bracing support to its
final operating position (90° to the main boom). The light in
the button illuminates. Then briefly press illuminated push-
button (81), thereby interrupting the auto--locking of the
”Reel in bracing rope” function.
This also serves for checking that the proximity switch S 39.2
”High position of the bracing support” is functioning correctly.

If winding in the rope is not possible there is a fault

which must first be rectified.

(Z 30 451)
7. Secure drop--back retaining rope (3) to point ”K” of the main
boom base section with pins, and guard.

Risk of falling.
The drop--back retaining rope is to be pin locked to the
main boom from the side using ladders and/or lifting
platforms.
However, should this be carried out from the main boom,
the crane operator is to guard against falling by wearing
a safety harness before the rope is fastened to the main
boom.

The bracing support is now fully erected. How to proceed further

(Erection of the main boom and telescoping to operating length)
is described in the following Section 30.7 ”Superlift operation”.

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1
”A” ”B”

Z 30 454

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30.7 Superlift Operation

The following details refer in the main to operating the Superlift
with the main boom. Other details on Superlift operation with
additional equipment can be found in the relevant notes and in
Section 30.7.4 ”Superlift operation with additional equipment”.

30.7.1 Operating Instructions

Before starting to operate the crane in Superlift mode, all the tele-
scopic sections must be pin locked. When the main boom has
been extended to its final operating length and pin locked, all the
telescopic sections must be retracted together to the stop. This
prevents overloading of the telescope cylinders and settling
movements of the boom sections when the load is picked up.
Before loading the crane in Superlift mode, the boom bracing
must be checked for proper pretension. If bracing rods have vis-
ible slack, the boom bracing must be retensioned (see Section
30.7.3).
The load limit device (including length coding) is to be set to the
load programme to be operated.

Check the correct Code No (DS) in the relevant load table as

well as the attached counterweight again, before picking up
the load.

(Z 30 454)
When operating the Superlift on the main boom, deflection roller
(1) of the bracing rope is to be pinned to the head of the 3rd tele-
scopic section (”A”).

With Superlift crane operation using additional equipment,

deflection roller (1) is to be pinned to mountings (”B”) on the
main boom head.

Before work is started, it must be ensured that the brake of the

bracing winch releases and the rope drum can turn.

When the main boom is loaded and/or used with additional

equipment, the brake of the bracing winch may not be re-
leased.

Before operation with the Superlift, the brake disc of the bracing
winch is to be checked for clogging. Clean the disc with wire wool
if necessary.

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30.7.2 Telescoping the Main Boom

When the main boom extension is folded into the transport

position, the main boom extension must be swung out and
away from the crane using the sliding cylinders, before the
main boom can be telescoped.
The procedure needed for this is described in Section 18
”Main boom extension” under the heading ”Main Boom Op-
eration with the main boom extension folded alongside” (see
Contents).

When telescoping, ensure that first the ”Reel in bracing

winch” button and then the ”Telescoping” button are acti-
vated.
Before each telescoping procedure, the appropriate tele-
scopic section must be unpinned. After each telescoping
procedure the appropriate telescopic section is to be pin
locked, before the next telescopic section can be extended.

30.7.2.1 Telescoping Out

1. Raise the main boom to an angle of approximately 80° by
means of the luffing gear.

2. Unpin the telescopic section according to the telescoping in-

dication given on the ECIS--display.

The code number and length code must be set according to the
crane configuration and the desired main boom length.

Make sure that the bracing rods are not taut once the unlock-
ing has taken place.
If they are taut, however, the boom MUST be retracted by a
minimal amount so that the bracing rods hang down slightly.
Only then may the bracing winch be switched to wind in and
the telescoping out procedure thus continued.

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3. Switch bracing winch using luminous pushbutton (82) to

”Reel in bracing rope”. After the button has been released,
the function will lock and the movement will thereby be main-
tained. The pushbutton (82) remains illuminated.

The auto--locking of this function can be interrupted in two ways:

-- automatically with every pin locking procedure (if all telescopic
sections have been pin locked)
-- manually by pressing luminous pushbutton (81).
However, this does mean that when repinning a telescopic sec-
tion at an intermediate length, steps 2. and 3. must be repeated
once more before telescoping can begin again.

Operation of the bracing winch, which leads to its brakes be-

ing released, is prohibited when the main boom is at an angle
of less than 80°.
The crane may be damaged due to sudden slackening of the
boom system and the strong resulting forces.

4. Telescope main boom out to the desired operating length,

whilst monitoring the ECIS display.
Shortly before the desired length is reached, slow down the
telescoping speed and preset the pin locking function of the
corresponding telescopic section. When the pin locking hole
is reached, the telescopic section will automatically be pin
locked.
When pin locked, the auto--locking action of the ”Reel in
bracing rope” function is ceased (should all telescopic sec-
tions be pin locked). Luminous pushbutton (82) is no longer
illuminated.

By reducing the speed, the tension of the Superlift bracing sys-

tem is maintained.

Before starting the telescoping procedure, check that the

bracing winch brake is released and that the rope drum can
turn freely. If this is not the case, stop the erection procedure
immediately.

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Z 30 453

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 Superlift 30

(Z 30 453)
5. When the main boom has been extended to its final operat-
ing length and pin locked, retract all the telescopic sections
together to the stop.
This prevents overloading of the telescope cylinders and set-
tling movements of the boom sections when the load is
picked up.

(Z 30 453)
6. Check to see that the rope of the bracing winch (2) rope and
the bracing rods (9) are not sagging and move the main
boom using the luffing gear into its operating position.

Should the rope have visible slack, i.e. bracing rope (2) by
more than 100 mm, bracing rods (9) by more than 50 mm,
then the system is to be pretensioned again by gently tele-
scoping in, and then back out again.
Please refer to Section 30.7.3 ”Checking the Main Boom
Bracing”.

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 Superlift 30

30.7.2.2 Telescoping In

1. Raise the main boom to an angle of approximately 80° using

the luffing gear.

2. Unpin the telescopic section in accordance with the tele-

scoping indication on the ECIS display.

The code number and length code must be set according to the
crane configuration and the desired main boom length.

3. Switch bracing winch to ”Reel in bracing rope” using lumi-

nous pushbutton (82). After the button has been released,
the function will lock and the movement will thereby be main-
tained. Luminous pushbutton (82) will remain illuminated.

The auto--locking of this function may be interrupted in two ways:

-- automatically, with every pin locking procedure, if all tele-
scopic sections have been pin locked
-- manually, by pressing luminous pushbutton (81).
However, this does mean that when repinning a telescopic sec-
tion at an intermediate length, steps2. and 3. have to repeated
once again, before telescoping can begin again.

Operation of the bracing winch, which leads to its brakes be-

ing released, is prohibited when the main boom is at an angle
of less than 80°.
The crane may be damaged due to sudden slackening of the
boom system and the strong resulting forces.

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4. Telescope in main boom to the desired operating length,

whilst monitoring the telescope indication on the ECIS dis-
play.
Shortly before the desired length is reached, slow down the
telescoping speed and preset the pin locking function of the
corresponding telescopic sections. When the pin locking
hole is reached, the telescope will automatically be pin
locked.
When pin locked, the auto--locking action of the ”Reel in
bracing rope” function is ceased (should all telescopic sec-
tions be pin locked). Luminous pushbutton (82) should no
longer be illuminated.

The boom can be telescoped--in much quicker than it can be tele-

scoped out. By reducing the speed of the telescoping action, the
tension of the Superlift bracing system is maintained.

When telescoping in, the bracing support rests against the rope
of the fall--back safety device.

Before starting the telescoping procedure, check that the

bracing winch brake is released and that the rope drum can
turn freely. If this is not the case, stop the erection procedure
immediately.
Select the telescoping speed so that the bracing rope re-
mains as taut as possible, and always make sure that the
deflection roller of the bracing rope does not collide with the
cantilever plate of the telescopic sections.
Should the rope slacken at any time, pull back the telescop-
ing control lever slightly until the bracing rope is sufficiently
taut again.
Ensure that the bracing rope winds correctly on the drum,
i.e. for example, the rope must not run up the drum flange.

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Z 30 453

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 Superlift 30

(Z 30 453)

5. When the main boom has been extended to its final operat-
ing length and pin locked, retract all the telescopic sections
together to the stop.
This prevents overloading of the telescopic cylinders and
settling movements of the boom sections when the load is
picked up.

6. Check to see that bracing winch (2) and bracing rods (9) are
not sagging, and move the main boom into its operating posi-
tion using the luffing cylinder.

If the rope of the bracing winch and bracing rods show vis-
ible signs of slack, i.e. bracing rope (2) more than 100 mm,
bracing rods (9) more than 50 mm, then the system is to be
pretensioned by telescoping in slightly and then telescoping
out again.
Please refer to Section 30.7.3 ”Checking the Main Boom
Bracing”.

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30.7.3 Checking the Main Boom Bracing

Before placing the crane under load in Superlift mode, the boom
bracing must be checked for proper pretension. If the bracing
rope is visibly sagging, by more than 100 mm, and the bracing
rods by more than 50 mm, -- then the boom bracing must be re-
tensioned by telescoping out the main boom.

Proceed as follows:

1. Raise or lower the main boom to an angle of approximately

80° using the luffing gear.

2. Unpin telescopic section 2 by pressing pushbutton (109).

3. Switch bracing winch to ”Reel in bracing rope” using lumi-

nous pushbutton (82).

When telescoping, ensure that the bracing winch is moved

first, and then the telescopic section is moved.

4. Use control lever (26) to retract telescopic section 2 by

approximately 1 m.

5. Actuate pushbutton (108), thereby preselecting the pin lock-

ing of telescopic section 2.

6. By using control lever (26), extend telescopic section 2 to the

desired length. Pin locking occurs automatically and the
auto--locking action of the ”Reel in bracing rope” function is
thus ceased.

7. Actuate control lever (26) to retract the telescopic sections as

far as they will go (to relieve the telescopic cylinders).

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Z 30 453

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 Superlift 30

(Z 30 453)
8. Check to see if the rope of bracing winch (2) and bracing rods
(9) are showing any signs of slack.
By doing this it is possible to determine whether the prelimi-
nary tension in this position is correct. Bracing rope (2) and
bracing rods (9) must be slightly taut.

If there are visible signs of slack, i.e. bracing rope (2) by more
than 100 mm, bracing rods (9) by more than 50 mm, then the
tensioning procedure described must be repeated once
again.

If correct tensioning of the Superlift equipment is not pos-

sible, further operation is prohibited.

If, after a Superlift hoist, this pretension has changed and the
main boom angle has remained the same, the function of the
band brake of the bracing winch must be checked. Call the
service department at ”MANNESMANN DEMAG Fördertech-
nik, Mobile Cranes” to carry out this check.

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 Superlift 30

30.7.4 Superlift Operation with Additional Equipment

When telescoping the boom with additional equipment at-

tached, proceed with particular care.
When telescoping out, the sections must first be unpinned.
Make sure that the bracing rods are not taut once the unlock-
ing has taken place.
If they are taut, however, the boom MUST be retracted by a
minimal amount so that the bracing rods hang down slightly.
Only then may the bracing winch be switched to wind in and
the telescoping out procedure thus continued.

30.7.4.1 Superlift Operation with Main Boom Extension

Before the bracing support is erected, the main boom extension

must already be attached.

To fold the main boom extension from transport position to oper-

ating position and/or to attach the main boom extension, see
Section 18 ”Main boom extension”.

The details needed for reeving the hoist rope and/or for guiding
the hoist rope can be found in Section 17 ”Reeving” and in Sec-
tion 18 ”Main boom extension”.

Please note the details given in Sections 30.7.1 -- 30.7.3.

30.7.4.2 Superlift Operation with Fixed Fly Jib

Before the bracing support is erected, the fixed fly jib must al-
ready be attached to the main boom head. Please refer to Sec-
tion 20 ”Fixed fly jib”.

The details needed for reeving the hoist rope and/or guiding the
hoist rope can be found in Section 17 ”Reeving” and in Section
20 ”Fixed fly jib”.

Please note the details given in Sections 30.7.1 -- 30.7.3.

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30.7.4.3 Superlift Operation with Luffing Fly Jib

The procedures for attaching and erecting the luffing fly jib with
the Superlift are described in Section 27 ”luffing fly jib with Super-
lift”.

The details needed for reeving the hoist rope and/or guiding the
hoist rope can be found in Section 17 ”Reeving” and Section 27
”Luffing fly jib with Superlift”.

Please note the details given in Sections 30.7.1 -- 30.7.3.

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 Superlift 30

30.8 Lowering the Bracing Support

Please remember that the same risks involved in erect-

ing and/or attaching the Superlift are also involved in
lowering the bracing support.
Therefore, proceed in an appropriately cautious manner.

Close the front window of the superstructure cab, as other-

wise damage may be caused to the main boom when setting
down and removing the bracing support.

1. Raise or lower the main boom to an angle of approximately

80°.

2. Telescope in the main boom to a length of approximately

19.3 m (actual value of telescope 2 indicated is 42%). This
length needs to be reached in order to be able to remove the
bracing support by retracting either telescopic section 1 or 2.

Check the main boom length and angle on the ECIS display.

2.1 Unpin each telescopic section.

2.2 Switch on bracing winch by pressing luminous push-

button (82) ”Reel in bracing rope”. After the button has
been released, the function will lock, and the move-
ment will thereby be maintained. Luminous pushbut-
ton (82) will remain illuminated.

The auto--locking action of this function may be interrupted in two

ways:
-- automatically with every pin locking procedure (if all telescopic
sections have been pin locked)
-- manually by pressing luminous pushbutton (81).
However, this does mean that when repinning a telescopic sec-
tion at an intermediate length, steps 2.1 and 2.2 must be re-
peated once more, before telescoping can begin again.

Operation of the bracing winch, which leads to the brake of

the Superlift bracing winch being released, is prohibited
when the main boom is at an angle of less than 80°.
The crane may be damaged due to sudden slackening of the
boom system and the strong resulting forces.

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2.3 Telescope in main boom to desired length, whilst moni-

toring the telescope indication on the ECIS display.

When telescoping in, ensure that the bracing winch is moved

first, before the telescopic section is moved.

As the final telescopic section can not be pin locked at a boom

length of 19.30 m, the auto--locking action of the ”Reel in bracing
winch” movement must be interrupted by pressing down once on
luminous pushbutton (81). Luminous pushbutton (82) should not
be illuminated thereafter.

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”K”

Z 30 451

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 Superlift 30

During telescoping, the bracing support rests against the

rope of the fall--back safety device.

Select the telescoping speed so that the bracing rope re-

mains as taut as possible, and always ensure that the deflec-
tion roller of the bracing rope does not collide with the canti-
lever plate of the telescopic sections.
Should the rope show signs of slack at any time, push the
telescoping control lever back slightly until the bracing rope
is sufficiently taut again.

Ensure that the bracing rope winds correctly on the drum,

i.e. for example, the rope must not run up the drum flange.

3. Lower the main boom to an angle of 5° using the luffing gear.

(Z 30 451, Z 30 455)
4. Release drop--back retaining rope (3) at point ”K” on the
main boom.

Risk of falling.
The drop--back retaining rope on the main boom is to be
released from the side using ladders and/or lifting plat-
forms.
However, should this be carried out from the main boom,
then the crane operator is to guard against falling by
wearing a safety harness, before the rope on the main
boom is released.

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12
Z 30 462

Z 30 456 Z 30 460

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(Z 30 462)
5. Now check whether erection cylinder (8) is completely ex-
tended.
If not, press pushbutton (79) in the crane operator’s cab to
fully extend the erection cylinder.

RISK OF ACCIDENTS!
When the erection cylinder is retracted, there is a risk,
with certain angle ratios, of the bracing support falling
through unchecked.

6. Ensure that the auto--locking of the ”Reel in bracing rope”

button has in fact been switched off. Luminous pushbutton
(82) should no longer be illuminated.

7. Lower bracing support to main boom length of 14.9 m by re-

tracting telescopic section 1 or 2, and rest it on extended
erection cylinder (8).

When the bracing support is being lowered, the rope

winch must not be operated, either with luminous push-
button (81) or with luminous pushbutton (82). AC-
CIDENTS MAY OCCUR.
When the bracing support is being lowered, no--one may
stand under the inclined bracing support. ACCIDENTS
MAY OCCUR.

When the bracing support is being lowered, ensure that:

-- the bracing rods fold correctly and rest in their transport
supports (Z 30 456).
-- the head of erection cylinder (8) slides into its support on
the bracing support (Z 30 460).
-- the deflection roller of the bracing rope lowers correctly.
It must not catch on the cantilever plate of the main boom
base section.

8. Lower the hook block onto the ground and slacken the hoist
rope by operating the hoist gear.

9. By simultaneously retracting the main boom and the erection

cylinder, lower the bracing support until the deflection
roller(s) of the hoist rope come to rest on the head of the brac-
ing support in operating position.

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13

12

16
15
Z 30 446

12 ”B” ”C” 12
11 14
13 11

C
D
13

Z 30 445

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 Superlift 30

Should the Superlift subsequently remain on the crane, then you

may continue with step ”12.”.

Should the Superlift subsequently be removed from the crane,

then the bracing rod strands must first be undone.

Bracing rods (13, L = 4500 mm) may be secured in transport sup-

ports on the bracing support using shackles. Bracing rods (L =
2510 mm) and (L = 6000 mm) may remain on the main boom.

(Z 30 446)
10. Release the connection of shackles (12) to bracing rod (15)
by removing pins (16).

(Z 30 445)
11. Remove pins (14) from transport position at ”D”, move to
bracing support (”C”), fit each shackle (12), and secure with
fore locks.

This must be done for the left and right hand bracing rod strand.
The weight of one bracing rod (L = 4500 mm) is approximately
54 kg.

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5.2 5.1

5.1
29

28
Z 30 440 Z 30 439

”B” ”A”

Z 30 455 Z 30 437

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(Z 30 440)
12. Remove rope run--off safety (29) for reeved deflection roller
(5.1).

13. Retract erection cylinder and at the same time unreel the
rope of the bracing winch slightly by actuating pushbutton
(81) in the crane operator’s cab.

Retract the erection cylinders until the deflection rollers of the

hoist rope are just above the main boom base section.

(Z 30 439)
14. Unreeve hoist rope from deflection roller (5.1), and set down
between both deflection roller (5.1) and (5.2). When the rope
has been unreeved, attach rope run--off safety (29) again,
fold deflection roller(s) in transport position, insert pin (28)
and guard.

(Z 30 455)
15. Connect the free end of the drop--back retaining rope (3) to
the bracing support at point ”A” (transport support) by insert-
ing and guarding pin(s).

16. Completely retract erection cylinder, thereby lowering brac-

ing support onto main boom base section.

(Z 30 437)
17. Fully telescope in main boom and when the exact pin locking
position has been reached, connect the bracing support and
deflection roller by inserting pins.

Insert pins from outside inwards and secure with fore locks.

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1 1

2 2

3
3

Z 30 436

13

Z 30 461

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(Z 30 436)
18. Remove the shackles (3) which connect the deflection roller
to the main boom by withdrawing the pins on shackles (2) of
the 3rd telescopic section or the pins on shackles (1) of the
main boom head.

(Z 30 461)
19. Move the deflection roller’s connecting brackets to transport
position, insert pins (13) and guard.

20. The rope of the bracing winch remains reeved and does not
need any additional safety locks.

The Superlift can now either be removed from the crane (Sec-
tion 30.9 ”Removing the Superlift”) or secured on the main boom
base section in transport position, e.g. for technical driveability
(Section 30.10, ”Superlift Remaining on the Main Boom”).

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Q 38

S 38

Z 30 438

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30.9 Removing the Superlift

When the bracing support has been lowered, the Superlift can be
removed from the crane as follows.

1. Unreeve the hook block and wind the hoist rope onto the
drum.

During unreeving, there is a danger of being caught and

dragged in at the head sheaves as well as at the hook
block.
Proceed in an appropriately cautious manner.

(Z 30 438)
2. Disconnect the hydraulic lines between superstructure and
bracing support, and seal the connections with protection
caps.

3. Release the electrical connection to distribution box (”X

510”) on the main boom base section.
Remove plug (”Q 38”) from distribution box (”X 38”) of the
bracing support.
Place protection caps over both the socket and the plug.

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1
”C”
3

Z 30 435

Z 30 432

15

Z 30 463

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(Z 30 435)
4. Raise deflection roller (1) using an auxiliary crane and pin
drop--back retaining rope (3) at point ”C” on the deflection
roller.

When the deflection roller is being raised, there is a dan-

ger of crushing between the deflection roller and the
base section. It is prohibited to remain in the danger
zone.

The drop--back retaining rope is to be pin locked from the

side using ladders and/or lifting platforms.
However, should this be carried out from the base sec-
tion, the crane operator is to guard against falling by
wearing a safety harness, before the rope is pin locked to
the deflection roller.

(Z 30 432)
5. Disconnect the auxiliary crane from deflection roller, and at-
tach the lifting ropes to the 3 eyes provided on bracing sup-
port (4). Attach the ropes to the auxiliary crane and draw the
ropes taut.

(Z 30 463)
6. Disconnect bracing support from the superstructure by re-
moving pins (15).

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1 S
Z 30 429

19

Z 30 449 Z 30 431

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7. Lift the Superlift off the main boom using the auxiliary crane
and lower onto a transport vehicle or to the ground.

When lowering the Superlift, ensure that brake band holder

of bracing winch (2) on the bracing support does not come
into contact with the chassis of the crane. OTHERWISE THE
CHASSIS WILL BE DAMAGED. (Z 30 429)

A proposal for transport of the Superlift can be found in Section

30.3 of these operating instructions.

(Z 30 449, Z 30 431)
8. Bracing rods (L = 6000 mm) and (L = 2510 mm) can:
− remain on the main boom, in which case they need to be
secured in their transport position using pins (19,Z 30 449).

or

− be removed. Disconnect bracing rods (9a, Z 30 431) from

main boom base section and from each other by withdraw-
ing the pins and removing the bracing rods from the crane
using the auxiliary crane.

The individual bracing rods weigh approximately 71 kg (L = 6000

mm) and approximately 33 kg (L = 2510 mm).

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a
a
9
11
b

Z 30 459

Z 30 447

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30.10 Superlift Remaining on the Main Boom

(Z 30 459)

The Superlift may remain on the crane for driving on construction

sites and on non--public roads.

With the Superlift resting on the main boom, the axle loads
are over 12 t.
Not suitable for road transport.

When the bracing support has been lowered (Section 30.8), the
Superlift can be secured in transport position.
-- Bracing rod strands (9) must rest in retainers (11) on the main
boom base section.
-- Both rope guide rollers (13) can be detached and placed in
transport holders (14) on the bracing support in order to be
able to clear the maximum height clearances (up to max.
4000 mm)

Risk of falling.
This work is to be carried out from the side using ladders
and/or lifting platforms.
However, should this work be carried out from the base
section, then the crane operator is to guard against fal-
ling by wearing a safety harness.

(Z 30 447)
-- In addition to the bracing support connection, the deflection
roller of the bracing support must also be pinned to the main
boom base section and secured.

All pins must be secured with fore locks and/or locking

springs.

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