Main Boom Extension 18

Main Boom Extension 18
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73
Z 40 249
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18 Main Boom Extension
-- The main boom extension is marked with the

construction number of the crane. It may only be fitted
on the crane with this construction number.
Exceptions are only permitted if this is expressly
stated in the crane papers (e.g. crane log book).
-- The main boom extension may only be fitted and re-
moved by trained and qualified personnel.
18.1 Important Information
- The main boom extension comprises parts of the luffing fly jib,
but is connected in a fixed position to the main boom head.
Consequently, only hoist 1 is required for work with the main
boom extension.
The crane can be operated with the main boom extension un-
der an angle of 0°, 20° and 40°. The angle is set by means of
tension bars on the intermediate section (8, Z 40 249). For
operation of the crane with a main boom extension, the inter-
mediate section (8) serves as a foot section.
These tension bars (73) must be inspected at least once a
year by a specialist (in accordance with the accident preven-
tion regulations ”Load lifting equipment in hoist operations
(VBG 9)”. In addition they must be checked by a specialist
between these intervals if required by the operating and site
conditions.
The inspection intervals are generally determined by the op-
erating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals
should be.
Records should be kept of when these inspections are car-

ried out (e.g. in the examination log book for the crane).
The following checks should be carried out:

* Checking for cracks
* Checking length
* Checking wear
* Checking paintwork
* Checking plastic deformation
Instructions on carrying out the inspection can be found in

part 3, ”Lubrication and Maintenance Instructions of the Su-
perstructure”.
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Z 47 346 Z 40 250
Z 47 347 Z 39 370
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- The main boom extension may only be fitted, removed and

operated when the crane is supported on its outriggers.
The reduced outrigger support area is only permitted in ac-
cordance with the specifications outlined in the correspond-
ing load tables.
- The main boom extension must be assembled so that the in-

termediate sections can be bolted in the horizontal position
(Z 47 346).
- To fit and remove the main boom extension, the superstruc-

ture must be turned so that the boom is positioned to the side
or rear (90°).
- The main boom extension can only be fitted and removed us-
ing an auxiliary crane.
- Check to make sure that the tubular structures of the lattice

mast components of the main boom extension are free of
damage. If you discover any damaged tubes during the visual
inspection, all work with the fly jib must be stopped immedi-
ately.
- Pay attention also to the safety instructions in section 1.4.8

on ”Assembling and Dismantling Crane Components”.
- When bolting the jib top section (9) with the intermediate sec-
tions (8), (11) or (55) the diameter of the top bolts equals 55
mm and the diameter of the lower bolts 65 mm at a length of
536 mm. Diese Doppelkonusbolzen werden mit je 2 Bolzensi-
cherungen gesichert. Vor dem Einsetzen dieser Bolzensi-
cherungen muß auf beiden Seiten eine Distanzscheibe über
den Doppelkonusbolzen geschoben werden (Z 47 347).
-- The biconical bolts and the corresponding distance plates are

located on the jib top section (9) in the parking position (Z 39
370).
-- Information on the combination of the lattice mast compo-
nents can be found in Sect. 18.2.1 of these operating instruc-
tions.
- The intermediate section (8) and the jib top section (9) are
bolted to the main boom head by means of 4 biconical bolts
with various diameters (upper bolt: ∅ 55, bottom bolt: ∅ 65).
The bolt length is 536 mm (Z 40 250).
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41
41b
51
Z 45 005 Z 45 004
41b
41a
Z 45 003
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- The main boom extension should be fitted with the crane out-
riggers extended to the support area at which the crane will
subsequently be operated.
- The counterweight required for operation of the crane must

be fitted before the main boom extension is fitted on the su-
perstructure.
- If the crane is equipped with a hinged head sheave, the

sheave must be removed before the fixed fly jib is fitted.
- The crane is operated with a 6 m main boom extension only

below an angle of 0° to the main boom. The 6 m main boom
extension comprises the jib top section (9). The rope is
guided to the head of this jib top section via a height--adjust-
able rope idler.
This rope idler (41) is fitted on the jib top section and must be
bolted in the middle hole (Z 45 005).
- There are two different types of rope idler (41) (Z 45 003):

-- fixed design (41a)
-- hinged design (41b)
The design of this rope idler does not affect its folding height.
The fold--up rope idler (41b) is only used for drawing forward
the flying bridle with rope ”hoist 1”.
In this case the hoist rope is fed through the sheave
(Z 45 004).
This step is carried out when fitting the luffing fly jib.
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”A”--74 73 ”B” ”C”-- 74

41
”A” 73 ”C”
0
75
75
8
41
X
73
8
8
41
41
”A”
73
Z 40 252
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- The crane can be operated with a 12 m to 36 m main boom

extension with the main boom extension at an angle (see the
corresponding load tables). The angle equals 20° or 40° and
is set by means of draw bars on the intermediate section (8)
(Z 40 252).
For crane operation with 0° ,20° or 40° extension angle, the
rope is guided to the jib top section (9) via a height--adjustable
rope idler (41) on the intermediate section (8).
− Main boom extension not angled (0° position).

With a straight main boom extension:
∗ bolts (74) are inserted in the draw bars (73) at points ”A”
and ”C”.
∗ the rope idler (41) is bolted in the middle hole.
− Main boom extension at an angle of 20°.

With the main boom extension at an angle of 20°:
∗ bolts (74) are inserted in the draw bars (73) at point ”B”.
The 2 remaining bolts must be inserted in the transport
receptacle (point ”X”) and secured.
To avoid damage, the bolts must be removed at point ”A”.
− Main boom extension at an angle of 40°.

With the main boom extension at an angle of 40°:
∗ bolts (74) are inserted in the draw bars (73) at point ”A”.
The 2 remaining bolts must be inserted in the transport
receptacle (point ”X”) and secured.
The bolts (74) must be inserted from the inside outwards and
secured with pin locks. Each bolt has two washers (75)
which must be fitted on either side when the bolts are in-
serted.
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10/71
9
5470 275
5745
9 8
5470 6000 275

11745
9 55 8
5470 6000 6000 275

17745
9 11 8
5470 12000 6000 275

23745
9 11 55 8
5470 12000 6000 6000 275

29745
9 11 55 55 8
5470 12000 6000 6000 6000 275

35745
Z 42 352
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18.2 Main Boom Extension Combinations
18.2.1 Combinations of the Lattice Mast Components
The main boom extension can be used for the following lengths:
− bei einem Winkel zum Hauptausleger von 0°:
von 6 m bis 36 m / 19,6 bis 118,1 ft.
von 12 m bis 36 m / 39,3 bis 118,1 ft.
von 12 m bis 36 m / 39,3 bis 118,1 ft.
The possible combinations are shown in the drawing (Z 42 352).

The number of lattice mast components in relation to the main
boom extension length can be taken from the picture (Z 42 352)
and the following table.
Length of the main Part no.

boom extension 8 9 11 55
6 m / 19,6 ft ./. 1x ./. ./.
12 m / 39,3 ft 1x 1x ./. ./.
18 m / 59,0 ft 1x 1x ./. 1x
24 m / 78,7 ft 1x 1x 1x ./.
30 m / 98,4 ft 1x 1x 1x 1x
36 m / 118,1 ft 1x 1x 1x 2x
The lattice mast components are marked as follows (see detail

”X”, Z 42 352).
Parts Designation Ident. no.
no.
8 1411--10--11 110 232 12
9 1411--5--11 110 233 12
11 1411--5--11 110 235 12
55 1411--6--11 110 690 12
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9
5470 275
5745
9 8
5470 6000 275

11745
9 55 8
5470 6000 6000 275

17745
9 11 8
5470 12000 6000 275

23745
9 11 55 8
5470 12000 6000 6000 275

29745
9 11 55 55 8
5470 12000 6000 6000 6000 275

35745
Z 42 353
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The length and weight of the individual lattice mast components

can be taken from the adjacent picture (Z 42 353) and the follow-
ing table.
Parts Designation Lgth. (mm) Approx.
no. weight
8 Intermediate sec- 6 000 1.6 t
tion
9 Jib top section 5 470 1.4 t
tion
tion
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18.2.2 Bolting Table
The main boom extension is attached to the main boom head and
the lattice mast components are connected together by driving
in bolts.
The number of these connecting elements can be taken from the
picture (Z 48 861) and the following table.
Legend:
(45) : Biconical bolt ∅ 65 x 536 -- Ident. no.: 110 961 12
(46) : Biconical bolt ∅ 55 x 536 -- Ident no.: 110 962 12
(76) : Washer ∅ 135 / 66 x 15 thick -- Ident no.: 117 093 12
(77) : Washer ∅ 135 / 57 x 15 thick -- Ident no.: 117 094 12
(HA) : Main boom head
Pin stop Connection of Connecting elements

A (9) mit (HA) 2 x (45) + 2 x (46)
B (8) mit (HA) 2 x (45) + 2 x (46)
C (9) mit (8) 2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
d (55) mit (8) 2 x (47) + 2 x (48)
E (9) mit (55) 2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
F (11) mit (8) 2 x (47) + 2 x (48)
G (9) mit (11) 2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
H (11) mit (55) 2 x (47) + 2 x (48)
I (55) mit (55) 2 x (47) + 2 x (48)
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Z 39 376 Z 39 377
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18.3 Fitting the Main Boom Extension
-- When assembling and dismantling the lattice mast

components of the main boom extension there is a
risk of crushing:
* when connecting / disconnecting between the indi-
vidual lattice mast components !
* between the main boom head and head connecting
piece.
The hazardous area must therefore be kept clear at all

times! Pay particular attention to the notes on hazards in
section 1.4.8 when ”Assembling and Dismantling Crane
Components” as well as the following instructions.
All assembly work is to be carried out with the help of
suitable equipment (ladders, hoist platforms, scaffolding,
auxiliary crane).
If work cannot be carried out using this type of equip-
ment or from the ground, assembly personnel must take
suitable precautionary measures to safeguard against
the RISK OF FALLING (e.g. safety belt).
During the fitting/removal procedure the area beneath

suspended loads or areas where there is a risk of falling
must be kept clear.
-- Select the auxiliary crane and lifting tackle so that the

lifting capacity clearly exceeds the weight of the lat-
tice mast section which is to be fitted or removed and
is sufficient to lift the sections at the required working
radius.
Proceed as follows:
1. Support the crane properly on outriggers and fit the counter-

weight required for operation of the crane (Z 39 376).
2. Prepare the main boom for fitting the main boom extension.
To this end:
− retract the main boom completely
− unreeve the hook block
− disconnect the shift weight of the hoist limit switch for
safety reasons and remove from the main boom head
(Z 39 377).
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Z 47 349
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3. Hook up the two ropes of the auxiliary crane to the eyes pro-
vided on the jib top section (9) and intermediate section (8).
-- For a 6 m main boom extension, only the jib top section (9) is
fitted on the main boom head.
Attachment points: see transport unit VIII in Sect. 19.13.1.8
of these operating instructions.
-- For a 12 m to 36 m main boom extension, intermediate sec-
tion (8) is now fitted on the main boom head.
Attachment points: see transport unit VII in Sect. 19.13.1.7 of
these operating instructions.
4. Fit the corresponding lattice mast section on the main boom

head and assemble the main boom extension.
4.1 6 m / 19,6 ft Hauptauslegerverlängerung
4.1.1 Raise the jib top section (9) using the auxiliary crane
and place in the bolting position on the main boom
head (Z 47 349, ”A”).
Risk of crushing !
There is a risk of crushing between the main boom head
and jib top section! Proceed with appropriate caution.
The area beneath suspended loads or where loads could
fall must be kept clear at all times.
4.1.2 Connect the main boom and jib top section using four
biconical bolts (Z 47 349, ”B”). Secure each bolt with
2 locking elements.
-- The use of biconical bolts guarantees that the bolts

can always be hit FROM THE OUTSIDE during the fit-
ting and removing procedure.
-- Please observe the bolting table in section 18.2.2. for
bolting.
4.1.3 Disconnect the lifting tackle from the jib top section
(9).
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Z 40 257
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4.1.4 Reeve the hoist rope over the rope idler (41) and
guide to the head of the jib top section (9) (Z 40 257).
Due to the risk of falling, it is forbidden to walk on the lat-

tice mast components to draw forward the hoist rope;
this must be carried out from the side.
Reeve the rope idler before securing at the prescribed
height.
4.1.5 Release the shift weight from the parking position

(detail ”X”) and reeve the hoist rope on the head of
the jib top section (9) (Z 40 257).
Information on reeving the hoist rope on the head of the main

boom extension can be found in section 17.6 of these operating
instructions.
During reeving there is a risk of becoming caught and

dragged into the equipment at the head sheaves and at
the hook block.
Verfahren Sie entsprechend vorsichtig und achten Sie
darauf, daß Schutzvorrichtungen wie z. B. Einlaufschutz
vorhanden sind.
Quetschgefahr !
Unterflasche ausschließlich an den vorhandenen Hand-
griffen anfassen (siehe Einzelheit ”Y”). Your hands must
expressly be kept clear of the following areas:
* between the sheaves, side plates and covers.
* in the area of the fixing points (sometimes of a hinged
design), of the hook, of the hook nut, of the lifting
beam or of protecting cages.
Work may only be carried out on the hook block (reev-
ing) when it is resting on firm ground.
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”A”-- 74 ”C”-- 74
Z 40 226
Z 40 227
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4.2 Main boom extension 12 m / 39,3 ft and above

For a main boom extension of 12 m to 36 m, the inter-
mediate section (8)must be fitted on the main boom
head first.
Proceed as follows:
4.2.1 By drawing the bolts (74) at point ”C”, set the inter-
mediate section (8) at an operating angle of 40°. The
two remaining bolts (74) remain inserted and se-
cured at point ”A” (Z 40 226).
4.2.2 Connect the two ropes of the auxiliary crane to the

eyes provided on the intermediate section (8) (Z 40
227).
Attachment points: see transport unit VII in Sect. 19.13.1.7 of

these operating instructions.
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”A”
8
”B”
Z 40 258
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4.2.3 Raise the intermediate section (8) using the auxiliary

crane and place in the bolting position on the main
boom head (Z 40 258, ”A”).
Risk of crushing !
There is a risk of crushing between the main boom head
and intermediate section ! Proceed with approriate cau-
tion.
The area beneath suspended loads or where loads could
fall must be kept clear at all times.
4.2.4 Connect the main boom and intermediate section by

means of four biconical bolts (Z 40 258, ”B”). Secure
each bolt with 2 locking elements.
-- The use of biconical bolts guarantees that the bolts

can always be hit FROM THE OUTSIDE during the fit-
ting and removing procedure.
-- Please observe the bolting table in section 18.2.2. for
bolting.
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Z 40 259
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4.2.5 Using the auxiliary crane, lower the intermediate sec-

tion (8) until the end of the intermediate section is
resting on a wooden support which has been placed
ready in advance (Z 40 259).
There is a risk of crushing when the intermediate section

is lowered onto the wooden block. Proceed with ap-
propriate caution.
4.2.6 Disconnect the lifting tackle from the intermediate

section (8).
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8
8
9
11
55
11
Z 47 350
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(Z 47 350)
4.2.7 Hook up the jib top section (9), intermediate section
(11) and intermediate section (55) to the auxiliary
crane.
-- For a 12 m main boom extension, the jib top section (9) is now
fitted.
Attachment points: see transport unit VIII in Sect. 19.13.1.8
-- For a 24 m main boom extension, intermediate section (11)
is now fitted. Attachment points: see transport unit IX in Sect.
19.13.1.9 of these operating instructions.
-- For an 18 m, 30 m or 36 m main boom extension, intermediate
section (55) is now fitted.
Attachment points: see transport unit XII in Sect. 19.13.1.12
4.2.8 Using the auxiliary crane, raise the corresponding
lattice mast component so that it can be fitted on the
intermediate section (8). First insert a biconical bolt
in each of the upper pin stops, and secure each bolt
with two pin locks (Z 47 350, ”A”).
When the upper bolting points have been bolted and
locked, lower using the auxiliary crane and discon-
nect the lifting tackle.
-- There is a risk of crushing between the individual lat-

tice mast components. Proceed with appropriate cau-
tion.
-- For bolting specifications, please refer to the bolt-

ing table in section 18.2.2.
4.2.9 To close the lower pin stop, attach the two strands of
the lifting tackle on both sides of the intermediate
section (8) (Z 47 350, ”B”). To avoid damage, secur-
ing straps should be used. Raise slightly using the
auxiliary crane. The lower pin stop is closed and can
be bolted and locked like the upper bolt connection
(pin stop). Place a wooden block beneath the end of
the intermediate section to provide support.
To close the lower pin stops, the auxiliary crane must al-
ways be hooked up to the component part which is posi-
tioned nearer to the main crane.
4.2.10 Disconnect the lifting tackle from the intermediate

section (8).
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41
8
73
9
8
Z 40 261
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4.2.11 Depending on the desired length of the main boom

extension, fit the required lattice mast components
as previously described.
Once the required main boom extension length has
been assembled, checks must be made to ensure
that all the pin stops are connected with the correct
biconical bolts and that each bolt is additionally
locked with two pin locks.
-- The lattice mast component combinations can be found in

section 18.2.1 of these operating instructions.
-- The bolting table for connecting the lattice mast components
can be found in Sect. 18.2.2 of these operating instructions.
Where the upper pin stop has already been closed, the lattice
mast component nearest the crane must be raised to close
the lower pin stop. If shackles are not available, the two
strands of the lifting tackle must be connected to the two up-
per tubes of the corresponding part.
4.2.12 Guide the hoist rope over the rope idler (41) on the
intermediate section (8) and, for the purpose of sub-
sequent reeving, feed to the head of the jib top sec-
tion (9) (Z 40 261).
Due to the risk of falling, it is forbidden to walk on the lat-

tice mast components to draw forward the hoist rope;
this must be carried out from the side.
Reeve the rope idler before securing at the prescribed
height.
4.2.13 The main boom extension is prepared for crane op-

eration at a working angle of 40°.
If you plan to operate the crane at an angle of 0° or
20°, you should now proceed as follows:
− Hook up the auxiliary crane to the eyes provided
on the jib top section (9).
− Raise the front lattice mast combination and, as
described in section 18.1, bolt the shackles (73)
on the intermediate section (8) accordingly
(Z 40 261).
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Z 40 257
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4.2.14 Release the shift weight from the parking position

(detail ”X”) and reeve the hoist rope on the head of
the jib top section (9) (Z 40 257).
Information on reeving the hoist rope on the head of the main

boom extension can be found in section 17.5 of these operating
instructions.
During reeving there is a risk of becoming caught and

dragged into the equipment at the head sheaves and at
the hook block.
Proceed with appropriate caution and make sure that the
safety guards, for example the intake guard, are fitted.
Risk of crushing !
Only handle the hook block using the hand grips pro-
vided (see detail ”Y”). Your hands must expressly be
kept clear of the following areas:
* in the area of the fixing points (sometimes of a
hinged design), of the hook, of the hook nut, of the lifting
Work may only be carried out on the hook block (reev-
ing) when it is resting on firm ground.
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82
83
Z 39 388 Z 39 389
94
Z 40 232
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5. Attach the mounting pipe with the fitted rotor of the anemom-
eter and the aircraft warning light on the jib top section (9) (Z
39 388).
6. Connect the electrical safety chain on the distribution boxes

(82, ”X550”) and (83, ”X552”) on the main boom head (Z 39
389) and on the distribution box (94, ”X570”) in the jib top
section (9, Z 40 232).
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86
82
83
1
Z 39 391
92
9
Z 42 355
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6.1 Connect the safety chain on the main boom head

The sockets on the distribution boxes (82) and (83) on the main
boom head should be assigned as follows:
(Z 39 391 and Z 42 355)
− Distribution box (82, ”X550”)
∗ Socket (1, ”Q4”)
Shut off with protective cap
∗ Socket (2, ”Q5”)
Plug connection to cable drum (92) in the jib top section
(9). (connection for distribution box ”X570”)
− Distribution box (83, ”X552”)
∗ Socket (3, ”Q2)
sealed with protection cap.
∗ Check to make sure that there is a connection to the angle
transmitter (86) on the main boom head.
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92
”S2D”
9
Z 42 355 Z 42 356
94
90 91
4 5
Z 39 702 Z 39 703
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6.2 Connect the safety chain on the head of the main boom ex-
tension
− Make the connection between the cable drum (92) and dis-
tribution box (94, ”X570”) in the jib top section (9) (connection
for anemometer, aircraft warning light and hoist limit switch),
(Z 42 355 and Z 39 702).
− Make the connection between socket (4, ”Q5N”) in the dis-
tribution box (94) and rotor (90, ”G7”) of the anemometer on
the jib top section (9) (Z 39 702 and Z 39 703).
− Make the connection between socket (5, ”Q4N”) in the dis-
tribution box (94) and aircraft warning light (91, ”H115.1/2”)
on the jib top section (9) (Z 39 702 and Z 39 703).
− Check to make sure that the hoist limit switch S2D” on the jib
top section is connected to the distribution box (94,”X570”)(Z
39 702 and Z 42 356.
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”S2D”
Z 40 237
1 2 3
Z 39 718
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7. To ensure that the hoist limit switch ”S2D” on the jib top sec-
tion (9) can function properly, the hoist limit switch ”S1” on the
main boom head must be bridged, the restraint must be
placed in the locking position (Z 40 237).
To switch the restraint from the storage position into the locking
position proceed as follows (Z 39 718):
7.1 Push the restraint to the left 1 to release it from the

storage position.
7.2 Pull the hoist limit switch cable downwards, then bend
backwards parallel to the boom and hold in this posi-
tion 2 .
7.3 Starting from the left, push the slit of the restraint be-
tween the switch and the attached cable stop over the
cable 3 . Now press up against the guide of the hoist
limit switch ”S1” 4 .
7.4 Pull the cable down again, guiding the slit of the re-
straint into position, and release 5 .
7.5 Turn the flag of the restraint to where it can best be

seen by the crane operator 6 .
8. On the ECIS console, enter the code no. (DS) for the desired
operating mode (operation of main boom extension) and the
length code no. (LK) for the desired operating length of the
main boom.
These entries must be made in accordance with the applica-

ble load capacity table.
The computer of the load limit device is then set for opera-
tion with the main boom extension. On the ECIS display, the
crane symbol is shown with a main boom extension fitted.
The current values for the crane geometry are now dis-
played.
Due to the risk of tipping, the code numbers which have

been entered (DS) and (LK) from the corresponding load
capacity table and the counterweight fitted should be
checked again !
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9. Using key--operated pushbutton (126), bridge the hoist limit

switch. Indicator light (125) lights up.
10. Using the luffing gear, raise the main boom until the hook
block is hanging free and deactivate the bridged condition of
the hoist limit switch. To this end, place key button (126) in
the operating position. Indicator light (125) goes out.
11. Check the function of the hoist limit switch on the head of the
main boom extension.
When the hoist limit switch is activated, ”raise hoist 1” must be

shut down. The hoist limit symbol appears in the top line of the
ECIS display. Indicator light (145) with the hoist limit symbol lights
up and an alarm buzzer sounds.
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73
Z 40 249
44/71 650--1180--033_en
18.4 Erecting
18.4.1 Checks Before Erecting
Before raising the main boom extension and selecting the

operating length check:
-- that the main boom extension and main boom head are
correctly locked together.
-- that all bolts are fitted and locked correctly.
-- that all connecting bolts have been secured with func-
tioning locks in accordance with regulations.
-- that there is no damage to the tubular structures of the lat-
tice mast components. If you discover damaged tubes
during your inspection, further work with the fly jib is pro-
hibited.
-- that the main boom is well lubricated. This is especially
important for long main boom extension lengths. Before
all operations, the slides and the rear linings must be well
lubricated.
-- that the load limit device is set to the load program to be
driven for ”main boom extension” operation (see section
10 of these operating instructions and the corresponding
load table).
-- that the main boom is retracted.
-- that the fitted counterweight corresponds to the one spe-
cified in the corresponding load table.
-- that the tension brackets (73) on the intermediate section
(8) are correctly bolted in relation to the operating angle
(Z 40 249). Information on the angle settings can be
found in section 18.1.
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18
Z 40 262
46/71 650--1180--033_en
18.4.2 Erection Procedure
Proceed as follows to erect to the operating position (Z 40 262):
1. Using the luffing gear, raise the main boom into the high
position (83°).
Move briefly against the safety pressure of the luffing gear

to make sure that the main boom is secured firmly in place.
2. Paying attention to the instructions of the telescoping infor-

mation system, telescope out to the main boom length in ac-
cordance with the load capacity table.
For crane operation with the main boom extension, the main
boom must be 60 m in length. For this main boom length, the 4
telescopic sections are 100% extended. To extend to this operat-
ing length of 60 m, the length code LK ”94” must be set on the
ECIS console.
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18
Z 40 263
48/71 650--1180--033_en
18.5 Lowering Procedure
18.5.1 Lowering Procedure at an Operating Angle of 20 and

40 degrees
To lower the main boom extension, proceed as follows:
1. Move the main boom with the luffing gear into the high posi-
tion (83°) (Z 40 263).
2. Enter the LK no. ”00” on the ECIS display for complete retrac-
tion of the main boom.
3. Telescope in the main boom completely while observing the

telescoping information system (Z 40 263).
When telescoping, the information on the ECIS display

should always be followed.
A precise description of the actual telescoping procedure
can be found in Sect. 12 ”Telescoping”.
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Z 42 357
50/71 650--1180--033_en
4. Rotate the superstructure so that it is facing the rear or the

side (if there are no restrictions in this respect in the corre-
sponding load capacity table).
5. Lower the main boom using the luffing gear until the jib top
section (9) is resting on the ground (Z 42 357).
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18
Z 40 265
52/71 650--1180--033_en
18.5.2 Lowering Procedure at an Operating Angle of 0

degree
To lower the main boom extension, proceed as follows:
1. Move the main boom with the luffing gear into the high posi-
tion (83°) (Z 40 265).
2. Enter the LK no. ”00” on the ECIS display for complete retrac-
tion of the main boom.
3. Telescope in the main boom completely while observing the

telescoping information system (Z 40 265).
When telescoping, the information on the ECIS display

should always be followed.
A precise description of the actual telescoping procedure
can be found in Sect. 12 ”Telescoping”.
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18
Z 42 358
54/71 650--1180--033_en
4. Rotate the superstructure so that it is facing the rear or the

side (if there are no restrictions in this respect in the corre-
sponding load capacity table).
5. Lower the main boom to the horizontal using the luffing gear
(Z 42 358).
6. Hook up the two ropes of the auxiliary crane to the eyes pro-
vided on the jib top section (9) (Z 42 358).
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18
9 8
”C”-- 74
8
Z 47 351
56/71 650--1180--033_en
7. Raise the jib top section (9) slightly using the auxiliary crane
to relieve the strain on bolt (74) at point ”C” on the intermedi-
ate section (8) (Z 47 351, ”A”).
8. Remove both bolts (74) at point C” (1 x left and 1 x right), (see

detail ”X”).
9. Using the auxiliary crane, lower the front part of the main
boom extension until the jib top section (9) is resting on the
ground (Z 47 351, ”B”).
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18
58/71 650--1180--033_en
18.6 Removing the Main Boom Extension
-- When assembling and dismantling the lattice mast

components of the main boom extension there is a
risk of crushing:
* when connecting / disconnecting between the indi-
vidual lattice mast components !
* between the main boom head and head connecting
piece.
The hazardous area must therefore be kept clear at all

times! Pay particular attention to the notes on hazards in
section 1.4.8 when ”Assembling and Dismantling Crane
Components” as well as the following instructions.
All assembly work is to be carried out with the help of
suitable equipment (ladders, hoist platforms, scaffolding,
auxiliary crane).
If work cannot be carried out using this type of equip-
ment or from the ground, assembly personnel must take
suitable precautionary measures to safeguard against
the RISK OF FALLING (e.g. safety belt).
During the fitting/removal procedure the area beneath

suspended loads or areas where there is a risk of falling
must be kept clear.
-- Select the auxiliary crane and lifting tackle so that the

lifting capacity clearly exceeds the weight of the lat-
tice mast section which is to be fitted or removed and
is sufficient to lift the sections at the required working
radius.
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18
82
83
Z 31 823 Z 39 389
Z 42 976
60/71 650--1180--033_en
As the main boom extension has now been lowered, as de-

scribed in sections 18.5.1 and 18.5.2, and the tension bars on the
intermediate section (8) have been set to the 40° operating angle,
the system can be dismantled further as follows.
1. Release the shift weight on the hoist rope and insert in the
parking position on the jib top section (Z 31 823).
2. Unreeve the hook block and reel the hoist rope onto the rope
drum.
When unreeving the rope there is a risk of personnel be-

coming caught and dragged into the equipment at the
head sheaves and the hook block.
Proceed with appropriate caution!
Risk of crushing !
Only handle the hook block using the hand grips pro-
vided (Z 42 976). Your hands must expressly be kept
clear of the following areas:
* in the area of the fixing points (sometimes of a hinged
design), of the hook, of the hook nut, of the lifting
Work may only be carried out on the hook block (unre-
eving) when it is resting on firm ground.
3. Disconnect the electric lines to the main boom extension on

the distribution boxes (82, ”X550”) and (83, ”X552”) on the
main boom head (Z 39 389).
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18
8
9
Z 40 268
62/71 650--1180--033_en
4. Remove the main boom extension (Z 40 268).
The equipment is dismantled analogously in the reverse order of

the installation. Please also refer, therefore, to the fitting instruc-
tions.
All pictures show the 12 m main boom extension as an example.

You should proceed accordingly with all other lengths.
4.1 Hook up the 2--strand lifting tackle on both sides on the

end of the intermediate section (8) on the upper mem-
bers. To avoid damage, securing straps should be
used.
The lifting equipment should be attached for all main

boom extension lengths to the section which is nearest
the main crane.
4.2 Raise using the auxiliary crane. It must take up the full
load, however without lifting the jib top section (9) off
the ground.
The bolts of the lower pin stop may only be removed

when the component sections are safely held by the aux-
iliary crane.
Otherwise, the lattice mast components can spring apart
suddenly when the lower pin stop is opened.
Danger to life and limb!
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18
8
9
Z 47 352
64/71 650--1180--033_en
4.3 Remove the bolts of the lower pin stop (Z 47 352, ”A”).
Always knock out biconical bolts from the outside in-

wards!
The area beneath the load or where the load could fall
must be kept clear at all times.
These bolts must be easily knocked out. Otherwise the

bolted connection is still under load!
Consequently, observe the bolts when knocking them out
and, if necessary, relieve the pin stop by corresponding
movement of the auxiliary crane.
4.4 When the hazardous area is clear, lower the auxiliary

crane so that the opened lower pin stop comes to rest
on the wooden blocks which have been laid ready and
the jib top section (9) rests on the ground (Z 47 352,
”A”).
-- Risk of crushing between the lattice mast components

and the wooden supports. Proceed with appropriate
caution.
-- The upper pin stops may only be released when

both sections are lying on the ground.
4.5 Release the upper pin stop, hook up the auxiliary crane
to the eyes provided on the jib top section (9) and re-
move the jib top section (Z 47 352, ”B”).
Attachment points on the jib top section (9): see transport unit VIII
in Sect. 19.13.1.8 of these operating instructions.
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18
73
”C”-- 74
Z 40 270
66/71 650--1180--033_en
4.6 Hook up the two rope strands of the auxiliary crane to

the eyes provided on the intermediate section (8) (Z 40
270, ”A”).
Attachment points on the intermediate section (8): see transport

unit VII in Sect. 19.13.1.7 of these operating instructions.
4.7 Using the auxiliary crane, raise the intermediate sec-

tion (8) so that the tension bars (73) can be bolted in
the 0°--position (Z 40 270”A”).
4.8 On both sides, insert one bolt (74) at point ”C” and lock
the bolts. The intermediate section (8) is bolted in the
0° position (Z 40 270 ”B”).
Information on setting the angle for the intermediate section (8)

can be found in section 18.1 of these operating instructions.
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18
46
45
”A”
8
Z 40 271
68/71 650--1180--033_en
4.9 Remove the top bolts (46) and bottom bolts (45) on the
pin stop of the main boom head (Z 40 271).
Always knock out biconical bolts from the outside in-

wards!
The area beneath the load or where the load could fall
must be kept clear at all times.
These bolts must be easily knocked out. Otherwise the

bolted connection is still under load!
Consequently, observe the bolts when knocking them out
and, if necessary, relieve the pin stop by corresponding
movement of the auxiliary crane.
4.10 Remove intermediate section (8).
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Z 48 837
70/71 650--1180--033_en
18.7 Superlift Operation with Main Boom Extension

(Z 48 837)
Information on operation of the Superlift with the main boom ex-

tension can be found in section 30.5 of these operating instruc-
tions.
650--1180--033_en 71/71

Main Boom Extension 18

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Main Boom Extension 18

18 Main Boom Extension

-- The main boom extension is marked with the

18.1 Important Information

Records should be kept of when these inspections are car-

The following checks should be carried out:

Instructions on carrying out the inspection can be found in

- The main boom extension may only be fitted, removed and

- The main boom extension must be assembled so that the in-

- To fit and remove the main boom extension, the superstruc-

- Check to make sure that the tubular structures of the lattice

- Pay attention also to the safety instructions in section 1.4.8

-- The biconical bolts and the corresponding distance plates are

- The counterweight required for operation of the crane must

- If the crane is equipped with a hinged head sheave, the

- The crane is operated with a 6 m main boom extension only

- There are two different types of rope idler (41) (Z 45 003):

”A”--74 73 ”B” ”C”-- 74

- The crane can be operated with a 12 m to 36 m main boom

− Main boom extension not angled (0° position).

− Main boom extension at an angle of 20°.

To avoid damage, the bolts must be removed at point ”A”.

∗ the rope idler (41) is bolted in the middle hole.

− Main boom extension at an angle of 40°.

5470 6000 275

5470 6000 6000 275

5470 12000 6000 275

5470 12000 6000 6000 275

5470 12000 6000 6000 6000 275

18.2 Main Boom Extension Combinations

18.2.1 Combinations of the Lattice Mast Components

The possible combinations are shown in the drawing (Z 42 352).

Length of the main Part no.

The lattice mast components are marked as follows (see detail

5470 6000 275

5470 6000 6000 275

5470 12000 6000 275

5470 12000 6000 6000 275

5470 12000 6000 6000 6000 275

The length and weight of the individual lattice mast components

18.2.2 Bolting Table

Pin stop Connection of Connecting elements

18.3 Fitting the Main Boom Extension

-- When assembling and dismantling the lattice mast

The hazardous area must therefore be kept clear at all

During the fitting/removal procedure the area beneath

-- Select the auxiliary crane and lifting tackle so that the

1. Support the crane properly on outriggers and fit the counter-

4. Fit the corresponding lattice mast section on the main boom

4.1 6 m / 19,6 ft Hauptauslegerverlängerung

-- The use of biconical bolts guarantees that the bolts

Due to the risk of falling, it is forbidden to walk on the lat-

4.1.5 Release the shift weight from the parking position

Information on reeving the hoist rope on the head of the main

During reeving there is a risk of becoming caught and

4.2 Main boom extension 12 m / 39,3 ft and above

4.2.2 Connect the two ropes of the auxiliary crane to the

Attachment points: see transport unit VII in Sect. 19.13.1.7 of

4.2.3 Raise the intermediate section (8) using the auxiliary

4.2.4 Connect the main boom and intermediate section by

-- The use of biconical bolts guarantees that the bolts

4.2.5 Using the auxiliary crane, lower the intermediate sec-

There is a risk of crushing when the intermediate section