AC25-Part1 en

25−0000−001 1/1
Contents
Manufacturer's Specifications
Foreword
1 Safety Instructions
1 Safety Instructions .................................................................... 1
1.1 General ..................................................................................... 1
1.2 Intended Use ............................................................................ 3
1.3 Operating Conditions and Computed Design of the Crane....... 7
1.3.1 General ..................................................................................... 7
1.3.2 Classification of the Crane ........................................................ 7
1.3.3 Classification of the Engines ..................................................... 9
1.3.4 Workplace Ergonomics ........................................................... 11
1.3.5 Load and Utilisation of the Crane ........................................... 11
1.3.6 Required Ambient Conditions ................................................. 13
1.3.7 Service Life ............................................................................. 15
1.3.8 Standards and Calculation Regulations .................................. 17
1.3.9 Dangers to Air Traffic .............................................................. 19
1.4 Safety Regulations ................................................................. 21
1.4.1 Organisational Measures ........................................................ 23
1.4.2 Selection and Qualifications of Personnel .............................. 25
1.4.3 Particular Hazards .................................................................. 27
1.4.4 Combination of Hazards with Combined Operation“of Two
or More Cranes ....................................................................... 39
1.4.5 Driving Operation .................................................................... 43
1.4.6 Crane Operation ..................................................................... 47
1.4.7 Power Supply Failure.............................................................. 65
1.4.8 When Assembling and Dismantling Crane Components ........ 67
1.5 Hand Signals .......................................................................... 73
1.5.1 General Hand Signals ............................................................ 75
1.5.2 Hand Signals for Working Movements ................................... 77
1.5.3 Hand Signals for Driving Movements ..................................... 79
2 Structure of the Mobile Crane

2.1 Overview ................................................................................... 3
2.2 Safety Signs ............................................................................. 5
2.3 Boom System ........................................................................... 7
2.3.1 Boom Lengths .......................................................................... 7
2.4 Serial Plates ............................................................................. 9
2.4.1 Serial Plate ............................................................................... 9
3 Cab
3.1 Operating Elements in the Driver's Cab ................................... 3
3.1.1 Operating Elements in the Driver's Cab ................................... 5
3.2 Monitoring Equipment ............................................................... 7
3.2.1 Monitoring Equipment in the Cab ............................................. 9
3.2.2 Monitoring Equipment in the Cab ........................................... 11
3.3 Symbols in Outrigger Control Box, Left-Hand Side ................. 13
3.3.1 Symbols in Outrigger Control Box, Right-Hand Side .............. 13
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Contents
4 Engine
4.1 Checks Before Starting the Engine ........................................... 3
4.2 Starting Procedure .................................................................... 5
4.3 Switching off the engine............................................................ 9
4.4 Jump Starting ......................................................................... 11
4.5 Automatic Engine Shutoff (Optional) ...................................... 11
5 Driving
5.1 Checks before Driving .............................................................. 3
5.2 General ..................................................................................... 7
5.2.1 Driving the Crane in Transport Condition ................................. 9
5.2.2 Driving with Axle Loads over 10 t or 11 t up to a Max. of 13 t . 13
5.3 Driving on the Construction Site ............................................. 15
5.4 Driving in Erect Mode ............................................................. 17
5.4.1 360o-Driving the Crane without Load ...................................... 19
5.4.2 Driving the Crane with the Main Boom Extension (7.1 or
13 m) Fitted ............................................................................ 19
5.4.3 Driving the Crane with Load (Travel Operation) ..................... 21
6 Transmission
6.1 Gear Lever ................................................................................ 3
6.1.1 Neutral Position “N” .................................................................. 5
6.1.2 Reverse Gear "R" ..................................................................... 5
6.1.3 Drive Position "D" ..................................................................... 5
6.1.4 Drive Positions "1" to "6" ........................................................... 5
6.2 All-Terrain Transmission (Optional) .......................................... 7
6.3 Starting ..................................................................................... 9
6.4 Stopping ................................................................................... 9
6.5 Driving on Downgrades .......................................................... 11
6.6 Procedure when the Crane is Stuck ....................................... 11
6.7 Gear Oil Information ............................................................... 13
6.8 Fault Codes ............................................................................ 15
6.9 Troubleshooting with the Fault Table ...................................... 17
7 Brakes
7 Braking System ........................................................................ 3
7.1 Service Brake ........................................................................... 3
7.2 Parking Brake ........................................................................... 3
7.3 Engine Brake (Sustained-Action Brake) ................................... 5
8 Steering
8.1 Steering during Road Travel ..................................................... 3
8.2 Independent Rear Axle Steering ............................................... 5
8.2.1 Steering Combinations ............................................................. 7
9 Differential Locks
9 Differential Locks ...................................................................... 3
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Contents
10 Hydraulic Suspension
10.1 Suspension Circuits .................................................................. 3
10.2 Level Adjustment ...................................................................... 5
10.3 Monitoring the Level ................................................................. 7
10.4 Locking the Suspension (Travel Operation) ............................. 9
10.4.1 Engaging Procedure ................................................................. 9
10.4.2 Disengaging Procedure .......................................................... 11
10.5 Height Adjustment .................................................................. 11
10.6 Raising the Axles .................................................................... 13
11 Outriggers
11.1 Instructions for Supporting the Crane on the Outriggers .......... 3
11.1.1 Support Pressure Display (optional) ......................................... 3
11.2 Arrangement of the Control Elements for the Outriggers .......... 5
11.3 Before Extending the Outriggers .............................................. 7
11.4 Procedure for Extending the Outriggers ................................... 9
11.4.1 Extending the Outriggers (Support Area 4 m x 5.95 m and
5.9 m x 5.95 m) ......................................................................... 9
11.4.2 Retracting the Outriggers
(for Driving the Crane in Transport Condition) ........................ 15
(for Driving the Crane in Configured Condition) ...................... 17
11.5 Permissible Ground Pressures ............................................... 19
11.5.1 Safety Distances from Slopes and Ditches ............................. 21
12 Parking
12.1 Leaving the Vehicle in Transport Condition .............................. 1
12.2 Leaving the Crane in Configured Condition and with
Outriggers Extended ................................................................. 1
13 Towing the Crane and Towing the Crane to Start

13.1 Towing the Crane to Start ......................................................... 1
13.2 General Towing Regulations .................................................... 1
13.2.1 Towing the Crane in case of Engine demage or defective
Automatic Transmission ........................................................... 1
13.2.2 Towing the Crane with Defective Distributor Gear
(4 x 4 Drive) .............................................................................. 7
13.2.3 Towing the Crane in the event of Engine Failure or Defective
Automatic Transmission (4 x 2 Drive) ....................................... 7
13.3 Towing the Crane Free on Soft Ground .................................... 7
14 Heating and Ventilation

14.1 Operating the Heating and Ventilation ...................................... 3
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Contents
15 Safety Equipment
15.1 Load Limit Device Console (LMB) ............................................ 3
15.1.1 Operating Elements .................................................................. 3
15.1.2 Display Contents During Crane Operation ............................... 5
15.2 Operating the Load Limit Device .............................................. 9
15.2.1 Setting the Screen Contrast .................................................... 11
15.2.2 Displaying the Fault Codes (4) ............................................... 11
15.2.3 Data Logger (Optional) ........................................................... 11
15.3 Hoist Limit Switch ................................................................... 11
15.3.1 Assembling the Hoist Limit Switch .......................................... 11
15.3.2 Caution, Function Test of the Hoist Limit Switch .................... 13
15.4 Troubleshooting ...................................................................... 15
15.4.1 Fault Codes ............................................................................ 16
15.5 Service and Maintenance ....................................................... 17
15.6 Bridging the Limit Switch ........................................................ 19
15.7 Bridging the Load Limit Device ............................................... 21
16 Notes on Operation
16.1 General Notes on Operation ..................................................... 1
16.2 Raising a Load Using Several Cranes ...................................... 7
16.3 Checking the Safety Measures ................................................. 9
16.4 Operating Information on Pilot Control.................................... 11
16.5 Emergeny Control ................................................................... 13
17 Slewing
17.1 Preparations for Slewing ........................................................... 3
17.2 Slewing the Superstructure ....................................................... 5
17.3 Slew Speeds ............................................................................. 5
17.4 Braking the Superstructure ....................................................... 7
18 Telescoping
18.1 Telescoping the Main Boom ..................................................... 3
18.1.1 Extension Length of the Telescopic Sections ........................... 5
18.1.2 Control Levers for Telescoping ................................................. 7
18.2 Telescoping Procedure ............................................................. 7
18.2.1 Telescoping without Load ......................................................... 7
18.2.2 Telescoping Loads ................................................................... 9
18.2.3 Telescoping Speeds ................................................................. 9
Stand: 26.KW/94
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Contents
19 Luffing
19.1 Raising and Lowering the Main Boom ...................................... 3
19.2 Luffing Speeds .......................................................................... 3
20 Hook Operation "Hoist"

20.1 Raising and Lowering the Load ................................................ 3
20.2 Hoist Speeds ............................................................................ 5
21 Main Boom Extension

21.1 Fitting the Main Boom Extension .............................................. 3
21.2 Folding the Main Boom Extension ............................................ 3
21.2.1 Folding the 7.1 m Basic Boom out of the Transport Position
into Operating Position ............................................................. 5
21.2.2 Folding the 13 m Main Boom Extension from the Transport
Position into Operating Position .............................................. 13
21.2.3 Folding the Main Boom Extension ( 7.1 m or 13 m) from 0o
into the 30o Operating Position ............................................... 19
21.3 Fitting Procedure .................................................................... 23
21.4 Boom Point (Hall Point, Option) .............................................. 25
21.4.1 Lift loads with a main boom angle of 24-44o
(medium length boom point) ................................................... 25
21.4.2 Lift loads with a main boom angle of less than 24o
(short boom point)................................................................... 27
21.4.3 Lift loads with a main boom angle of greater than 44o
(long boom point) .................................................................... 27
21.4.4 Lifting loads ............................................................................ 29
21.4.5 Boom Point in the Transport Condition ................................... 29
21.5 Hook (15t) for boom point (Option 1) ...................................... 31
21.5.1 Double Load Hook (15t) for boom point (Option 2) ................. 35
21.6 Searcher Hook (Option) .......................................................... 39
21.6.1 Operating with the Searcher Hook .......................................... 39
22 Reeving
22.1 Rope Equipment and Reeving .................................................. 3
22.1.1 Reeving the Hoist Rope on the Main Boom Head .................... 5
e25-1000-193 5/5
Manufacturer’s Specifications
Manufacturer’s Specifications
The operating, lubricating and maintenance instructions included

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

(as per DIN 15001,15018 T3)
Crane type AC 75 / AC 25
Construction number 89
Maximum load 25 t
Manufacturer Terex−Demag
e25−1001 1/1
Foreword
Foreword
For you,
as owner of a crane manufactured by us, we have produced

this manual, comprising the most important instructions for its
operation, lubrication and maintenance.
These instructions should enable you to familiarise yourself with
your crane and to use the operating applications as intended.
The instructions must always be kept to hand at the operating
site.
The complete manual comprises 3 parts:

Part 1 - Operating Instructions for the Crane
Part 2 - Lubrication and maintenance instructions for the crane
Part 3 - Various
Please note that the information contained in this manual corre

sponds to the state of machine engineering at the time the
literature was drawn up. Deviations in the technical specifications,
figures and dimensions are therefore possible.
In such cases we make every effort to bring your

documentation up to date by sending you modified pages.
But we must ask for your kind cooperation. For it is only you
who can ensure, that such modifications will be included into
your original documentation.
This does apply also and especially for the part of the
documentation that is permanently with the crane.
e25-1002 1/13
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Foreword
Pass this manual on to your crane operator and driver and

to the specialised personnel responsible for the
maintenance of the crane with the request that they read the
instructions carefully before the crane is operated for the first
time and later at regular intervals.
Important instructions are included which ensure that the
crane is operated safely, correctly and economically.
Observing these instructions will help to avoid dangerous
situa tions, repair costs and down-times as well as to increase
the reli ability and service life of your crane.
Periodic, preventive inspection and maintenance are the

surest way to keep your crane in good operating order. The
early recog nition and elimination of minor irregularities and
the immediate re placement of worn and damaged parts
prevents downtimes and the associated costs. Replace any
damaged signs or symbols.
You will appreciate that we can accept no claims for damage

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

or if you have further sugges-tions and hints, please contact:
Terex - Demag GmbH & Co.KG

Abt. 2135
Postfach 1552
D-66465 Zweibrücken
The editors would welcome your involvement.

"Putting experience into practice"
e25-1002 3/13
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Foreword
Handover of the crane
The crane is delivered to you from the works ready for

operation, and is already supplied with fuel and hydraulic oil.
All lubrication points have been greased.
If the crane is delivered from the works with a protective coating

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

Cold cleaners, e.g. Allpur 150 X or Purtex 65
Stream spray gun
Before commissioning
you should inspect the crane thoroughly together with our

service engineer.
Spare parts
When ordering spare parts, please refer to the first page of our
spare parts catalogue:
"Instructions on using the catalogue".
Use only original spare and wear parts authorized by the crane
manufacturer.
e25-1002 5/13
WARRANTY
We warrant new products sold by us to be free of defects in material and workmanship under the following conditions,
unless otherwise provided in the sales contract:
1. The warranty period is defined by the sales contract.
2. We repair or replace at our discretion parts or components which we recognize to be defect. Claims for
diminution or redhibition of the sales contract are excluded.
3. If a technical problem arises during warranty period and cannot be solved within 6 months after expiration of
warranty by no fault of TEREX-DEMAG, the claim will lapse.
4. TEREX-DEMAG has to be notified in writing about all defects or damages before the end of the warranty period.
5. Adequate time to perform the required work and to supply spare parts in cases of warranty must be granted.
6. Repairs within the warranty period will be carried out during regular working hours. Expenses for overtime, work
during weekends or holidays will be invoiced if such overtime has been expressly requested by the customer.
7. The warranty for parts repaired or replaced expires with the warranty period for the equipment.
8. Parts replaced during the warranty period become our property.
9. Correct maintenance according to the maintenance manual must be certified.
10. Repairs and interventions, not effected by us resp. staff authorized by us or the use of spare parts not delivered
by TEREX-DEMAG during the warranty period results in a loss of warranty.
11. The right of claim under warranty expires for components dismantled without our consent.
12. Our warranty is limited to maintaining a serviceable condition of the product. Additional costs, such as
transport, customs duty, auxiliary labour etc. are not borne by us.
13. We do not accept liability for consequential damage such as economic loss, compensation, rental of replaced
machines or lost profit resulting from a failure during the warranty period.
14. Damage caused by misuse - including continued operation after recognizing a defect, improper operation and
maintenance, use of unsuitable fuel, oil etc. - as well as by disregard of the operation manual and the lubrication
and maintenance manual are not included in the warranty. The same is valid for damage caused by normal wear.
15. Operation not corresponding to the intended purpose or the use in combination with additional equipment not
released by us result in a loss of warranty.
16. We do not accept responsibility for the commissioning or use in any country other than the original country of
destination (road permit, standards, etc.).
17. TEREX-DEMAG reserves the right to change or modify design or specification of their products. This does not
include subsequent claims for modifications of products already sold but still in warranty.
18. The above terms of warranty apply for all sales of TEREX-DEMAG. Any other agreements are valid only if
confirmed in writing by the general management of TEREX-DEMAG.
Z 49 606e
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Foreword
Service
Please contact the service department if you have any

questions about your crane. Always quote the type designation
and construction number of your crane in all correspondence.
Tel: (49)06332/83-0
Fax: (49)06332/16715
E-Mail: info@terex-demag.com
Modifications to the crane
We would point out that any modifications to the crane (e.g. the
purchase of boom parts, etc.) may invalidate the information in
these operating instructions or make it insufficient.
After modifications or repairs to parts which affect the safety of

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

tions which you carry out or have carried out on your crane.
Warranty
(Z 49 606e)
Observe here the information on the opposite page.
e25-1002 7/13
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Foreword
...and you can find your way around this manual as follows:
From the example given here, you can see how fast and
accurately I can arrive at the required information.
WHAT do I want to know ?
I would like to know for instance what control elements are pro
vided for outriggers.
WHERE do I find the information required above ?
The complete manual comprises 3 parts:

Part 1 - Operating Instructions for the Crane
Part 2 - Lubrication and maintenance instructions for the crane
Part 3 - Various
These parts are divided by index sheets. I need Part 1

because the outriggers are part of the crane chassis.
1. I look for the index sheet "1" (for Part 1), and open the
crane chassis operating instructions at this point and find
the Contents of Part 1.
2. I glance over the bold headings of the sections until I

come to Section 11, Outriggers.
3. In Section 11 I then find "Arrangement of the Control

Elements for the Outriggers" under 11.2.
The page details on the right-hand side of the page refer
to the page number within the section.
e25-1002 9/13
Z 26 350
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Foreword
HOW can I find the specified page in the corresponding

chapter?
1. I take the pages of Part 1 and flick through the pages as

shown in (Z 26 350).
Whilst doing this, I always keep the top, right-hand edge
(1, Z 26350) in view.
As soon as the required section number appears, I stop
flicking through the pages.
The name and number of the section are on the top right-hand
edge (1, Z 26 350) of each page.
2. Then, with the help of the page number on the bottom

right-hand edge (2, Z 26 350), I decide whether I must
flick back wards or forwards in order to reach the page
number re quired.
The page number within the section is given on the bottom

right-hand side (2, Z 26 350) of each page. This number is
given along with the total number of pages in the section. This
means, for instance, that 12 is given as the page number in the
contents and the page itself is numbered 12/125. This makes
for better orientation within a section.
Please note that this option of fast and accurate access

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

"Note" and "Environment" are used in these operating
instructions as follows:
DANGER !
"Danger" is used for operating procedures where failure

to observe the prescribed assembly sequence or the
stipulations made may result in the death of or injury to
persons.
CAUTION !
"Caution" is used for operating procedures, mounting se

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

pro cedure or to draw attention to further information.
ENVIRONMENT:
This symbol is used when an action serves to protect the
environment or avoid unnecessary pollution.
Information such as „left“ and „right“ of the crane must always

be understood as looking in the direction of travel.
e25-1002 13/13
Safety instructions 1
1 Safety Instructions
1.1 General
This section ”Safety Instructions” provides a compact and gene-

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

work can be found in part 2 of this documentation.
The term ”operating instructions” refers to the operating instruc-

tions and the lubrication and maintenance instructions.
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1.2 Intended Use
The crane is designed for lifting loads.
It is prohibited to transport people with personnel carrying

equipment!
In many cases, there have been serious injuries when peo-
ple have been transported using personnel carrying equip-
ment (or even on the hook or on loads). In these cases, they
have no control over crane movements and are not protec-
ted against bumps or falls. Even the smallest of errors can
have fatal consequences.
In exceptional cases (for example, the use of personnel ca-
ges which were not supplied by the crane manufacturer),
please consult the responsible authorities / agencies con-
cerning relevant permits, fixed special conditions, safety
regulations, additional tests and demands on the crane and
similar issues. In Germany, the authority / institution con-
cerned in the first place is the Berufsgenossenschaft.
The use of such additional devices is then the responsibi-
lity of the crane operator following the valid safety and acci-
dent prevention regulations!
Risk to life and limb!

It is expressly forbidden to use the crane for jumps with
rubber ropes (bungee jumping)!
Using the crane for such jumps represents a misuse of the
crane and entails extreme danger for life and limb!
The crane is designed exclusively for assembly operation.

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

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

Crane
1.3.1 General
The crane has been constructed using state of the art technology
and in accordance with recognised safety regulations. Neverthe-
less, its use can lead to hazards for the life and limb of the opera-
tor and third parties, and/or damage to the machine and other ob-
jects.
Use the crane only when it is in full working order and only for its
intended use, paying attention at all times to safety and potential
hazards, and in observance of the operating instructions. In parti-
cular have any malfunctions which might impair safety rectified
immediately.
The term ”operating instructions” refers to the operating instruc-

tions and the lubrication and maintenance instructions.
1.3.2 Classification of the Crane
The crane is classified as follows (ISO 4301--2 and FEM 1.001):

-- Operating class => U2
-- Collective class => Q2
-- Crane group => A1
All important components of the crane are designed and manu-

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

tion require the permission of the manufacturer and normally lead
to a reduction in the lifting capacities.
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1.3.3 Classification of the Engines
The power units are also classified in accordance with ISO

4301--2 and FEM 1.001. They have been calculated and desi-
gned based on specific operating conditions which are laid down
in European standards.
The winches of your crane are classified as follows:

Power unit group: M........
Load collective: Q....... (L.......)
Factor of the load collective: km = ..........
The valid values can be taken from the table ”Monitoring the Win-
ches” in the crane log book.
The classification of the power units is the base for their assess-
ment during the annual inspection (see part 2, Maintenance and
lubrication instructions).
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1.3.4 Workplace Ergonomics
The following noise levels can occur near the crane operator’s
seat in the crane operator’s cab:
-- Engine at idle speed (550 rpm) < 75 dB(A)
-- Engine max. revs without load (2750 rpm) < 85 dB(A)
-- Engine speed at highest engine torque
without load (1300 rpm) < 80 dB(A)
The measurements were taken at the ear of the crane operator

using a sound level meter. The A--valued permanent sound level
at the driver’s seat, as measured over the shift period of 8 hours,
is below 70 dB(A). For this purpose, measurements were taken
during operation on construction sites using dosimeters.
The crane operator is protected against mechanical vibrations by

means of a tilting seat which can be adjusted to his weight. The
crane operator’s seat offers infinite adjustment options for the
seat height and tilt, backrests and armrests. It is therefore possi-
ble to select the optimum working position for every driver.
The weighted effective value of acceleration which the upper

body extremities are subject to, is below 2.5 m/s2.
The weighted effective value of acceleration, which the body
(feet and seating area) is subject to, is below 0.5 m/s2.
Both values are therefore below the statutory specifications.
1.3.5 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the configu-
ration, boom length and working radius. It is specified by the
crane manufacturer in the load capacity tables.
The load capacity tables supplied with the crane specify limit va-
lues which may not be exceeded.
The loading capacity limits of the winches are reached in principle
when the rope force has reached its maximum permissible value.
Low loads with a small amount of reeving can place the winch un-
der just as much load.
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1.3.6 Required Ambient Conditions
The permitted ›‹temperature range for operating the crane is

--20°C to +40°C, if the maximum or minimum temperature occurs
only a few days a year›‹.
Optional equipment for other operating conditions can be sup-

plied.
The crane can be operated under full load up to a height of 1000

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

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

larly. Dust concentration levels of up to 35 mg/m›‹3 are permitted
for a short period of time.
Observe the corresponding regulations in the maintenance and

lubrication instructions, part 2.
With an oncoming wind the crane operator must follow the rules
outlined in the operating instructions. Refer to the operating in-
structions, section 16 ”Working instructions”.
The ground, on which the crane is supported -- or driven with load

-- must be strong enough to support the load.
Use of the crane in a potentially explosive atmosphere or in

operating conditions where combustible gas can be drawn in is
only permitted following corresponding conversion.
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1.3.7 Service Life
Classification of the crane is based on a total operating life (ser-

vice life) of 20 years under the following conditions:
-- the crane is operated as an erection crane.
The load capacity tables that are authorised for the crane are
based on assembly operation only. General cargo handling
or grab operation can only be permitted following express
permission from the manufacturer under suitable condi-
tions.
-- the entire number of the crane’s load cycles in this time is less
than 32 000 (e.g. 5 -- 10 strokes / day on 200 days / year).
A “LOAD CYCLE” encompasses processes which begin when a

load is raised and end when the crane is ready to raise the next
load.
-- The type of load (the load collective) of the entire crane does
not indicate any proportions which are less favourable than
the following:
∗ for 1/10 of the load cycles the crane is placed under max.
load
∗ for 4/10 of the load cycles with 44 % of the max. load
∗ for 5/10 of the load cycles with 16 % of the max. load
“Load” in this context refers to the sum of the load, load--handling

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

ried out properly, the theoretical service life can be more than 20
years.
Harder operating conditions naturally lead to a reduction in the
service life.
For the winches, however, the rules for calculating the re-
maining theoretical service life must be observed, as outli-
ned in part 2, Lubrication and Maintenance Instructions, sec-
tion 1.8.
Some components (e.g. ropes) are not designed for the en-
tire service life of the crane, but must be replaced after a cer-
tain amount of time.
Information on this can be found in the lubrication and main-
tenance instructions for the crane.
1.3.8 Standards and Calculation Regulations
The specifications contained in section 1.3.7 on service life, loa-

ding and utilization of the crane are taken from the European
standards ISO 4301--2 and FEM 1.001, FEM 5.004 and
ISO 9927--1.
The base for the strength proof of the framework, the compo-
nents and the crane components are the standards: FEM 5.004,
ISO 4301--1, ISO 4301--2, FEM 1.001 and ISO 4308--2.
The ropes are selected and calculated in accordance with ISO

4308--2.
All required proofs of stability (buckling and bending) were car-

ried out in accordance with DIN 18800. The minimum safety fac-
tors are taken from FEM 5.004.
The proof of standing stability for the crane is based on ISO 4305.
For countries in which different standards and calculation regula-

tions apply, special calculations or proofs can be carried out.
If required, these calculations must be specially ordered by the
crane operator. This does not alter the operating conditions for
the crane. If necessary the lifting capacities must be limited.
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1.3.9 Dangers to Air Traffic
As considerable heights are reached when the crane is operated,

this can lead to air traffic being endangered.
For this reason the crane may only be operated in the vicinity of
airports, landing areas and flight safety facilities (so--called pro-
tected or safety zones) following permission from the correspon-
ding authorities (for example in Germany -- Landesluftfahrtbe-
hörde, Wehrbereichsverwaltung, Deutsche Flugsicherung
GmbH).
You can obtain more detailed information from:

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

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

procedures only the crane operator is allowed on the crane
(and he must be in the crane operator’s cab). Remaining
personnel must remain clear of the hazardous area on and
around the crane.
The only exception to this rule is when the counterweight
is being fitted and when a load is being attached or released
with the help of a fitter.
When stacking the counterweight the person attaching the

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

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

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These means of identification should be in a distinctive co-
lour and where possible of an identical design and must be
exclusive to the fitter.
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1 12 3 9 7 3 12
10
1 11 2 7 5 6 8 1
12 3
1
1 7 5 6 1
Z 50 310
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1.4.1 Organisational Measures
In addition to the operating instructions, applicable national re-

gulations and any other binding regulations on the prevention of
accidents and protection of the environment must be followed
and passed on. These should be added to the operating instruc-
tions.
Such stipulations may involve, for example, handling hazardous

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

tion regulations valid in the country and on the operating site
where the crane is in use, the recognised technical regulations
pertaining to safe and correct working procedures must also be
observed.
The operating instructions should be supplemented by any other

instructions that are necessary, including supervisory and repor-
ting duties for any special operating occurrences, for example
with regard to work organisation, operating procedures, alloca-
ted personnel etc.
(Z 50 310, similar depiction)
Keep a complete and legible set of all safety and hazard instruc-
tions on the crane at all times.
Safety guards on the crane must not be opened or removed du-

ring crane operation.
Provide instructions on the location and use of fire extinguishing

equipment.
The fire extinguisher supplied is situated in the storing box of the

crane chassis. The lid of the storing box is marked by a stick--on
label: ’Fire extinguisher’.
The first aid kit (and any other accessories according to national
motor vehicle safety standards) must be taken from the range
supplied by the crane operator and kept in the crane operator’s
cab.
In case of poor visibility or darkness, the immediate area in front

of the crane operator’s cab, the outriggers and the winches must
be illuminated by the spot lights, which are fitted on the crane
(rear outside lighting, front outside lighting, side outside lighting).
The side outside lighting can be switched from the crane opera-
tor’s cab or from the driver’s cab.
The extended area (load, load path, slewing range, driving route
etc.) is to be illuminated using suitable equipment, separate from
the crane. The responsibility for this belongs to the crane opera-
tor.
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1.4.2 Selection and Qualifications of Personnel
In order to operate a crane optimally within its proper parameters,

the crane operator and personnel working on maintenance, as-
sembly and dismantling must be properly qualified and trained.
The crane operator / owner is responsible for providing this trai-
ning.
Use only reliable, trained and/or experienced personnel for work

on and with the crane.
Make sure that only authorised personnel are allowed to carry out
work .
Pay attention to the minimum working age.
Clearly specify all areas of responsibility:

− for operation, configuration and maintenance.
− for machine operators, also pertaining responsibilities con-
cerning traffic regulations. Allow him to refuse instructions
from third parties which contravene safety regulations!
Personnel who are still being trained and instructed in the use of
the crane, or who are completing a general apprenticeship, may
only be allowed to work on the crane under the constant supervi-
sion of an experienced member of staff.
Personnel who are authorised with the activities on the crane

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

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

cal specialists.
If these measures cannot be carried out, a sufficient safety clea-

rance must be maintained between the crane (and hoist rope, lif-
ting tackle, hook block, load) and current--carrying lines. Danger
to life and limb!
Keep a clearance of at least 10 m. If this is not possible, you must
obtain information on required minimum safety distances from
the electric power company responsible.
With extremely long boom equipment, these safety clearances

are very difficult to judge. To be on the safe side, increase the sa-
fety clearance to 20 m.
The safety clearance must still be available for unfavoura-

ble crane or load positions.
Allow for possible swinging of the load or swinging out of
the free line as a result of the wind.
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If, however, the crane accidentally comes into contact with high
voltage power lines:
− Bring the crane out of the danger zone: drive out, swing out,
adjust boom!
If this is not possible:

− Do not leave the crane or crane operator’s cab.
− Warn anyone in the vicinity against approaching or touching
the crane.
If the crane operator leaves the crane or if another person

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

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

ters
Charging
It can cause dangerous electrical charging if track--free mobile

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

-- discuss the problem with the operator of the transmitter
(maybe switch off the transmitter).
-- Connect the track--free mobile crane to ground.
In order to protect the rotating connection the grounding ca-
ble must be fastened directly to the superstructure of the
crane or to the boom.
Risk of injury!
If the prescribed measures are not taken the persons con-
necting the charged components to ground will be violently
and painfully electrified at touch.
Interference with the crane electrics
In addition, the crane electrics, especially the load limit device,

cannot be presumed to be functioning safely, depending on the
strength and frequency of the transmitter.
The risk of the load limit device being influenced by high--fre-

quency radiation is minimised by state of the art technology
(shielding). However, it cannot be fully discounted, especially un-
der extreme circumstances.
This is especially valid if the crane is used in the close vici-

nity of high--frequency radiation sources (e.g. radar sta-
tions, radio transmission stations, radio and television sta-
tions).
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Lightning
If storms are approaching, if possible lower the crane equipment

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

the crane or its immediate vicinity during the storm. Warn
any other people in the vicinity of the crane.
If there is a fear that lightening has struck, the general functions

of the crane must be checked. It is especially important that the
following is checked:
-- Electrics in general, especially:
∗ Load limit device; if it is defective a fault message appears
on the display.
∗ Limit switches; to see if they are functioning.
∗ inductive proximity switch for function.
-- Luffing and outrigger cylinder with a visual check for external
damage caused by voltage flashovers or fusing.
By retracting and extending the relevant cylinders several ti-
mes, check if there are suspected internal leaks due to dama-
ged seals.
-- Hoists, especially for damage to ball and roller bearings.
1.4.3.2 Gas, Dust, Steam, Smoke
Only operate combustion engines and fuel--operated heaters in

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

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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Z 29 800 Z 29 801
Z 29 802
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1.4.3.3 Crushing / jolting

(Z 29 800)
For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating in-
structions.
-- Hook block / load when rotating the superstructure
1.4.3.4 Entanglement / Dragging In

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

(Z 29 800)
structions.
-- when telescoping the main boom in and out
-- when lowering the main boom on the foot bearing of the su-
perstructure frame
-- when slewing the superstructure
-- when extending and retracting the outriggers and cylinders
-- when releasing the suspension block after the supporting the
crane on outriggers near the wheels
-- near the hook block or the load during uncontrolled move-
ments
-- when stacking the counterweights
-- when fitting and removing hoist 2
-- when fitting and removing the main boom or the superstruc-
ture
-- when tilting the crane operator’s cab
-- when fitting and removing the additional equipment
∗ HD attachment
∗ Main boom extension
∗ Laterally hinged head sheave
1.4.3.6 Danger Due to Slipping, Tripping, Falling

(Z 29 803)
Only the catwalks and ladders described may be used. These

provide sufficient places to hold on to and the catwalks are desi-
gned to prevent slipping (e.g. sanding, checker plate etc.).
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1.4.4 Combination of Hazards with Combined Operation

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

collisions.
The operating company or its representative must:
-- specify the working sequence in advance.
-- make sure that the crane operator can communicate clearly!
If the crane operator does not have spoken or visual contact, sui-
table measures must be taken, e.g. use of radios, spotters/
banksmen etc.
If spotters are used, suitable signals must be agreed between the

spotters and the crane operators. In this regard, please refer to
section 1.5 of this chapter ”Safety Instructions”.
Crane operators must operate the crane in such a way that un-
controlled movements and subsequent collisions are avoided.
They must receive suitable training and instructions to this end.
1.4.4.2 Several Cranes Raising a Load Together
If a load is to be raised by more than one crane, the operator of

the crane or his representative must first set up a working proce-
dure and appoint a supervisor, in whose presence the operations
are carried out.
The most important requirement for this type of operation is, ho-
wever, careful planning, covering the following points:
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∗ The mass (the weight) and the centre of gravity of the load
must be known exactly.
∗ The load must be shaped in such a way as to avoid extra ha-
zards during the lifting procedure.
∗ The other cranes which are taking part in the operation must
have nearly the same lifting capacity.
∗ Additional dynamic load effects when the load is raised and
set down and load effects as a result of environmental in-
fluences (e.g. wind) must be allowed for during planning.
The actual danger is during joint lowering of the load. Using

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

turer should be consulted to see whether the crane can be fitted
with any additional safety devices (e.g. limiters) or whether the lif-
ting capacity needs to be restricted additionally for the operation
in question.
Avoid pulling a load sideways or at an angle!
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1.4.5 Driving Operation
1.4.5.1 Before Driving
Check the effectiveness of brakes, steering and signal and illumi-

nation equipment daily; if a crane is only used occasionally, it
must be checked every time before it is operated (or driven).
Before driving the crane, always make sure that there is no--one
in the danger zone of the crane. If necessary give a warning sign
(actuate the horn before starting the engine for example! ).
If you do not have an overview of the danger zone from the crane
operator’s cab, you must employ a banksman (see section 1.5).
This also applies if normal voice communication is not possible
as a result of an increased noise level.
Keep the windows of the crane operator’s cab clean to ensure

good visibility!
Make sure that all accessories are stored safely and cannot
cause an accident.
The crane may only be operated, if the control panels of the ou-
triggers are closed and locked.
When driving on public roads, highways and precincts observe

the relevant traffic safety regulations and make sure that the
crane is properly equipped for road travel.
Adjust the steering wheel in a suitable driving position!
In the case of the axle loads a differentiation is made between

the technically possible load (technical driveability) and the load
permitted in accordance with the road traffic regulations.
”Technical driveability” is only permitted on construction sites or
private roads (with the exception of countries which permit axle
loads over 12 t).
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Axle loads above 12 t are not permitted in countries which have

regulations in accordance with the EEC (or reduced axle loads)
for road travel. If the crane is driven with axle loads above 12 t,
the crane operator carries full responsibility. All components and
systems are designed and calculated for a 12 t axle load at maxi-
mum speed.
If the 12 t axle load is exceeded, the life expectancy (service life)
of the axles, wheel hubs, bearings, suspension cylinders and
brakes is reduced. In particular wear to the brake linings and the
risk of the brakes overheating and fading are increased.
The brake delay for the brakes (EEC: 50 %) is reduced in propor-
tion to the increase in axle load or to the transportation weight of
the crane.
1.4.5.2 During Travel
When driving on the road, in the transport position the boom must
be resting on the travel rest and the connecting device must be
fitted between the main boom head and basic case!
When driving on inclines, always adapt the speed of the crane to

the conditions. Never shift gear once on the slope, but change to
a lower gear before reaching the slope.
When passing under bridges, tunnels, overhead power cables

etc. always make sure that there is sufficient clearance!
When towing, follow the towing regulations with respect to the

prescribed transport position, permitted speed and distance tra-
velled.
Passengers are not allowed !
In case of emergencies, the swivelling front window may be used

as an exit.
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1.4.6 Crane Operation
1.4.6.1 Before Crane Operation
Before crane operation, check the load conditions again: are the
mass (the weight) of the load and the operating procedure known
and are, for example, lifting capacity, working radius and hoist
height sufficient? Compare the values with the load capacity ta-
ble.
Check whether outside conditions such as wind, snow, poor visi-

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

when supporting the crane on outriggers.
For more detailed information, see section 16 ”Working Instruc-

tions” and section 11 ”Outriggers” in these operating instructions.
Maintain a safe distance between the supported crane and slo-

pes and ditches.
For more detailed information, see section 16 ”Working Instruc-

tions” in these operating instructions.
Before commencing work, familiarise yourself with the operating

site and its surroundings! The working environment includes, for
example, obstructions in the operating and traffic areas, the
load--bearing capacity of the ground and the necessary safety
precautions required to cordon off the construction site from pu-
blic traffic areas.
To operate the crane, unhindered sight of the crane, load and
load path must be ensured.
Carry out the necessary measures to ensure that the crane is

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

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

equipment, limit switches and overload cut--off device daily, for
cranes that are seldom used -- every time that they are operated.
Before commencing work with the crane make sure that no--one
is in the hazardous area. If necessary give a warning sign (ac-
tuate the horn before starting the engine for example! ).
As oil can be emitted during maintenance and assembly work,

suitable collecting vessels and binding agents must be kept re-
ady.
If necessary or required by the regulations, personnel must use

personal protective equipment (i.e. protection against falling, sa-
fety clothing, goggles, face mask or similar items) !
Remember that protective equipment does not offer 100%

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

work. If a load that is attached to the crane is released from
its previous connection to other parts and is too heavy, the
crane will be unavoidably destroyed or will tip over, regard-
less of the load limit switch.
When dismantling hollow components (pipelines, cement si-
los etc.) allowance must be made for the weight of possible
residues inside these components.
When determining the size of the components that are to be

dismantled, never utilise the full values allowed in the load
capacity tables of the crane, but allow for a safety buffer.
Select the correct boom length and reeve the hoist rope in accor-
dance with the individual load case.
Select the lifting tackle in accordance with the weight of the load,
the type of attachment and the angle of inclination.
Only hook blocks supplied by the crane manufacturer may be

used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.
Pay attention to the rules and regulations for working with load
handling equipment (attachment ropes etc.). Never use lifting
tackle if there is any doubt as to its lifting capacity. Check to make
sure that the lifting tackle is in perfect condition.
Set the steering wheel to the steepest position so that you have
sufficient space during crane operation.
The outriggers should be operated and adjusted using the con-

trols in the crane chassis (see section 11).
The outriggers may only be retracted and extended from the
crane operator’s cab if the crane is set to superstructure opera-
tion and should only be applied in exceptional cases.
Take note that the outriggers may only be operated when the
crane operator has a clear view, either directly or via a mirror.
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1.4.6.2 During Operation of the Crane
When carrying out power--driven working procedures

(raise / lower load) only the crane operator is allowed on the
crane (and he must be in the crane operator’s cab). Remai-
ning personnel must remain clear of the hazardous area on
and around the crane.
The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work immediately if persons fail to leave the hazardous area
in spite of the warning.
The crane operator may only start movements if he has good visi-
bility of the hazardous areas. In case of poor visibility suitable per-
sons must be selected as spotters and must be instructed on the
correct signals before commencing work (see section 1.5).
This also applies if normal voice communication is not possible
as a result of an increased noise level.
Keep the windows of the crane operator’s cab clean to ensure

good visibility!
In order to safeguard immediate response to changing ambient

conditions, it is prohibited to switch off the drive of the crane and/
or to leave the crane operator’s cab when a load is attached!
An exception is only permitted in emergency situations. To

avoid hazardous situations, in the final instance the drive
source (diesel engine) can be switched off using the emer-
gency off button in the crane operator’s cab. First, where
possible, any movements which have been started should
be completed using the control lever.
Before raising a load, you must always make sure that the hook
block is positioned vertically over the load’s centre of gravity.
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The crane may only be operated (superstructure operation), if the

control panels of the outriggers are closed and locked.
The erected crane without load may only be left without the su-
pervision of a trained crane operator if certain conditions are met
(see operating instructions, section 12 ”Parking”).
Conveying of persons with the load or the load lifting tackle is pro-
hibited!
The crane may only be accessed and left following agreement

with the crane operator and only when the crane is at a standstill .
Observe all safety and hazard instructions on the crane !
Avoid any type of action that could possibly impair the safety of
the crane (for example that may reduce the stability of the crane)!
Never slew loads over people.
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Only start the crane engine from the driver’s seat. Only actuate
the control lever from the crane operator’s cab.
Keep the control lever close to hand as long as there is a load sus-
pended on the crane or a crane is driven!
To prevent the unintended activation of crane movements, both

control levers are equipped with an additional button (deadman’s
button).
The crane movement can only be carried out as long as one of
these buttons is pressed.
It is only permitted to activate (press or release) the dead man
button in the control levers as well as the limit switch bridging in
the instrument panel if the corresponding control lever is in “neu-
tral position” and/or the initiated working movements has been
completed.
RISK OF ACCIDENTS!
Actuation of one of these buttons when the control lever is
fully deflected leads to an abrupt activation or braking of
the corresponding movement.
For all crane movements, pay particular attention to the load, for
unladen operation the load--handling device, and the boom tip !
Also take the swinging--through radius of the counterweight or si-
milar items into consideration!
Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision.
The load must never come into contact with the framework of the
crane (boom system, superstructure, crane chassis, outriggers
etc.).
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Oblique pulling and dragging of loads is prohibited for operation

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

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

diately and secure it. Have any faults rectified immediately !
Make sure that the crane equipment is switched on and off and
that the indicator lights are observed in accordance with the ope-
rating instructions!
In case of poor visibility and/or darkness, switch on the outside

lighting! The inside lighting should be switched off to enable pro-
per sight of the load and the immediate environment of the crane.
Always carry the operating instructions in the crane, ready at

hand!
Make sure that all personnel are conversant with fire reporting
and fire fighting equipment and procedures!
Pay attention to the weight and surface area of the load exposed
to the wind.
Loads that are in water are lighter for the crane than those in air
(due to buoyancy). When the load leaves the water, it becomes
heavier. If this results in the crane being overloaded the load limit
device would be triggered.
There is a risk to the lifting tackle, however, if this is not measured
for the actual load weight.
40--1--1010B_en 59/79
1
60/79 40--1--1010B_en
Set the load limit device in accordance with the details of the sup-
plied load capacity tables!
Observe the permitted wind speeds!
The superstructure may only be slewed when the crane is sup-

ported on outriggers. Note that slewing is only permitted for cer-
tain crane configurations (e.g. with regard to outrigger support
area, counterweight etc.). Always observe the specifications of
the load capacity tables.
Slewing of the superstructure in the overload range (load limit de-
vice has shut down) is generally prohibited.
In an emergency the wide--opening front window can be used as

an exit.
40--1--1010B_en 61/79
1
62/79 40--1--1010B_en
1.4.6.3 Following Crane Operation
When you leave the crane:

∗ the load must be detached from the crane hook or set down
on the ground.
∗ the engine must be switched off!
∗ the heating must be switched off.
∗ the parking brake must be closed.
∗ the crane must be secured to prevent unauthorised use and
unintentional movement.
If the crane is parked on steep ground, the travel gear must be

additionally secured with chocks, the slew brake applied and the
boom secured.
Lock all control stands with a lock if they are not currently being
used.
When parking the crane pay attention to the permitted wind

speeds (also for the time when the crane is at a standstill). If ne-
cessary telescope in and set down the boom.
40--1--1010B_en 63/79
1
64/79 40--1--1010B_en
1.4.7 Power Supply Failure
General
If the power supply fails, all movements are stopped. An uninten-

tional restart is not possible. When the diesel engine comes to a
standstill, the driven hydraulic pumps also stop. The oil which is
currently in circulation also comes to a standstill. As soon as the
control pressure reaches zero, all actuators return spring--loaded
to the zero position, regardless of the position of the pilot control
lever.
In the hydraulic circuits which are directly relevant to safety, there

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

seen to lower a load that is on the hook. In this case, the crane
must either be supplied by an optional emergency control device
or customer services must be contacted.
If hoses or pipes should burst, therefore, there will be no dange-

rous crane movements as a result.
In addition, in the case of a standstill the hydraulically actuated

disc brake of the slew gear is applied.
Driving the crane in the erect (configured) condition
When the crane is driven in the configured position, the load rests
on the suspension cylinders. These are not equipped with pipe
burst valves, in order to guarantee problem--free suspension be-
haviour during driving of the crane. To avoid hazardous situa-
tions, the regulations outlined in the operating instructions, sec-
tion 5, ”Driving in the Configured Condition” must be strictly ob-
served.
40--1--1010B_en 65/79
1
66/79 40--1--1010B_en
1.4.8 When Assembling and Dismantling Crane Compo-

nents
Although all possible protective and safety measures have

been provided, there is still a risk of crushing during assem-
bly and dismantling work.
To avoid these remaining dangers the following rules must
be observed.
These operating instructions describe the standard assembly se-

quence.
The equipment must be dismantled exactly in the reverse order

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

and dismantled by untrained personnel. This also applies to staff
providing temporary help.
Incorrect assembly can result in danger to life and limb.
As a result of the risk of slipping, stumbling and falling, it is prohibi-

ted to walk on the boom and equipment -- or parts thereof.
All assembly work is to be carried out with the help of suitable ac-
cessories (ladders, hoist platforms, scaffolding, auxiliary crane
etc.).
Exceptions are only permitted if access areas are provided.

This requires additional safety measures however.
Normal assembly involves all separately transported component

parts being transported using suitable auxiliary cranes and lifting
tackle (ropes) near the ground -- and subsequently being safely
connected with the basic crane.
40--1--1010B_en 67/79
1
68/79 40--1--1010B_en
Before assembly personnel approach suspended loads, for ex-

ample counterweights, outrigger struts, intermediate sections,
boom foot section and top pieces, these loads must be placed
on the ground, on trestles or other supports with sufficient load
bearing capacity.
Persons in the vicinity of suspended loads are exposed to

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

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

carried out, the crane operator must ensure that no--one is in the
hazardous area affected.
A securing procedure is not completed until the suspended load

has been secured firmly to the stable part of the crane, e.g. by
driving pins into an extension or by tightening all bolts of a threa-
ded connection to the specified torque etc.
A safe distance should be kept from unavoidable crushing ha-

zard points, in particular outrigger struts, between the superstruc-
ture and crane chassis, cylinders, on the telescopic boom and on
the jib, as long as a component is suspended in the air during as-
sembly and/or is not safely secured and/or as long as the engine
of the crane or the auxiliary assembly crane is running.
Connecting bolts are always knocked in from the outside inwards

during the assembly of fly jibs, unless the operating instructions
expressly state otherwise.
Only when all pins of a component have been driven in are the
auxiliary bolts and clip pins to be fitted.
40--1--1010B_en 69/79
1
70/79 40--1--1010B_en
Connecting bolts may only be knocked out during the dismantling

of jib components or other parts when all individual components
are safely supported symmetrical to their centre of gravity. After
release, the responsible shift foreman must decide whether
sudden falling or folding movements are to be expected due
to the releasing procedure. In case of doubt, a service specia-
list from the crane manufacturer should be consulted.
In particular the knocking out of bolts must be carefully planned

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

work! Falling or flung tools can cause risk to life and limb!
Often it is necessary to bridge limiters (e.g. limit switches) during

assembly and dismantling work. This can also lead to additional
hazards. The systems may therefore only be bridged if this is re-
quired in the operating instructions for a certain piece of work.
40--1--1010B_en 71/79
1
72/79 40--1--1010B_en
1.5 Hand Signals
If the crane operator cannot oversee the operation and working

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

bols may be employed as banksmen.
The spotter should be in a safe position, from where he can

SEE THE LOAD and can himself be clearly SEEN BY THE
CRANE OPERATOR.
The spotter must be easily recognisable for the crane ope-

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

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

should not carry out any movement with the crane. Before
commencing work the crane operator and spotter must work
out a signal for this scenario.
40--1--1010B_en 73/79
1
Z 26 024
74/79 40--1--1010B_en
1.5.1 General Hand Signals

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

wards.
2. STOP !
Interruption, completion of a movement procedure
Right--hand arm upward, the palm of the right hand turned

to the front.
3. END
of a movement
The hands folded at chest height.
4. DANGER !
Emergency stop
Both arms upwards, palms turned to the front.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
40--1--1010B_en 75/79
1
Z 26 026
76/79 40--1--1010B_en
1.5.2 Hand Signals for Working Movements

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

Signal with both hands. Thumbs pointing outwards.
6. TELESCOPE IN boom
Signal with both hands. Thumbs pointing inwards.
40--1--1010B_en 77/79
1
Z 26 025
78/79 40--1--1010B_en
1.5.3 Hand Signals for Driving Movements

(Z 26 025)
1. Drive FORWARDS
Arms angled; palms pointing inwards; underarms making
slow movements towards the body.
2. Drive BACKWARDS
Arms angled; palms of the hand facing outwards; the unde-
rarms making slow movements away from the body.
3. Drive to the RIGHT (seen from the spotter)

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

Left arm stretched out more or less horizontally, palm of the
left hand facing downwards, small movements in the direc-
tion shown.
40--1--1010B_en 79/79
Structure of the Mobile Crane 2
Date: 17.CW/97
bs_e075-1020/a 1/9
2
Date: 17.CW/97
Z 75 004
2/9 bs_e075-1020/a
2.1 Overview
(Z 75 004)
Item Designation
1 Main Boom
2 Superstructure frame + Counterweight
3 Drive
4 Slew ring bearing
5 Luffing cylinder
6 Slew gear
7 Rope drum
8 Hydraulic carrier
9 Crane chassis
10 Frontaxle, steered and driven
11 Rearaxle, rigid, not driven (steered and driven with
4x4, optional)
12 Outrigger
13 Outrigger pad
17.CW/97
Date: 27.CW/94
Date:
bs_e075-1020/a 3/9
2
Date: 17.CW/97
Z 75 118
4/9 bs_e075-1020/a
2.2 Safety Signs

(Z 75 118)
(1)- Warning: Crushing / jolting

(2)- Warning: Dragging / entanglement
(3)- Warning: Danger of falling
(4)- Prohibited: Pedestrians
(5)- Warning: Danger of fire
(6)- Prohibited: Open fire
Signs (5) and (6) are attached to the filler necks of the diesel
and hydraulic tanks.
(7)- Prohibited: Access for unauthorised personnel

(8)- Warning: Crushing
(9)- Warning: Suspended load
(10)- Instruction: Fire extinguisher
The fire extinguisher supplied with the crane is located next to

the driver's seat in the crane cab.
(11)- Instruction: First aid
The first aid kit (and any other accessories according to

national motor vehicle safety standards) must be taken from the
range supplied by the crane operator and kept in the crane cab.
All safety instructions on the crane must be maintained in

complete and legible form.
Date: 17.CW/97
bs_e075-1020/a 5/9
2
7,1 m
Date: 17.CW/97
Z 75 005
6/9 bs_e075-1020/a
2.3 Boom System

(Z 75 005)
Item Designation
1 Main Boom
2 Luffing cylinder
3 Main boom extension
4 Hook block
5 Hoist rope (hoist 1)
2.3.1 Boom Lengths

(Z 75 005)
Main boom 7.5 - 25.0 m

Main boom extension 7.1 - 13.0 m
For combinations of the different boom components and the

resulting total lengths, please refer to the load tables.
Date: 17.CW/97
bs_e075-1020/a 7/9
2
Date: 17.CW/97
Z 75 002
8/9 bs_e075-1020/a
2.4 Serial Plates
Chassis Number and Serial No. Plate

(Z 75 002)
The chassis number can be found at the front right-hand end of

the crane chassis (Point “Y”)
2.4.1 Serial Plate

(Z 75 002)
The serial plate is located on the side of the dashboard, item (1).
Date: 17.CW/97
bs_e075-1020/a 9/9
Cab 3
Stand: 02.KW/00
bs_e075-1030/d 1/13
3
Stand: 02.KW/00
Z 75 191
2/13 bs_e075-1030/d
Cab 3
3.1 Operating Elements in the Driver's Cab

(Z 75 191)
Item Designation Function
1 Pedal Engine speed control

2 Steering switch Rear-axle steering
3 Rocker switch Slew gear brake
4 Lever Retract/extend platform
5 Pedal Foot brake
6 Control lever Telescopic section / slew gear
7 Rocker switch Fine adjustment for crane
movements,
Slew gear left/right, hoist up/down
8 Floor switch Engine brake / with crane
operating horn
9 Pedal Slew gear brake
10 Toggle Adjustment of steering wheel
11 Combi lever Turn signal indicator, full beam,
horn, windshield wiper/washer
12 Steering
Wheel
13 Box level Straight position indicator
14 Rocker switch Fine adjustment for crane
movement, luffing gear down
15 Knob Hoist rotation indicator
16 Control lever Luffing gear / hoist
17 Thermostat Thermostat for engine-indepen-
dent heater
18 Display Selector keypad
19 Lever Parking brake
20 Cigarette lighter
21 Socket
22 electr. adjustment of mirror
23 Lever Door catch
110 Rocker Switch Hoist function on/off (optional)
111 Button High speed hoist up/down, luffing
gear up
112 Button Switch to precision control
Crane movement hoist up/down
Stand: 02.KW/00
bs_e075-1030/d 3/13
3
Stand: 02.KW/00
Z 75 192
4/13 bs_e075-1030/d
Cab 3
3.1.1 Operating Elements in the Driver's Cab

(Z 75 192)
Item Element Function

25 S 303 Dipped beam, parking lights
26 S 304 Fog tail light
27 S 305 Rotaflare light
28 S 311 Fog lamps (optional) or
S 311 Spotlight "outrigger" (optional)
29 R 710 Egulate emergency steering
30 S 308 Hazard warning lights
31 S 352.2 All-terrain transmission/engage axle 2
32 S 314 Transverse differential lock
33 S 357 Disengage separate rear axle steering
34 S 328 Seat heating
35 S 326 Mirror heating
36 S 131 Wiper, roof window (2 steps)
37 S 802 Disengage outriggers left
38 S 803 Disengage outriggers right
39 S 804 Disengage all outriggers
40 S 805 Retract/extend horizontal outriggers
41 S 801 Retraxt/extend vertical outriggers
42 S 301.1 Superstructure / chassis in operation
43 S 363.1 "Raise"/"lower" suspension front left-hand side
44 S 362.1 "Raise"/"lower" suspension front right-hand side
45 S 361.1 "Raise"/"lower" suspension rear left-hand side
46 S 364.1 "Raise"/"lower" suspension rear right-hand side
47 S 370.1 "Raise"/"lower" together
48 S 360 Raise axles
49 Blank plate
50 S 100 Emergency stop (superstructure operation)
51 S 170 Air conditon (optional)
52 S 191 Blower fan
53 A 190 Heating clock
54 S 302 Ignition lock
55 S 700 Bridge load limit device
56 S 701 Bridge hoist limit switch
57 S 705 Bridge telecontrol
58 Blank plate
59 CGC Load limit device
60 R 301 Engine speed locking
61 S 710 Emergency steering
The location of the indicator lights in your crane may differ from
Stand: 02.KW/00
the installation locations shown here.

The symbol on the light is always valid for the function of the
switch.
bs_e075-1030/d 5/13
3
Stand: 02.KW/00
Z 75 193
6/13 bs_e075-1030/d
Cab 3
3.2 Monitoring Equipment

(Z 75 193)
65 H 373 Suspension circuit to the front and left

not level
66 H 372 Suspension circuit to the front and right not
level
67 H 371 Suspension circuit to the rear and left not
level
68 H 374 Suspension circuit to the rear and right not
level
69 H 170 Air condition (optional)
70 H 440 Do not change gear
71 Pressure Brake system pressure
gauge
72 H 310.6 Indicator light -pressure in brake system has
dropped below 5 bar
73 Blank plate
74 P 301 Tachograph
75 P 109 Wind speed indicator
76 H 700 Load limit device bridged
77 H 701 Hoist limit switch bridged
78 H 705 "Raise luffing gear function" bridged
79 H 710 Emergency control (enable)
The location of the indicator lights in your crane may differ from
the installation locations shown here.
The symbol on the light is always valid for the function of the
switch.
Stand: 02.KW/00
bs_e075-1030/d 7/13
3
Stand: 02.KW/00
Z 75 194
8/13 bs_e075-1030/d
Cab 3
3.2.1 Monitoring Equipment in the Cab

(Z 75 194)
79 P 200 Indicator light module 1

80 H 430 Flame starting system
81 H 308.7 Direction indicator
82 H 305.3 Upper beam switched on
83 H 301 Battery charge indicator
84 H 352.2 All-terrain transmission switched on
85 H 352.1 Road travel transmission switched on
86 H 319 Engage axle 2/longitudinal differential locked
87 H 314 Transverse differential locked
88 H 388 Retarder
89 H 392 Superstructure in operation
90 P 201 Indicator light module 2
91 H 323 Air filter clogged
92 H 324 Hydraulic oil filter clogged
93 H 322.1 Steering circuit I "no flow"
94 H 322.2 Steering circuit II "no flow"
95 H 108 Hydraulic oil temperature too high
96 H 310 Parking brake applied
97 H 356.1 Rear-axle steering
98 H 356.2 Rear-axle steering not locked
(not authorised for road travel)
99 H 386 ABS
100 H 411 Transmission oil temperature too high
Indicator lights in your crane may not be located at the same

points shown here. The symbol on the light indicating the
relevant function always applies.
Stand: 02.KW/00
bs_e075-1030/d 9/13
3
Z 75 120
Stand: 02.KW/00
10/13 bs_e075-1030/d
Cab 3
3.2.1 Monitoring Equipment in the Cab

(Z 75 120)
101 P 100 MFA 10 display unit

1. warning signal 2. warning signal
102 Fuel level 10 % 5%
103 Engine oil pressure
104 Coolant temperature 103 oC 110 oC
105 Transmission oil temp. 120 oC 130 oC
106 Engine speed
107 Daily operating hours
108 Battery check 20 V 16 V
109
The various items of information (102 - 108) can be called up on the MFA 10 display unit (101)
at the press of a button. The relevant LED comes on.
The assigned light-emmitting diode (LED) comes on. When the ignition is switched off, the display
shows the time (above) and the total operating hours (below). If no information is called up when
the ignition is on, (all light-emitting diodes (LED) are off), this information is likewise displayed.
To reset the daily operating hours, button (107) must be held down for three seconds.
If transmission oil or coolant temperature are too high or if voltage supply or engine oil pressure
are too low, this information flashes on the display, even if it has not just been selected. At the
same time, the assigned light-emitting diode (LED) flashes and a warning signal sounds. These
warning signals can be acknowledged by actuating the particular button (3 seconds).
Setting the clock:

- simultaneously press keys (107) and (108) for five seconds
- the displayed time will blink
- press keys (106), (107) and (108) or (109) until the correct time is set
- the corresonding number is increased by one
Accepting the newly set time:

- simulaneously press keys (107) and (108) until the time stops blinking
Indicator lights in your crane may not be located at the same points shown here. The
Stand: 02.KW/00
symbol on the light indicating the relevant function always applies.
bs_e075-1030/d 11/13
3
Z 170 505
Stand: 02.KW/00
Z 170 506
12/13 bs_e075-1030/d
Cab 3
3.3 Symbols in Outrigger Control Box, Left-Hand Side

(Z 170 505)
Pos. Element Function
1 S 501 Outrigger cylinder "front right"

2 S 503 Outrigger cylinder "front left"
3 S 505 Outrigger "front left"
4 S 360.1 Raise axles
5 S 507 Outrigger "rear left"
6 S 509 Outrigger cylinder "rear left"
7 S 511 Outrigger cylinder "rear right"
3.3.1 Symbols in Outrigger Control Box, Right-Hand Side

(Z 170 506)
Pos. Element Function
1 S 508 Outrigger cylinder "rear left"

2 S 510 Outrigger cylinder "rear right"
3 S 504 Outrigger "rear right"
4 S 360.2 Raise axles
5 S 506 Outrigger "front right"
6 S 500 Outrigger cylinder "front right"
7 S 502 Outrigger cylinder "front left"
Stand: 02.KW/00
bs_e075-1030/d 13/13
Engine 4
Date: 45th CW/96
bs_e075-1040 1/11
Engine 4
Z 75 147
Z 155 014
Z 75 040
Date: 45th CW/96
Z 75 039 Z 75 041
2/11 bs_e075-1040
a/25/98
Engine 4
4.1 Checks Before Starting the Engine
Please consult the operating instructions for the diesel engine.

(Z 155 014)
Before starting the engine, check:
- if the parking brake (19) is applied (Z 75 147)
- if the neutral position is pre-selected on the display of

the selector keypad (18) (Z 75 147)
- engine oil level (Z 75 039)
- coolant level (Z 75 040)
Only open cover if coolant temperature is below 90oC.

Only turn the cover to the first detent to start with, so that
excess pressure can be released.
- hydraulic oil level (Z 75 041)
When the engine is started, the hydraulic pumps for

superstructure operation and steering also start running
immediately.
The engine must therefore not be started if the viscosity
of the hydraulic oil is over 1600 cSt (see relevant
information in Section 2 "Fuels and Lubricants" in the
lubrication and maintenance instructions).
- See also Section 5.1 "Checks before starting to drive"

Date: 45th CW/96
bs_e075-1040 3/11
a/25/98
Engine 4
Z 75 042 Z 75 147
Date: 45th CW/96
4/11 bs_e075-1040
a/25/98
Engine 4
4.2 Starting Procedure

(Z 75 042)
Start the engine as follows:
1. Insert the ignition key in the ignition lock (54, S 302)

and turn it one position to the right.
2. The charge control light (83, H 310), indicator light for
parking brake (96, H 310), the indicator light "Do not shift"
(70, H 440) and the indicator lights for steering
circuit 1 (93, H 322.1) and steering circuit 2
(94, H 322.2) and the indicator light for the flame
starting system (if the engine is cold) (80, H 430) must
come on.
3. Once indicator light (80, H430) has gone out,
turn the ignition key as far as it will go and
keep it in this position until the engine starts (without
actuating the speed control).
4. While the engine is running, the charge control light
(83) and the indicator light for steering circuit 1 (93) must
go out.
The indicator light (70, H 440) also goes out.
Release the ignition key as soon as the engine starts.

Under no circumstances should the starter be activated
with the engine running.
- Handbrake valve must be closed

(Push handbrake lever back) (Z 75 147, Item 19)
- “N” position must be pre-selected (Z 75 147, Item 18)
In order to prevent an excessive build-up of soot, do not

actuate the speed control when starting a warm engine.
Date: 45th CW/96
bs_e075-1040 5/11
a/25/98
Engine 4
Z 75 043
Date: 45th CW/96
Z 75 044
6/11 bs_e075-1040
Engine 4
If the engine does not start after 5 seconds, please observe

the following points (Z 75 044):
- Slowly depress the speed control (1).

- Repeat the starting procedure. Do not try
to start the engine for longer than 20 seconds.
- Wait 60 seconds before trying to start the engine
again.
- If the engine fails to start on the third attempt,
determine the cause of the fault with the engine
manufacturer's operating instructions.
After starting the engine, please observe the following:

(Z 75 043)
- If no oil pressure is indicated on the multi-display

(101) or the indicator light flashes to show that engine
oil pressure is too low (103), switch off the engine
immediately and determine the cause.
- If the indicator light comes on to show that the air filter

is clogged (91, H 323), clean or replace the air filter.
- If the indicator light for "hydraulic oil filter clogged"

(92, H 324) comes on when the hydraulic oil is warm,
replace the filter.
- Avoid high engine speeds when the engine is cold.
- Run the engine only when the battery is connected
otherwise the alternator will be damaged.
- See also Section 5.1 "Checks before starting to drive".
Switch off the engine immediately if:
- oil pressure falls or fluctuates severely

- ventilation is not constant
- engine output and speed fall without movement of
the speed control or change in the operating
conditions
- the exhaust emits a large amount of smoke
- coolant or oil temperature is too high
- the engine makes strange noises
Date: 45th CW/96
bs_e075-1040 7/11
Engine 4
Z 75 044
Date: 45th CW/96
Z 155 108 Z 75 069
8/11 bs_e075-1040
Engine 4
4.3 Switching off the engine

(Z 75 044)
Switch off the engine as follows:
1. Return the speed control pedal (1) to the idle position.

2. Apply the parking brake (19) to prevent the crane
from rolling.
3. Preselect position “N” at the selector keypad (18).
- Use chocks to secure the crane additionally on

inclines and downhill slopes.
(Z 155 108)
4. Let the engine idle for approx. 2 minutes.

5. Turn the ignition key (54, S 302) back to the left to the
"0" position and remove (Z 75 044).
- Do not open the throttle just before switching off the

engine.
- Do not switch off the engine immediately; let it idle for

a few more minutes so that the temperature can
equalise.
- In emergency situations the engine can also be

stopped mechanically using the engine cable
(1, Z 75 069).
Date: 45th CW/96
bs_e075-1040 9/11
a/43/98
Engine 4
Date: 45th CW/96
10/11 bs_e075-1040
Engine 4
4.4 Jump Starting
Observe the enginge manufacturer's regulations.
4.5 Automatic Engine Shutoff (Optional)
For work in explosive environments (e.g. air with highly

combustible gases or increased oxygen levels) your crane can
be equipped with an automatic engine shutoff device. At an
increased speed (3200 rpm) a valve is automatically closed in
the air intake line of the engine. The engine then shuts down.
(Above a speed of 3000 rpm early warning is given by the
display unit MFA 10).
This valve must be opened manually again before the engine
can be restarted (lever in air intake line).
Date: 45th CW/96
bs_e075-1040 11/11
Driving 5
Date: 5.CW/97
bs_e075-1050-193 1/21
5
Z 75 046
Date: 5.CW/97
Z 75 073
2/21 bs_e075-1050-193
Driving 5
5.1 Checks before Driving

(Z 75 046)
The following checks should be carried out each time before

the crane is driven:
- Check the transport condition of the mobile crane

(see Section 5.2)
- Check the engine oil level and top up, if necessary

(see "Lubrication and Maintenance Instructions").
- Check the hydraulic oil level. If the oil level is too low,
the cause of the oil loss must be determined.
- Check the oil level in the transmission combination

and top up, if necessary ( see "Lubrication and
Maintenance Instructions").
- Check radiator coolant level. If the level is low, deter-

mine the cause of the coolant loss and top up.
- Check steering system.

Indicator light (93, H 322.1 - "steering circuit 1 no flow)
must go out shortly after the engine has started.
Since the emergency steering pump is driven by the
rolling vehicle, indicator light (94, H 322.2 - "steering
circuit 2 no flow") goes out only when the crane has
started to move.
Driving with a defective steering system represents a

great safety risk. Be sure to have any malfunctions elimi-
nated before starting to drive the mobile crane.
- Release the steering column with the T-handle and place

the steering wheel into an ergonomic position (Z 75 073).
- Indicator light (98, H 356.2 - "rear axle steering

not locked) must be out.
As long as the indicator light (98, H 356.2) is on, the
steering system is not yet in position for "Road travel", i.e.
check switch-over from "separate rear axle steering"
to "steering for road travel" (see Section 8.1).
Date: 5.CW/97
bs_e075-1050-193 3/21
5
Date: 5.CW/97
Z 75 047
4/21 bs_e075-1050-193
Driving 5
(Z 75 047)
- Check the braking system. If a pressure below 7 bar is

displayed on manometer (71), the air tanks of the braking
system must be filled at medium engine speed, until both
pointer of the manometer indicates 8.3 bar.
Indicator light (72, H 310.6) must be off. When the parking
brake (19) is applied, indicator light (96, H 310) lights up.
- Check the suspension level (see Section 10) and

adjust the individual suspension circuits as necessary.
- Check the tyre pressures; the following values apply

for all the wheels:
Tyres Tyre pressure
425/65 R 22.5 10 bar

(Standard)
14.00 R 25 10 bar
If the air pressure is too low the tyres may be damaged.
- Check the lights and the vehicle markings, i.e. light

system and side markings (reflectors).
- The fuel level in the fuel tank can be checked at fuel

gauge (102) on the dash panel.
- Do not fill up with fuel whilst the engine is running.

Date: 5.CW/97
bs_e075-1050-193 5/21
5
Z 75 048
Date: 5.CW/97
6/21 bs_e075-1050-193
Driving 5
5.2 General
(Z 75 048)
- The transport condition of the mobile crane depends

on the road traffic regulations applicable in the
country in which the crane is to be operated.
- A distinction must be made between the axle loads
which are technically permissible and the axle loads
which are permissible under the local road traffic
regulations.
Maximum permissible values for driving on public roads:

Speed Tyre size
limit 425/65 R 22.5 14.00 R 25
max. 80 km/h 10 bar 10 bar
The maximum permissible speed for this vehicle in the Federal

Republic of Germany is 80 km/h (observe respective national
regulations).
Maximum speeds for the crane should take into considera-
tion the prevailing road surface and curvature.
Axle loads of more than 10 t are not permitted when driving on

public roads in countries in which the EEC regulations (or
reduced axle loads) apply. If the crane is driven on public roads
with axle loads over 10 t, the crane operator is responsible for
any consequences.
In the interests of the service life of axles, wheels hubs,

bearings, suspension cylinders and brakes, we recommend that
the technical maximum values for the axle loads are not
exceeded. In particular the wear on the brake linings is in-
creased due to overheating of the brakes. The rate of
deceleration for the brakes decreases in the ratio of axle load to
gross weight of the crane.
When the crane is driven over uneven terrain or onto or off

sloping ground, the outrigger plates must be removed (they may
otherwise may torn off).
37. KW/94
Date: 5.CW/97
Stand:
bs_e075-1050-193 7/21
5
Z 75 045
Date: 5.CW/97
8/21 bs_e075-1050-193
Driving 5
5.2.1 Driving the Crane in Transport Condition
Observe the stipulations of the operating permit and the

exceptions permitted in accordance with § 70 of the road traffic
licensing regulations.
The following should be checked before the vehicle is driven on
public roads:
1. The main boom head must be lashed to the basic

boom with the retaining rope (Z 75 045).
2. The main boom must be set down on the crane chassis.
3. The underride guard must be secured to the main boom

head.
4. The hook block must be placed in the holding device

provided.
5. The outrigger beams and plates must be correctly

secured. (see Section 11.4.2)
6. The separate rear axle steering must be disengaged

(see Section 8.1)
7. The suspension level must be correctly set.

(see Section 10.1)
8. Check that all auxiliary equipment and components

are correctly pin locked and secured.
9. Make certain that there are no unattached

components on the vehicle.
10. Insert a new tachodisc in the tachograph in the

driver's cab of the crane chassis.
11. The mirror rod is located in the driving position (to fold the
mirror rod see Sect. 17.1).
- The drive speed must not exceed 80 km/h.

Date: 5.CW/97
bs_e075-1050-193 9/21
a/44/98
5
Date: 5.CW/97
10/21 bs_e075-1050-193
Driving 5
- The maximum speed is regulated by the road traffic

licensing regulations as well as the construction
features of the crane.
- These design characteristics with standard tyres permit a

speed of 80 km/h, with a 10 t axle load at the front and
11 t axle load at the rear.
In the recommended transport condition, with a total weight of

21 t, an individual axle load of 10 t at the front and 11 t at the
rear is not exceeded. All technical specifications on dimension
sheets etc. concerning driving characteristics apply for this
condition.
Configuration of the vehicle
- Crane with main boom

- 1 sheave hook block (up to max. 100 kg)
- 4 x 2 drive
- Tyres 425/65 R 22.5
Every addition or removal of crane components alters or displaces

the axle loads (see table).
Weight Alteration of axle load (kg)

Axle 1 2
Spare wheel carrier 52

Spare wheel 14.00 R 25 313 +15 +298
Spare wheel 16.50 R 22.5 213 +10 +203
Main boom extension 13 m 800 +662 +138
Main boom extension 7.1 m 550 +304 +246
Hook block 5 sheaves 220 +240 -20
Hook block 3 sheaves 160 +175 -15
Single line hook 80 +87 -7
Drive 4 x 4 280 +113 +167
Date: 5.CW/97
bs_e075-1050-193 11/21
5
Date: 5.CW/97
12/21 bs_e075-1050-193
Driving 5
5.2.2 Driving with Axle Loads over 10 t or 11 t up to a Max.

of 13 t
With the technically permissible crane transport condition

(observe also the national road traffic regulations), parts in
addition to the configuration described under 5.2.1 may be
carried. The influence of the individual components on the axle
load should be taken from the table supplied.
- Before starting to drive the mobile crane, observe all

the points under 5.2.1.
- The configuration described under 5.2.1 can be

varied by adding or removing individual components.
As far as possible, the axles should be under equal
load. The national regulations governing the axle
loads must be observed.
- An axle load over 10 t at the front and 11 t at the rear is

reached normally only when driving on the construction
site in erect condition (see "Travel Operation", Sect. 5.4.3)
- With configurations over 10 t and 11 t the max. permis-

sible driving speed is 62 km/h.
- The stopping distance is increased due to the total
weight being greater.
Date: 5.CW/97
bs_e075-1050-193 13/21
5
Date: 5.CW/97
14/21 bs_e075-1050-193
Driving 5
5.3 Driving on the Construction Site
General
Maximum permissible values for driving on the construction

site:
Tyre size Tyre size

14.00 R 25 / 10 bar 16.5 R 22.5 / 10 bar
max. speed axle loads axle loads
2 km/h 22 t 18.8 t
The values should not be exceeded while driving with loads.
The ground conditions must be suitable for the tyres, i.e. flat,
level surface, suitable for a soil pressure of 10 bar.
Date: 5.CW/97
bs_e075-1050-193 15/21
5
Z 75 157
Date: 5.CW/97
16/21 bs_e075-1050-193
Driving 5
5.4 Driving in Erect Mode
- The ground must be level and capable of supporting the

vehicle.
- The gradient of the ground must not exceed 2%.
- Before driving the mobile crane in erect mode, always

check the condition of the tyres and the tyre pressure.
Tyres Tyre pressure
14.00 R 25 10 bar
16.50 R 25 10 bar
The tyres may not be damaged in any way. Danger of

toppling!
- The outrigger plates must be kept close to the ground when

driving (see Sect. 11).
- Apply the slew gear parking brake (3, S14). (Z 75 157)
- Care should be taken if there is a side wind, particularly if

the wind is acting in the same direction as a lateral ground
gradient.
- Fully retract the suspension cylinders (see Section 10.4).
- max. speed 2 km/h (walking pace).

Date: 5.CW/97
bs_e075-1050-193 17/21
5
Z 75 157 Z 75 140
7,1
Date: 5.CW/97
Z 75 075
18/21 bs_e075-1050-193
a/49/97
Driving 5
5.4.1 360o-Driving the Crane without Load
- the main boom extension is either in the transport position or

removed.
- maximum main boom length is 16.3 m (see load table "360o

on the wheels").
- select mobile load program "360o on the wheels".
- release parking brake and select gear.
- the maximum working radius is limited to 3.5 m

(Danger of tipping backwards).
- driving with a load is not allowed ("360o on the wheels").

The load present in the load limit device is a necessary
and configured load and may not be removed.
5.4.2 Driving the Crane with the Main Boom Extension (7.1
or 13 m) Fitted (Z 75 075)
Basic unit with hook block (100kg) and main boom extension.
Slew superstructure (0o facing backwards or 180o facing forwards).
Apply the slew gear parking brake (3, S14), (Z 75 157).
Turn switch (42, S 301.1) to drive (Z 75 140).
The different boom positions and axle loads with respect to the
configuration of the crane can be taken from the table below.
max. min.
A B C D Axle load Axle load
7.5m 18o 7.1m 0o 9.7t 9.6t

7.5m 30o 7.1m 30o 10.0t 9.2t
7.5m 39o 13m 0o 9.8t 9.8t
7.5m 44o 13m 30o 9.8t 9.8t
When changing the hook block or when driving with just the fly
jib base section folded out, a balanced axle load can be
Date: 5.CW/97
achieved once more by adjusting the main boom slightly.

Ensure that the tyres are compressed evenly!
bs_e075-1050-193 19/21
a/4/98
5
Z 75 157
Date: 5.CW/97
20/21 bs_e075-1050-193
a/49/97
Driving 5
5.4.3 Driving the Crane with Load (Travel Operation)
When driving the crane with a load, the following points must
be observed along with the conditions stipulated in Sect. 5.4:
-The load is taken up. Then slew the superstructure into the
direction of travel with the main boom facing towards the front
or rear.
- Apply the slew gear parking brake (3, S14), (Z 75 157).
Slewing the superstructure out of this position is

prohibited!
-The outrigger beams can now be fully retracted.
If space allows, the outriggers should be either fully extended

(5.9 m) or partially ectended (4.0 m).
- Set the load limit device to "mobile 0o/180o" mode,

(see Sect. 15).
- The outrigger cylinders can now be retracted such that the

outrigger plates are just above the road. Take up the load
again and hold briefly over the ground.
- The crane must remain switched to "crane operation" during

driving so that the CGC display is retained.
- Pay attention to the ground clearance of the outrigger plates

and the load while driving.
- The steering is operational as soon as a gear is engaged.
The load capacities specified in the load table under

"freestanding" (note the corresponding symbol) must not
be exceeded.
- The load must not start to oscillate as the vehicle is driven.

If necessary, lash the load.
Date: 5.CW/97
bs_e075-1050-193 21/21
c/02/00
Transmission 6
Date: 25th CW/98
bs_e075-1060/a 1/17
6
Z 75 143
Date: 25th CW/98
2/17 bs_e075-1060/a
Transmission 6
The crane chassis is equipped with a combination consisting of

a hydrodynamic torque converter with lockup clutch and a
secondary automatic transmission with 6 forward gears and 1
reverse gear. The gears in the transmission are pre-selected
manually with the selector button so that no clutch pedal is
required with this design.
6.1 Gear Lever

(Z 75 143)
The following gears can be selected with selector keypad (18)
in the driver's cab.
In order to shift gear, the shift lock on the gear lever must be
pressed and thereby released
R - reverse
N - neutral
D - forwards
The selector keypad also has options for selecting automatic

gear change.
These can be selected by pressing the "MODE" key:
- "ECONOMY" drive programme (for economical driving with

low fuel consumption) (standard setting: starting up in 2nd
gear). The mode indicator is off.
- "POWER" drive programme (In this instance higher revs are

selected for shifting gear to enable better acceleration).
The mode indicator is on.
When changing down, the selector button must be

actuated for each individual shift position.
Date: 25th CW/98
bs_e075-1060/a 3/17
6
Z 75 143
Date: 25th CW/98
4/17 bs_e075-1060/a
Transmission 6
6.1.1 Neutral Position “N”

(Z 75 143)
To park the crane and to start the engine, "N" must be
selected on the selector keypad (18).
(Required position when using auxiliary drives.)
Pre-select neutral position only when the crane is station-

ary. Do not pre-select neutral position while travelling.
6.1.2 Reverse Gear "R"
To reverse, select "R".
Actuate the foot brake when shifting the gear. Vehicle must be
stationary.
6.1.3 Drive Position "D"
Drive position "D" is always to be selected when driving the

crane on the road under normal conditions.
Actuate the foot brake when shifting from position "N" to

position "D" so that the vehicle does not begin to roll.
6.1.4 Drive Positions "1" to "6"
When driving on downgrades or slippery road surfaces, the

transmission can be prevented from shifting into the higher
gears by moving the selector button to drive position "5", "4",
"3", "2" or "1".
This blocks the higher gears of the transmission. The gears
can only be upshifted up to the selected drive position.
The transmission can be upshifted from one drive position to

the next without the foot brake being actuated.
Downshifting to lower ranges requires to reduce the speed of
the vehicle by applying the service brake until the pre-selected
range is activated.
Note:
As a rule, the same gear range shall be used for travelling
Date: 25th CW/98
up- and downgrades.
bs_e075-1060/a 5/17
6
Z 75 059
Date: 25th CW/98
6/17 bs_e075-1060/a
Transmission 6
6.2 All-Terrain Transmission (Optional)

(Z 75 059)
When driving the crane off the road, the all-terrain transmission
can be engaged by pressing switch (31, S 352.2; unlock the
switch). The rear-axle drive is engaged and the speed ratio of
the drive in the distributor gear, increased. The longitudinal
differential lock is engaged at the same time.
When the all-terrain transmission is engaged, indicator light

(84, H 352.2) comes on and the "road travel" indicator light (85,
H 352.1) goes out.
The following conditions must be satisfied before the all-

terrain transmission can be engaged:
1. The crane must be at a standstill.

2. The engine must be switched on.
3. The pressure in the compressed air reservoirs must be
at least 5 bar.
Before switching off the engine, switch the all-terrain

transmission off again by pressing switch (31, S352.2). The
"road travel" indicator light (85, H 352.1) must come on.
If a switch position for road travel, or all-terrain transmis-

sion is not definitely indicated by the indicator lights, the
crane must not be driven.
All-terrain transmission should only be engaged when it is
required.
During normal road travel, the all-terrain transmission
must remain off, to prevent any damage to axles and
distributor gear.
Date: 25th CW/98
bs_e075-1060/a 7/17
6
Date: 25th CW/98
Z 75 208
8/17 bs_e075-1060/a
Transmission 6
6.3 Starting
(Z 75 208)
Note the following points when starting:
1. Start the engine with the transmission in neutral as

described in Section 5.
2. Pre-select the desired gear range on the selector
keypad (18) (if necessary, press the "MODE" key to start
up in 1st gear).
3. Release the parking brake (19).
4. Depress the accelerator pedal (1) to set the mobile crane
in motion.
Sump Fluid Temperature And Transmission Operation
Sump Oil Temperature CHECK-TRANS- Operation

Light
(A)
below -8oC OFF Neutral (N)

Reverse (R)
and 2 normal
upshifts
above -7oC OFF Full operation in
all ranges
6.4 Stopping
(Z 75 208)
The mobile crane can be stopped at any time, irrespective of

the position of the gear lever.
To stop the crane:
1. Release the accelerator pedal (1)

2. Depress the foot brake (5)
Date: 25th CW/98
bs_e075-1060/a 9/17
6
Date: 25th CW/98
Z 75 145
10/17 bs_e075-1060/a
Transmission 6
6.5 Driving on Downgrades

(Z 75 145)
Select an appropriate gear before starting to drive on the

downgrade.
To prevent the engine from overspeeding , the transmission is

equipped with a downshift safety device - if it is not possible to
change down, the vehicle should be braked accordingly.
Do not exceed the rated engine speed of 2850 rpm when

driving on downgrades.
6.6 Procedure when the Crane is Stuck

(Z 75 145)
If the crane becomes stuck in poor terrain, attempt to free it by

engaging forward and reverse gears alternatively.
1. Engage the differential lock (see Section 9).

2. Select drive position "1" using selector button (18).
3. Depress the accelerator pedal and start to drive forwards.
4. Release the accelerator pedal and apply the hand brake.
5. Engage the reverse gear "R".
6. Depress the accelerator pedal and release the hand brake
at the same time etc.
7. Repeat this alternative driving forwards and backwards
until the vehicle is free.
If these manoeuvres do not bring the desired success, on no

account should you try to free the crane by force.
Rocking the crane free is prohibited!

Date: 25th CW/98
bs_e075-1060/a 11/17
6
Z 75 146
Date: 25th CW/98
12/17 bs_e075-1060/a
Transmission 6
6.7 Gear Oil Information

(Z 75 146)
You have the option of reading off information on the gear oil from
the display of the drive switch.
Proceed as follows:
1. Stop the vehicle at the next available parking space.
2. Apply the parking brake and leave the transmission in

the same position as it was before the fault code was
indicated.
3. Leave the engine running at idle speed.
4. The gear oil information are called up on the display (1) by

simultaneously pressing the arrow keys (3 and 4) once.
The fault codes (max. 5) are displayed by a sequence of

digits lighting up in the display (1):
Display Cause of fault
o,L, 0,X Settling time too short

o,L, 5,0 Engine speed (rpm) too low
o,L, 5,9 Enginge speed (rpm) too high
o,L, 6,5 Neutral must be selected
o,L, 7,0 Sump fluid temperature too low
o,L, 7,9 Sump fluid temperature too high
o,L, 8,9 Output shaft rotation
o,L, 9,5 Sensor failure*
Low or high fluid level can cause overheating and irregular

shift patterns.
* This fault message (fault code) should be reported immediately

to the customer service of Allison Getriebe Services or
Terex- Demag.
Date: 25th CW/98
bs_e075-1060/a 13/17
6
Z 75 146
Z 75 148
Date: 25th CW/98
14/17 bs_e075-1060/a
Transmission 6
6.8 Fault Codes

(Z 75 146)
If indicator light (70, Z 75 148) comes on, the fault codes

have to be read off the display of the keyboard.
Carry out any required measures immediately!
Proceed as follows:
1. Stop the vehicle at the next available parking space.
2. Apply the parking brake and leave the transmission in

the same position as it was before the fault code was
indicated.
3. Leave the engine running at idle speed.
4. The fault codes are called up on the display (1) by

simultaneously pressing the arrow keys (3 and 4) twice.
The fault codes (max. 5) are displayed by a sequence of

digits lighting up in the display (1):
d1, d2, d3... numbers of the fault codes
1, 2, 3, 4 4-digit fault code
Please refer to the table in part 3 for an explanation of the

4-digit fault codes.
5. Actuating the neutral key on the control pad switches

the display (1) back to gear display.
Date: 25th CW/98
bs_e075-1060/a 15/17
6
Date: 25th CW/98
16/17 bs_e075-1060/a
Transmission 6
6.9 Troubleshooting with the Fault Table

(see part 3 of these operating instructions)
Detecting and rectifying faults using the fault code table

requires basic knowledge in the field of electrical engineering.
The transmission control may only be measured and

checked by trained personnel.
Incorrect measurement or incorrect connection of the
cables can lead to damage or destruction of the ECU
(transmission computer) or other components.
When the components are still under guarantee, the faults may
only be rectified by the Customer Service Dept. of Allison
Getriebe Services or Terex-Demag.
Even when the parts are no longer under guarantee, we advise

that faults still be rectified by a technician from Terex-Demag
or Allison Getriebe Services.
The end customer or operating agent therefore detects and

rectifies faults at his own risk.
Date: 25th CW/98
bs_e075-1060/a 17/17
Brakes 7
Date: 45.CW/96
bs_e075-1070 1/5
7
Date: 45.CW/96
Z 75 018
2/5 bs_e075-1070
Brakes 7
7 Braking System
(Z 75 018)
The mobile crane is equipped with a dual-circuit braking

system.
To monitor the braking system, the instrument panel features a
pressure gauge (71) which constantly indicates the pressure
level in the braking system and a warning light (72) - "Pressure
in the braking system below 5 bar".
7.1 Service Brake

(Z 75 018)
The service brake (5) is the brake for normal driving operation.
The dual-circuit braking system acts on all the wheels.
7.2 Parking Brake

(Z 75 018)
The parking brake (hand brake) (19) is used when parking the
vehicle. The brake is released by compressed air and engaged
by the springs installed in the brake cylinders of the 2nd and
3rd axle. To apply the brake, move lever (19) of the hand brake
valve up and allow to engage. To release the brake, overcome
the lever lock by pulling upwards. When the parking brake is
engaged, indicator light (96, H 310) comes on.
It can be used as an emergency brake in the event of service

brake failure.
Since the parking brake does not act on all the wheels, its
braking effect is less than that of the service brake.
Only use the brake to stop the crane in an emergency and
immediately repair the brake fault.
- When parking on upgrades or downgrades, always

use the wheel chocks!
- When using the parking brake as an emergency

brake, move lever (19) on the hand brake valve quickly
but without jerking. Do not allow the lever to engage.
The braking effect can be infinitely varied, similar to
that of the service brake.
Date: 45.CW/96
bs_e075-1070 3/5
7
Date: 45.CW/96
Z 75 019
4/5 bs_e075-1070
Brakes 7
7.3 Engine Brake (Sustained-Action Brake)

(Z 75 019)
The engine brake is of particular use when driving on long

downhill sections. The engine brake is engaged by depressing
foot switch (8) with the left foot.
As long as a gear is engaged, the crane will then be braked by
the engine.
Date: 45.CW/96
bs_e075-1070 5/5
Steering 8
Date: 45.CW/96
bs_e075-1080 1/7
8
Date: 45.CW/96
Z 75 049
2/7 bs_e075-1080
Steering 8
8.1 Steering during Road Travel

(Z 75 049)
The vehicle is equipped with a hydraulic dual-circuit steering
system, which is supplied by two engine-driven and one
emergency pump.
Indicator lights (93, H 322.1 and 94, H 322.2) show that the
steering system is functioning - with the vehicle at a standstill,
only indicator light (94, H 322.2) should come on as the
emergency steering pump is not in operation.
When the crane is driven, the indicators must go out. If

this fails to occur, stop the vehicle and repair the fault.
When the crane is driven on public roads, the front axles are
steered with the steering wheel (12). The rear axles remain
rigid.
The "independent rear axle steering" must not be switched

on when the crane is driven on the road, indicator light (98,
H 356.2) must not light up - extreme risk of accidents!
Always check this condition by monitoring indicator light (98, H

356.2) on the dash panel of the driver's cab. It is always on
when the steering has not been switched from "independent
rear axle steering" to "steering for road travel" (e.g. engine of
the mobile crane has been switched off with "independent rear
axle steering" - engaged).
Caution, vehicle may swing out.

Date: 45.CW/96
bs_e075-1080 3/7
a/02/01
8
Date: 45.CW/96
Z 75 212
4/7 bs_e075-1080
a/4/99
Steering 8
8.2 Independent Rear Axle Steering

(Z 75 212)
With this steering system the rear axles can be steered

independently of the front axles.
Engage independent rear axle steering as follows:
1. Stop the vehicle in the "straight ahead" position, i.e. vehicle

at a standstill and all wheels straight.
2. Pre-select the "N" position on the selector keypad (18).
3. Unlock the rear axle by pressing switch (33, S 357).
4. Indicator lights (97, H 356.1) "independent rear axle

steering" and (98, H 356.2) "independent rear axle steering
not locked" come on to signal that axles have been
unlocked.
5. The front axle is steered with the steering wheel (12).
6. The rear axle can be steered with rocker switch (116,

S 356).
7. The automatic transmission only permits gears "1", "2"

and "R".
Date: 45.CW/96
bs_e075-1080 5/7
8
Z 75 051
Date: 45.CW/96
Z 75 213
6/7 bs_e075-1080
b/4/99
Steering 8
8.2.1 Steering Combinations
Independent rear axle steering facilitates the following steering

combinations:
(Z 75 051)
-a) All wheel steering:

This allows a smaller steering radius.
-b) Front axle or
-c) Rear axle steering:

In certain situations, it can be advantageous to steer only
with the front axles or only with the rear axles.
-d) Crab walk:

The wheels on all steered axles have the same wheel
cycle.
Disengage independent rear axle steering as follows:

(Z 75 213)
1. Stop the vehicle in the "straight ahead" position, i.e. vehicle

at a standstill and all wheels straight.
2. Press switch (33, S 357) again (the switch slots into place).
3. Indicator lights (97, H 356.1 and 98, H 356.2) must go out.
4. If recoupling is not effective (indicator light 98, H 356.2 -

"independent rear axle steering not locked" does not go
out), make minor steering movements to the left and right
with rocker switch (116) until the locking pin engages.
Use of independent rear axle steering leads to poor tracking

conditions for individual tyres during more extensive steering
movements. This in turn leads to greater tyre wear - therefore
only use in exceptional cases.
"Independent rear axle steering" may not be engaged

when driving the crane on the road or when driving the
crane in configured condition.
Date: 45.CW/96
bs_e075-1080 7/7
Differential Locks 9
Date: 35.CW/00
bs_e075-1090/a 1/7
9
Z 75 200
Date: 35.CW/00
2/7 bs_e075-1090/a
9 Differential Locks
In order to distribute the drive torque from the engine to the

driven wheels and to equalize the wheel rotational speeds
when driving around corners or through curves, the mobile
crane is equipped with the following differentials:
All differentials can be locked. When locked, a rigid link is

formed between the two outputs of the differentials.
The differential locks may only be engaged when the

wheels are stationary.
Engagement of the differential locks is necessary under the

following conditions:
- One wheel of a driven axle is standing on loose

ground and spinning:
The transverse differentials have to be locked.
- Both wheels of the front axle are spinning:

The rear axle have to be engaged, it means the longitudi-
nal differential (with drive 4 x 4) have to be locked.
The crane must not be driven on firm ground with the

differential locks engaged. The speed limit with the diffe-
rential locks engaged is 20 km/h.
The longitudinal differential must be engaged for the transverse

differential of the rear axle is to be effective (All terrain-
transmission).
To avoid front wheel spinning during cornering, the longitudinal

differential lock is automatically switched on if required. The
lamp (86, H 319; longitudinal differential lock) lights up for a
short period of time. If there is an error in the corresponding
electronics of the distributor gear, the lamp flashes (70, H 440;
gearbox error). (Z 75 200)
Date: 35.CW/00
bs_e075-1090/a 3/7
9
Z 75 154
Date: 35.CW/00
4/7 bs_e075-1090/a
Engage the transverse differential lock as follows:

(Z 75 154)
1 Stop the vehicle.

2. Press switch (32, S 314).
The transverse differential locks of the drive axles are
engaged together.
3. Indicator light (87, H 314) comes on.
Disengage the transverse differential lock as follows:

(Z 75 154)
1. Stop the vehicle.

2. Press switch (32, S 314) again.
All transverse differential locks of the drive axles are
disengaged together.
3. Indicator light (87, H 314) goes out.
Engage the longitudinal differential lock or drive 4 x 4 as

follows:
(Z 75 154)

2. Press switch (31, S 352.2).
The longitudinal differential lock or drive 4 x 4 is engaged.
3. Indicator lights (86, H 319 and 84, H 352.2) come on.
Disengage the longitudinal differential lock as follows:

(Z 75 154)

2. Press switch (31, S 313) again.
The longitudinal differential lock or drive 4 x 4 is
disengaged.
3. Indicator lights (86, H 319 and 84, H 352.2) go out, the
indicator light (85, H 352.1) have to come on.
Date: 35.CW/00
bs_e075-1090/a 5/7
9
Date: 35.CW/00
6/7 bs_e075-1090/a
If the corresponding indicator light does not go out when the

differential locks are disengaged, turn the wheels of the axle
slightly to the left and right a few times and then disengage the
differential lock again.
When the differentials are locked, drive parts may become

overloaded. Particular care must therefore be taken when
driving with locked differentials:
- Use the differential locks only when driving on very

difficult ground conditions ( sand, mud, loose ground).
- Engage the differential locks only shortly before

coming to the obstacle and switch off again
immediately after having overcome the obstacle.
- Engage and disengage the differential locks only with

the wheels at standstill.
The risk of damage to the chassis is great if the differ-
ential locks are engaged whilst drive wheels are still
spinning.
- When the transverse differential is locked, the vehicle

may only be driven straight ahead. When the
longitudinal differential is locked, the steering wheel
may be turned very carefully.
- Use differential locks only when the crane is in the

transport condition or when the gross weight does not
exceed the transport weight. On no account should
the differential locks be engaged with the crane
erected!
- Drive carefully !
Do not start sharply !
Do not rev the engine at full throttle !
- Never drive for long distances or on normal, solid

roads with the differentials locked.
Date: 35.CW/00
bs_e075-1090/a 7/7
Hydraulic Suspension 10
Date: 35.CW/98
bs_e075-1100/a 1/13
10
Z 75 155
Date: 35.CW/98
2/13 bs_e075-1100/a
10.1 Suspension Circuits

(Z 75 155)
Both axles of the crane have hydraulic suspension.
The hydraulic suspension system consists of 4 suspension

circuits:
- Suspension circuit I - axle 1, left

- Suspension circuit II - axle 1, right
- Suspension circuit III - axle 2, left
- Suspension circuit IV - axle 2, right
The control elements for the hydraulic suspension system are

housed in the dash panel.
Date: 35.CW/98
bs_e075-1100/a 3/13
10
Z 155 087
Date: 35.CW/98
Z 75 156
4/13 bs_e075-1100/a
10.2 Level Adjustment
In order to drive the mobile crane in transport position (site or

road travel), all the suspension cylinders must be in the middle
position.
If the suspension is defect, the level on the suspension cylin-

ders can be measured.
The distance between the mounting eyes of the suspension

cylinders (1) is thereby X = 600 mm. This value represents the
average value of the individual hydraulic circuits I, II and III
(Z 155 087).
Adjust the hydraulic suspension system as follows:

(Z 75 156)
1. Park the crane on level and horizontal ground and

engage hand brake valve (19) to prevent the vehicle
from rolling away.
2. Start the engine (gear in neutral) and set the switch (119,
S301.1) to drive operation.
3. Switch (48, S 360 “Raise axles”) is not actuated.
4. Press and hold rocker switch (47, S 370.1) to raise or

lower the overall level of the crane until all the suspension
cylinders are level.
The 4 indicator lights (65, H 373), (66, H 372), (67, H 371),
(68, H 374) go out. If one of the indicator lights comes
on again, for example, adjust level again.
The hydraulic suspension of the crane is only correctly ad-

justed when all 4 indicator lights (65, H 373), (66, H 372), (67,
H 371), (68, H 374) have gone out.
5. To adjust a particular suspension circuit, the suspension

can be levelled individually using the rocker switches (43,
S 363.1), (44, S 362.1), (45, S 361.1), (46, S 364.1).
Date: 35.CW/98
bs_e075-1100/a 5/13
10
Z 75 157
Date: 35.CW/98
6/13 bs_e075-1100/a
10.3 Monitoring the Level

(Z 75 157)
Four indicator lights are provided in the driver's cab for

constant monitoring of the level in the hydraulic suspension
circuits.
They are assigned to the suspension circuits as follows:
- Indicator light (65, H 373): Suspension axle 1, left
- Indicator light (66, H 372): Suspension axle 1, right
- Indicator light (67, H 371): Suspension axle 2, left
- Indicator light (68, H 374): Suspension axle 2, right
If one of the indicator lights (65, H 373), (66, H 372),

(67, H 371), (68, H 374) comes on or does not go out when
driving, the crane must be stopped and the corresponding
suspension circuit(s) charged again. Flickering of the
indicator lights while driving is normal.
Date: 35.CW/98
bs_e075-1100/a 7/13
10
Z 75 158
Date: 35.CW/98
8/13 bs_e075-1100/a
10.4 Locking the Suspension (Travel Operation)
The hydraulic suspension system must be fully retracted for

"driving the crane on the construction site in erect condition",
i.e. all axles are raised and the crane is lowered.
- The hydraulic suspension must not be locked when

the crane is driven on the construction site or on the
road in transport condition. In this instance, locked
suspension would lead to extensive damage to the
crane chassis.
- As long as the crane is in the "mobile" operating
condition, separate rear axle steering may not be
engaged.
- The hydraulic suspension system must be fully
retracted for "driving the crane on the construction
site in the configured condition with load attached".
10.4.1 Engaging Procedure

(Z 75 158)
1. Actuate toggle switches (43, 44, 45, 46) until the

suspension cylinders are fully retracted (suspension in
block position, axles fully raised).
2. Extend the outrigger cylinders (see Sect. 11) until the out-
rigger plates are just above the ground.
3. Actuate switch (48, S 360 “Raise axles”).
If the crane is in a slanting position, extend the outrigger

cylinders again and support the crane on the outriggers.
The suspension level must not be adjusted if the crane

is in the "mobile" operating condition or in the erect
condition.
Date: 35.CW/98
bs_e075-1100/a 9/13
10
Z 75 159
Date: 35.CW/98
10/13 bs_e075-1100/a
10.4.2 Disengaging Procedure

(Z 75 159)
1. Retract the outrigger cylinders and move the crane into the
transport position.
2. Actuate switch (119, S301.1) to switch to drive operation.
3. Actuate switch (48, S 360) and switch off the enable

function for “raise axles”.
4. Adjust hydraulic suspension as described in Section 10.2.
10.5 Height Adjustment
The level of the 4 suspension units can be individually

adjusted. This can always be useful, e.g.:
- If the headroom is not sufficient for the crane;

- If more ground clearance is required;
- If the mobile crane is stuck during off-road operation;
When adjusting the height, always leave a small distance to

upper or lower stop position of the suspension cylinders so
that the suspension still has a minimum effect in reserve.
Date: 35.CW/98
bs_e075-1100/a 11/13
10
Z 75 160
Date: 35.CW/98
Z 170 532
12/13 bs_e075-1100/a
Individual height adjustment can be carried out as follows:

(Z 75 160)
- Press push-button (43, S 363.1):

“Raise and lower level at front left-hand side”

“Raise and lower level at front right-hand side”

“Raise and lower level at rear left-hand side”

“Raise and lower level at rear right-hand side”
Drive extremely carefully and then set the level back to

"Road travel" immediately (see Section 10.2).
After any special adjustment, the hydraulic suspension

must be set back to transport position for driving ( see
Section 10.2).
10.6 Raising the Axles
The axles must be raised after the crane has been supported
on the outriggers (see also Section 11).
To raise the axles, actuate button (48, S 360).
The axles are raised by pressing button (4, S 360.1 or

S 360.2) in the left and right-hand switch boxes inside the
crane chassis (only possible in travel mode, switch 119,
S 301.1; Z 75 064); (Z 170 532).
After any special adjustment, the hydraulic suspension

must be set back to transport position for driving ( see
Section 10.2).
Date: 35.CW/98
bs_e075-1100/a 13/13
a/43/98
Outriggers 11
Date: 15.CW/05
e25-1110-114 1/21
11
Z 170 653
Date: 15.CW/05
2/21 e25-1110-114
Outriggers 11
11.1 Instructions for Supporting the Crane on the

Outriggers
Before every crane operation, extend the outriggers. If you

wish to work with the crane set down on the wheels, the
load limit device program "free on wheels 360o" must be
selected.
Caution - risk of crane overturning!
- Always extend the outrigger beams to the corresponding

colour mark.
- The outrigger plates need some room for lateral adjustment

while the outriggers are being extended.
- After extension of the outrigger cylinders, the axles must be

raised.
- The crane must be levelled in all directions (360o).
- Ensure flat ground with adequate load-bearing

capacity for positioning of the outrigger plates!
(See Section 11.5)
The maximum ground pressure is approx. 190 t/m2.
Depending on the load bearing capacity of the ground, the

ground pressure must be reduced by using solid support
plates.
The crane should generally be supported for all opera-

tions. The crane may be used without supports only in the
cases which are expressly stated in the load table.
For safety reasons, the outrigger beams can only be extended

on the side on which the corresponding control panel is
located. The crane operator can thus only extend the outrigger
beams which he can constantly observe.
The outriggers should generally be extended to the maximum

support area of 5.9 x 5.95 m .
11.1.1 Support Pressure Display (optional)

(Z 170 653)
The support pressure display shows the load per support

cylinder in tons.
The support pressure that is displayed lies within the

Date: 15.CW/05
tolerance range of ± 10 % of the actual support pressure,

depending on the hydraulic oil temperature in the
outrigger cylinders.
e25-1110-114 3/21
11
Z 170 505
Date: 15.CW/05
Z 170 506
4/21 e25-1110-114
Outriggers 11
11.2 Arrangement of the Control Elements for the Outrig-

gers
The control panels for operating the outriggers are located on

the left-hand and right-hand sides of the mobile crane in the
crane chassis.
Outriggers left-hand side

(Z 170 505)
1 S 501 "Outrigger cylinder front right-hand side"

2 S 503 "Outrigger cylinder front left-hand side"
3 S 505 "Outrigger front left-hand side"
4* S 360.1 "Raise axles"
5 S 507 "Outrigger rear left-hand side"
6 S 509 "Outrigger cylinder rear left-hand side"
7 S 511 "Outrigger cylinder rear right-hand side"
8 Straight position indicator
The symbol on the push-buttons always determines the

function ot the outrigger cylinder.
Outriggers right-hand side

(Z 170 506)
1 S 508 "Outrigger cylinder rear left-hand side"

2 S 510 "Outrigger cylinder rear right-hand side"
3 S 504 "Outrigger rear right-hand side"
4* S 360.2 "Raise axles"
5 S 506 "Outrigger front right-hand side"
6 S 500 "Outrigger cylinder front right-hand side"
7 S 502 "Outrigger cylinder front left-hand side"
8 Straight position indicator
The symbol on the push-buttons always determines the

function ot the outrigger cylinder.
* only possible in travel mode

Date: 15.CW/05
e25-1110-114 5/21
11
Z 30 039
Date: 15.CW/05
6/21 e25-1110-114
Outriggers 11
11.3 Before Extending the Outriggers

(Z 30 039)
1. Start the vehicle engine (see Section 4).
2. Engage the parking brake (18) to prevent the vehicle

rolling away.
3. Move the gear lever (17) to position “N”.
4. The crane superstructure must not be turned before

the outriggers have been extended.
5. Switch on crane operation using rocker switch (127, S

301.1)
When the crane is not supported on outriggers, it must

only be slewed when the load limit device program "on
wheels 360o" has been selected.
Date: 15.CW/05
e25-1110-114 7/21
11
Z 75 121 Z 75 122
Date: 15.CW/05
8/21 e25-1110-114
Outriggers 11
11.4 Procedure for Extending the Outriggers
Comply with the following instructions to ensure that the crane

is supported correctly and safely on the outriggers:
11.4.1 Extending the Outriggers

(Support Area 4 m x 5.95 m and 5.9 m x 5.95 m)
1. (Z 75 121, Z 75 122) Remove lock (1) of outrigger plates

(2), and pull out outrigger plates to supporting position.
Reinsert lock.
Date: 15.CW/05
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11
Z 170 505
Date: 15.CW/05
Z 170 506
10/21 e25-1110-114
Outriggers 11
(Z 170 505)(Z 170 506)
2. To extend the outrigger struts to the corresponding

outrigger support area, press button (3, S 505) or (5, S 507)
in the control panel on the left-hand side (or (3, S 504) or
(5, S 506) in the control panel on the right-hand side).
3. To extend the outrigger cylinders, press button (2 (7), S

503 (S 502)), (6 (1), S 509 (S508)), (1 (6), S 501 (S 500))
or (7 (2), S 511 (S 510)) in the control panel on the left or
right-hand side.
4. Extend each outrigger cylinder individually until all outrigger

plates are touching the ground.
5. Continue to extend the outrigger cylinders until all the axles

are relieved of weight and the crane is practically level.
6. Press button (4, S 360.1/2) and “raise axles” (completely).
When operating the outrigger control elements, the engine

speed is automatically increased to 1400/min.
The outrigger struts can only be extended on the side which

can be observed by the crane operator from his position at the
control panel. If the crane is clearly standing at an angle, this
must be corrected by continuing to extend the corresponding
outrigger cylinders. Ensure, however, that the outrigger
cylinders have sufficient extension stroke for subsequent
levelling.
7. Extend or retract the outrigger cylinders further and level

the crane to a maximum tilt of 0.1o.
Use the straight position indicator (8) for checking that the
crane is level.
When the crane has been levelled, the bubble in the spirit
level must not pass the 0o ring by more than 1 mm.
8. After every new configuration of the crane, the set level

must be checked again.
Date: 15.CW/05
e25-1110-114 11/21
11
Date: 15.CW/05
12/21 e25-1110-114
Outriggers 11
9. Check the set level once again.
If the transversal bar has come out of alignment, levelling must

be repeated.
The symbol on the push-button always determines the

function of the outrigger cylinders.
For correct levelling of the crane, all outrigger cylinders

must be operated from the control panel on one side of the
crane for fine adjustment. (In this case operate extremely
carefully if outrigger cylinders are extended which cannot
be directly observed).
Date: 15.CW/05
e25-1110-114 13/21
11
Z 30 040 Z 75 121
Date: 15.CW/05
Z 170 532
14/21 e25-1110-114
Outriggers 11

(for Driving the Crane in Transport Condition)
1. Move the boom to transport condition.
2. Make sure that the parking brake in the cab is actuated.
3. By actuating button (48, S 360), lower the axles

(Z 30 040).
When retracting the outrigger cylinders with the crane

facing downhill in the longitudinal direction, chocks
should be placed underneath the axle which first has
ground contact to prevent the vehicle from rolling.
4. Press button 1 (S 501), 2 (S 503), 6 (S 509) or 7 (S 511) on

the left-hand side or 1 (S 508), 2 (S 510), 6 (S 500) or 7 (S
502) on the right-hand side and hold until the outrigger
cylinders have been fully retracted individually.
5. Press button (3, S 505) or (5, S 507) on the left-hand side

and (3, S 504) or (5, S 506) on the right-hand side and hold
until the outrigger struts have been fully retracted
individually.
6. Remove the safety lock on the outrigger pads and move

the pads into travel mode position. Re-insert the lock.
7. Bring all axles to the proper level. (See Section 10.1).
Extending or retracting of the outriggers with a load on the

crane hook is forbidden -THE CRANE IS IN DANGER OF
TIPPING!
Date: 15.CW/05
e25-1110-114 15/21
11
Date: 15.CW/05
16/21 e25-1110-114
Outriggers 11

(for Driving the Crane in Configured Condition)
See also Section 10.4.1 "Engaging suspension lock".
Before lowering the crane onto the wheels, always check

which values with regard to configuration, superstructure
position, boom length and boom angle are permissible
(see operating instructions for the crane superstructure,
Section 5, "Driving the
Mobile Crane in Configured Condition").
The outriggers should generally be operated and adjusted

using the operating elements located in the crane chassis.
The outriggers may only be driven from the superstructure cab
if the crane is set for superstructure operation, and only in
exceptional cases (see operating instructions for the crane
superstructure , Section 5).
It must be observed that only the outrigger beams which

are directly visible to the crane operator may be moved.
Date: 15.CW/05
e25-1110-114 17/21
11
Date: 15.CW/05
Z 75 076
18/21 e25-1110-114
Outriggers 11
11.5 Permissible Ground Pressures

The following values for the load bearing capacity of various
soil types are stated in DIN 1054.
If there are any doubts regarding the load capacity of the

ground where the crane is to be situated, an inspection of
the ground must be carried out.
Soil type p
(kg/cm2)
A) Backfilled soils, not artificially compressed 0-1
B) Clearly uncultivated natural soils
1. Mud, peat, marshy soil 0
2. Non-cohesive soils, evenly and firmly

layered:
- Fine to medium grain sand 1.5
- Course sand to gravel 2.0
3. Cohesive soils
- pulpy 0.0
- soft 0.4
- rigid 1.0
- semi-solid 2.0
- solid 4.0
4. Rock surface with small fissures in

good, non-weathered condition and in
decent location:
-of closed bed secession 15.0
- of massive and columnar formation 30.0
Example (Z 75 076):
For non-cohesive fine-grain soils (p=1.5 kg/cm²), the values should
be taken from the adjacent diagram:
If p=1.5 kg/cm², the values from curve 3 are to be taken. (see
table)
With a maximum outrigger force of (Fs=19 t) the required surface
area for the outrigger plate is (As=1.25 m²). The standard outrigger
plate supplied has a diameter of 400 mm, giving an outrigger
support area of 0.13 m2 (= 1300 cm2). This surface area can be
Date: 15.CW/05
produced by using suitable underlay plates (e.g. wooden planks

etc.) .
(Outrigger forces are to be taken from the load tables.)
e25-1110-114 19/21
11
Z 170 688
Date: 15.CW/05
20/21 e25-1110-114
Outriggers 11
11.5.1 Safety Distances from Slopes and Ditches

(Z 170 688)
The crane must be erected at a safe distance from slopes or

ditches. The necessary distance from slopes and ditches
which are not re-inforced also depends on the soil type.
The clearance from the edge of the ditch/slope (X) must

equal at least 2 m.
As a general rule the following applies:
- for loose or backfilled soils the safety distance (a) must be

twice the size of the ditch depth (b).
The angle of the slope a must equal < 30o.
- for natural, firm soils the safety distance (a) must be as

large as the ditch depth (b).
The angle of the slope a must equal < 45o.
The safety distance is measured from the foot of the ditch (C).
Date: 15.CW/05
e25-1110-114 21/21
Parking 12
Before leaving the crane, it must be parked in a safe way so

that no accidents can occur.
Always observe the following points:
12.1 Leaving the Vehicle in Transport Condition
1. Apply the parking brake of the crane chassis.
If the crane has to be parked on a slope, additionally

block the wheels with wheel chocks.
2. The main boom head must be connected to the basic

boom using the turnbuckle (transport lock, see Sect. 5.2.1,
Z 75 045).
3. Move all control levers to the "Off" or middle "0"
position. The left-hand pilot control column must be folded
back (see Sect. 1.3.1).
4. Move the gear lever to neutral position “N”.
5. Stop the engine.
6. Switch off the ignition.
7. Switch off the heater, if necessary.
The heater fan of the standstill heating system continues

to run for 1 - 2 minutes until the heater has cooled down.
8. Close the cab on leaving.
12.2 Leaving the Crane in Configured Condition and with

Outriggers Extended
1. Lower the crane load to the ground and remove from

the hook ( whenever the crane operator leaves the
crane cab).
2. Apply the slew gear brake (see operating instructions
for the crane superstructure17.4).
3. Retract telescopes (see Sect. 18).
4. Move all control levers to the "Off" or middle "0"
position. The left-hand pilot control column must be folded
back (see Sect. 1.3.1).
5. Stop the engine.
6. Switch off the heater, if necessary.
The heater fan of the standstill heating system continues

Date: 45.CW/96
to run for 1 - 2 minutes until the heater has cooled down.
7. Close the cab on leaving.
bs_e075-1120 1/1
Towing the Crane and Towing the Crane to Start 13
13.1 Towing the Crane to Start
The engine cannot be started by towing. If the engine does not

fire during starting because the battery is partially or completely
discharged, the engine may be started using a jump lead from
the battery of another vehicle (24 V-system).
13.2 General Towing Regulations
The conditions listed in the following sections 13.2.1 to 13.2.3

must be observed. They serve to make the crane safer and
prevent further damage.
It is entirely the responsibility of the crane owner or the

recovery service commissioned by him to tow the mobile
crane.
The towing procedure is an exceptional situation, which
entails an increased risk.
If it is possible to repair the crane at the respective site, it

may not be towed away. The crane may be towed only to
the nearest workshop which can be reached. For
questions reagarding this matter, please refer to our
customer service in Zweibrücken.
In addition to the regulations listed below the respective

statutory national regulations, in particular those
concerning traffic are to be observed.
13.2.1 Towing the Crane in case of Engine demage or

defective Automatic Transmission
To tow the crane in the event of engine failure or defective

automatic transmission, the distributor gear (for 4 x 4 drive)
must be placed in neutral. In this condition, the crane must not
be towed any faster than 20 km/h and no further than 30 km.
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Z 75 070
Date: 45.CW/96
Z 75 071
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If the distributor gear is in neutral, the drive shaft must

not turn, no gear must be engaged.
The indicator light "all-terrain transmission" must come
on.
Check that the "road travel transmission" and "all-

terrain transmission" indicator lights are functioning.
- If the distributor gear cannot be placed in neutral, the

joint shaft (3) between the distributor gear (2) and
automatic transmission (1) must be removed (Z 75 070).
The crane can now be towed in road travel
transmission or all-terrain transmission.
Engaging neutral position on the distributor gear
Initial position:
- Vehicle switched to road travel, corresponding
indicator light comes on.
- The vehicle engine is switched off.
- The air supply in the compressed air system must be at
least approx. 6 bar
To switch to neutral position, proceed as follows:

(Z 75 071)
- Unscrew T-union (2) on shift cylinder (x) and line (3).
- Unscrew plug (1) on shift cylinder (x).
- Firmly secure T-union (2) with the connecting line to
connection (C) on the distributor gear.
- Connect line (3) with union (4) and screw them firmly
to connection "A".
- Screw plug (1) into connection "B".
- Move the selector switch in the cab from "road travel
mode" to "all-terrain mode".
Indicator light "road-travel mode" continues to be lit.

The joint shaft between the distributor gear and the auto-
matic transmission must not turn.
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General points to be observed when towing:
1. The driver of the towing vehicle must be able to

communicate with the driver of the vehicle being towed.
2. An authorized towbar only may be used for towing.
3. Avoid causing any oblique pull during the towing operation.
The hydraulic steering operates at a reduced output

(dependent on the speed) and is supplied with hydraulic
oil during the towing procedure by the emergency steering
pump attached to the distributor gear. This means:
- The steering times (time required to engage full left or
right-hand lock from forward steering position) for the
vehicle being towed are approx. 3 to 4 times longer
than those of the towing vehicle.
- When negotiating tight corners, a certain amount of
manoeuvring may e required.
- Considerably more effort is required to turn the
steering wheel.
4. The braking system and the traction power of the towing

vehicle must be sufficient to perform this task.
5. The spring accumulators - brake cylinders may not be

locked mechanically.
6. The compressed air for the brakes on the defective vehicle

must be fed into the braking system upstream of the four
circuit safety valve of the defective vehicle via a hose line
from the towing vehicle. Air is fed from the outside into the
air system on the left hand side of the vehicle.
(Connection M 22 x 1,5)
Stop the vehicle immediately if:
- The indicator light for the emergency steering pump

comes on during towing.
- The air pressure in the supply tanks has dropped

below 5 bar and the corresponding indicator light
comes on.
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Z 75 163
Z 75 124
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13.2.2 Towing the Crane with Defective Distributor Gear

(4 x 4 Drive)
When the crane is towed with a defective distributor gear, the

speed of the chassis engine is to be set to approx. 1200 rpm
using the manual control. Then switch the crane to
superstructure operation using rocker switch (119, S 301.1;
Z 75 163). No gear should be engaged.
If the distributor gear is damaged, the following drive shafts

must be removed before the crane is towed.
(Z 75 072)
- Drive shaft (3) between the automatic transmission (1) and
the distributor gear (2), (4 x 4 drive)
- drive shaft (4) between axle 1 and distributor gear
(4 x 4 drive)
- drive shaft (5) between axle 2 and distributor gear
(4 x 4 drive)
13.2.3 Towing the Crane in the event of Engine Failure or

Defective Automatic Transmission (4 x 2 Drive)
To tow the crane in the event of engine failure or defective

automatic transmission without distributor gear (4 x 2 drive),
the joint shaft (3) between the automatic transmission and the
intermediate bearing (2) must be removed (Z 75 124). Here
again the towing speed must not exceed 20 km/h nor the
distance 30 km.
To ensure that the road and operational safety of the

vehicle is not endangered, this work may only be
performed by trained specialist personnel.
13.3 Towing the Crane Free on Soft Ground
Towing of the stuck vehicle where the wheels have dug into the
loose or soft ground must be performed with great care,
particularly if the crane superstructure is in configured
condition.
Pulling out in the direction of travel is not permitted. The ring in
the front bumper brace is only intended for towing the vehicle
on solid ground.
Date: 45.CW/96
If it is not possible to tow the crane out in a straight line, a

deflection point between crane and towing vehicle may be
arranged. Ensure that the air pressure in the brake system is
sufficient.
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Heating and Ventilation 14
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14.1 Operating the Heating and Ventilation
Hot water heating (independent of engine)
This heating system has its own water circuit.
With the thermostat control (17; Z 75 057), the temperature in

the cab is infinitely variable.
In order to accelerate air circulation in the cab, a blower can

also be activated using switch (52, S 191; Z 75 056).
The heating is switched on and off via the heater time switch
(53; Z 75 056), as described on pages 4 and 5 of this section.
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Safety Equipment 15
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Safety Equipment 15
15.1 Load Limit Device Console (LMB)
For the crane to operate safely, it is essential that the load

limit device functions in original condition.
15.1.1 Operating Elements

(Z 75 180)
F1 Function key 1
- to change display settings
- call up diagnosis menu
to change solenoid valve settings (for service
personnel only)
F2 Function key 2
to select the crane configuration - boom point
with 0o hoist tackle (see section 15.2)
ENTER Enter key

To confirm commands
QUIT Quit key

- activate / deactivate buzzer
- to leave the menu points without saving the
changes
- to save the actual load as the tara load
(net load display jumps to “zero”)
Arrow keys
- to change the display
- to change the crane configuration, depending on
display
- to change the input values
All crane configurations enabled for this crane are set using
these operating elements. Depending on the display design, the
operating elements are assigned the displayed functions. Using
the arrow symbols shown in the display, you can select the
desired crane configuration , confirming the selection with the
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ENTER key.
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Safety Equipment 15
15.1.2 Display Contents During Crane Operation

(Z 75 180)
The crane configuration last set is displayed.
(1) Bar display of the exploited load capacity
(2) Percentage display of exploited load capacity
(3) Current gross load

The gross load includes the weight of the hook block,
hoist rope and all lifting tackle.
(4) Load limit device warning or shutdown
(5) Max. load in accordance with load table
(6) Current net load

The net load is the actual load on the hook block
without the lifting tackle. Display errors are possible
as a result of external factors, eg wind acting on the
crane and/or load.
(7) Slewing speed *
(8) Hoist speed*
(9) Speed of luffing lowering movement*
(10) Display - telescopic section 1 is completely

retracted ( ).
(11) Percentage display of the telescopic lengths

selected
* For adjustment of the working speeds, please refer to the

section on operating instructions.
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Safety Equipment 15
(Z 75 180)
(12) Radius
(13) Outrigger support area
(14) -
(15) Angle of main boom

As soon as the main boom reaches an angle of less
than 0o to the horizontal and the main boom is not
completely retracted, the load limit device shuts down
the movement. The main boom can only be luffed
further if the load limit device is bridged.
The crane operator, however, carries full responsibility if

the load limit device is bridged.
(16) Head height
(17) Main boom length
(18) Reeving number
The displays for the radius (12) and main boom length (17)
flash and at the same time „MIN“ and „MAX“ are blended in
(depending on the crane configuration) as soon as the
corresponding limit value is reached. The load limit device then
switches off the crane movement.
When luffing to the minimum or maximum main boom angle,
the load limit device also switches off and the symbol or
flashes.
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Z 75 181 Z 75 182
Z 75 183 Z 75 184
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Safety Equipment 15
15.2 Operating the Load Limit Device
After every change to the configuration of the crane, the crane

operator is responsible for adjusting the load limit device to the
new conditions.
The correct settings for the load limit device are absolutely
essential to ensure that the system and crane can function
correctly. For this reason, the crane configuration may
only be set by crane operators who are fully conversant
with the load tables and operation of the system.
The following must be entered or confirmed:
- Main boom operation (Z 75 181) or operation with
- hoist or with 0o hoist equipment (lifting beam)

(Z 75 185)
- Main boom extension or boom point

(Z 75 181)
- angle of the main boom extension (0o, 30o)

(Z 75 182)
- length of the main boom extension (7.1 m; 13 m)

(Z 75 182)
- position of the boom point (short, medium, long)

- Boom point with 0o hoist tackle (head lifting beam)
(Z 75 186)
- Reeving number (Z 75 183)
- Outrigger support area (Z 75 184) 2.25 m; 4.0m; 5.9 m or

- Mobile operation with and without load (Z 75 184) 0/180o and
- Working unsupported on wheels 360o
In the crane configuration with the main boom extension or

assembly top section the operating modes „mobile operation“
and „2.25 m support area“ may not be selected and are
therefore phased out.
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Z 75 187
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Safety Equipment 15
15.2.1 Setting the Screen Contrast (Z 75 187)
After pressing the F1 key, you can change the screen contrast
(1) and brightness (2). To leave the display you must place the
cursor in front of the end symbol (3) and press ENTER.
15.2.2 Displaying the Fault Codes (4)
The fault codes stored in the CGC can be called up by pressing

the F1 key.
Only the last 10 fault codes can be called up. If a new fault oc-
curs, the oldest stored fault code is deleted.
15.2.3 Data Logger (Optional)
If the diskette symbol (5) appears in the display, a data logger

is installed and active.
15.3 Hoist Limit Switch
Before operating with the crane, the following electrical

connections must be checked to ensure that the components of
the load limit system are connected correctly and in
accordance with the configuration of the crane.
15.3.1 Assembling the Hoist Limit Switch
When the crane is being operated only with the boom and
without the boom extension, no extra connections are
required.
You should, however, ensure that the hoist limit switch weight
of the main boom hoist rope is fitted.
With an even number of rope falls, the hoist limit switch weight
is fitted to the "dead end" of the hoist rope.
With an odd number of rope falls, the hoist limit switch weight is
fitted to the rope fall with the lowest operating speed.
(see Sect. 22)
When the crane is being operated with a main boom extension

or top section, the particular plug-in cable connections must be
changed round. The hoist limit switch shift weight of the main
Stand: 02.KW/00
boom is then uncoupled, and is fitted and secured to the main

boom head on the appropriate bracket. (see Section 21)
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Safety Equipment 15
The hoist limit switch can be fitted on the right and the left-hand
side.
If the hoist limit switch weight has not been correctly

positioned, the hoist limit switch system cannot function
correctly. When working with an extension/top section, a
weight may not be fitted on the hoist limit switch of the
main boom.
15.3.2 Caution, Function Test of the Hoist Limit Switch
The following inspections must be carried out carefully to

prevent damage to the crane or injury to persons.
The way these inspections are carried out determines
whether the load limit system will function smoothly or
not.
If the crane operator is not able to clearly observe the approach

of the hook block towards the sheave head, he should appoint
a banksman for the purpose.
The crane operator must be prepared to stop the crane
immediately if the load limit device is not functioning correctly,
ie if the STOP symbol fails to light up, the acoustic alarm does
not sound and dangerous crane movements are not shut down.
1.) Check the hoist limit switch warning and the acoustic alarm
by lifting the hoist limit switch weights manually.
2.) Carefully pull the hook block with the main hoist against the
hoist limit switch weight.
As soon as the hook block raises the weight, the acoustic
alarm must be triggered, the hoist limit switch warning must
light up and the main hoist must be switched off. Lower the
hook block somewhat to rectify this condition.
3.) Now telescope out to create a possible hoist limit condition.

As soon as the hook block raises the weight, the acoustic
alarm must sound, the hoist limit switch warning must light up
and the telescoping procedure must be shut down.
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Z 115 164
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Safety Equipment 15
If the warning and acoustic alarm fail to function as described

and the crane movements are not shut down, the system is not
working problem-free. The fault must be rectified before work
with the crane is resumed.
4.) If the crane is fitted with the main boom extension or a top
piece, the testing procedure must be repeated for the hoist
limit switch on these.
Once correctly adjusted, the load limit system operates fully

automatically.
The crane operator must therefore be fully conversant with the
operating elements of the load limit device and must set all
switches correctly before carrying out work with the crane.
All settings must be checked by raising a known load and
comparing it to the information displayed on the load limit
device.
The values of the load table comprise the weight of the hook
block, the sling ropes and the other load handling devices.
These weights must be deducted from the values of the load
table in order to attain the net load to be raised.
15.4 Troubleshooting
(Z 115 164)
If a fault occurs in the control system, a fault list appears on the

display (for a list of the fault codes see the following page).
Each fault must be confirmed with the „Acknowledge key“.
Each time the ignition is switched on, all faults which have not
yet been rectified are displayed again.
To call up the stored fault code list, see 15.2.2.
Faults in the electronic microprocessor must be dealt with by

trained service personnel from Mannesmann Dematic AG.
Malfunctions in the load limit system which have been caused

by the stipulated ranges being exceeded or by mistakes in
operation on the part of the crane operator, are indicated on the
LCD display together with an explanation.
These faults can normally be rectified by the crane operator
himself.
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15
15.4.1 Fault Codes
Fault code Fault description
E502 Length transducer telescoping section defective

E503 Angle transducer defective
E504 Pressure transducer defective
E506 Hoist limit switch: Short circuit or

potential divider resistance too small
E507 Hoist limit switch: circuit break or
potential divider resistance too large
E521 CGC fault to chassis DIGSY

E522 CGC fault to superstructure DIGSY
E523 CGC fault to superstructure and chassis DIGSY
E530 Signal interruption Joystick left

E531 Signal interruption Joystick right
E532 Direction contacts Joystick left
E533 Direction contacts Joystick right
E540 No internal or external release of

hydraulic module 1
E542 No system data and/or magnetic data stored

in hydraulic module 1
E551 Proportional valve channel open or

short circuit in hydraulic module 1
E570 Short circuit marker of the CGC outputs

E571 Short circuit marker of the binary board
superstructure outputs
E572 Short circuit marker of the binary board
chassis outputs
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Safety Equipment 15
15.5 Service and Maintenance
The maintenance of the load limit system involves the

following tasks:
1.) Checking all cable connections in the system.

Damaged cables must be replaced immediately.
2.) Checking the insulation of the length transducer

cables and the cable guides.
Worn insulation and damaged cable guides must be
replaced.
3.) Checking that the hoist limit switches operate smoothly.
4.) Checking that the cable drum is sufficiently pre-

tensioned.
5.) Checking the pressure contact on the luffing

cylinder and the connecting hoses for oil leaks.
Personnel who have not been specially trained must only

attend to the faults listed in the maintenance table; they must
not be allowed to replace defective mechanical parts or
cables.
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Z 75 188
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Safety Equipment 15
15.6 Bridging the Limit Switch

(Z 75 188)
When the hoist limit switch (HLS) or lowering limit switch (LLS)
symbol lights up, a limit switch is triggered. The alarm sensor
sounds.
When the limit switches are bridged, indicator light (77, H 701)
must light up.
The limit switches may only be bridged under exceptional

circumstances, eg when configuring the crane (fitting or
changing the equipment parts, fitting ropes etc.).
Operating the crane with the limit switches bridged is

prohibited. RISK OF ACCIDENTS
The hoist limit switch is bridged with key-operated pushbutton

(56, S 701).
To bridge the lowering limit switch, the camswitch on the hoist

drum must be bridged.
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Z 75 189
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Safety Equipment 15
15.7 Bridging the Load Limit Device

(Z 75 189, Z 75 190)
Operation of the load limit device can be observed on the bar

display (1).
The bar display is divided into 3 fields, each of a different col-

our:
(A) Green field:

Crane in safe operating range
(0 - 90 % of the load torque)
(B) Amber field:

Prewarning range (90 - 100 % of the load torque)
Prewarning symbol flashes
(C) Red field:

Overload range (over 100 % of the load torque)
Overload symbol flashes.
In addition to this visual check, the buzzer signal
sounds. The load limit device switches of the movements
"Raise load", "Telescope out" and "Lower luffing gear".
The QUIT key can be used to switch off the acoustic alarm.
This function remains uninterrupted until the overload signal
sounds again.
The load limit device can be bridged by means of the key-oper-

ated push button (55, S 700).
Indicator light (76, H 700) comes on when the load limit device
is bridged.
Under no circumstances should the load limit device be bridged

in order to increase the load torque.
Raising the load with the load limit device bridged is

hazardous and is prohibited.
A load may only be raised using the hoist.

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Notes on Operation 16
16.1 General Notes on Operation
With all crane configurations the boom system may only be

erected, when the expected wind speeds (weather forecast)
are also permissible for operatiing the crane.
Observe the permissible wind speed.
Wind speed Procedure
Up to 9.8 m/s Crane operation does not

need to be restricted.
Over 9.8 m/s Cease working with the

crane
15 m/s and above Telescope the main boom

in, the main boom extension
can remain in the operating
position. As far as possible,
position the boom system
into the wind.
20 m/s and above Set the main boom system

in transport position.
The applicable national regulations must also be adhered

to.
The wind speed of 9.8 m/s (dynamic pressure of 60 N/m2)

allows for a load area presented to the wind of 1m2/t of load.
For loads with greater surface area into the wind please consult
the crane manufacturer.
It is part of the planning for every operation to enquire at

the meteorological office responsible about the wind
conditions to be expected.
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Z 155 063 Z 75 065
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To enable the wind speed to be determined precisely, the

crane may be fitted with an air speed indicator (anemometer).
The air speed indicator consists of two elements:
a) a rotor (Z 155 063), secured to the head of the main

boom or main boom extension;
b) an indicator (75) in the crane cab, on which the wind

speed can be read off in m/s. (Z 75 065)
If the crane is to be switched off for longer periods, e. g. at

night, without supervision, the main boom must be
retracted. If winds stronger than 15m/s are expected, set
the main boom system in transport position.
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16.1 General Notes on Operation
- When operating the crane with the main boom

extension, the following must be observed:
* the hoist limit switch on the hoist rope must be connected to

the plug of the main boom head.
* the shift weight of the hoist limit switch must be secured on

the main boom head or refitted to the main boom extension.
If there is no hoist rope reeved, the shift weight must be

suspended in the holding device provided.
- The working loads indicated in the load tables are

reduced in operation with the main boom extension in
the travel lock (see Notes on Crane Operation).
- Crane operation with additional equipment fitted:
* The lifting of loads simultaneously on the main boom

and the main boom extension is prohibited.
* The lifting of a load on the main boom with main boom

extension free of load is prohibited. Special duty charts
including working load reductions for configurations not
designated must be obtained.
These duty charts can be purchased from the spare parts
centre in Bierbach.
- The crane may be operated with the main boom extension

only with the crane supported on outriggers. The crane
may be operated without being supported on outriggers
only during main boom operation, and in specific cases
only. The lifting capacity of the crane in consideration of
the main boom length and the counterweight fitted can be
taken from the load tables. The axle suspension must be
locked.
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16.2 Raising a Load Using Several Cranes
If a load is to be raised using several cranes, the working

procedure must be determined beforehand, in particular when:
- the cranes do not have the same lifting capacities;

- the suspended load is not of uniform shape or the
centre of gravity is not known;
- dynamic influences are expected when releasing
the load.
The load must then be raised in the presence of a supervisor.
When raising a load using several cranes, it must be ensured

during raising and lowering that:
- the permissible load for each crane is not exceeded.
- the load is not damaged by excessive strain on the
attachment points (fixing the crane hook to the load).
- the cranes lift the load at the same rate
The permissible crane load will be exceeded or the attachment

point of a load will be excessively strained if:
- a crane raises the load too quickly during the
simultaneous raising of the load;
- a crane lowers the load too slowly during the simultaneous
lowering of the load.
Operators are recommended to avoid making full use of the

max. permissible load.
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16.3 Checking the Safety Measures
Before work is begun, i.e before a load is lifted, the following

points are to be checked:
- Crane chassis suspension system is switched to "raise

axles".
- Underlying ground is firm enough to support the weight of

the crane.
- All 4 outrigger struts are extended to the support area

given in the duty chart.
- Outrigger plates are secured.
- Crane is in level position.
- Crane is not situated near a ditch or sloping ground.
- All axles are without load, i.e no wheel is in contact with

the ground.
- No live cables are situated within the operating radius of

the crane.
- Crane is positioned such that it can be operated with a

minimal operating radius.
- There are no obstructions which may restrict necessary

crane movements.
- the axles are locked during travel operation

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Z 75 214
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16.4 Operating Information on Pilot Control
Electric pilot control
The control levers have differing effects on the various crane

movements.
1. Crane movements dependent on engine speed:

- Hoist up / down
- Luffing gear up
For these crane movements, proportional valves which are

dependent on engine speed are activated. This means that
with the lever of the pilot control sensor (control lever) in the
same position, the valves are opened wider at high than at low
engine speeds.
This ensures an adequate supply to the valves.
As a result:
with the lever in the same position, movement is, for example,
slower at 1200 rpm than at 2350 rpm.
2. Crane movements independent of engine speed:

- Retracting / extending telescopic sections
- Luffing gear down
- Slew gear right / left
These movements operate in accordance with a fixed control

characteristic which cannot be altered by external control
elements (e.g. rocker switch on control lever when operating
telescopic sections).
As a result:
movement speed remains the same even if engine speed is
increased (throttle opened).
3. Crane movements altered at the press of a button:

- Luffing gear down
- Hoist up/down (switchover via button (112), Z 75 214)
- Slew gear right / left
The speed of these movements is not dependent on engine

speed. In the pilot control levers there are rocker switches
which can be used to vary speed manually. This device is
designed to enable more sensitive operation. When the buttons
Date: 5.CW/97
are actuated, speed is indicated (in %) on the CGC display.
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Z 75 165
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This also remains visible a short time after the buttons have
been activated. The display then jumps back to the previous
display mode. The speeds which were last set remain stored.
4. High-range button
The high-range button at the right-hand of the pilot control

sensor is only active for the following:
- Hoist up / down
- Luffing gear up
i.e. crane movements dependent on engine speed.
This means that within a given speed range, the control current
to the proportional valve is readjusted proportionally to the
change in engine speed in the high range.
5. Speed reduction in the pre-warning range of the

load limit device
On reaching the pre-warning range of the load limit device (90

% of max. load), the speed of the movement currently being
activated is reduced to 50 %.
16.5 Emergeny Control

Z 75 165
The crane has the option of emergency control. This is inteded

to offer the crane driver the possibility of continuing work
should the SPC fail. For this, the outputs of the hydraulic card
are divided up via switch (61, S 710) on the dashboard.
Using the direction keys in the pilot control transmitters, an
electrical current is fed directly onto the proportional valves via
a potentiometer.
It is possible to regulate the operating speed with a
potentiometer (29, R 710), as the pilot control lever can no
longer be used for driving sensitively.
The load limit device and hoist limit switches remain not
active during emergency operation.
When luffing down, the potentiometer must be set to 0.

You first have to initiate the movement and then slowly
turn up the potentiometer until the movement is
Date: 5.CW/97
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Slewing 17
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Z 75 166 Z 75 153
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Slewing 17
17.1 Preparations for Slewing
Ensure that the crane has been supported correctly on the

outriggers (see Sect. 11).
When operating with the crane on the wheels, the axles must
be raised and locked. The load limit device program "on wheels
360o" must have been selected.
Before turning, make sure that the mirror has been folded
out of the way (danger of it being shorn off if the boom
angle is too low).
- To fold away the mirror rod (1), loosen the clamps (2) and
retaining hooks (3), pull out the mirror rod (1) and fold down
completely (Z 75 166).
The mirror rod is folded into the driving position analogously
in the reverse order.
Release the slew gear brake by pressing switch (120, S 14) on

the console of the left pilot control lever. (Z 75 153)
Raise the boom sufficiently high for it not to catch on other

parts of the crane.
(See Section 19)
All control equipment for slewing is located in the cab.

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17
Z 75 195
Date: 45.CW/96
Z 75 198
4/7 bs_e075-1170-193
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Slewing 17
17.2 Slewing the Superstructure

(Z 75 195)
To slew the superstructure, proceed as follows:
- Turn lever (6) to the right R,

Slewing clockwise
- Turn lever (6) to the left L,

Slewing anticlockwise
- Lever (6) must not be switched from one slewing position

to the other; it must first be allowed to rest in the "Off"
position. Do not switch on slewing in the opposite direction
until the superstructure has come to a halt.
The control levers have been allocated in accordance with your

specification and may differ from the allocation shown here.
Please observe the symbols on the side screen of the cab.
- The superstructure may be slewed only within the

range of reach for which lifting capacity values are
specified in the tables.
- Do not slew above people.
- Do not jump off the crane during slewing.
17.3 Slew Speeds

(Z 75 195, Z 75 198)
The slew gear is electrically pre-controlled. Slew speed de-

pends on the position of control lever (6). A precision setting is
also possible using button (7) in control lever (6) (switch to the
right - fast; switch to the left - slow). During operation this is
indicated in % in the lower display of the Cockpit-Graphic-
Center (CGC) (7, Z 75 198).
(See also Section 16.4)
Make sure slew speed is reduced (lower scale range)

when:
- working with loads > 30 % of the maximum load
- working with a long boom
- working with main boom extension fitted
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Z 75 215
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Slewing 17
17.4 Braking the Superstructure
(Z 75 215)
To brake the superstructure, proceed as follows:
1. Place lever (6) in the "Off" position.
2. Depress pedal (9) until the superstructure comes to a halt.
If the load swings, there is a danger of the crane tipping;

therefore do not suddenly brake slewing movements. Only
work at a low slewing speed when the main boom
extension is mounted.
- Before starting crane operation, release the slew gear brake

by means of switch (120, S 14) once the crane is supported
on outriggers.
- With the slew gear brake released and the pedal not
depressed, the slew gear is switched to idle to prevent
oblique pull as a load is raised.
- With the slew gear brake released, the superstructure

can slew of its own accord if the crane is at an angle or
as a result of wind forces. (Keep clear of buildings.)
- Before the crane cab is left, the slew gear brake must
be locked by pressing switch (120, S 14).
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Telescoping 18
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18
Z 75 045 Z 75 025
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Z 75 173
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Telescoping 18
18.1 Telescoping the Main Boom
Before telescoping, the turnbuckle (1) on the main boom

head must be removed (Z 75 045).
The main boom comprises 4 boom sections.

The outer section, i.e. the base section, which is pin locked to
the luffing cylinder and superstructure frame and 3 telescopic
inner boom sections (telescopic sections).
Telescopic section 1 is extended and retracted via a hydraulic

cylinder.
Telescopic sections 2 and 3 are connected to the 1st telescopic

section via cables. They retract or extend in synchronization
with the 1st telescopic section as soon as control lever (6) is
moved forward or backwards.
(Z 75 173)
The main boom can be telescoped out from 7.5 m to

25 m.
For telescoping with a load, please refer to Sect. 18.2.2.
When working with the crane, it is essential that the prescribed

boom lengths are observed.
When the hook has been raised up to the top and the hoist limit
switch has tripped, the main boom cannot be extended any
further. The hook must first be lowered using the hoist (see
Sect. 20).
All control equipment for telescoping is located in the crane

operator's cab.
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18
Date: 45th CW/96
Z 75 035
4/11 bs_e075-1180-193
Telescoping 18
18.1.1 Extension Length of the Telescopic Sections
The display for the load limit device (CGC) (see Section 15) is
located in the crane operator's cab and is used to control the
extension length.
The display indicates the extension lengths of the individual
telescopic sections as a percentage.
For crane operation, the extension lengths and individual

telescoping lengths corresponding to the respective
configurations and lifting capacity must be taken from the
load tables supplied.
If the extension length of the telescopic sections is at an inter-

mediate length not stipulated in the load table (and see Z 75
035) and a load is to be raised, the load displayed by the load
limit device can still be raised, using the hoist. These load
values can be smaller than the load values of the next highest
extension sequence in the load table.
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18
Z 75 173
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Telescoping 18
18.1.2 Control Levers for Telescoping

(Z 75 173)
Use the left-hand lever for telescoping:
Lever (6) forwards a - extend telescopic sections
Lever (6) backwards b - retract telescopic sections
- If the hook has reached the top and the hoist limit switch has
actuated, the main boom cannot be extended further. The
hoist must first be lowered (see Section 20.1).
- The control levers have been allocated in accordance

with your specification and may differ from the allocation
shown here. Please observe the symbols on the side
screen of the cab.
18.2 Telescoping Procedure
18.2.1 Telescoping without Load
(Z 75 173)
To telescope without load, move control lever (6) forwards (a)
or backwards (b).
The boom length can therefore be observed continuously on

the digital display of the CGC (Sect. 15).
(See Sect. 18.1.1)
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18
Z 75 173
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Telescoping 18
18.2.2 Telescoping Loads
The load tables supplied show the loads which can be lifted by
telescoping relative to boom length, extension length of the
individual telescopic sections, boom angle and hoist rope
reeving.
The telescopic loads stated in the tables are attained under the
following conditions:
- Sliding surfaces of the telescopic sections well greased.
- Normal ambient temperature (major reductions should be

anticipated if the temperature is below 0 oC).
- The actual loads to be telescoped must be reduced to the

values of the corresponding load tables.
- The values specified apply to the extension of the

telescopic sections. The values are reduced when
retracting the telescopic sections at a shallow angle.
- The extension length of the individual telescopic sections is

prescribed to form the whole length. This boom length must
not be exceeded.
- The boom angle must not exceed the values stated in the
tables.
18.2.3 Telescoping Speeds

(Z 75 173)
The telescoping system is electrically pre-controlled. The

telescoping speed depends on the position of control lever (6)
(see also Sect. 16.4).
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18
Date: 45th CW/96
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Telescoping 18
Telescoping loads (t)
) Main boom (m)

main
boom 11.9 16.3 20.7 25.0 20.7 16.3 11.9 7.5
Pos. arrangement
78o 8.0 6.5 5.5 3.3 9.0 10.0 10.0 10.0
70o 8.0 6.5 5.2 2.4 5.6 10.0 10.0 10.0
60o 8.0 6.5 4.6 1.8 2.8 10.0 10.0 10.0
50o 8.0 6.5 4.2 1.4 1.7 7.5 10.0 10.0
40o 8.0 5.0 2.9 1.2 1.2 5.0 10.0 10.0
30o 7.5 3.8 2.3 1.0 0.8 3.8 7.5 10.0
20o 3.8 1.6 2.0 1.0 0.4 1.6 3.8 10.0
10o 3.8 1.6 1.0 1.0 0.4 1.6 3.8 8.0
0o 3.8 1.6 1.0 0.5 0.4 1.6 3.8 8.0
% 25 50 75 100 75 50 25 0
EXTENSION RETRACTING
Neg. arrangement
78o 5.0 4.5 3.5 1.0 2.5 9.0 9.0 9.0
70o 5.0 4.0 2.5 0.8 1.2 8.0 9.0 9.0
60o 5.0 3.5 2.0 0.4 0.5 5.5 9.0 9.0
50o 5.0 3.0 1.5 0.2 0.5 3.3 9.0 9.0
40o 5.0 3.0 1.5 0 0.5 2.3 9.0 9.0
30o 5.0 3.0 1.5 0 0.5 1.7 6.0 9.0
20o 3.8 1.6 1.5 0 0.5 1.3 3.8 9.0
10o 3.8 1.6 1.0 0 0.5 1.1 3.8 8.0
0o 3.8 1.6 1.0 0 0 0.9 3.8 7.0
Positive arrangement = under best conditions

Negative arrangement = under bad conditions
The telescoping loads apply only with max. outrigger support

area.
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Luffing 19
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Z 75 172 Z 75 066
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Z 75 199
2/5 bs_e075-1190-193
Luffing 19
19.1 Raising and Lowering the Main Boom

(Z 75 172) (Z 75 066)
The main boom must only be raised when the mobile crane is
supported on outriggers (see Sect. 11).
Lever (16) to the right R - lower main boom

Lever (16) to the left L - raise main boom
Lever (16) springs back automatically into the 0 position when

released.
When the hook has been raised up to the top and the hoist limit
switch has tripped, the main boom cannot be lowered any
further. First activate "lower hoist"
(see Sect. 20).
As soon as the main boom reaches an angle of less than 0o to

the horizontal and the main boom is not completely retracted,
the load limit device shuts down the movement. The main
boom can only be luffed further if the load limit device is
bridged.
The crane operator, however, carries full responsibility if

the load limit device is bridged.
When luffing to the minimum or maximum main boom angle, the

load limit device also switches off and the symbol or
flashes (Z, Z 75 199).

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19
Z 75 172
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Z 75 198
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Luffing 19
19.2 Luffing Speeds

(Z 75 172)
The luffing gear is electrically pre-controlled. The speed when

raising the main boom depends on the speed of the hydraulic
pump and the position of control lever (16). For luffing down,
fine adjustment can be made using button (114) in control lever
(16) (actuate button to the right - faster; actuate button to the
left - slower). While they are being actuated, this is displayed in
the display of the Cockpit-Graphic-Center (CGC) (9, Z 75 198)
When raising the main boom, you have the option of using the
high range key (111) which is located on the front of the right-
hand control lever.
Ensure that the luffing speed is kept low (lower scale

value) when operating:
- with loads > 30 % of the working load value
- with long main boom
- with fitted main boom extension
Using the high range is not permitted here.
To achieve a progressive acceleration of operating move-

ments, the particular crane movement must already have
been introduced before the high range is switched on.
Date: 02th CW/00
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Hook Operation "Hoist" 20
Date: 32th CW/03
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20
Z 75 026
Date: 32th CW/03
Z 75 171
2/5 bs_e075-1200-193a
20.1 Raising and Lowering the Load

(Z 75 026) (Z 75 171)
The hoist of the crane is located on the base section of the

boom.
Lever (16) forwards a - lower load
Lever (16) backwards b - raise load
- The "raise load" movement is automatically shut down

when:
* the load limit device has shut down.
*The hook block has reached the hoist limit shut-down.

It is possible to lower the load.
- The "lower load" movement is automatically shut down

when the lower limit switch for hoist 1 has been reached.
It is possible to raise the load.
The lower limit switch switches off "lower load" when the
hoist rope has been unreeled from the rope drum as far as is
permitted. At least 3 complete rope windings must then be
remaining on the rope drum.
Risk of accidents!
Operation of the crane is only permitted when at least 3
complete rope windings remain on the drum.
Otherwise there is a risk that the load could fall down with
the rope and attachment equipment.
- Control lever (16) springs back automatically to the 0

position when released.
- As soon as the hoist begins to turn, you will feel a defi-

nite vibration in control lever (16) at point (115).

Date: 32th CW/03
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20
Z 75 171 Z 75 027
Date: 32th CW/03
Z 75 198
4/5 bs_e075-1200-193a
20.2 Hoist Speeds

(Z 75 027) (Z 75 171)
The hoist is electrically pre-controlled. The hoist speed

depends on the speed of the hydraulic pump and the position
of control lever (16). It is also possible to increase the speed
using the high range (see also Sect. 16.4).
A precision setting is also possible using button (113)
(switchover via button 112) in control lever (6) (switch to the
right - fast; switch to the left - slow).
While they are being actuated, this is displayed in the display of
the Cockpit-Graphic-Center (CGC) (8, Z 75 198) (see also
Sect. 16.4).
It is also possible to increase the speed using the high range

The high range for the hoist remains in operation for as long as
button (111) on the right-hand control lever is held down.
The high range for the hoist must only be actuated :

- with a small load (max. 30 % of the working load
value)
- without load
- when the main boom extension is not fitted.

To achieve a progressive acceleration of operating move-

ments, the particular crane movement must already have
been introduced before the high range is switched on .
Date: 32th CW/03
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Main Boom Extension 21
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21
Z 75 092
Z 75 093 Z 75 142
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Z 75 094
2/41 bs_e075-1210-193
21.1 Fitting the Main Boom Extension
For transport position, or for as long it is not required, the main

boom extension can be carried on the main boom. Here, the
main boom extension is folded on the side of the main boom
and locked (Z 75 092). The permissible axle loads must be
observed.
When the main boom extension is folded on the side, the

load values given in the tables are reduced.
21.2 Folding the Main Boom Extension
Before folding out, the main boom must be fully retracted (anti-
torsion fittings must be in position).(Z 75 093)
The protection bar on the underride guard must also be folded

forwards. For this, withdraw pin (1) at point (A) and pin lock the
bar after folding it again into point (B), (Z 75 094).
Now place the main boom into the 0o position (horizontal).
Never try to fold the main boom extension in the transport

position of the crane. Risk of accidents.
(Z 75 142)
If the locking plugs (1) are used in place of locking springs
(2), you may only use the pins (3) which are cylindrical (A)
in shape at one end. The locking plugs (1) may not be used
in pins (4) as these fall out by themselves.
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Z 75 095
Z 75 096 Z 75 098
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Z 75 097
4/41 bs_e075-1210-193
21.2.1 Folding the 7.1 m Basic Boom out of the Transport

Position into Operating Position
o
Operating position 0
1. Remove pin (2) at point (C) and after swinging, insert

it again at the same place and guard; loose hook tightener
(14), (Z 75 095).
2. Unlock stop pin (7) on the roll way (B) (Z 75 096).
3. Swing the main boom extension around lateral

rotation point (E) (Z 75 097) until the right-hand fork heads
line up with the holes of the locking eyes on the boom head
(D).
It is advisable to fasten a rope to the head of the basic

boom of the extension for guiding it.
With this, the main boom extension can then be pulled as
well as braked (Z 75 098).
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Z 75 099
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4. Lock the main boom extension at fixing points (D1) and

(D2) with pins (3) and guard with locking spring (4).
(Z 75 099)
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Z 75 100
Z 75 101
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5. Withdraw pins (5) and (6) from lateral rotation point

(E) and (G) using a bell crank. (Z 75 100)
Do not remove the pins from rotation point (E and G) until

the extension has be pin locked and guarded at points
(D1 and D2).
6. Swing the main boom extension round to the front.

Here it must be ensured that the stop pin (8)
slots into place on the cross axle the left-hand (Z 75 101).
7. The main boom extension by insert pins (9 and 10) into

points (H1) and (H2) and guard with locking springs
(Z 75 102).
The pins are inserted at the top and bottom

respectively.
Both pins are driven in alternately until the locking springs
for guarding the pin can be inserted.
8. Move the hoist limit switch (1) and shift weight (2) from the
main boom head and refit it at the point on the main boom
extension provided. Remove plug (11) of the hoist limit
switch from the right-hand socket on the main boom head
and insert it into the socket on the front end of the main
boom extension. (Z 75 103)
Check that all pins and locks are secured firmly.

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Z 75 105
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9. Insert plug (19) on the basic boom into the left-hand socket
on the main boom head (Z 75 105).
10. Reeve the hook block. (see Sect. 22)
11. Set the load limit device according to the current

configuration of the crane. (see Sect. 15)
Conversion into the transport position is carried out

analogously in reverse order.
The pins at points (D1) and (D2) must not be removed until
the main boom extension has been swung back and is pin
locked and guarded again at points (E) and (G).
The use of high range during operation with the main

boom extension is prohibited.
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Z 75 106
Z 75 107
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Z 75 108
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21.2.2 Folding the 13 m Main Boom Extension from the

Transport Position into Operating Position
(Z 75 106)
When operating with the main boom extension (basic boom

and box top piece), the following must be ensured:
- the box top piece must be locked at the rear end on

the basic boom with pins (12) and (13) and guarded.
(Z 75 107)
- The box top piece must be braced at the front using

hook tightener (14) at position (R) on the basic boom and
guarded. (Z 75 108)
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Z 75 109
Z 75 096 Z 75 098
K 15
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o
Operating position 0
1. Remove pin (2) at point (C) and insert at point (D)

(Z 75 109) and guard.
2. Unlock stop pin (7) on the roll way (B) (Z 75 096).
3. Withdraw pin (15) from position (K) using a bellcrank

(Z 75 110).
4. Swing the main boom extension around lateral

rotation point (E) and the main boom extension has to be
pin locked and guarded at the main boom head (see Sect.
21.2.1; Point 2 to 7), (Z 75 111).

boom of the extension for guiding it (Z 75 098).
With this, the main boom extension can then be pulled as
well as braked.
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Z 75 112 Z 75 113
Z 75 098 Z 75 103 Z 75 105
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Z 75 114
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5. Release hook tightener (14) at point (R). (Z 75 112)
6. Swing the box top piece around pin (12) and (13).
Here it must be ensured that stop pin (16) slots into place
afterwards. (Z 75 113)

boom of the extension for guiding it.
With this, the box top piece can then be pulled as well as
braked (Z 75 098).
7. Lock and guard box top piece at points (L1) and (L2)
using pins (17 and 18). (Z 75 114)
Pins (17) and (18) are inserted at the top and bottom
respectively. Both pins are driven in alternately until the locking
springs for guarding the pin can be inserted.
8. Move the hoist limit switch (1) and shift weight (2) from the
main boom head and refit it at the point on the box top
piece provided.
Remove plug (11) of the hoist limit switch from the right-
hand socket on the main boom head and insert it into the
socket on the front end of the box top piece. (Z 75 103)
9. Insert plug (19) on the basic boom into the left-hand socket
on the main boom head (Z 75 105).
10. Insert plug (20) of the box top piece into the socket of the
basic boom thus guaranteeing the power supply for the
hoist limit switch of the box top piece. (Z 75 114)
Check that all pins and locks are secured firmly.
11. Reeve the hook block. (see Sect. 22)
12. Set the load limit device according to the current

configuration of the crane. (see Sect. 15)
The use of high range during operation with the main

boom extension is prohibited.
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Z 75 100
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Z 75 115
18/41 bs_e075-1210-193
Conversion into the transport position is carried out

analogously in reverse order.
The pins at points (D1) and (D2) must not be removed until
the main boom extension has been swung back and is pin
locked and guarded again at points (E) and (G) (Z 75 100).
21.2.3 Folding the Main Boom Extension ( 7.1 m or 13 m)

o o
from 0 into the 30 Operating Position
1. Swing the main boom extension as described

above and pin lock it to the main boom head.
2. Luff the main boom downwards until the supporting

roller rests on the ground and pins (3) and (9) at points
(D1) and (H1) are relieved of strain.
Remove the pins and store them in the bearing plates
provided on the main boom extension; guard with locking
springs (Z 75 115).
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Z 75 116
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3. Remove pin (21) and fold tension brackets ('X') into the
fitting position ; using pin (21), pin lock it to the
main boom head (P) and guard (Z 75 116).
4. Luff the boom upwards until the plastic idler lifts off the
ground.
5. Conversion into the 0o position is carried out in the

reverse order.
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Z 75 117
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22/41 bs_e075-1210-193
21.3 Fitting Procedure
If the main boom extension is transported separately, it can be

fitted in the following way:
1. Set the main boom extension down on the ground

and then build it up so that when the main boom is
telescoped out, the fixing pins can be inserted and guarded
at points (D1), (D2), (H1) and (H2). For this, the boom must
be luffed upwards slightly.
The main boom and main boom extension then form a
straight line. (Z 75 117)
Risk of crane overturning
Max. extension length is 16 m.
When the crane is supported over a small outrigge area (4

m), it is only permitted to fit the main boom extension in
the longitudinal direction of the chassis.
2. Pin lock and guard the fixing points.
3. Continue as described in point 21.2.
When fitting or removing the main boom extension, the

basic boom and box top piece must always be fitted
individually - there is otherwise a risk of the main boom
extension overturning.
Stand: 40.KW/99
bs_e075-1210-193 23/41
21
Z 75 127
Z 75 176
Z 75 130 Z 75 129
Stand: 40.KW/99
Z 75 128
24/41 bs_e075-1210-193
21.4 Boom Point (Hall Point, Option)
By using the boom point (1), (Z 75 176) on the main boom

head, it is possible to reach the maximum hoist height during
main boom operation
Fitting the boom point
1. Remove underride guard from main boom head.
2. Lift boom point from holder using rope lashings (Z 75 129)
3. Pin and lock supporting rods (1) in middle hole at point ‘A’
(Z 75 127)
4. Set down boom point on level ground before the crane and
secure to stop from rolling away. Radius indicator on CGC
must show 10.7m.
5. Fold down draw bar (2) forwards (Z 75 127).
6. Luff down main boom (length: 12.8 m) to -9o and position

behind the boom head (Z 75 128)
7. Insert boom point from the front in head axle ‘B’ and pin
and lock from both sides of point ‘B’ (Z 75 128).
If bolt (4) is fitted in bracket (3) it must be removed

(Z 75 177, Sect. 21.4.5).
Risk of damage to the hoist rope!
21.4.1 Lift loads with a main boom angle of 24-44o (medium

length boom point)
8. Pin and lock medium-length draw bar (2).

9. Luff boom down and pin and lock draw bars on both sides
at point ‘C’ (Z 75 130).
Stand: 40.KW/99
bs_e075-1210-193 25/41
21
Z 75 131
Z 75 132
Stand: 40.KW/99
Z 75 133
26/41 bs_e075-1210-193
21.4.2 Lift loads with a main boom angle of less than 24o
(short boom point)
Fitting steps 1-9
10. Luff main boom up; remove supporting rods on both sides
at point ‘D’ (Z 75 131).
11. Luff main boom down until supporting rods lie on the
ground (Z 75 131).
12. Unpin draw bars (2) on both sides at point ‘C’ (Z 75 131)
13. Pin and lock short draw bars
14. Luff down main boom further and pin and lock draw bars on
both sides at point ‘C’ (Z 75 132)
21.4.3 Lift loads with a main boom angle of greater than 44o
(long boom point)
Fitting steps 1-7
8. Pin and lock long draw bars (2)
9. Luff up main boom and pin and lock draw bars on both
sides at point ‘C’ (Z 75 133).
Do not luff up main boom too far. Otherwise the boom point
will fall onto the main boom head.
Stand: 40.KW/99
bs_e075-1210-193 27/41
21
Z 75 177 Z 75 178
Stand: 40.KW/99
28/41 bs_e075-1210-193
21.4.4 Lifting loads
- remove supporting rods

- reeve hoist rope according to load table
- key load table values into the CGC and observe these values.
- fit hoist end switch to boom point/hoist rope
- for an even reeving number (2-, 4-, 6-fold) the fixing point (2) of
the rope must be selected as shown in picture Z 75 178.
Dismantling is carried out using the same procedure in the

reverse order.
21.4.5 Boom Point in the Transport Condition
Place the boom point in the transport receptacle using the main
crane equipment and bolt and lock in position (points “X”,
Z 75 177).
Bracket (3) must be folded up for storing the boom point in

the transport position. To this end, rope protection rods
(14) must be dismantled and refitted again after the bracket
has been folded up.
(Z 75 178).
Stand: 40.KW/99
bs_e075-1210-193 29/41
21
Z 75 137 Z 75 141
Stand: 40.KW/99
Z 75 135
30/41 bs_e075-1210-193
21.5 Hook (15t) for boom point (Option 1)
Loads to a max. of 15t can be lifted without using the hoist or

hoist rope. For this purpose, a hook can be fitted to the boom
point (Z 75 137)
Procedure is as follows:
- set main boom in transport position
- unreeve hoist rope (2) and wind in completely.
Secure hoist rope to basic boom section; there is

otherwise a risk of injury from a falling hoist rope.
- release pin lock (4)

- draw out sheave axle (5) to half-length
Risk of injury from falling parts when extending the sheave

axle.
(Z 75 141)
- rope protection bars (14), rope protection plate (6),
distance sleeve (16), roller set (7) and idler (15) must be
completely removed.
- sheave axle (5) must be completely drawn out with the
rope protection plate (13) removed
- drive in sheave axle (5) to approx. half length (Z 75 135)
- push both distance sleeves (8) and clevis holder (9) onto
the sheave axle.
- insert the sheave axle (5) fully once more and secure
with pin locks (4)
The clevis holder must be mounted in the middle of the

sheave axle and protected from displacement by the
distance sleeves (8).
The sheave axle (5) must be securely locked with the pin
locking (4) (torque MA of bolts M 10= 49 Nm). Otherwise
there is a danger of the load falling or boom point being
destroyed.
- Fit clevis (11) and lock with cotter pin (10).

Stand: 40.KW/99
bs_e075-1210-193 31/41
21
Z 75 134 Z 75 137
Stand: 40.KW/99
Z 75 136 Z 75 141
32/41 bs_e075-1210-193
Max. clevis load is 15t.

Only the original clevis may be used. The load must be
raised and may only be transported when hanging freely.
The load may not be dragged across the ground.
The load may not exert any torque (12) upon the clevis (11)
or the clevis holder (9) (Z 75 136).
In order to avoid torque on the boom point, a rotating hook

(3) should be used (optional), (Z 75 137)
For this, remove clevis (11), fit rotating hook (3) and re-fit clevis
(11), locking with cotter pin (10).
For lifting loads select boom point crane configuration (short,

medium or long) on the CGC.
The dismantling of the sheave axle (5) must be carried out

using the same procedure in exactly the opposite order
(Z 75 141).
Danger of injury from falling parts when extending the

sheave axle.
lock (torque MA of bolts M 10= 49 Nm). Otherwise there is a
danger of the load falling or boom point being destroyed
(Z 75 134).
The rope protecting bars (14) must be secured with fore
locks (17).
Stand: 40.KW/99
bs_e075-1210-193 33/41
a/02/00
21
Z 75 134 Z 115 165
Stand: 40.KW/99
Z 75 141 Z 115 166
34/41 bs_e075-1210-193
21.5.1 Double Load Hook (15t) for boom point (Option 2)
Loads to a max. of 15t can be lifted without using the hoist or

hoist rope. For this purpose, a double load hook can be fitted to
the boom point (Z 115 165)
Procedure is as follows:
- set main boom in transport position
- unreeve hoist rope (2) and wind in completely.
Secure hoist rope to basic boom section; there is

otherwise a risk of injury from a falling hoist rope.
(Z 75 141)
- release pin lock (4)
- draw out sheave axle (5) to half-length
Risk of injury from falling parts when extending the

sheave axle.
(Z 75 141)
- rope protection bars (14), rope protection plate (6),
distance sleeve (16), roller set (7) and idler (15)
must be completely removed.
- sheave axle (5) must be completely drawn out with the
rope protection plate (13) removed.
(Z 115 166)
- Bolt the double load hook by inserting the bolts (20) on
the boom tip.
Make sure that the equipment is properly seated and that the
two bushings (21) in the bores of the double load hook are well
lubricated.
- Secure the bolts (20) with the two bolt locks (4).
The bolts (20) must be secured with the bolt locks (4)
(tightening torque MA of the bolts M 10 = 49 Nm). Otherwise
there is a risk of the load falling or the boom tip being de-
stroyed.
Stand: 40.KW/99
bs_e075-1210-193 35/41
21
Z 75 141 Z 75 134
Stand: 40.KW/99
36/41 bs_e075-1210-193
Max. clevis load is 15 t.

The load must be raised and may only be transported
when hanging freely. The load may not be dragged across
the ground.
For lifting loads select boom point crane configuration (short,

medium or long) on the CGC.
The double load hook is dismantled and the roller set

assembled analogously in the reverse order.
The dismantling of the sheave axle (5) must be carried out

using the same procedure in exactly the opposite order
(Z75 141).
Danger of injury from falling parts when extending the

sheave axle.
lock (torque MA of bolts M 10= 49 Nm). Otherwise there is
a danger of the load falling or boom point being destroyed
(Z75 134).
The rope protecting bars (14) must be secured with fore
locks(17).
Stand: 40.KW/99
bs_e075-1210-193 37/41
a/02/00
21
Z 75 126 Z 115 074
Stand: 40.KW/99
Z 115 089
38/41 bs_e075-1210-193
21.6 Searcher Hook (Option)
Fitting the Searcher Hook (0o Hoist Apparatus)
It is possible to lift loads up to 12.5 t without using the hoist or

hoist rope.
For this, a searcher hook can be fitted on the main boom head.
When working with the searchre hook, select the

"0o hoist apparatus" program on the CGC display.
Fitting procedure:
1. The underride guard on the main boom head must be re-

moved.
2. Unreeve the hook block and draw the hoist rope under
tension onto the hoist rope drum. Insert the rope eye (1) on
the collar of the boom basic case and draw the hoist rope
taut (Z 115 089).
(optional)
3. Actuate switch (110, Z 115 074) to switch off the hoist
function. Otherwise there is a risk of damage due to
unwanted hoist movements.
4. Secure the searcher hook on the main boom head using
pins (1) and guard with fore locks (2) (Z 75 126).
5. As required - version 1: fit only clevis (3)
or - version 2: fit clevis (3) and
spin stabilizer hook (4)
(Z 75 126)
21.6.1 Operating with the Searcher Hook
6. Raise the main boom out of transport position.
7. The searcher hook can be used anywhere in the slewing

range (360o).
The boom must not be raised higher than max. 40o as the
sheaves may otherwise be damaged by the searcher hook.
Stand: 40.KW/99
The load values in the main boom table apply.
Observe the safety instructions on the next two pages.
bs_e075-1210-193 39/41
21
Stand: 40.KW/99
40/41 bs_e075-1210-193
Stand: 40.KW/99
bs_e075-1210-193 41/41
Reeving 22
Date: 45.CW/96
bs_e075-1220-193 1/5
22
Z 155 179
Date: 45.CW/96
Z 75 067 Z 75 361
2/5 bs_e075-1220-193
a/12/98
Reeving 22
22.1 Rope Equipment and Reeving

(Z 75 067)
The safety of the crane is impaired by incorrect reeving.
Each crane configuration is assigned a corresponding

reeving number, which can be taken from the load table
supplied.
This reeving number must be set at the CGC.
The crane must be operated only with the reeving
numbers stated in the load table.
In particular, when the crane is operated with the main

boom extension, the reeving must not be smaller than that
specified in the load table for the appropriate crane con-
figuration.
During reeving, hoist rope (1) must be drawn through the

shift weight (2) of the hoist limit switch (Z 155 179).
Spin problems can occur when fitting a hoist rope which

has never been subjected to a load before. We therefore
recommend the use of a spin stabiliser in such cases
(Example: see Z 75 361).
To keep wear on the hoist rope and shift weight to a

minimum, the weight should, where possible, be secured
tp the "idle" rope.
Date: 45.CW/96
bs_e075-1220-193 3/5
c/02/00
22
Date: 45.CW/96
Z 75 020
4/5 bs_e075-1220-193
Reeving 22
22.1.1 Reeving the Hoist Rope on the Main Boom Head
The safety of the crane is impaired by incorrect reeving.

Attention should therefore be paid to the reeving examples
(Z 75 020).
Alternative reevings impair operation of the load limit device.
When reeved 7-fold the shift weight of the hoist limit

switch must not - as an exception - be mounted to the
rope closest to the fixing point, but to the rope section
between sheaves U3 and K4 .
Otherwise the hoist rope will be destroyed.
The following hook blocks can be used:
- Type 32/5/13/E (32 t) 5 sheaves, max.10 falls,

(with auxiliary sheave)
Double hook, weight 220 kg
- Type 25/3/13/E (25 t) 3 sheaves, max. 7 falls,

Single hook, weight 160 kg
- Type 10/1/13/E (10 t) 1 sheave, max. 3 falls,

Single hook, weight 100 kg
- Type 3.2/-/13/E ( 3.2 t) Hook suspension gear,

weight 130 kg
- The weights of the hook blocks, hook suspension gear,

lifting devices, etc. must be deducted from the working
loads in the tables.
Use only the original Demag hook blocks which are

intended for this crane.
Date: 45.CW/96
bs_e075-1220-193 5/5
a/40/97

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25−0000−001 1/1

2 Structure of the Mobile Crane

13 Towing the Crane and Towing the Crane to Start

14 Heating and Ventilation

20 Hook Operation "Hoist"

21 Main Boom Extension

The operating, lubricating and maintenance instructions included

Crane classification Mobile crane

as owner of a crane manufactured by us, we have produced

The complete manual comprises 3 parts:

Please note that the information contained in this manual corre

In such cases we make every effort to bring your

Pass this manual on to your crane operator and driver and

Periodic, preventive inspection and maintenance are the

You will appreciate that we can accept no claims for damage

Should you discover any mistakes when reading this manual

Terex - Demag GmbH & Co.KG

The editors would welcome your involvement.

Handover of the crane

The crane is delivered to you from the works ready for

If the crane is delivered from the works with a protective coating

The protective coating can be removed using:

Washing thinners, e.g. Conrad thinners RV 5339 E 45430

you should inspect the crane thoroughly together with our

"Instructions on using the catalogue".

1. The warranty period is defined by the sales contract.

8. Parts replaced during the warranty period become our property.

9. Correct maintenance according to the maintenance manual must be certified.

Please contact the service department if you have any

Modifications to the crane

After modifications or repairs to parts which affect the safety of

For this reason, please notify us without delay of any modifica

Observe here the information on the opposite page.

WHAT do I want to know ?

WHERE do I find the information required above ?

The complete manual comprises 3 parts:

These parts are divided by index sheets. I need Part 1

2. I glance over the bold headings of the sections until I

3. In Section 11 I then find "Arrangement of the Control

HOW can I find the specified page in the corresponding

1. I take the pages of Part 1 and flick through the pages as

2. Then, with the help of the page number on the bottom

The page number within the section is given on the bottom

Please note that this option of fast and accurate access

The headings and corresponding symbols "Danger", "Caution",

"Danger" is used for operating procedures where failure

"Caution" is used for operating procedures, mounting se

"Note" is used to indicate an important operation or mounting

Information such as „left“ and „right“ of the crane must always

This section ”Safety Instructions” provides a compact and gene-

The safety instructions for lubrication, maintenance and service

The term ”operating instructions” refers to the operating instruc-

1.2 Intended Use

The crane is designed for lifting loads.

It is prohibited to transport people with personnel carrying

Risk to life and limb!

The crane is designed exclusively for assembly operation.

If operation of the crane for part--load handling or another type

1.3 Operating Conditions and Computed Design of the

The term ”operating instructions” refers to the operating instruc-

1.3.2 Classification of the Crane

The crane is classified as follows (ISO 4301--2 and FEM 1.001):

All important components of the crane are designed and manu-