Manufacturer Specifications for Crawler-Mounted Crane

043−0000−001 1/1
Index
Manufacturer’s Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Operating Conditions and Computed Design of the Crane . . . . . . 9
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.2 Classification of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.3 Classification of the Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.6 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.7 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.8 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 21
1.3.9 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.2 Personnel Selection and Qualifications . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.3 Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.3.1 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.3.2 Gas, Dust, Steam, Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4.3.3 Crushing / Collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4.3.4 Snagging / Dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4.3.5 Crushing / Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.4.3.6 Danger Due to Slipping, Tripping, Falling . . . . . . . . . . . . . . . . . . . . . 41
1.4.4 Combination of Hazards with Combined Operation of Two or
More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4.4.1 Operating Areas of Several Cranes Overlap . . . . . . . . . . . . . . . . . . 43
1.4.4.2 Several cranes raising a load together . . . . . . . . . . . . . . . . . . . . . . . 45
1.4.5 Before Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4.6 During Operation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4.7 Following Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4.8 When Assembling and Dismantling Crane Components . . . . . . . . 63
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 71
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 73
1.6 Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
043−1000−056 1
Index
2 Structure of the Crawler−Mounted Crane . . . . . . . . . . . . . . . . . . 3

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Crawler Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Counterweight Dolly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Boom Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.3 Additional Equipment (Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6.4 Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7 Safety−relevant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.1 Ladders and Catwalks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.2 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7.3 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8 Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8.1 Signs in the Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8.2 Signs and Symbols on the Superstructure . . . . . . . . . . . . . . . . . . . . 39
2.8.3 CE−Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.4 Safety Signs (USA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 −
4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Operating Elements in the Crane Operator’s Cab . . . . . . . . . . . . . 3
4.2 Control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Add−on Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.1 General Arrangement of Construction Consoles . . . . . . . . . . . . . . . 13
4.3.2 Display and Operating Elements on the Add−on Consoles . . . . . . 15
4.3.3 Display and Control Console LLD System . . . . . . . . . . . . . . . . . . . . 19
4.3.4 Display and Operating Console for Monitoring the Engine . . . . . . 21
4.4 Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Side Panel, Seat Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.7 Mobile Control Panel for Emergency Control . . . . . . . . . . . . . . . . . . 41
4.8 Warning Light (Required version in the area of the European
Union) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.9 Warning Light (Required version in several countries outside
of the European Union) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.10 Entering / Leaving the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.11 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.12 Adjustment of the Crane Operator’s Seat . . . . . . . . . . . . . . . . . . . . 53
4.13 Charging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
043−1000−056 2
Index
5 Engine and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.1 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.1 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.2 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2.3 Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.3.1 External Start With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.3.2 External Start With the Integrated Socket . . . . . . . . . . . . . . . . . . . . 13
5.2.4 To Be Observed Following Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.5 Warming up the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2.6 Warming up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2.7 Checks With the Diesel Engine Running . . . . . . . . . . . . . . . . . . . . . 19
5.2.8 Instructions for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.9 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.10 Shutting Down With Quick Stop Fitting (Optional) . . . . . . . . . . . . . 23
5.3 Automotive Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Load Limit Sensing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5 Diesel Particle Filter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.1 Purpose Specified − Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5.2 Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5.3 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Driving the Crawler−Mounted Crane . . . . . . . . . . . . . . . . . . . . . . . 3

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.1 Main Driving Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.2 Requirements for Road Surface Conditions . . . . . . . . . . . . . . . . . . . 5
6.1.3 Regulations for Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2 Controlling the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.1 Control Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.2 Control Movements for Tailing Operation . . . . . . . . . . . . . . . . . . . . . 9
6.2.3 Options for Controlling the Driving Speed . . . . . . . . . . . . . . . . . . . . 11
6.3 Driving Without Load on the Horizontal and Angled
Road Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3.2 Driving Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Driving With Load on a Horizontal and Graded Road
Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4.2 Driving With Load on Horizontal, Even Terrain
( 0.3° Slope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.3 Driving With Load on Inclined, Even Territory
(u 0.3° Incline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 Slewing and Braking the Superstructure . . . . . . . . . . . . . . . . . . 3

7.1 Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2 Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Braking the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4 Mechanical Locking of the Holding Brake in Open Position . . . . . 9
043−1000−056 3
Index
8 Operating the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 IC−1 Crane Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1.1 Load Limit Device (LLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.1.1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.1.1.2 Bridging the Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.1.1.3 LLD Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1.2 Description of the Monitor Screens and Function Keys . . . . . . . . . 37
8.1.2.1 Opening Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1.2.2 Symbols “Main Menu of the Display and Operating Console of
the LLD System” (LLD Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1.2.3 Symbol “Main Menu of the Display and Operating Console of
the Engine and Crane Operating System” (MOT Screen) . . . . . . . 39
8.1.2.4 “System Settings” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.2.5 “Set Crane Type” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.2.6 “Set Display” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.2.7 “LLD” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1.2.8 “MOT” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.1.3 Operating the LLD System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1.3.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1.3.2 Entering the Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1.3.3 Setting the Configuration Programs for Crane Assembly . . . . . . . 69
8.1.3.4 Configuration Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1.4 “View Table” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.1.5 “Operating Range Limit” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.5.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.5.2 Setting up the Various Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.1.6 Display of the Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.1.7 Logger (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.1.7.1 Calling up the Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.1.8 “Data Logger” Screen (Data Recorder) . . . . . . . . . . . . . . . . . . . . . . . 93
8.1.9 “Windlogger” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.1.9.1 Reading out the Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.1.10 “Parameters” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8.1.11 Load Monitoring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8.1.12 Gradient and Slewing Angle Display . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.1.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.1.13.1 “Error Messages” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.1.14 “CAN” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.1.15 “I/O” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8.1.16 “Function Diagnostics” Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.1.17 Malfunction Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.1.17.1 Error−free Operation/Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.1.17.2 Failure of the Crane Control (CAN Stop) . . . . . . . . . . . . . . . . . . . . . 137
8.1.17.3 Failure of a Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.2 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.2.1 Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.2.2 Lower Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.3 Dead Man’s Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
043−1000−056 4
Index
9 Working With the Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . 3

9.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1.1 Positioning the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1.2 Working Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.1.3 Wind Speeds − Dynamic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.1.3.1 Permitted Wind Speeds With Crane Operation . . . . . . . . . . . . . . . . 9
9.2 Selection of the Functions for Crane Operation . . . . . . . . . . . . . . . 15
9.2.1 Allocation of the Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.2.2 Selection of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.3 Configuring the Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3.1 Simultaneous Operation of Derricking Gear (E) and
Luffing Gear 1 (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Luffing Gear (W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3.3 Simultaneous Operation of Luffing Gear 1 (W1) and
Luffing Gear 2 (W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.4 Operating the Reeving Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.5 Operation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5.1 Winch Selection for Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5.1.1 Operating the Derricking Gear (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5.1.2 Simultaneous Operation of Derricking Gear (E) and
Hoist 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5.1.3 Operating Range of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5.2 Luffing Gear 1 (W1) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.5.2.1 Simultaneous Operation of Luffing Gear 1 (W1) and
Hoist 2 (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.5.2.2 Operating Range of the Fly Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.5.2.3 Luffing Gear 1 as Hoist 3 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.5.3 Operation of the Luffing Gear 2 (W2) . . . . . . . . . . . . . . . . . . . . . . . . 31
Hoist Gear 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.5.3.2 Operating Range of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.5.4 Crane Operation With Double Hook Block, Hoist 1 and
Hoist 2 in Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.5.4.1 Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.5.4.2 Crane Operation With Inclination Surveillance of the
Double Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.5.4.3 Operation at Normal Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.5.4.4 Operation at High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.5.4.5 Error Messages during Operation of the Radio−transmitted
Inclination Surveillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5.5 Operation with 2 Reeved Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . 49
043−1000−056 5
Index
10 Working With the Superlift Equipment . . . . . . . . . . . . . . . . . . . . 3

10.1 Description of the Superlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.2 Modus Operandi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.3 Safety Instructions for Working With the Superlift
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10.4 Working With the Crane Without Superlift
Counterweight (SLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10.5 Working With the Crane With Superlift
Counterweight (SLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.5.1 With Standard Superlift Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.4.1 With the Tele Superlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.4.2 With variable Superlift apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11 Operating the Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . 3

11.1 Operating the Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.2 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.1 Setting the Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.2 Heating Operation Without Preselection With Ignition “OFF” . . . . 9
11.2.3 Heating Operation Without Preselection With Ignition “ON” . . . . . 11
11.2.4 Heating Operation With Preselection . . . . . . . . . . . . . . . . . . . . . . . . 13
11.2.5 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.3 Liquid Gas Heating System (Optional) . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.3.4 Shutting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.3.5 Notes on Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.4 Operating the Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . 25
11.4.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12 Parking the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12.1 Wind Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Lowering the Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13. Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

13.1. Emergency Control System with the Mobile Control Panel . . . . . . 3
043−1000−056 6
Index
14 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Preparations for Assembly Using the Radio
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.3 Tabular Collation of the Assembly Procedures . . . . . . . . . . . . . . . . 7
14.3.1 Assembly Procedures on the Superstructure . . . . . . . . . . . . . . . . . 7
14.3.2 Assembly Procedures on the Chassis . . . . . . . . . . . . . . . . . . . . . . . 7
14.3.3 Assembly Procedures on the Counterweight Dolly . . . . . . . . . . . . . 9
14.3.4 Assembling the Counterweight (CWT) . . . . . . . . . . . . . . . . . . . . . . . 9
14.3.5 Adjustment of Crossbar Hoist Cylinder (SuperLift) . . . . . . . . . . . . . 11
14.3.6 Adjustment of the Winch for Vario SuperLift . . . . . . . . . . . . . . . . . . 11
14.4 Assembly Procedures in Case of Radio Remote
Control Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14.5 Virtual Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14.6 Manual Control of Assembly Procedures . . . . . . . . . . . . . . . . . . . . . 15
14.7 Tabular Collation of the Assembly Procedures in Case of
Radio Remote Control Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
14.7.1 Assembly Procedures on the Superstructure . . . . . . . . . . . . . . . . . 17
14.7.2 Assembly Procedures on the Chassis (CR) . . . . . . . . . . . . . . . . . . . 17
14.7.3 Assembly Procedures on the Counterweight Dolly (GW) . . . . . . . 19
14.7.4 Assembling the Counterweight (CWT) . . . . . . . . . . . . . . . . . . . . . . . 21
14.7.5 Adjustment of Crossbar Hoist Cylinder (Superlift) . . . . . . . . . . . . . . 21
14.7.6 Adjustment of the Winch for Vario Superlift . . . . . . . . . . . . . . . . . . . 21
15 −
16 Driving With the Counterweight Dolly . . . . . . . . . . . . . . . . . . . . . 3

16.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.3 Description of Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.3.1 Basic Position and Angle Functions . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.3.2 Reversing (Definition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Description of Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.4.1 Counterweight Dolly Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.5 Setting the Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
16.5.1 Selection “Operation with Counterweight Dolly” (CWT Dolly) . . . . 13
16.5.2 Selection of the “Counterweight Dolly” (CWT Dolly) Menu . . . . . . 15
16.5.3 Procedure When Changing Operating Mode . . . . . . . . . . . . . . . . . . 17
16.5.4 Shutoff Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
16.5.5 Operating Mode “Trailing” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16.5.6 Operating Mode “Circular Travel” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
16.5.7 Operating Mode “Parallel Travel” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
16.5.8 Changing the Swivelling Bolster Positions . . . . . . . . . . . . . . . . . . . . 31
16.5.9 Leaving the Operating Mode “Counterweight Dolly” . . . . . . . . . . . . 35
043−1000−056 7
Index
20 Working With the Superlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

20.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.2 Modus Operandi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20.3 Safety Instructions for Working With Superlift Equipment with
Counterweight Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20.4 Requirements Regarding the Ground Conditions at the
Operating Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20.5 Operating the Crane Without the Superlift Counterweight . . . . . . . 13
20.6 Operating the Crane With the Superlift Counterweight . . . . . . . . . 15
20.6.1 With Variable Superlift Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
20.6.1.1 Preparations for Raising a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
20.6.1.2 Adjusting the Superlift Counterweight Radius (SCR) . . . . . . . . . . . 17
20.6.1.3 Entering the Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
20.6.1.4 Raising the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
20.6.1.5 Setting the Load Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
043−1000−056 8
Manufacturer’s Specifications
Manufacturer’s Specifications
The operating, lubricating and maintenance instructions included

here are valid for the crawler−mounted 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 Crawler−mounted crane

(as per DIN 15001,
15018 T3)
Crane type CC 2400−1
Construction number ___________________
Maximum load 400 t / 881 kip (DIN 15019.2)
Manufacturer Terex−Demag GmbH

Dinglerstraße 24
D−66482 Zweibrücken
Phone: +49 6332 83−0
Fax: +49 6332 16715
www.terex−demag.com
043−1001c_en 1/1
Foreword
Foreword
For you,
the owner of the crane built by us, we have assembled in this ac-
companying documentation all of the information needed for op-
eration, lubrication and servicing.
This information will make it easier to operate the crane and to
utilise its intended operational capabilities.
This documentation is comprised of these operating instructions,

among other items.
It has been compiled for the understanding of trained personnel.
The operating instructions for this crane consist of 4 parts:

Part 1 − Operating manual
Part 2 − Lubrication and maintenance instructions
Part 3 − Assembly instructions
Part 4 − Various
At a minimum, the operating manual (Part 1) must be perma-

nently on hand at the operating site.
Please note that the information given in this documentation cor-

responds to the state of machine technology at the time of writing.
Deviations may therefore occur with regard to technical informa-
tion, drawings and measurements.
In such cases, we make every effort to update your documents

by means of subsequent deliveries (“updates”).
For this we need your co−operation. You must ensure that such
updates are inserted/added to the documentation that already
exists.
This especially applies to the documents that are actually stored
on the crane.
043−1002−056 1/13
Z 64 249
2/13 043−1002−056
Foreword
Pass on these documents to your crane operator and all spe-

cialist personnel assigned the task of servicing and mainte-
nance with the request that they read them before initial use of
the crane and at regular intervals after that (Z 64 249).
They contain important information on operating the crane safely,
correctly and economically.
Observation of the instructions helps to avoid dangers, repair
costs and down times and to increase the reliability and life ex-
pectancy of the crane.
Periodic, preventative inspections and maintenance are the saf-

est way to keep your crane operational. The early recognition and
remedying of minor irregularities as well as the immediate re-
placement of worn or damaged parts prevent down times with in-
creased costs. Any damaged signs and symbols should also be
replaced.
You will understand that we cannot recognise any claims that re-
sult from incorrect use and operation as well as insufficient main-
tenance work.
If you find any mistakes while reading these documents or have

any comments or queries please contact:
Terex−Demag GmbH
Abt. 1160
Postfach 1552
D − 66465 Zweibrücken
The technical writing team will be very glad to hear from you.
“Putting practice into practice”.
043−1002−056 3/13
4/13 043−1002−056
Foreword
Delivery of the crane
The crane is supplied to you from the factory ready for operation,
including fuel and hydraulic oil.
All lubricating points are supplied with grease.
All exposed parts are protected with preserving wax.
If the crane is supplied to you from the factory with a paint protec-
tion coating (preserving wax), this doesn’t necessarily have to be
removed. It offers additional protection against corrosion.
The preserving material can be removed by:
cleaning thinners, e.g. Conrad thinner RV 5339 E 45430

cold cleaner, e.g. Allpur 150 X or Purtex 65
steam jet
Before operating for the first time
you should thoroughly inspect the crane along with our customer
service specialist.
Spare parts
Use only original spare and wear parts authorised by the crane
manufacturer.
043−1002−056 5/13
6/13 043−1002−056
Foreword
Service
Please contact our service department if you have any questions

about your crane. Always specify the type designation and
construction number of your crane.
From inside Germany

Tel: 0180−300 3090
Fax: 06332/83−1711
E−mail: demag−service−germany@terex.com
From abroad
Tel: +49 6332/83−0
Fax: +49 6332/16715
E−mail: info@terex−demag.com
or contact your nearest Terex−Demag associate.
Changes to the crane
Please note that any changes to the crane (e.g. addition of boom
components etc.) in some cases will invalidate or render insuffi-
cient parts of the operating instructions.
Following modifications and/or repairs to parts that affect the

safety of the crane, the crane may only be placed back in opera-
tion following an inspection and authorisation from a specialist
engineer as subject to national regulations.
Therefore please inform us immediately of any modifications car-

ried out to your crane.
043−1002−056 7/13
8/13 043−1002−056
Foreword
...and this is how you can find your way around the docu-
mentation!
Take this example of how I can find the information that I need
quickly and directly.
WHAT do I want to know?
I would like to know, for example, which control elements are

available for the display and operating console “load limit
device system”.
WHERE can I find the desired information?
The complete documentation is made up of 4 parts:
Part 1 − Operating manual

Part 2 − Lubricating and maintenance instructions
Part 3 − Assembly instructions
Part 4 − Various
These parts are divided up by index cards.
As the load limit device is described in the operating instructions,

I need part 1.
1. I look for the index card “1” (for part 1), open the documents
at this point and find the index for section 1.
2. I glance through the headings in bold for the chapters, until

I find section 8, “Operating the Safety Equipment”.
3. In this section 8, I find as item 8.1.2 the “Description of

the Display and Function Buttons”.
The page number given on the right hand side of the sheet
gives the page within the section.
043−1002−056 9/13
Z 26 350
10/13 043−1002−056
Foreword
HOW can I find the specified page in section 8?
1. I take hold of the pages of part 1 as shown in (Z 26 350) and

flick through the pages.
I keep my eye on the top right−hand corner (1, Z 26 350).
As soon as the desired section number appears I stop flick-
ing through the pages.
The name and the number of the section are in the top right−hand
corner of each page (1, Z 26 350).
2. I then check the number of the page at the bottom right−hand

corner to see whether I need to turn the pages forwards or
backwards to find the page I am looking for (2, Z 26 350).
The number of the page in the section is located at the bottom

right−hand corner (2, Z 26 350) of each page of text. It is listed
next to the total number of pages in that section. That means for
example that in the index the page number is given as 5 and the
page itself is numbered 5/47. This provides a better overview
within each section.
Please note that this possibility of acquiring specific and tar-

geted information does not mean that the operating instruc-
tions do not need to be read through in their entirety before
the crane is operated.
043−1002−056 11/13
12/13 043−1002−056
Foreword
In these operating instructions the titles and the corresponding

symbols “danger”, “caution” and “note” are used as follows:
DANGER!
“Danger” is used if failure to follow an operating procedure,

an assembly sequence etc. could lead to the death or injury
of persons.
CAUTION!
“Caution” is used if failure to follow an operating procedure,

an assembly sequence etc. could lead to damage to the ma-
chine or equipment.
NOTE:
“Note” is used to designate an important operating or assembly

procedure as well as more detailed information.
Specifications such as “left” or “right” always relate to the crane

in the forward driving direction.
043−1002−056 13/13
Safety Instructions 1
043−1010−010c 1/75
1
Z 59 992
2/75 043−1010−010c
1 Safety Instructions
1.1 General
This section on “Safety Instructions” gives a concise and general

overview of hazards which can occur during operation of the
crane.
Where necessary, these safety instructions are referred to and
dealt with in further detail in the corresponding sections of the op-
erating manual.
The safety instructions for lubrication, service and maintenance
work are contained in part 2 of this documentation.
The safety instructions for assembling the crane are contained in

part 3 of this documentation.
043−1010−010c 3/75
1
4/75 043−1010−010c
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
people have been transported using personnel carrying
equipment (or even on the hook or on loads). In these
cases, they have no control over crane movements and are
not protected against bumps or falls. Even the smallest of
errors can have fatal consequences.
In exceptional cases (for example, the use of personnel
cages 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 responsibil-
ity of the crane operator following the valid safety and acci-
dent prevention regulations!
Risk of fatalities!
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.

Any other type of use or use which goes beyond the limits speci-
fied, for example handling of general cargo or grab operation, are
not classified as intended use. The manufacturer shall not be
held liable for any damage which results. The operator carries full
responsibility for this type of use.
043−1010−010c 5/75
1
6/75 043−1010−010c
Intended use also includes observation of all load tables, the op-
erating instructions − in particular with regard to the prescribed
assembly sequence − and the lubricating and maintenance in-
structions.
If operation of the crane for general cargo handling or another

type of use is required, please contact the crane manufacturer.
When operating with luffing fly jib, only the hook block is permitted
to be used on the fly jib.
If operation with an additional hook block on the main boom is un-
avoidable, then authorisation for this must be obtained before-
hand from Terex−Demag.
043−1010−010c 7/75
1
8/75 043−1010−010c
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 oper-
ator and third parties, and/or damage to the machine and other
objects.
Use the crane only when it is in full working order and only for its
intended use, paying attention at all times to safety and potential
hazards, and in observance of the operating instructions. In par-
ticular have any malfunctions which might impair safety rectified
immediately.
The term “operating instructions” refers to the operating manual

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 => U1
− 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
operational 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 oper-

ation 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 de-
signed based on specific operating conditions which are laid
down in European standards.
The winches of your crane are categorised as follows:

Power unit group: M........
Load collective: Q = L.....
Load collective factor: km = ......
Theoretical service life: D = ........
The valid values can be taken from the table “Monitoring the
Winches” in the crane log book.
The classification of the power units is the basis for their evalu-
ation during the annual inspection (see Part 2, “Lubrication and
Maintenance Instructions”).
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1.3.4 Workplace Ergonomics
The noise levels listed in below could arise at the crane driver’s
place of work in the crane cab. To reduce noise during crane
operation, we recommend keeping the cab doors and windows
and the cover flaps of all drive units closed.
− Engine idle (750 min−1/rpm) < 75 dB(A)
− Maximum engine speed without load < 85 dB(A)
(2000 min−1/rpm)
− Engine speed at highest engine torque < 80 dB(A)
without load (1080 min−1/rpm)
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.
Outside the crane cab and/or when the crane cab door is open,
the driver of the crane and/or the helpers will be subjected to
higher levels of exposure to noise. It is for that reason that per-
sonnel may not work there without hearing protection.
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. This means that the
seat can be adjusted to the optimum working position for any
crane operator.
The weighted effective value of acceleration to which the upper

body is exposed is below 2.5 m/s2 (8.2 ft/s2).
The weighted effective value of acceleration to which the lower
body is exposed (feet and seat) is below 0.5 m/s2 (1.6 ft/s2).
Both values are therefore below the statutory specifications.
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1.3.5 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the configur-
ation, 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 load limit of the winches is effectively reached when the rope
force has reached its permitted value. Low loads with a small
amount of reeving can place the winch under just as much load.
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1.3.6 Required Ambient Conditions
The permitted temperature range for operating the crane is

−25°C to +40°C (−13°F to +104°F), if the maximum or minimum
temperature occurs only a few days a year.
Additional equipment and lubricants for other operating condi-

tions are available.
The crane can be operated under full load up to a height of

1000 m (3280 ft) above mean sea level. It is not hazardous to op-
erate the crane up to an operating height of 2000 m (6560 ft)
above mean sea level.
The crane can also be operated without danger with high / low
relative air moisture.
Continuous operation in aggressive air (e.g. harbours, chemicals

industry, steel works etc.) combined with high relative air mois-
ture can require an adapter kit/optional equipment.
High levels of dust require the filter to be changed more reg-

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

Maintenance Instructions, part 2.
With oncoming wind the crane operator must observe the sti-
pulations laid down in the operating manual. Refer to the operat-
ing manual of the crane, section 9.1.3 “Wind speeds”.
The ground, on which the crane stands − 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 specified for the crane are for as-
sembly operation only. General cargo handling or grab oper-
ation can only be permitted following express permission
from the manufacturer under suitable conditions.
− the entire number of the crane’s load cycles in this time is less
than 32 000 (e.g. 5 − 10 strokes / day on 200 days / year).
A “LOAD CYCLE” encompasses processes which begin when a

load is raised and end when the crane is ready to raise the next
load.
− The type of load (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 maxi-
mum 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” is to be understood in this connection as the sum total of

load, load handling devices and lifting tackle (e.g.: load + hook
block + sling rope).
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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, the regulations for calculating the remain-

ing theoretical service life should be observed, as listed in
part 2, lubrication and maintenance instructions, section
22.1.3.
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, load-

ing and utilisation of the crane are taken from the European stan-
dards ISO 4301−2 and FEM 1.001, FEM 5.004 and
ISO 9927−1.
The basis 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 other regulations and standards apply,

special−case service life calculations can be carried out.
If required, these calculations must be ordered specifically by the
crane operator. The operating conditions for the crane are not al-
tered, however it may be necessary to limit the lifting capacities.
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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) if permission has been obtained from the
respective authorities (for example in Germany − Landesluft-
fahrtbehörde, Wehrbereichsverwaltung, Deutsche Flugsiche−
rung GmbH).
In Germany, more information can be obtained from:

Deutsche Flugsicherung GmbH (DFS)
Kaiserstraße 29−35
D−63067 Offenbach a. M.
Tel. 069/8054−0
The requirement to obtain permission from the authorities applies

to the Federal Republic of Germany. Outside the FRG, the appli-
cable national regulations must be observed.
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1.4 Safety Regulations
During power−erection and assembly work only the crane

operator may be 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
colour and where possible of an identical design and must
be exclusive to the fitter.
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1.4.1 Organisational Measures
In addition to the operating instructions, applicable national 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 report-
ing duties for any special operating occurrences, for example
with regard to work organisation, operating procedures, allo-
cated personnel etc.
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 dur-

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

equipment.
In case of poor visibility or darkness, the immediate area in front

of the crane operator’s cab, the outriggers and the winches
should be illuminated using the spot lights on the crane.
The extended area (load, load path, slewing range, driving route
etc.) is to be illuminated using suitable equipment, separate from
the crane. You − the crane operator − are responsible for provid-
ing this lighting.
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1.4.2 Personnel Selection and Qualifications
To make optimum use of a crane, without overloading it or failing

to use it to its full potential, the crane operator and the mainten-
ance, assembly and dismantling engineers must be thoroughly
trained.
The crane operator / owner is responsible for providing this train-
ing.
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 the machine driver, also with regard to responsibility for
observing road traffic regulations. Allow him to refuse instruc-
tions 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 responsible for work on the crane must have
read the operating instructions before commencing work, and
in particular the section on “Safety Instructions”.
It is too late in the middle of crane operations.
This applies especially to personnel who only work on the crane
occasionally − e.g. for configuration or maintenance work.
Check − at least now and then − to make sure that all personnel
are working safely and are following the operating instructions.
Personnel are not allowed to wear their hair long, wear loose
clothing or jewellery, including rings. There is a risk of injury, e.g.
as a result of being caught or dragged by moving parts.
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1.4.3 Particular 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 clear-

ance must be maintained between the crane (and hoist rope, lift-
ing tackle, hook block, load) and current−carrying lines. Danger
to life and limb!
Keep a clearance of at least 10 m (32.8 ft). If this is not possible,
you must obtain information on required minimum safety dis-
tances from the electric power company responsible.
With extremely long boom equipment, these safety clearances

are very difficult to judge. To be on the safe side, increase the
safety clearance to 20 m (65.6 ft).
The safety clearance must still be available for unfavour-

able crane or load positions.
Allow for possible swinging of the load or swinging out of
the free line as a result of the wind.
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If, however, the crane accidentally comes into contact with high
voltage power lines:
− 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 driver’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 volt-
age)!
− Arrange for the power in the cable to be switched off.

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

mitters
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
cable 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
under extreme circumstances.
This is especially valid if the crane is used in the close vicin-

ity of high−frequency radiation sources (e.g. radar stations,
radio transmission stations, radio and television stations).
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Lightning
If bad weather and storms appear imminent, lower the crane

equipment where possible and leave the crane.
If this is not possible, lower and unhook the load, 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 switches; to see if they are functioning.
− Assembly and outrigger cylinder with a visual check for exter-
nal damage caused by voltage flashovers or fusing.
By retracting and extending the relevant cylinders several
times, check if there are suspected internal leaks due to dam-
aged seals.
− Hoists, especially for damage to ball and roller bearings.
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Z 29 802
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1.4.3.2 Gas, Dust, Steam, Smoke
Only operate combustion engines and fuel−operated heaters in

sufficiently ventilated spaces. Before starting in closed spaces,
make sure that sufficient ventilation is available.
Follow the applicable regulations for the operating site.
The state of California draws attention to the fact that the

exhaust gases of diesel engines and some of their integral
parts are carcinogenic and cause both birth defects and ge-
netic damage.
1.4.3.3 Crushing / Collision

(Z 29 800)
For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating man-
ual.
− During assembly of the main boom, fly jib and Superlift mast
− Hook block / load when rotating the superstructure
− During the coupling and decoupling of the counterweight ve-
hicle
1.4.3.4 Snagging / Dragging

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

(Z 29 802)
ual.
− when rotating the superstructure
− when extending and retracting outrigger cylinders
− near the hook block or the load during uncontrolled move-
ments
− when stacking the counterweights
− when slewing the crane operator’s cab
− when tilting the crane operator’s cab
− when fitting and removing the additional equipment
− when assembling and disassembling the boom system
− when assembling and disassembling the superstructure
− when coupling and decoupling the counterweight vehicle
1.4.3.6 Danger Due to Slipping, Tripping, Falling

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

there are sufficient places to hold on to and the catwalks are of
a non−slip design (e.g. sanding, checkered plating etc.).
1.4.3.7 Wind
The crane may only be operated up to specific wind speeds, de-

pending on the boom length, equipment fitted and dynamic pres-
sure.
If these are exceeded there is a RISK OF ACCIDENTS!
The section 9.1.3, “Wind Speeds” must be observed”.
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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 operators can communicate with
each other.
If the crane operators are unable to communicate verbally or by

giving visible signs, suitable means must be used, for example
walkie−talkies, banksmen etc.
The communication connections for communicating with the
crane drivers (e.g. walkie−talkies, etc.) must be inspected for reli-
able functioning before beginning any work on the crane.
If banksmen are used, suitable signals must be agreed between

these banksmen and the crane operators. In this regard, please
refer to section 1.5 of this “Safety Instructions” section.
The crane operators must operate their cranes carefully and in

a restrained manner to make sure that collisions cannot occur as
a result of uncontrolled movements.
They must receive suitable training and instructions to this end.
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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 pro-
cedure and appoint a supervisor, in whose presence the oper-
ations are carried out.
The most important requirement for this type of operation is, how-
ever, careful planning, covering the following points:
∗ 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 haz-

ards 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
employer’s liability insurance association (BGV D6) can be
used as an aid. It contains regulations and safety instruc-
tions for operation with several cranes. It especially notes
that sufficient safety reserves must be planned for each
crane and that the full load value of the load capacity table
may never be used.
If there are any doubts concerning the accuracy of the data,
e.g. the accuracy of the details with regard to mass and the
position of the centre of gravity of the load, the safety re-
serves must be increased accordingly.
Before carrying out heavy−duty operations, the crane manufac-

turer should be consulted to see whether the crane can be fitted
with any additional safety devices (e.g. limiters) or whether the
lifting capacity needs to be restricted additionally for the oper-
ation in question.
Avoid oblique pull under all circumstances!
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1.4.5 Before Crane Operation
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
public 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 op-
erated in a safe and functional condition!
Operate the crane only if all safety guards and equipment are
fitted and functional!
Note that mobile boom cranes can only be operated on ground

which has sufficient load−bearing capacity.
Check the effectiveness of brakes, steering, signal and lighting

equipment, limit switches and overload cut−off devices daily, or
in the case of cranes which are seldom used, before the equip-
ment is placed in operation (or driven).
Before commencing work (or driving the crane), make sure that
no−one is in the hazardous area around the crane. If necessary
give a warning sign (activate the horn before starting the engine,
for example!).
Before commencing work, check all crane movements to make

sure that they are working properly.
As oil may be emitted during maintenance and assembly work,

keep suitable collecting vessels and binding agents to hand.
Insofar as necessary or required by regulations, personnel must

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

protection! A helmet can protect you against small falling
objects, but not against falling loads!
You should therefore remain attentive and safety−con-
scious at all times!
Before driving the crane, make sure that all accessories have
been stored away properly!
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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
silos etc.) allowance must be made for the weight of possible
residues inside these components.
When determining the size of the components that are to be

dismantled, never utilise the full values allowed in the load
capacity tables of the crane, but allow for a safety buffer.
Select the correct boom length and reeve the hoist rope in ac-
cordance 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.
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1.4.6 During Operation of the Crane
During power−operated erection and assembly work only

the crane operator may be on the crane (and he must be in
the crane operator’s cab). Remaining personnel must re-
main clear of the hazardous area on and around the crane.
The only exception to this rule is when the counterweight
is being fitted with the help of a fitter. The fitter must, how-
ever, leave the slewing area immediately upon completion
of his work.
The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work if people fail to leave the hazardous area in spite of
warning signals!
The crane operator may only start movements if he has good vis-
ibility of the hazardous areas. In case of poor visibility suitable
persons must be selected as spotters and must be instructed on
the correct signals before commencing work (see section 1.5).
This also applies if noise levels are too high to allow normal verbal
communication.
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, as a last option the drive
source (diesel engine) can be switched off using the
emergency stop switch 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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Conveying of persons with the load or the load lifting tackle is pro-
hibited!
The crane may only be entered and left following permission from
the crane operator and only when the crane is at a complete
standstill!
Observe all safety and hazard instructions on the crane!
Fixed mechanical safety guards may not be opened or removed

during operation of 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.
Persons must stay clear of the slewing area of the crane at all
times! Stop work if people fail to leave the hazardous area in spite
of warning signals!
Only start the diesel engine from the crane operator’s cab. Actu-
ate the control lever only from the crane cab!
Keep the controls lever within reach as long as a load is sus-

pended on the crane or the crane is driven.
If you do not have a complete view of the utilisation of the working

equipment (or of the hazard area) from the operator’s cab, the as-
sistance of a banksman will have to be obtained (see section
1.5)!
This also applies if noise levels are too high to allow normal verbal
communication.
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54/75 043−1010−010c
All control levers are equipped with an additional button each

(dead man’s switch) to prevent accidental activation of crane
movements.
The crane movement can only be carried out as long as one of
these buttons is pressed.
Activating (pressing and releasing) the dead man’s switch on the
control levers as well as activating the limit switch overrides on
the control panel is only permitted when the control lever is posi-
tioned in “0” and/or after the initiated crane movement has been
completed.
Risk of accidents!
When one of these button has been released, the corre-
sponding movement will shut down after approx. 7 sec-
onds. This could lead to uncontrolled movements of the
load and/or of the boom system.
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Z 27 796
56/75 043−1010−010c
Above all, during all crane movements keep your eye on the load,
or if no load is fitted, the boom tip! Also observe the slewing radius
of the counterweight, among other things!
Oblique pulling and dragging of loads is prohibited for operation

of the crane!
Monitor the rope drums in order to avoid the hoist ropes winding
in opposite directions on the rope drums!
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 per shift for any visible signs of
damage and faults! Any changes (including to operating behav-
iour) should be reported immediately to the point/person respon-
sible. If necessary, switch off and safeguard the crane.
In case of malfunctions, shut down the crane immediately and se-

cure the crane! 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 oper-
ating manual!
In case of poor visibility and/or darkness, switch on the outside

lighting! The inside lighting should be switched off to enable
proper sight of the load and the immediate environment of the
crane.
Always keep the operating manual readily accessible in their in-

tended container at whatever location the crane is being oper-
ated! This container is located on the rear wall of the cab
(Z 27 796).
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.
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Keep a safe distance from slopes and ditches!
Before parking, make sure that the crane is well clear of slopes
and the edges of ditches!
Set the computer of the load limit device in accordance with the
load tables supplied!
Observe the permitted wind speeds!
Slewing of the superstructure in the overload range (load limit de-

vice has shut down) is generally prohibited.
When driving on inclines, always adapt the speed of the crane to

the conditions.
When passing under bridges, tunnels, overhead power cables

etc. always make sure that there is sufficient clearance!
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1.4.7 Following Crane Operation
When you leave the crane:

∗ the load must be detached from the crane hook or set down
on the ground.
∗ the engine must be switched off and all control levers placed
in the “O” position or in the “locked” position!
∗ the heating must be switched off.
∗ the crane must be secured to prevent unauthorised use by
locking the crane operator’s cab and against the risk of rolling
by fitting chocks!
If the crane is parked on steep ground, the travel gear must be

additionally secured with wheel chocks!
Lock all control stands with a lock if they are not currently being
used.
When parking, also pay attention to the permitted wind speeds.

If necessary lower the boom system!
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1.4.8 When Assembling and Dismantling Crane Compo-

nents
The regulations listed below also apply in addition to those listed

in this section for assembling and dismantling work.
In this operating manual, the standard, normal assembly se-

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

(unless otherwise stated).
Crane components may not, under any circumstances, be as-

sembled and dismantled by untrained personnel.
Incorrect assembly can result in danger to life and limb.
Due to the risk of slipping, stumbling and falling, persons may not
access the boom and equipment − or their components.
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.
Before assembly personnel approach hanging loads, for

example counterweights, intermediate sections, boom foot sec-
tion and top pieces, or luffing masts, these loads must be set
down on the ground, on supports or other equipment with suffi-
cient 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.
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A load is properly attached when the suspended load is firmly

connected to the lowered component of the crane, e.g. following
fixation with the bolts of an intermediate section or the tightening
of all the bolts of a bolted connection to the prescribed tightening
torque etc.
Keep sufficient safety clearance from unavoidable crushing and

shearing points, in particular between the superstructure and
crane chassis, on cylinders, on the main boom, on the fly jib and
on the Superlift mast, as long as a construction element is hang-
ing in the air during assembly and/or is not safely secured or as
long as the engine of the crane or auxiliary crane is running.
Connecting bolts are always hammered in from the inside out-

ward during assembly of the main boom, fly jib and Superlift mast.
Only when all bolts of a construction element have been knocked
in is it possible to secure them with auxiliary bolts and clip pins.
Connecting bolts may only be knocked out during dismantling of

boom parts or other parts when all individual components have
been safely supported symmetrical to their centre of gravity. The
responsible shift foreman must ensure, before the bolts are
knocked out, that unexpected falling or folding movements are
avoided when the bolts are released.
In case of doubt, a service specialist from Customer Service
should be consulted.
In particular, the knocking out of bolts must be planned with ex-

treme care and it must be ensured that no−one is inside the main
boom, the fly jib or the Superlift mast, where there is a risk of
crushing. 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!
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1.5 Hand Signals
If the crane operator is unable to observe the use of the working

equipment (and danger zone) from the crane operator’s cab, a
banksman must be employed.
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 banksman should position himself in a safe location

from where he can SEE the load and can BE SEEN clearly
by the crane operator.
The banksman must be easily identifiable to the crane op-

erator. The banksman should wear one or more suitable
means of identification e.g. jacket, helmet, collars, arm-
bands, signalling discs.
These signs of identification must be in a distinctive colour
and uniform in design and must be worn exclusively by the
banksman.
If the crane operator does not fully understand the signal, he

should not carry out any movement with the crane. Before
commencing work the crane operator and banksman can
agree on a suitable communication system if this is the case.
043−1010−010c 67/75
1
1 2
3 4
Z 26 024
68/75 043−1010−010c
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, ending of a movement
Right arm up, palm of the right hand facing forward.
3. END
of a movement
The hands folded at chest height.
4. DANGER!
Emergency stop
Both arms up, palms of the hand facing forwards.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
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1
1 2
3 4
Z 29 352
70/75 043−1010−010c
1.5.2 Hand Signals for Working Movements

(Z 29 352)
1. RAISE load
Right arm up, palm of the right hand facing forwards, moving
slowly in a circle.
2. LOWER load
Right arm down, palm of the hand facing inwards, moving
slowly in a circle.
3. RAISE boom
Signal with a hand. Right arm stretched outwards, thumb
pointing upwards.
4. LOWER boom
Signal with a hand. Right arm stretched outwards, thumb
pointing downwards.
043−1010−010c 71/75
1
1 2
3 4
Z 26 025
72/75 043−1010−010c
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 upwards; palms of the hand facing outwards;
the underarms making slow movements away from the body.
3. Drive to the RIGHT ›‹(as seen from the banksman)

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

Left arm stretched out more or less horizontally, the palm of
the left hand facing downwards, with small movements in the
direction shown.
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1.6 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
(lowering brake valves). If the power supply (diesel engine) fails,
all hoists and cylinders may be operated only by connecting an
emergency aggregate and an external power supply. The lower
brake valves are directly fitted to the winch motors and cylinders
(no hose lines).
If hoses or pipes should burst, therefore, there will be no danger-

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

disc brake of the slew gear is applied.
043−1010−010c 75/75
Structure of the Crawler−Mounted Crane 2
043−1020−056 1/57
2
32
13
19
24.1
16
29 6
22
1 2 3
Z 53 108
2/57 043−1020−056
2 Structure of the Crawler−Mounted Crane
2.1 Overview
Legend:
(Z 53 108)
1 Superstructure (OW)
2 Track carrier (UW)
3 Counterweight
6 A−frame
7 Main boom (HA)
13 Hook block
16 Luffing gear 1 (W1)
19 Stay bars HA
22 Derricking rope
24.1 Hoist rope H1
29 Back stops HA
32 Transducer 130 t (286.6 kip) − installed on the left
043−1020−056 3/57
2
7.1
16
21 8.1
25
20
1000
122
53,2
59,6
85
ø603
30
ø1000
ø632
107
Z ø570
129
ø1060
ø90
ø1115
1550
1670
4
1600
1000
1164
30
1170
25
700
186
170
3
22 5 14 2 9 4 1
10 1125
250
15
230
357,5
1156
190
1022
6700
1292
174
655,5
H2
10 12
5 13 17 18 11
A B
Z 53 109
4/57 043−1020−056
2.2 Superstructure
Legend:
(Z 53 109)
1 Frame
2 Hoist 1 (H1)
3 Counterweight
4 Drive
5 Slewing gear pivoting transmission
6 A−frame
7.1 Main boom − Foot section

8.1 Superlift mast − Foot section
9 Hoist 2 (H2)
10 Derricking gear (E)
11 Roller set, superstructure
12 Oil cooler
13 Air filter
14 Slew ring connection − slew ring
15 Reeving winch
16 Luffing gear 1 (W1)
17 Catwalks
18 Hydraulic oil reservoir
19 −
20 Outrigger cylinder Superlift mast
21 Outrigger cylinder MB (MB = main boom)
22 Cab
23 −
24 −
25 Hydraulics for self−assembly of the counterweight
043−1020−056 5/57
2
10 2; 3 4
5 5 5 5 11 9
6 12 8
7
15
16
1
13
14
Z 53 110
6/57 043−1020−056
2.3 Crawler Chassis
Legend:
(Z 53 110)
1 Intermediate section
2 Track travel gear, right
3 Track travel gear, left
4 Track group
5 Track roller
6 Idler
7 Drive sprocket
8 Drive gearbox
9 Hydraulic motors
10 Carrier roller
11 Track shoe
12 Track frame
13 Slewing rim support
14 Rotary joint
15 Outriggers, operating position
16 Outriggers, transport position
043−1020−056 7/57
2
b
1524
200
ø700
7
4 5 6 2
7
Z 54 333
8/57 043−1020−056
2.4 Counterweight Dolly (Optional)
Legend:
(Z 54 333)
1 Frame
2 Swivelling bolster
3 Support cylinder
4 Support plate
5 Drive axle
6 Wheel
7 Slew gear
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2
Z 63 240
10/57 043−1020−056
2.5 Boom Variants
Abbreviations for the boom variants

SH Heavy main boom
SH+LF Heavy main boom + lightweight, fixed fly jib
SH/LH Heavy main boom/lightweight main boom, stepped
SH/LH+LF Heavy main boom/lightweight main boom, stepped +
fixed fly jib
SSL Heavy Superlift
SSL+LF Heavy Superlift + lightweight, fixed fly jib
SSL/LSL Heavy Superlift/lightweight Superlift, stepped
SSL/LSL+LF Heavy Superlift/lightweight Superlift, stepped + light-
weight, fixed fly jib
SW Heavy, luffing fly jib
SWSL Heavy, luffing fly jib with Superlift
LFVL Lightweight, fixed Vessellift with Superlift, lightweight
boom head
SFVL Heavy, fixed Vessellift with Superlift, heavy boom head
SL mast Superlift mast
Data concerning the boom variants

(Z 63 240)
SGL = heavy basic length
Variant Boom length Type
(m) (ft)
SH 24 − 84 78.7 − 275.6 2721
SH/LH 42 − 108 137.8 − 354.3 2721/2317
(SGL=variable)
SSL 30 − 96 98.4 − 315.0 2721
SSL/LSL −126 − 78 255.9 − 413.4 2721/2317
(SGL= 70.5) (SGL= 231.3)
SW SH= 24 − 72 + SH= 78.7 − 236.2 + 2721+2317
SW= 24 − 72 SW= 78.7 − 236.2
SWSL SH= 36 − 96 + SH= 118.1 − 315.0 + 2721+2317
SW= 24 − 84 SW= 78.7 − 275.6
SL mast 30 98.4 2116
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2
Z 63 241
12/57 043−1020−056
Continued: Data concerning the boom variants

(Z 63 241)
Variant Boom length Type

(m) (ft)
SH+ SH= 24 − 84 SH= 78.7 − 275.6 + 2721+1813
LF2 + LF2= 12 − 36 LF2= 39.4 − 118.1
(SGL=variable)
SH/ SH/LH= 42 − 108 SH/LH= 137.8 − 2721/2317+
LH+LF2 + LF2= 12 − 36 354.3+ 1813
(SGL=variable) LF2= 39.4 − 118.1
SSL+LF2 SSL= 36 − 96 + SSL= 118.1 − 315.0 + 2721+1813
LF2= 12 − 36 LF2= 39.4 − 118.1
SSL/ SSL/LSL= 78 − 126 SSL/LSL= 255.9 − 2721/2317+
LSL+LF2 + LF2= 12 − 36 413.4 + 1813
LF2= 39.4 − 118.1
SL mast 30 98.4 2116
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2
14/57 043−1020−056
2.6 Technical Description
2.6.1 Chassis
The crawler−type chassis is in three parts, consisting of a centre
section and two crawlers. The centre section and crawlers are hy-
draulically pinned and are easy to disassemble for the purpose
of obtaining more favourable transport dimensions and weights.
Drive
The crawler−type carriages are each driven by one hydraulic

motor via enclosed, splash−lubricated planetary gears with
spring−loaded hydraulically ventilated holding brakes.
2.6.2 Superstructure
Drive
Daimler Chrysler diesel engine type OM 501 LA, 260 kW at

2000 min−1 (2000 rpm). The diesel engine is in compliance with
the EUROMOT A3 / EPA T3 regulation.
Winches
The superstructure is standard−equipped with two rope winches

− Hoist 1 and derricking gear − and set up for Hoist 2. The rope
winches are driven by hydraulic motors via applied, splash−lubri-
cated planetary gears. The rope winches are equipped with
spring−loaded, hydraulically ventilated retaining brakes and
non−wearing hydraulic brakes for the lowering sequence. The
rope winch H1 (and optionally H2 as well) can be removed in
order to reduce transport weight.
Slew Gear
Two slew gears with hydraulic motor drive via enclosed, splash−
lubricated planetary gear. Spring−loaded, hydraulically bleed-
able retaining brake and non−wearing hydraulic braking.
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2
16/57 043−1020−056
Control
DEMAG IC−1: Electronic proportional valve pilot control inte-

grated in a memory−programmed control system with error diag-
nosis. Two colour monitors, operation with touch screen. The op-
erating speeds are continuously adjustable by lever position.
Power regulation of the drives for optimal utilisation of the engine
output.
Safety devices
Electronic load limit device (LLD), hoist limit switches, limit

switches for boom movements, hydraulic boom fallback guards,
air speed indicators.
Cab
Comfort cab with large front window and air−conditioning. Safety

glass all around, roof window, engine−independent hot air heat-
ing system and operating and control instruments for the crane
functions. The cab can be tilted to the rear to improve the oper-
ator’s view. A camera system is installed for monitoring the rope
winches in the superstructure. During transportation the cab can
be slewed in front of the superstructure.
Electrical System
Operating voltage 24 V (two batteries 12 V/180 Ah).
Quick−Connection (optional)
Standard quick release coupling (quick−connection) to connect

the superstructure and carrier.
2.6.3 Additional Equipment (Options)

40 t (88.2 kip) additional counterweight; Central ballast 40 t
(88.2 kip); lateral additional support; Assembly support; cylinder
on the A−frame; counterweight vehicle; Superlift equipment; run-
ner.
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2
18/57 043−1020−056
2.6.4 Hook Blocks

Hook block system 2 x 200 t (2 x 440 kip) convertible
Hook block system 2 x 160 t (2 x 352kip) convertible
Hook block type 300 − load 300 t (661 kip)
043−1020−056 19/57
2
1900
(75 in)
R 9250
(R 364 in)
R 7100
(R 280 in)
2315
(91 in)
1750
(69 in)
approx. 10250
(approx. 406 in)
Z 58 398
6700
(264 in)
2995
(118 in)
1475
(58 in)
449
(18 in)
1200
(46.80 in)
7250
(2825 in)
8450
(333 in)
Z 58 399
20/57 043−1020−056
2.6.5 Technical Data
Main dimensions
See Illustrations Z 58 398 and Z 58 399

(OP = optional)
Weights
t kip
Total weight, including 100 t (220.5 kip) 233 513.7
counterweight, 24 m (78.7 ft) main
boom and hook block
Superstructure (with 3 rope winches, 59.6 131.4
A−frame, centre section and self−as-
sembly equipment
Superstructure (with three rope 39.6 87.3
winches, A−frame and a quick release
coupling)
Chassis centre section with an outrigger 21.9 48.3
and a quick release coupling
Crawler−type carriage with track shoes 2x23.4 2x51.6
(1200 mm / 47.2 in)
Counterweight 100 220.5
Ground pressure
At 233 t (513.7 kip) total weight = 13.0 N/cm2 (19 psi)
043−1020−056 21/57
2
22/57 043−1020−056
Operating speeds
Speed Perm. Length/diameter of the
rope pull ropes
per line
Hoist H1 max. 150 m/min 150 kN 1020 m / 26 mm
max. 492.1 ft/min 33721 lbf 3347 ft / 1.0 in
Hoist H2 (OP) max. 130 m/min 150 kN 700 m / 26 mm
max. 426.5 ft/min 33721 lbf 2297 ft / 1.0 in
Derricking max. 54 m/min 2 x185 m / 26 mm
gear E max. 177.2 ft/min 2 x 607 ft / 1.0 in
Luffing gear max. 139 m/min 530 m / 26 mm
W1 (optional
equipment) max. 456.0 ft/min 1739 ft / 1.0 in
Luffing gear Max. 110 m/min 700 m / 26 mm
W2 (optional
equipment) max. 360.9 ft/min 2297 ft / 1.0 in
Reeving winch 320 m / 10 mm
R1 (OP) 1050 ft / 0.4 in
Slew Gear 1,4 min−1 (1.4 rpm)
Driving speed max. 2 km/h
max. 1.2 mph
Luffing gear W1 is required for boom variants SW and SWSL.
Luffing gear W2 is required for boom variants SSL, SSL/LSL and
SWSL.
043−1020−056 23/57
2
3 2 (5) 1 (4)
8 7 6 9
Z 53 117
24/57 043−1020−056
Hydraulic Pumps
(Z 53 117)
8 hydraulic pumps are fitted on the pump distributor gear (9).

Item Pump Hydraulic Functions supplied
no. block
1 P 1.1 Block 1 H1, left−hand crawler, W2 (OP)
2 P 1.2 − Reeving winch, slew gear
3 P 1.3 − Hydraulic oil cooler
4 P 2.1 Block 2 EW, H2 (OP), right−hand crawler−type carriage
5 P 2.2 − SLGGW
−outriggers
−travel drive
6 P 3.1 Block 3 W2 (OP), W1 (OP), EW
−self−assembly cylinder on the A−frame (OP)
−counterweight lift cylinder
7 P 3.2 − − Main boom back stop
− Mast support
− A−frame derricking cylinder (OP)
− Main boom pinning
− Gradient cylinder, cab
−Counterweight locking cylinder (OP)
−Control pressure
SLGGW
−Superlift counterweight lift cylinder
−SLGW adjustment winch (OP)
−SLGW sliding cylinder (OP)
CR
−Outriggers, “Centre section track carrier” inter-
locks,
−Quick release coupling
8 P 3.3 − −Return line oil pressure
Explanation of the abbreviations:
H1; H2 = Hoist
W1; W2 = Duffing gears
EW = Derricking gear
SLGGW = Superlift counterweight dolly
HA = Main boom
CR = Carrier
OW = Superstructure
SL = Superlift
SLGW = Superlift counterweight
043−1020−056 25/57
2
6 6 6 1A 6
1c
1A
7 6 8
1c
5
1c
Z 50 305
26/57 043−1020−056
2.7 Safety−relevant Components
2.7.1 Ladders and Catwalks

(Z 55 305)
In addition to suitable auxiliary equipment which has also

been set up for use, only the ladders which have been de-
scribed for climbing on to the superstructure may be uti-
lised. There are sufficient gripping points to hold onto. The
catwalks are designed to be slip−free (sanding, checker
plating etc.).
(1a) − Ladder, can be dismantled on the superstructure
For transport purposes, the ladders (1a) must be removed

and the cat walks (1c) hinged up and secured in transport
position.
The handling of the handrail (6) and of the cat walks is described
on the following pages.
(1c)− Catwalks on the superstructure

(5)− Locking pin
(6)− Handrail
(7)− Fastening point for the removable ladder on the super-
structure
(8)− Chain at the rear end of the cat walks
043−1020−056 27/57
2
6
2
1c 5 1c
4
1c
1c
Z 55 306
28/57 043−1020−056
Handling of the catwalks and of the handrail on the super-

structure frame
(Z 55 306)
For purposes of transporting the superstructure, the handrail (6)

on the cat walks (1c) needs to be dismantled and the cat walks
folded up into transport position.
To remove the handrails, remove the locking pins (5) and lift out
the handrail. Transport the handrails separately.
Fold up the cat walks (1c) on the superstructure and secure by
inserting the locking pins (4) at the superstructure side wall.
Lock the catwalk (2) behind the cabin with the lock bar (3).
Remove the detachable ladder on the superstructure and trans-
port separately.
2.7.2 Headlights
Three headlights are mounted on the superstructure in series

version:
− on the front of the cab
− on the back of the cab
− in the area of the winches
2.7.3 Emergency Exit
The front window of the superstructure cab can be opened wide.

It is therefore suitable as an emergency exit.
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2
Z 64 241
30/57 043−1020−056
2.8 Signs and Symbols
Obtain all signs specified in the following and make sure

they are legible!
2.8.1 Signs in the Crane Operator’s Cab

(Z 64 241)
(1) − CE crane identification plate
043−1020−056 31/57
2
Z 64 215
32/57 043−1020−056
Only for China

(Z 64 215)
(2) − Crane identification plate China
043−1020−056 33/57
2
Z 64 217
34/57 043−1020−056
Only for USA

(Z 64 217)
(3) − Auxiliary crane identification plate USA

(mounted in the crane cab)
043−1020−056 35/57
2
Z 54 016
36/57 043−1020−056
Only for Germany

(Z 54 016)
(4) − Plate 215 x 300: Operating regulations for cranes in ac-

cordance with accident prevention regulations “Cranes”
(VBG 9)
043−1020−056 37/57
2
Obehöriga äger ej
tillträde till kranens
farliga arbetsomrade.
Z 64 213
38/57 043−1020−056
2.8.2 Signs and Symbols on the Superstructure

(Z 64 213)
−Warning sign: Hazardous area
043−1020−056 39/57
2
HYDRAULOLJA
Specifikation, se handbokenn !
Z 64 216
Z 64 214
40/57 043−1020−056
Continuation: Signs on the superstructure
(Z 64 216)
− Plate: Hydraulic oil (on the hydraulic oil tank)
(Z 64 214)
(3) − Plate: Diesel (on the fuel tank)

(4) − Plate: Sound power level
(the specifications regarding the sound power level may
vary from one type of crane to another)
043−1020−056 41/57
2
1 2 3 4 5
6 7 8 9 10 11
Z 66 767
42/57 043−1020−056
2.8.3 CE−Safety Signs

(Z 66 767)
(1) − Warning: Crushing

(2) − Warning: Entanglement/dragging
(3) − Prohibited: Access for unauthorised persons
(4) − Warning: Risk of falling
(5) − Warning: Fire hazard
(6) − Prohibited: Naked flame
The plates (5) and (6) are attached to the diesel tank.
(7) − Warning: Crushing/Collision

(8) − Warning: Swinging load
(9) − Note: Fire extinguisher
(10) − Note: First aid
The First−aid kit must be removed by the crane operator from the
pallet provided and stored in the cab of the crane chassis.
(11) − Warning: Open box cover
The supplied fire extinguisher is behind the cab.
All safety instructions on the crane must be complete and

fully legible.
043−1020−056 43/57
2
1 2 3 4 5
6 7 8 9 10 11
Z 66 768
44/57 043−1020−056
Continuation: CE Safety Signs

(Z 66 768)

(5) − Warning: Fire hazard
(6) − Prohibited: Naked flame
The plates (5) and (6) are attached to the diesel tank.

(8) − Warning: Swinging load
(11) − Warning: Open box cover

fully legible.
043−1020−056 45/57
2
7 3; 4 1 1 7 7 1 1 3; 4 7
7 7 7 7
A
7 7
7 7 B
2 D
C
7 7
Z 64 218
46/57 043−1020−056
Continuation: CE Safety Signs
Legend:
(Z 64 218)
A Counterweight vehicle
B Counterweight telescopic cylinder
C Counterweight crossbar frame
D Vario winch (optional, only in conjunction with Vario−Super-

lift)

043−1020−056 47/57
2
11
3
5
11
3
9
9
24
15;16
22
25
4
le + ri
10 9 15 11 23 5 1 9 10
le + ri Z 66 765
11
9 10 5 15 10 5
le + ri
21 21
17 20 12 11
le 6+ ri
10
2; 7; 8;
13; 14; 15
1
21 21 18
12 9
18;19 5 11
Z 66 766
48/57 043−1020−056
2.8.4 Safety Signs (USA Only)

(Z 66 765, Z 66 766)
You will find the pictorial presentation of the individual signs − in

the sequence listed below − on the following pages (pg. 52ff).

fully legible.
(1) − Danger: Voltage − great

(2) − Danger: Voltage
(3) − Danger: Assembling boom
(4) − Danger from machinery
(5) − Risk of crushing hand
(6) − Danger from outriggers
(7) − Warning before using crane
(8) − Warning: Raising persons
(9) − Risk of falling
(10) − Risk of crushing body
(11) − Danger: Pulling in
(12) − Fire hazard
(13) − Crane operation
(14) − Risk of overturning
(15) − Hand signals USA
(17) − Danger of burns

(18) − Warning: Blower
(19) − Danger: Pressure
(20) − Danger: Battery
(21) − Danger: Oil stream
(22) − Danger: Passengers
(23) − Caution: Welding prohibited
(24) − Danger during assembly of boom − great
043−1020−056 49/57
2
4 4
4 le + ri le +ri 4
6 6
4 4
le + ri le + ri
4 4
le + ri le + ri
Z 64 226
50/57 043−1020−056
Continuation: Safety Signs (USA Only)

(Z 64 226)
You will find the pictorial presentation of the individual signs − in

the sequence listed below − on the following pages (pg. 52ff).

fully legible.
(1) − Danger: Voltage − great

(2) − Danger: Voltage
(3) − Danger: Assembling boom
(4) − Danger from machinery
(5) − Risk of crushing hand
(6) − Danger from outriggers
(7) − Warning before using crane
(8) − Warning: Raising persons
(9) − Risk of falling
(10) − Risk of crushing body
(11) − Danger: Pulling in
(12) − Fire hazard
(13) − Crane operation
(14) − Risk of overturning
(15) − Hand signals USA
(17) − Danger of burns

(18) − Warning: Blower
(19) − Danger: Pressure
(20) − Danger: Battery
(21) − Danger: Oil stream
(22) − Danger: Passengers
(23) − Caution: Welding prohibited
(24) − Danger during assembly of boom − great
043−1020−056 51/57
2
Z 63 901
Z 63 902
3 Z 64 219
52/57 043−1020−056
4 Z 63 904
5 6
Z 63 905 Z 63 906
7
Z 63 907 Z 63 908
043−1020−056 53/57
2
9
Z 63 909
10
11
Z 63 910 Z 63 911
12
13
Z 63 912 Z 63 913
54/57 043−1020−056
14
Z 63 914
15
Z 64 220
043−1020−056 55/57
2
16
Z 63 916 17 Z 64 221
18 19
Z 63 918 Z 63 919
20
21
Z 63 920 Z 63 921
56/57 043−1020−056
22
23
Z 63 922 Z 63 923
25
24
Z 63 924 Z 63 925
043−1020−056 57/57
Crane Operator’s Cab 4
043−1040−056 1/55
4
15
150
12
13
14
19 1
16
17
Z 57 121
2/55 043−1040−056
4 Crane Operator’s Cab
4.1 Operating Elements in the Crane Operator’s Cab

(Z 57 121)
Item Element Designation Function
1 8001B Control lever Pilot control assignment, see sec-
tion 4.2
2 8001B Control lever Pilot control assignment, see sec-
tion 4.2
3 B 8002 Control lever Pilot control assignment, see sec-
tion 4.2
12 B 1251 Pedal (acceler- Speed adjustment of the engines
ator)
13 S 7112 Foot−operated Horn
switch
14 S 7914 Foot−operated Enable bridging load limit device
switch and hoist limit switch
15 Add−on Console (see section 4.3)
Display and operating consoles of
IC−1 system
16 Side Panel Operation of the lighting equipment
of the diesel engine, of the heating
system and of the air conditioning
system (see section 4.4)
17 Seat console, (see section 4.5)
right
19 Pedal Release of “Slew brake, dynamic”
Pedal pressed: slew brake applied
Pedal not pressed down: slew brake
opened
150 B 7161 Monitor 1 Display of the images from the video
camera
043−1040−056 3/55
4
6 6 6
10 11 4 5 8 9
18
18 18
7 7
3 1 2
A
A A
D C
B B B
Z 56 247
4/55 043−1040−056
4.2 Control lever

(Z 56 247)
OP = optional
HA = Main boom
1 8001B Control lever Hoist H1:
A = “lower” hook
B = “lift” hook
During crane operation with
double hook block hoist unit H1
+ H2:
B = “raise” hook
derricking gear W2 (OP):
A = HA “lower” in case of Superlift
B = HA “lift” in case of Superlift
Undercarriage:
A = left crawler forwards
B = left crawler reverse
2 8001B Control lever Hoist H2
B = “raise” hook
Self−assembly cylinder (OP):
A = “retract” cyl.
B = “extend” cyl.
Derricking gear E:
A = HA “lower”
B = HA “lift”
Undercarriage:
A = right crawler forwards
B = right crawler reverse
The control lever function with the individual functions is selected

using the display (21, Z 53 120, page 20/55) of the display and
operating console for monitoring the engine and the crane oper-
ation of the IC−1.
043−1040−056 5/55
4
6 6 6
10 11 4 5 8 9
18
18 18
7 7
3 1 2
A
A A
D C
B B B
Z 56 247
6/55 043−1040−056
(Z 56 247)
OP = optional
HA = Main boom
HI = Fly jib
3 B 8002 Control lever Derricking gear DG:
A = “lower” HA
B = “raise” HA
Derricking gear W1 (OP):
A = “lower” HI
B = “raise” HI
derricking gear W2 (OP):
A = HA “lower” in case of Superlift
B = HA “lift” in case of Superlift
Undercarriage (tailing mode):
A = both tracks forwards
B = both tracks backwards
Slew gear:
D = slewing to the left
C = slewing to the right
Reeving winch R1 (OP):
C = R1 “Wind auxiliary reeving rope”
D = R1 “Reel out auxiliary reeving
rope”
Raise Hydraulic cylinder for A−
frame and pinning; (OP):
A = “retract” cyl.”
B = “extend” cyl.
counterweight vehicle (optional)
A = driving forwards
B = driving in reverse
4 B 8001 / S11 Push button “Idle gear for slew gear”

043−1040−056 7/55
4
6 6 6
10 11 4 5 8 9
18
18 18
7 7
3 1 2
A
A A
D C
B B B
Z 56 247
8/55 043−1040−056
Continued − Control levers

(Z 56 247)
OP = optional
5 B 8001 / Push button Hoist H1:
S12 − High range on/off
Hoists H1 and H2 (synchronous):
− High range on/off
Luffing gear W2:
Travel gear:
− High range on / off
6 B 8001 / Flip switch “Enable control”
TS1 / TS2, (Dead man’s handle)
B8002/TS2
7 B 8001 / Vibrator coil Winch rotation indicator
Y1 / Y2,
B8002 / Y1
8 B 8001 / Push button “Idle gear for slew gear”
S21
9 B 8001 / Push button Hoist H2:
Hoists H1 and H2 (synchronous):
Derricking gear E:
Travel gear:
10 B 8002 / Push button Slew gear:
S11 − Pressure increase

043−1040−056 9/55
4
6 6 6
10 11 4 5 8 9
18
18 18
7 7
3 1 2
A
A A
D C
B B B
Z 56 247
10/55 043−1040−056
Continued − Control levers

(Z 56 247)
OP = optional
11 B 8002 / Push button Derricking gear DG:
Luffing gear W1:
Luffing gear W2:
Travel gear:
18 B 8001/S13 Self−return rocker switch Smooth setting of the final speed of
S23 max = 100% to min. 20% with max.
B8002/S13 control lever movement (possibility
of fine control).
Display of the set value using a
green bar in the displays, items 59,
60, 61 (Z 53 127, page 26/55).

043−1040−056 11/55
4
20
21
Z 57 117
Z 57 318
12/55 043−1040−056
4.3 Add−on Console
The add−on consoles include the display and operating el-

ements of the IC−1 system (Intelligent Control System) on two
monitors.
The IC−1 System is controlled by touching the screen (touch
screen).
The add−on console can be swung to the right−hand side of the

cab for transportation. Towards the end of the swinging pro-
cedure, the add−on console slides onto the transport lock (3,
Z 57 318), where it locks itself in place automatically.
4.3.1 General Arrangement of Construction Consoles

(Z 57 117)
The displays in your crane may differ from the ones shown here.
The symbol on the display also carries ultimate validity for the
function of the display.

20 A5362 Display 2 for LLD Display and operating console
System LLD System
(description in − Setting the operating conditions
sections 4.3.3 − Display of the load capacity
and 8) tables
and additional − Display of the work load
crane data) − Display of error messages
− Display of the tilt of the crane
21 A5361 Display 1 for Display and operating console
monitoring of en- for engine and crane operation:
gine and crane − Engine control
operation − Winch operation
(description in − Travel gear operation
section 4.3.4) − Slew gear operation
− Preset final speed with max. con-
trol lever movement
− Joystick modes
If a display and operating console fails the other can assume its
function after switching to 1−screen operation.
043−1040−056 13/55
4
20.11
20.1
20.12
20.2
20.13
20.3
20.14
20.4
20.15
20.5
20.16
20.6
20.7
20 or 21
Z 58 400
14/55 043−1040−056
4.3.2 Display and Operating Elements on the Add−on Con-

soles
(Z 58 400)

20.1 − Button On/off switch
If rebooting of IC−1 required:
switch off ignition, wait at least
30s, keep button pressed for at
least 3s. Switch ignition on again.
20.2 − “+” button manual brightness adjustment of
the background lighting − “brighter”
20.3 − “−” button manual brightness adjustment of
the background lighting − “darker”
20.4 − Button w/o function
20.5 − Light−emitting Excess temperature in the console
diode “red” If the temperature in the computer
is smaller than 0°C (32°F), the LED
illuminates red and the computer is
heated internally. The computer
will start automatically at tempera-
tures greater than 0°C (32°F). The
heating process can take from one
to eight minutes, depending on the
exterior temperature.
The computer is ready for use as
soon as the red LED (temp, 20.5)
goes out and the green LED
(power, 20.7) illuminates.
20.6 − Light−emitting Lights up when memory card is ac-
diode “green” cessed
20.7 − Light−emitting Console is switched on (supply
diode “green” voltage available)
Cleaning the display (touch screen)

You will get the best results using a clean, damp, non−abrasive
cloth and any window cleaning agent without ammonia which is
available in stores. The window cleaning agent should be applied
to the cloth first instead of directly onto the surface of the touch
screen.
043−1040−056 15/55
4
20.11
20.1
20.12
20.2
20.13
20.3
20.14
20.4
20.15
20.5
20.16
20.6
20.7
20 or 21
Z 58 400
16/55 043−1040−056
(Z 58 400)

20.11 − Button Moves the mouse cursor upwards
20.12 − Button Moves the mouse cursor down-
wards
20.13 − Button Moves the mouse cursor to the left
20.14 − Button Moves the mouse cursor to the
right
20.15 − Button On/off switch for key−operated
mouse control
20.16 − Button Triggers a mouse−click.
Corresponds to one touch−pres-
sure
Cleaning the display (touch screen)

You will get the best results using a clean, damp, non−abrasive
cloth and any window cleaning agent without ammonia which is
available in stores. The window cleaning agent should be applied
to the cloth first instead of directly onto the surface of the touch
screen.
043−1040−056 17/55
4
B C A E F D
20 O K
Z 53 119
18/55 043−1040−056
4.3.3 Display and Control Console LLD System

(Z 53 119)
The actual symbol on the display is what determines its function.
The display (20) is made up of the following areas:

A − Crane display Display of the current crane con-
figuration
B − Menu bar Display of the symbols and error
codes, menu switchover, load limit
device bridging
C − Operating mode Display of the symbolsof the oper-
line ating mode
D − Variable display Continually changing display of the
(load moment) load moment
E − Variable display Display of the attached load (after
(net load) activation of the taring process)
F − Variable display Display of the attached total load
(total load) incl. hook block, hoist rope and
load−handling device
G − Variable display Display of the maximum load for
(maximum load) the current crane configuration
I − Variable display Slewing angle and inclination indi-
cators
K − Menu area
O − Force in the der- Display of the maximum and mini-
ricking rope mum force in the derricking rope
For instructions on operating the load limit device system, see

section 8.
043−1040−056 19/55
4
A C2 E
C3
C1 C 21 D
Z 53 120
20/55 043−1040−056
4.3.4 Display and Operating Console for Monitoring the En-

gine
(Z 53 120)
The symbol on the display also carries ultimate validity for the
function of the display.
The display (21) is made up of the following areas:

A − Indicator light Displays of engine and filter moni-
area toring
B − Menu bar Display of symbols and error
codes, menu switchover
C − Crane operation Display− and operating elements
area (overall) for crane operation
C1 − Operation of the Operating options with control
Crane lever 1
Crane lever 2
Crane lever 3
D − Variable display Displays when operating with
counterweight vehicle; joystick
modes; Operating hours
E − Variable display Current engine data and volume
capacities
043−1040−056 21/55
4
31 32 33 34 35 36
Z 53 121
A
37
38
39
B
37
38
39
40
Z 53 122
22/55 043−1040−056
Engine Control
− The (fitting) location of the switches, lamps and displays may
be different in your crane to the ones shown here.
The function is always determined by the symbol on the
switch, the lamp or display.
− The switches are switched by contact with the screen (touch
screen). When a switch is actuated, it changes in colour
(green = switched on).
The signal lights area “A” (Z 53 121) is made up of the following

components:
− Indicator lights 31 − 33 glow red in the event of an error
Indicator lights 34 − 36 glow orange in the event of an error

31 H Indicator light Malfunction in the engine control
system (FMR/PLD)
32 H 0451 Indicator light Battery charge indicator
33 H1416 Indicator light Coolant level too low
34 H 1432 Indicator light Air filter clogged;
35 H 3361 Indicator light Hydraulic filter pump 1.2 clogged
36 H 3256 Indicator light Hydraulic level too low
The engine gauges display (Z 53 122) can be switched to differ-
ent displays using the selector switches 37 − 39.
Item Element Designa- Function
tion
37 Selector Selection: Engine revs
switch Selection: Voltage in vehicle electrical system
Selection: Engine oil pressure
Selection: Coolant temperature
Selection: Hydraulic oil temperature
Selection: Fuel supply
38 Selector Selection: Engine oil pressure
Selection: Engine revs
Selection: Coolant temperature
39 Selector Selection: Coolant temperature
Selection: Engine revs
Selection: Engine oil pressure
40 Symbol Operating hours
043−1040−056 23/55
4
42
44
46
Z 53 123
48
43
45
Z 53 124
24/55 043−1040−056
Continued − Engine control

− The switches are switched by touching the screen (touch
screen).
When a switch is touched, it changes its colour (green =
switched on).
The display (21, Z 53 120, page 20/55) is made up of the following

components:
The display can be switched back and forth between bar
graphics (Z 53 124) and numerical values (Z 53 123) by touch-
ing the display fields.

42 Display Engine speed, can be switched
between bar graphics / numerical
values
43 Display Engine oil pressure, can be
switched bar graphic / numerical
value
44 Display Coolant temperature, can be
switched bar graphic / numerical
value
45 Display Hydraulic oil temperature, can be
switched between bar graphics /
numerical values
46 Display Fuel level, can be switched bar
graphic / numerical value
48 Display Battery voltage
The displays can be switched back and forth by touching the
buttons (37, 38 and 39, Z 53 122, page 23/55).
043−1040−056 25/55
4
64
0 68
67
61
71
69
72
78
74
76
70
73
75
51 53 63 53 79 53
60
1
77
78
48
62 65 59 Z 53 127
26/55 043−1040−056
Crane operation − joystick modes

(Z 53 127)
OP = optional

− The switches are switched by touching the screen (touch
screen).
When a switch is touched, it changes its colour (green =
switched on).
O = default setting of the control lever

1 = functions of the left−hand control lever (3) in position forward/
reverse exchanged with right−hand control lever (1)
The display (21, Z 53 120, page 20/55) is made up of the following

components:
51 Switch, white Pressure increase slew gear
52
53 Switch white Variable free surface for selecting
overdrive. Depending on the pres-
election, the symbol appears for
hoist 1, hoist 2 (OP), luffing gear 1,
luffing gear 2 (OP), derricking gear,
travel gear overdrive
54 − −
55 − −
56 − −
57 − −
58 − −
59 Display Weakening of Control lever 3
043−1040−056 27/55
4
64
0 68
67
61
71
69
72
78
74
76
70
73
75
51 53 63 53 79 53
60
1
77
78
48
62 65 59 Z 53 127
28/55 043−1040−056
Continuation − Crane operation − joystick modes

(Z 53 127)
OP = optional

62 S Switch Preselection slew gear right/left on
control lever 3
63 Switch Preselect control lever 1
Space between slewing gear unit
64 Switch Preselect control lever 2
Space between slewing gear unit
65 S Switch Preselect control lever 3
− Operation hydraulic cylinder SL
to circuit P2.3
67 S Switch, white Preselection control lever 1:
− Operation hoist 1 on circuit P1.1
− Operation hoist 2 on circuit P2.1
69 − − −
− operation derricking gear on cir-
cuit P3.1
− operation luffing gear 1 on circuit
P3.1
− Operation luffing gear 2 to circuit
P3.1 (OP)
73 S Switch, white Slewing gear − overdrive
− Operation of travel gear on circuit
P3.1
− Operation reeving winch R to cir-
cuit P1.2
043−1040−056 29/55
4
64
0 68
67
61
71
69
72
78
74
76
70
73
75
51 53 63 53 79 53
60
1
77
78
48
62 65 59 Z 53 127
30/55 043−1040−056
Continued − Operation of the crane

(Z 53 127)
OP = optional

− Operation derricking gear to cir-
cuit P2.1
P1.1 (OP)
78 S Switch, white Preselect control lever 1 and 2:
− Operation of left−hand crawler−
track carrier to circuit P1.1
P1.1
043−1040−056 31/55
4
93 92
102
112
115 111
114
116
109 108
107 106
103 104
101
96 110
105
97
100
95
99
94
91
98
Z 57 118
32/55 043−1040−056
4.4 Side Panel

(Z 57 118)
The (fitting) location of the switches, lamps and displays may be
different in your crane to the ones shown here.
The function is always determined by the symbol on the switch,
the lamp or display.
The side panel (16, Z 57 121, page 2/55) consists of the following
components:
91 S 1260 Pressure switch Rapid STOP drive motor
(EMERGENCY OFF)
92 X 5452 Socket, Cigarette lighter
2−pole, 24 V
93 X 5455 Socket, Power supply for various auxiliary
2−pole, 12 V consumers
94 S 1257 Toggle switch Engine “Start”
95 S 1259 Toggle switch Engine “Stop”
96 R 6640 Rotary switch Dimmer for instrument illumination
97 S 1265 Toggle switch Changing, engine speed setting
98 S 0150 Key switch Voltage supply, complete
99 S 5251 Toggle switch, yellow Windscreen wiper system front
window
100 S 5253 Toggle switch, yellow Windscreen wiper system roof win-
dow
101 S 6420 Toggle switch, yellow Rotaflare light
102 P 5153 Heater Operation and timer
103 S 6640 Toggle switch, yellow Instrument illumination
104 S 6540 Toggle switch, yellow Aircraft warning lighting
105 S 5260 Toggle switch, yellow Windscreen washing assembly
106 S 6130 Toggle switch, yellow Additional lighting container
107 S 6250 Toggle switch, yellow Additional lighting, superstructure
108 S 6621 Toggle switch, yellow Indoor lighting
109 S 6280 Rocker switch, yellow Auxiliary outside lighting, winch
110 R 1255 Rotary switch Speed adjustment engine
111 S 5152 Rotary switch Fan speed, air−conditioning equip-
ment
112 R 5170 Rotary switch Air−conditioning, warm
113 − − −
114 S 5176 Toggle switch Air−conditioning, on; cold
115 S 5183 Toggle switch Cab ventilation superstructure,
ventilation operation
116 S 1165 Toggle switch Auxiliary heating system cooling
circuit engine − optional
043−1040−056 33/55
4
3 4 5
1 2
Z 63 693
34/55 043−1040−056
Side desk (continued)

(Z 63 693)
The display and operating part of the diesel particle filter (op-
tional) is located on the side desk.
1 Display and operating part

2 Pushbutton
3 LED red
4 LED yellow
5 LED green
Notes and instructions regarding operation and maintenance of

the diesel particle filter can be obtained from Sect. 5, Part 1 and
Sect. 16, Part 2 of the documentation.
043−1040−056 35/55
4
120
Z 62 715
36/55 043−1040−056
4.5 Side Panel, Seat Bracket

(Z 62 715)
The (fitting) location of the switches, lamps and displays may be

different in your crane to the ones shown here.
The function is always determined by the symbol on the switch,
the lamp or display.
The seat bracket (17, Z 57 121, page 2/55) is made up of the fol-
lowing components:
120 S 9310 Toggle switch, Adjustment cab tilt
yellow
043−1040−056 37/55
4
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4 130.6
130.8
130.7 130.9
130.11
130.10 130.12
130.14
130.13 130.15
130.16 130.18
130.17
Z 49 294
38/55 043−1040−056
4.6 Radio Remote Control

(Z 49 294)
The radio remote control can be used to operate remotely all as-
sembly procedures.
Work with the radio remote control is described in section 14.

The radio remote control (130) is made up of the following com-

ponents:
130.1 Button Direction: Extending
130.2 Button Direction: Retracting
130.3 Button Outriggers: General
130.4 Button Direction: left
130.5 Button Direction: right
130.6 Button Outriggers: front, left
130.7 Button Pinning: left
130.8 Button Pinning: right
130.9 Button Outriggers: rear, left
130.10 Button Pinning: General
130.11 Button Mounting cylinder: General
130.12 Button Outriggers: front, right
130.13 Button Swivelling bolster 1: left, general
130.14 Button Swivelling bolster 2: right, general
130.15 Button Outriggers: rear right
130.16 Display Counterweight assembly
130.17 Button Horn
130.18 Button Frequency control
130.19 Button STOP
130.20 Light diode Service display
043−1040−056 39/55
4
140.1 3 140.2 1 2
140.7 140.10 140.5 140.4 140.13 140.16
Z 57 120
40/55 043−1040−056
4.7 Mobile Control Panel for Emergency Control

(Z 57 120)
Using the mobile control panel for emergency control enables all
movements of the crane to be controlled.

The control panel for emergency control (140.1) is made up of the

following components:
1 S 2472 Control lever Hoist 1 raise/lower
Left crawler forwards/backwards
2 S2476 Control lever Hoist H2 raise/lower
Right crawler forwards/reverse
3 S 2482 Control lever Derricking gear “E” raise / lower
Luffing gear “W1” raise / lower
3 S2486 Control lever Slew slew gear right / left
140.1 Mobile control panel
140.2 Switch STOP
140.3 − − −
140.4 S 2495 Switch Counterweight vehicle operation off/on
140.5 R2495 Governor Speed control counterweight dolly
140.7 S 2481 Selector switch Derricking gear E / luffing gear W1 /
Luffing gear W2
140.10 S 2485 Switch Operation “slew gear”
140.13 S2471 Selector switch Hoist 1/ left crawler
140.16 S 2475 Selector switch Hoist H2 / right−hand crawler
043−1040−056 41/55
4
A
B
Z 63 956
Z 63 957
42/55 043−1040−056
Caution: the load limit device of the crane is non−functional

when the mobile emergency control system is being used.
For this reason it may only be used to set a load on the
ground when crane control IC−1 has failed.
A crane may only ever be activated from a driver’s cab/con-

trol console.
As both the assembly remote control as well as emergency
control is viewed as a control panel, it is prohibited to work
with the assembly remote control and emergency control
at the same time.
Activating the emergency control system

(Z 63 956, Z 63 957)
Emergency control is activated by turning the key switch (A) in the

receiver (B) by 90° to the right.
LED (C) is illuminated.
Symbol D continues to be displayed in the LLD monitor.
Emergency control is deactivated by turning the key switch (A) in

the receiver (B) by 90° to the left.
043−1040−056 43/55
4
Z 64 228
44/55 043−1040−056
4.8 Warning Light

(required version in the area of the European Union)
(Z 64 228)
The warning light’s (1) function is to display the load of the max.
permitted load moment also outside of the crane operator’s cab:
− green: Load moment within the permitted range (0% − 90%)
− yellow: Load moment within the advance range (90% −
100%)
− red: overload (over 100%); Load limit device switches off
− blue: remote control is activated; This can be not only the as-
sembly radio remote control but also the emergency control
system.
Depending on the display status of the warning light, an acoustic

signal will also sound in warning.
The key switch (2) at the rear wall of the cabin is used in cer-
tain situations for overriding the LMI (load limit device).
See Sect. 8 in Part 1 of this documentation for the intended
use of the key switch (2) as well as detailed information con-
cerning the function of the warning light (1).
043−1040−056 45/55
4
122
Z 62 668
46/55 043−1040−056
4.9 Warning Light

(required version in several countries outside of the
European Union)
(Z 62 668)
The warning light’s (122) function is to display the load of the max.
permitted load moment also outside of the crane operator’s cab:
− green: Load moment within the permitted range (0% − 90%)
− yellow: Load moment within the advance range (90% −
100%)
− red: overload (over 100%); Load limit device switches off
043−1040−056 47/55
4
42
41
41
31
42
Z 54 311
48/55 043−1040−056
4.10 Entering / Leaving the Cab

(Z 54 311)
Access to the cabin takes place − depending on the relative posi-

tion of the cabin to the carrier − via folding ladders or via the ac-
cess ladder and the crawlers.
Actuate the lockable door presser (41) for opening the cab door
from outside. The door lock is released and the cab door can be
pushed open (or closed) at the hand grip (42).
The opened cab door engages when it is completely open in

order to avoid unintentional shutting.
To close the cab door, pull the hand grip (31) upwards to unlock
the engagement.
Risk of crushing!
A danger of crushing exists between the door and cab
frame while the door is being closed. For that reason, use
the hand grips provided to ensure that one’s hands are not
in an area of danger!
Use the hand grip (31) for opening the cab door from inside.
043−1040−056 49/55
4
Z 63 951
120
Z 63 400
50/55 043−1040−056
4.11 Tilting the Cab

(Z 63 400, Z 63 951)
To allow work with the crane to be followed better, the cab can be
tilted backwards using hydraulic cylinders.
Actuating the rocker switch (120) above − tilts the cab to the front.
Actuating the rocker switch (120) below (on the symbol) − tilts the
cab to the back.
The adjustment range is approx. 20°.
In this case, the sliding door must be locked in the closed or com-
pletely open position.
No persons or objects are permitted to be present on the lat-

eral and front cabin platform while the cabin is being ad-
justed.
Should the speed of the cab adjustment need to be adjusted,

then this can be accomplished at the throttle (A).
Loosen the lock nut (B) with a circular spanner SW10 and screw
the peg screw (C) either in or out with socket screw key SW2.5.
Screwing it in causes speed to be decreased, screwing it out
causes speed to be increased.
Tighten the lock nut (B) again after the adjustment procedure.
A risk of crushing exists when the cabin is tilted!

No personnel is permitted in the danger zone!
043−1040−056 51/55
4
1 2
8
7
4
5 6
3
Z 57 137
52/55 043−1040−056
4.12 Adjustment of the Crane Operator’s Seat

(Z 57 137)
The crane operator is protected against mechanical vibrations by

means of a hydraulically cushioned 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
possible to select the optimum working position for every driver.
The seat can be adjusted smoothly using the following devices:

(1) − Rotary knob for angle adjustment of the armrests,
Risk of crushing!
The armrests are hinged. A risk of crushing exists while
folding them down from the vertical to the horizontal posi-
tion between the armrest and the side panel.
Proceed with appropriate caution!
(2) − Rotary knob for setting the back support (lumbar verte-
brae support),
(3) − Control element for backrest setting,
(4) − Bracket for horizontal adjustment of the seat (without
console),
(5) − Rotary knob for weight setting,
(6) − Bar for horizontal adjustment of the seat (with console).
(7) − Luminous switch seat heating on / off,
After the seat heating has been switched on, its operation is con-
trolled by a thermostat, i.e. it switches itself on and off again, de-
pendent on the temperature, as long as the switch is switched to
position “On”. The integrated preheating indicator is illuminated.
(8) − Control element for adjusting the tilt of the seat,

(9) − Control element for vertical adjustment of the seat.
043−1040−056 53/55
4
Z 63 952
54/55 043−1040−056
4.13 Charging the Batteries

(Z 63 952)
A battery charging device (A) is installed in the crane cab as stan-

dard equipment; it can be found under the cab floor.
If the batteries are discharged, then the installed charging device

can be used to charge the batteries, in addition to the possibilities
of starting the engine using outside sources as described in sec-
tion 5.
To charge the batteries, one need only plug in one end of the sup-
plied cable (B) to the socket (C) located on the rear wall of the cab
and the other end to a voltage source providing 110 or 230 Volt
AC.
The charging device is switched on at the factory and set to

230 Volt. The ON/OFF (D) switch is accessible from below.
In countries where 110 Volt voltage is used, the voltage must
be set to 110 Volt on the rear side of the charging device. The
charging device needs to be removed for this purpose.
If the batteries are completely dead, then a charging period of ap-

prox. 24 hours is required before the engine can be started again.
043−1040−056 55/55
Engine and Driving Unit 5
043−1050−054_en 1/33
5
2/33 043−1050−054_en
5 Engine and Drive
The engine OM 501 LA is a six−cylinder engine with direct injec-

tion, exhaust turbocharger and charge air cooling. It has particu-
larly low emission levels (EUROMOT 3A and EPA T3 regula-
tions). It is equipped with an electronic control system (control
units and sensors).
Safety measures for engines with electronic control units
The following safety measures must be observed to pre-

vent injury to persons and damage to the engine, compo-
nents or cables.
− Only start the engine when the batteries are connected

properly. Do not disconnect the batteries when the engine is
running.
− Only start the engine when the speed sensor is connected.
− Never use a boost charger to start the engine.
Jump starting only with separate batteries.
− For rapid charging of the batteries, the battery terminals must
be removed. Follow the operating instructions for the boost
charger.
− The batteries must be disconnected when electric welding
work is carried out, and the “+” and “−” cables connected to
one another.
− The lines of the control units may only be disconnected and
connected when the electrical system is switched off.
− Switching the poles of the supply voltage for the control units
(e.g. by connecting the poles of the batteries incorrectly) can
lead to the destruction of the control units.
− Tighten the plug connections on the injection system to the
prescribed torque.
− At temperatures above +80° C / +176 °F (dry furnace) remove
the control devices.
− Use only suitable test lines for taking measurements on plug
connections (Mercedes−Benz connector set).
− Telephones and radio equipment which are not connected to
an external antenna can cause malfunctions to the vehicle
electronics and endanger the operating safety of the engine.
043−1050−054_en 3/33
5
Z 58 901
31
Z 58 902 Z 57 514
4/33 043−1050−054_en
5.1 Engine Control

(Z 58 902)
Detailed information on this subject as well as error codes

can be found in the operating instructions of the engine
manufacturer (see part 4 of these documents).
This information must be observed in addition to the basic
information contained in the following.
The engine is equipped with a fully electronic control system in-

cluding self−diagnosis, that comprises the following compo-
nents, in addition to the engine and the corresponding sensors:
− MR control device (directly at the engine)
− ADM adaptation module (1, Z 58 901) incl. FR control unit in
the distributor box at the rear on the right on the superstruc-
ture.
They are connected together by means of a CAN (Controller Area

Network) line, via which all necessary data / information can be
exchanged.
If the engine monitoring system recognises an error, this is dis-

played (indicator light “31”, Z 58 902), saved in the control de-
vices as an error code and evaluated.
Depending on the errors that occur, a safety or emergency pro-
gram can be activated.
Error messages are read from a diagnosis device (to be con-

nected to the socket (2, Z 57 514). For more information, contact
our customer service.
The gravity of the error can only be determined using the di-
agnosis unit.
The following applies for that reason: as soon as the indica-
tor light (31, Z 58 902) lights up and displays an engine error,
the engine must be switched off immediately and the cause
of the error determined (to prevent damage to the engine).
The crane may only be operated again once the error has
been rectified.
Risk of accidents!
If this is not possible due to an existing hazard, the running
characteristics of the engine may change (emergency
operation) and the engine may be damaged. Proceed with
appropriate caution!
043−1050−054_en 5/33
5
21 39 46
Z 58 903
6/33 043−1050−054_en
5.2 Starting
5.2.1 Before Starting

(Z 58 903)
Before operating the engine for the first time, the operating
instructions of the engine manufacturer for the OM 501 LA
diesel engines must be observed. These can be found in part
4 of these documents.
The following information is limited to details which refer
specifically to the crane.
1. Before starting, check:

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

ance and lubrication instructions of the superstructure.
− The fuel level (46) on the screen (21).
Only operate the diesel engine in sufficiently ventilated spaces.

Before starting in closed spaces, make sure that sufficient ven-
tilation is available.
Before starting, sound the horn to warn people to leave the haz-
ardous area.
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5
94 110
98
31 32
98
98a
Z 58 904
8/33 043−1050−054_en
5.2.2 Starting Procedure

(Z 58 904)
Before starting, always check that all control levers are in the
“Off” position.
1. Place the electrical system ready for operation by plugging in

the ignition key (98a).
2. Insert the ignition key (98a) in the ignition lock (98) and turn
clockwise up to the second notch.
The charge control light (32) and engine control light (31)
must light up.
The key switch of the ignition lock is designed as a three−

position switch:
− position “0”: “Off” position. The key can only be removed
in this position.
− position “1”: Voltage supply for radio.
− position “2”: “On” position. The ignition is switched on.
3. Place the accelerator pedal or rotary switch (110) in the idle

position.
4. Start the engine by pressing the pushbutton (94).
5. If required, interrupt the starting procedure after a maximum

20s and repeat after approx. 60s.
With the engine running, charge control light (32) and engine
control light (31) must go out.
Release key (94) as soon as the engine starts. Do not, under

any circumstances, actuate the starter when the engine is
running.
If indicator light (32) does not go out, there is an error in the
power supply.
Observe the corresponding instructions in the operating in-
structions of the engine manufacturer.
If the indicator light (31) fails to go out there is an error in the
engine control. This is identified by an error code. Error
codes can only be read off at the diagnosis socket in the
switch box using a Mercedes diagnosis unit. If a diagnosis
unit is not available, please contact the customer service de-
partment. Operation of the crane is not permitted!
043−1050−054_en 9/33
5
10/33 043−1050−054_en
5.2.3 Starting Aid
5.2.3.1 External Start With Jumper Cables

When the batteries are drained, the engine can be started using
jump leads and an external battery source.
Only use suitable jump leads (lead diameter at least 70 mm2/

0.1085 inch2) with insulated pole clamps!
Starting aid may only be given using external source bat-
teries! Do not use a rapid charger!
Make sure that the batteries have the same nominal voltage!
When jump starting, never lean over the batteries! Risk of
scalding!
Avoid naked flames and sparks in the vicinity of the bat-
teries! No smoking! Risk of explosions!
Do not place metal objects on the batteries! Risk of short−
circuiting!
Discharged batteries can freeze at approx. −105C (+145F).
This will normally result in them being destroyed. Therefore,
always keep the batteries well charged.
If, however, the batteries have only been lightly frozen, and
you would like to attempt to recharge them, the batteries
must be thawed BEFORE you attempt to start them with the
help of another battery!
1. Switch off the ignition.
2. Connect the minus poles of the batteries using starter

cables.
Make sure that the terminals of the starter cables are always
firmly and securely attached.
3. Connect the + poles of the batteries together.
Make sure that the free plus + does not accidentally come
into contact with the ground contact (frame etc.). Risk of
short−circuiting!
The specified sequence is not the one normally used for cars and
lorries. This is designed to protect the crane components roller
bearing slewing rim and slip ring from possible short−circuiting.
4. Start the engine and leave running for a while.
5. Remove the starter cables in the reverse order.
043−1050−054_en 11/33
5
B C
Z 63 663
12/33 043−1050−054_en
5.2.3.2 External Start With the Integrated Socket

(Z 63 663)
Depending on the version of your crane, there is an optional
socket (A) located in the rear interior area of the superstructure.
The detached, factory−supplied external start cable (B) or the
jumper cable (C) can be connected at this position.
If external batteries are available, then these are connected to
the discharged batteries by means of the supplied cable ( B) and
the socket (A).
If another crane of the Terex−Demag product array is available
which is also equipped with the socket (A), then a connection can
be made between the batteries of the two vehicles using jumper
cable (C).
External start with external start cable (B)
1. Switch off the ignition.
2. Connect the black pole clamps with the minus pole of the bat-
teries providing the current.
Make sure that the terminals of the external start cables are
always firmly and securely attached.
3. Connect the red pole clamps with the plus pole of the bat-
teries providing the current.
Make sure that the free plus + does not accidentally come
into contact with the ground contact (frame etc.). Risk of
short−circuiting!
4. Plug the external start cable into the socket (A).
The specified sequence is not the one normally used for cars and
lorries. This is designed to protect the crane components roller
bearing slewing rim and slip ring from possible short−circuiting.
5. Start the engine.
6. Remove the starter cables in the reverse order.
If both vehicles are equipped with the socket (A), then use
the cable to connect these with one another (C) and carry out
Steps 5 and 6.
043−1050−054_en 13/33
5
35 44
38
43
39
Z 63 352
12
2
1
110
Z 63 353 Z 63 354
14/33 043−1050−054_en
5.2.4 To Be Observed Following Starting

(Z 63 352, Z 63 353, Z 63 354)
− Directly after starting, have the oil pressure (43) displayed in
the operating and display console by pressing switch (38).
Do not rev up the engine until oil pressure is displayed. If oil

pressure is not displayed after approx. 10 seconds, switch
off the engine and determine the cause.
− If the indicator light (35) lights up, service the hydraulic oil filter
(see lubricating and maintenance instructions of superstruc-
ture).
− Shortly after starting, do not place the engine under full load
or at its highest speed. Do not apply ”full throttle” either in the
loaded or unloaded condition.
− Leave the engine running for some time at no more than 2/3
of the maximum speed (approx. 1400 min−1 / 1400 rpm).
− Only when the coolant temperature is approx. 70°C (158° F)
may the engine run at full performance.
The coolant temperature (39) can be called up in the operating

and display console by pressing the switch (44).
− The fans for the radiator and oil cooler must remain at a
standstill as long as the engine, the hydraulic oil and the lube
oil in the pump distributor gear are cold.
− The idle speed should not fall below 800 min−1 (800 rpm). At
low idle speed turn the control knob (110) for enabling the
speed adjustment to the right in the “max” direction and regu-
late the idle speed with the accelerator pedal (12).
− At extreme minus temperatures do not place the cold engine
under full load.
Switch off the engine immediately in case of:

− abnormally low or strongly fluctuating oil pressure.
− falling performance and speed with the accelerator pedal
(12) and control knob (110) in the same position.
− strongly smoking exhaust.
− abnormally high coolant and oil temperature.
− sudden abnormal noises on the engine or turbocharger.
043−1050−054_en 15/33
5
2000000
1000000
500000
300000
200000
100000
Viscosity temperature sheet
70000
50000 in accordance with Prof. Ubbelohde
30000
20000 Temperature axle: log (abs. temperature)
10000 Viscosity axle: log (log (kin. viscosity + 0.8))
7000
5000
4000
3000
2000
1500
1000
500
400
300
Kinematic viscosity [mm**2/s]
200
150
100
90
80
70
60
1
50 2
40
30
25 Tellus TX 46
20
18
16
14
12
10
9
8
7
5
4.5
4
Shell Tellus oil TX 32”
3.5 V40: 32; V100: 6.5
3
V40: 46; V100: 8.4
2.5 V40: 68; V100: 11.4
2
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Oil temperature [°C]
Z 59 740
16/33 043−1050−054_en
5.2.5 Warming up the Hydraulic System

Warming up the hydraulic system is only required if:
− in relation to the ambient temperature, the oil viscosity is be-
tween 1000 and 1600 cSt (for a standard−series hydraulic
oil filling, that means between −13° C / 8.6° F and −18° C /
−0.4 ° F, see table)
and
− following a longer stationary period (approx. 8 to 10 hours)
the hydraulic oil has cooled down to the ambient tempera-
ture.
5.2.6 Warming up Procedure

1. Using the following table, first make sure that, in relation to
the prevailing temperatures, the correct hydraulic oil has
been added. The viscosity of the oil must be below 1600 cSt.
2. Start the diesel engine.
The permitted engine speeds are specified in the following table.
Standard hydraulic oil filling for medium temperatures

Speed of die-
Oil tempera- Oil viscosity
Shell Tellus oil TX 46 sel engine
ture (°C / °F) (cSt)
(min−1)
Starting without load below 1000
−18 / −0.4 1600
(1) (idle)
min −13 / + 8.6 1000
Operation (2) max
max + 92 / +197.6 10
As soon as the diesel engine is running − initially in idle −, the hy-

draulic pumps are automatically activated. This causes the hy-
draulic oil to be circulated without pressure and heated up.
The hydraulic system must be allowed to warm up until the vis-
cosity of the oil is below 1000 cSt.
With a running time of 30 minutes and approximately 1000 min−1

(1000 rpm) the hydraulic oil is warmed by 4° C to 5° C (39.2° F to
41° F).
3. After this, carefully carry out all movements repeatedly for

approximately 10 to 15 minutes without load. The system is
then warmed up.
043−1050−054_en 17/33
5
38 43
Z 53 135
33 35 37 39 42
44
21 Z 53 136
18/33 043−1050−054_en
5.2.7 Checks With the Diesel Engine Running

When the diesel engine is running the monitoring instruments
must be checked regularly.
Engine oil pressure
(Z 53 135)
The oil pressure (43) for the diesel engine can be shown by actu-
ating button (38) in the display (2, 1Z 53 136). The oil pressure
should not fluctuate strongly at a constant speed.
If the oil pressure in an engine is too low (less than 0.3 bar /
4.35 psi) at the minimum speed of 500 min−1 (500 rpm), then it
must be switched off immediately. Determine the cause using the
error−finding chart in the engine operating instructions.
Hydraulic oil filter
(Z 53 136)
When the indicator light (35) lights up, the filter cartridge on the
hydraulic pump (1.2) is clogged. The filter element must be re-
placed with a new one.
Coolant
(Z 53 136)
The indicator light (33) lights up if the coolant level is too low. The
cooling water temperature of the warm−running motor needs to
be between 70° C (158 ° F) and 95° C (203 ° F) and can be called
up by actuation of the push button (39) on the display (21).
If thecoolant temperature is too high (if 103° C / 217.4° F is ex-
ceeded), the engine must be switched off immediately. Deter-
mine the cause of overheating using the error−finding chart of the
engine operating instructions.
Idle speed
(Z 53 136)
The idle speed (42) should not fall below 800 min−1 (800 rpm).
The idle speed can be regulated with the accelerator pedal or be
set with the rotary know (110, Z 58 905, page 20/33). The speed
for the engine can be displayed by actuating the button (37) on
the display (21).
043−1050−054_en 19/33
5
12
110
97
95 98
Z 58 905
20/33 043−1050−054_en
5.2.8 Instructions for Operation
− Avoid long idling times. They are detrimental to the engine.

− Pay attention to the fuel gauge. Do not allow the tank to run
dry.
− The alternator must always be connected to the batteries
when the diesel engine is running. The cable connections
may therefore not be disconnected during operation.
5.2.9 Switching off

(Z 58 905)
1. Place the control knob (110) and accelerator pedal (12) in the
“idle” position.
Following operation with full engine output or high coolant

temperature, leave the engine running without load for 1 − 2
minutes at idle speed.
2. Press and hold the button (95) until the engine comes to a
standstill.
3. Turn the ignition key (98) in an anti−clockwise direction (to

position “0”) and remove the ignition key.
When leaving the crane, remove the ignition key and lock the
cab.
043−1050−054_en 21/33
5
91
Z 59 536
12 17
Einzelheit “X”
Detail “X”
Z 62 136
22/33 043−1050−054_en
5.2.10 Shutting Down With Quick Stop Fitting (Optional)

In an emergency the diesel engine can be switched off by pres-
sing the quick stop button (91, Z 59 536). These buttons latch into
place when they are in the actuated position. The air intake can
be closed by the air shut off valve (12, Z 62 136).
Independent of manual activation, when a certain speed is ex-

ceeded (approx. 2900 min−1 / 2900 rpm) the engine shutoff is
automatically activated. At the same time the fuel supply is inter-
rupted.
Only use the quick stop button (91, Z 59 536) to switch off the
engine in an emergency.
Before starting the engine again, this quick stop button must
be unlocked again. To this end, turn the button slightly.
If the engine is to be restarted, the air shutoff valve has to be man-

ually released. To do this, put the lever (17, Z 62 136) back into
its initial position.
Risk of damage.
The engine may not be started with the air blocking valve
closed. Repeated starting attempts lead to engine damage.
Before starting again, check that none of the air hoses (in-
cluding charge air hoses) has become loose due to the
emergency shutoff and that none of the pipes are blocked.
043−1050−054_en 23/33
5
12
110
97
95 98
Z 59 546
24/33 043−1050−054_en
5.3 Automotive Driving

(Z 59 546)
By pressing the switch (97) the control device of the load limit con-
trol is switched to “automotive driving”.
This ensures comfortable work as the speed of the engine does
not need to be additionally activated.
After actuating switch (97) the desired maximum engine speed

is set with the control knob (110). The pedal (12) is without func-
tion. The speed of the diesel engine is adjusted infinitely variably
by pressing the corresponding control lever (1, 2, 3).
In addition, the speed of the diesel engine can be increased at
any time by actuating the pedal (12).
5.4 Load Limit Sensing Control

The crane control IC−1 is also equipped with a component which
protects the diesel engine from stalling if too much performance
is required by the hydraulic pumps.
This can happen, for example, if 3 functions are driven, each at

100% speed. That would amount to an overloading of the diesel
engine.
In such cases, the load limit control integrated in the IC−1 re-
duces the swinging out of the hydraulic pumps to the extent re-
quired for the diesel engine to work again in a favourable torque
and output range.
For the crane operator, the use of the load limit control can be re-
cognised by the fact that the operating speeds of the functions
he or she actuates, as well as the speed of the diesel engine, will
be altered briefly.
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3 4 5
1 2
Z 63 693
3 2 1 1 2 3
Z 63 694
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5.5 Diesel Particle Filter (Optional)
Risk of accidents!
Installation, operation, regeneration and elimination of er-
rors in the diesel particle filter may only be performed by
persons who have been instructed in filter regeneration
and who are familiar with the hazards which may arise. No
work is permitted on the diesel particle filter during oper-
ation.
The diesel particle filter is to be put out of operation im-
mediately in the event of recognisable damage or malfunc-
tion.
The presence of combustible substances in the area of the
filter is to be excluded.
The display and operating part (Z 63 693) is located in the crane

cab.
The driver is informed by means of LEDs (3, 4, 5, Z 63 693) on
the display and operating part when a regeneration procedure is
necessary.
The regeneration procedure is initiated by means of the button
(2, Z 63 693).
Danger of burns!
Hot fumes emerge from the fume discharge pipe during re-
generation.
The exhaust system (Z 63 694) is comprised of 2 identical units.
Each unit is comprised of

1 burner
2 monolith
3 fume discharge
5.5.1 Purpose Specified − Intended Use
The diesel particle filter is intended solely and without exception

for the filtration of fumes emerging from utility devices with diesel
engines. No additive is required for this purpose. The filter will be
burned clean during the regeneration procedure.
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1 2
Z 63 693
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5.5.2 Functional Characteristics
When the engine is running, the diesel engine fumes flow through
the diesel particle filter (silicone carbide monolith), which holds
back practically all of the destructive rust particles. The filling
amount of the diesel particle filter increases with the running time
of the diesel engine, resulting in a concomitant increase in ex-
haust backpressure. The operator can monitor the filling status
of the diesel particle filter on the LEDs on the display and operat-
ing part and carry out the regeneration in a timely manner.
Once a defined maximum backpressure and/or a maximum load-
ing time has been reached, the installation control system
triggers the “Filter full” alarm.
Four statuses can be displayed with respect to the degree of fill-

ing of the filters:
Status 1
green LED is illuminated and yellow LED is flashing:
50% of the loading time has been reached.
Status 2
green and yellow LEDs light up:
80% of the loading time has been reached.
Status 3
green and yellow LEDs light up, red LED flashes and the buzzer
is also active for 5 seconds every minute:
Advance alarm level is reached, a regeneration must be carried
out.
Status 4
green, yellow and red LEDs light up:
The main alarm “Loading pressure” has been exceeded for at
least 20 seconds and/or the loading time is exceeded, while in
addition the buzzer is uninterruptedly active.
The buzzer sounds for 1 second when the ignition is switched on.
At the same time, all of the LEDs light up briefly (self−test).
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Z 63 693
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Continued: Functional characteristics
In order to burn off the rust particles which have gathered in the
filter, the regeneration is started by pressing the key (2, Z 63 693)
with the engine switched off and the ignition switched on.
The combustion of the diesel particles − by means of an inte-
grated fuel burner − is accomplished without leaving any resi-
dues, i.e. all particles, in addition to the hydrocarbon compounds
which after formed deposits on them, are converted into carbon
monoxide (CO), carbon dioxide (CO2) and water vapour. The
fumes escape through the end pipe of the filter.
The combustion cleaning process takes approximately 25 min-
utes.
The red LED lights up permanently during the entire combustion
procedure.
Once the regeneration process has been completed, the green

LED will flash and the buzzer will sound for approximately 2 sec-
onds.
No external energy sources are required.
A start interlock is integrated in the control system for the purpose

of protecting both the engine and the diesel particle filter.
The engine must be switched off and the ignition must be

switched on in order to start the regeneration process.
The ignition can be switched off once the regeneration process
has started.
If the regeneration process needs to be interrupted, e.g. in order

to carry out an emergency start of the diesel engine, then the re-
generation process is cancelled by pressing the pushbutton (2,
Z 63 693) for 5 seconds.
The red LED flashes and the buzzer is uninterruptedly active

when the regeneration is cancelled.
Emergency start:
To carry out an emergency start of the diesel engine, the pushbut-
ton (2, Z 63 693) must be pressed and held down at the same time
that the starter switch of the diesel engine is actuated.
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Z 63 693
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5.5.3 Malfunctions
If a malfunction occurs, then the regeneration will be cancelled
automatically and the red LED will be illuminated.
Malfunction query and reset is accomplished by a Service techni-
cian using special software.
The display and operating part (1, Z 63 693) can be used to call
up saved errors but not to reset them.
To call up the errors, switch on the ignition and press the pushbut-
ton (2, Z 63 693) 3 times in quick succession.
Description LED flashing sequence

Alarm pressure exceeded 1 x yellow
Loading time exceeded 2 x yellow
Regeneration cancelled 3 x yellow
Operating voltage <8 Volt 3x yellow / 1x green
Heater plug error 3x yellow / 2x green
Blower error 3x yellow / 3x green
Pump error 3x yellow / 4x green
Delta temperature error 3x yellow / 5x green
Data logger memory error 4 x yellow
Minimum temperature error 3x yellow / 6x green
Maintenance interval expired 5 x yellow
White ash 6 x yellow
Internal error red and yellow
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Driving the Crawler−Mounted Crane 6
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6
Z 63 388
2/25 043−1060−056
6 Driving the Crawler−Mounted Crane
6.1 General
Drive:
Each crawler is driven by a hydraulic motor via a planetary gear.
Each side is infinitely variable, and can be controlled individually
and in opposite directions.
Braking:
The driving movement is braked by means of a non−wearing, hy-
draulic service brake.
Each planetary gear is closed by means of spring resistance and
hydraulically vented retaining brake.
Counterweight dolly (optional):

The crawler−mounted crane can be operated with or without the
counterweight dolly. You will find the description of the counter-
weight dolly as well as the setting of the various parameters dur-
ing driving with the counterweight dolly in section 16.
6.1.1 Main Driving Direction
The main driving direction of the crane can be either to the

front or to the rear, depending on the position of the super-
structure to the carrier.
This is caused by the reversing function.
If for example the superstructure is standing in the range be-
tween 905 and 2705, then the IC−1 will automatically switch
the function of the control levers during travel. I.e, if the
superstructure is facing to the rear and the driver of the
crane wants to drive the crane in the direction he is looking,
then he will need to move the control levers to the front.
If the crane controls IC−1 have switched into the reversing func-
tion, then this will be displayed by the symbol (1, Z 63 388).
There is no reversing function when the IC−1 crane control fails

and emergency control is used.
This must also be taken into consideration when driving with a
fitted counterweight dolly.
There is no correlation between the load bearing capacity of the

crane and the main driving direction of the crane.
043−1060−056 3/25
6
4/25 043−1060−056
6.1.2 Requirements for Road Surface Conditions
The road surface must be level and have sufficient load−bearing

capacity. When driving with different configurations, certain slop-
ing and inclination angles in the driving direction as well as toler-
ance limits for the transverse road gradient may not be exceeded.
Dips and mounds in the road surface must be rectified using suit-
able measures, at least in the areas where the crane is actually
driven. (Cover the surface with sand or gravel; remove soil and
then level out.)
6.1.3 Regulations for Driving Operation
− Make sure that there is sufficient clearance under overhead

obstacles and watch out for overhead power cables, if
necessary employ a banksman.
− When driving on uneven terrain near electric power cables
make sure that an extra safety clearance of 10 m (32.8 ft) is
provided to allow for swinging out of the boom system.
− Switching to the opposite driving direction is only permitted
when the crane is at a standstill.
− The temperature of the hydraulic oil, the drive gearbox and
the bottom rollers must be observed.
− Where possible, drive the crane with the drive to the rear, as
seen in the driving direction (especially in steep terrain).
− Before driving on a bridge check that the lifting capacity for
the service weight of the crane is sufficient.
− Keep a safe distance from slopes and ditches!
− To prevent damage to the crawlers, turning over ditches and
hollows must be avoided at all times.
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Z 40 520 Z 40 521
Z 40 522 Z 40 523
6/25 043−1060−056
To prevent damage to the track groups, the following must

be observed when driving on ramps or slopes:
− As a rule, only drive onto the ramp in a straight line

(Z 40 520).
Driving on or off the ramp at an angle is prohibited!
(Z 40 521)
− The approach and exit paths of the ramp must be pre-

pared so that the change in angle does not exceed 0.55/m
(0.55/3.28 ft), (Z 40 522).
− The ramp surface must be even. The maximum cross

gradient of 1.55 must not be exceeded.
− Changing direction when driving on or off the ramp is pro-

hibited! (Z 40 523)
− A change of direction on the ramp is only permitted if all

the links of the track group are on the ground and the
drive sprocket as well as the idler are free. The maximum
cross gradient of 1.55 must not be exceeded.
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Z 00 025
Z 39 428
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6.2 Controlling the Undercarriage

6.2.1 Control Movements
(Z 00 025)
Using the control levers (1 and 2) the control movements shown
in figure Z 00 025 can be carried out.
In the various positions, the following driving movements can be
carried out:
Item Movement of Movement of Movement of

control levers (1 + 2) the track the undercar-
groups riage
left (1) right (2) left right
1 forwards forwards for- for- forwards
wards wards
2 back- backwards back- back- backwards
wards wards wards
3 back- forwards back- for- turn left on the
wards wards wards spot
4 forwards backwards for- back- turn right on the
wards wards spot
5 − forwards − for- left curve for-
wards wards
6 forwards − for- right curve
wards forwards
7 back- − back- − right curve
wards wards reverse
8 − backwards − back- Left curve
wards reverse
6.2.2 Control Movements for Tailing Operation

(Z 39 428)
Switch on switch (74). With control lever (3) the control move-
ments shown in figure Z 39 428 can be carried out.
For tailing operation only driving straight ahead is possible.
Item Movement of the Movement of Movement of the

the track undercarriage
control lever (3) groups
left right
1 forwards for- for- forwards
wards wards
2 backwards back- back- backwards
wards wards
043−1060−056 9/25
6
11 5 9
18 18 18
3 1 2
A
A A
D C
53
B B B
Z 66 762
10/25 043−1060−056
6.2.3 Options for Controlling the Driving Speed

(Z 66 762)
The travel gear has two speed ranges. You switch using the
switch (5, 9, 11) in the control levers (1, 2, 3).
Smooth setting of the final speed using the self−return rocker
switch (18) will also function during normal or high range.
Switching on the various speed ranges:
Normal range:
− Buttons (5, 9, 11) not pressed.

The symbols appearing under item 53 in the display for en-
gine control and operation of the crane remain grey.
High speed:
− Pushbutton (5, 9, 11) is pressed or the symbols under item 53

are pressed.
The colour of the symbols under item 53 change to green in
the display for engine control and crane operation: Over-
drive activated
Before introducing the driving movement observe the fol-

lowing:
The travel gear can be driven in every speed range from 0 to the
maximum driving speed. For steering movements, ’driving in
heavy terrain’, on inclines and with load, the normal speed must
always be selected. The speed range should generally be se-
lected when the crane is at a standstill.
Braking:
During normal driving operation, braking takes place by throttling

the oil flowing back from the engines. The braking effect is greater
in the normal speed range than in the high speed range.
When at a standstill, the travel gear is braked using the hydrauli-

cally locked engines and the disc brake which is fitted to every
drive.
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20
Z 64 234
12/25 043−1060−056
6.3 Driving Without Load on the Horizontal and Angled

Road Surface
6.3.1 General
The boom positions specified in the following tables provide opti-

mum centres of gravity, allowing even distribution of the ground
pressures.
The boom angles are measured with a permanently installed

angle sensor and can be read off the display in the cab (20,
Z 64 234).
On the display in the cab, the angle to the horizontal is always

specified. This means that the same angle position of the boom
can be selected when driving up and downhill.
In addition to the specified gradient (slope) the cross gradient of

the road surface must also be taken into consideration.
Also when driving without load, dips and mounds in the road must
be taken into consideration.
Sudden changes in the centre of gravity by the crane tilting must

be avoided, as this can cause the hook block to collide with the
boom construction.
This risk is particularly high when the boom is in a high position!
On even territory the crane can be driven in the high speed range
regardless of the boom variant.
With a stepped main boom (variants SH/LH and SSL/LSL) the

heavy basic length (SGL) of the main boom must be allowed for.
Simultaneous movements are only permitted when the crane is

driven straight ahead (Tailing).
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20
Z 64 234
14/25 043−1060−056
6.3.2 Driving Without Load
Boom in longitudinal axes of the crawler

Equipment 2 Ha 3 HiA perm. slope Condition / limitation
HA + HiA 72 m 85° 65° 10° total* − Boom on the hill side
(236.23 ft) 3° transverse − No limitation of the driv-
HA + HiA u 72 m 85° 65° 5° total* ing stretch
(236.23 ft) 2° transverse
boom 3605
Equipment 2 Ha 3 HiA perm. slope Condition / limi-
tation
HA + HiA 72 m (236.23 ft) 85° 65° 3° total*
HA + HiA u 72 m (236.23 ft) 85° 65° 2° total*
Legend:
HA = main boom
HiA = fly jib
2 = angle
= same as or smaller than
u = greater than
*total= sum of the longitudinal and transverse gradient e.g.
permitted
tilt 10° total = max. 7° longitudinal and
max. 3° transverse gradient
The main boom must be set with the derricking gear and / or luf-
fing gear 2 to the angles indicated in the table.
On the screen (20, Z 64 234) the angle of the main boom to the
horizontal is displayed.
The fly jib must be set with the luffing gear W1 to the angle speci-
fied in the table.
On the screen (20, Z 64 234) the angle of the fly jib to the horizon-
tal is displayed.
When the angles specified in the table are observed, the opti-
mum centres of gravity result when driving on even road sur-
faces.
When driving on hills and inclines the angles specified in the table
can be maintained.
When the crane is driven on an incline, the boom system
must always be “hill−side”!
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16/25 043−1060−056
6.4 Driving With Load on a Horizontal and Graded Road

Surface
6.4.1 General
− The crane can be driven under load with all boom combina-
tions.
− When driving with load, the load capacity tables and the
notes on the load capacity tables apply.
− As a rule, loads should be moved at the lowest possible
radius and as near to the ground as possible.
− Driving with load is only permitted in the normal speed range.
Changes in direction should be made as slowly as possible.
− Swinging of the load must always be avoided (if necessary,
the load should be lashed in place).
− The ground must be even and able to support the load placed
on it (compare ground pressure values).
− Driving with load is permitted up to a max. wind speed of
9.8 m/s (32.15 ft/s2).
Lower wind speed values on the corresponding load capacity

tables must be observed.
− When driving the crane with the Superlift you must make sure
that the Superlift counterweight has been raised.
This clearance between the base frame and the ground must
constantly be observed when driving!
Minimum distance: 100 mm (3.94 inches)
Maximum distance: 400 mm (15.75 inches)
It must be possible to set down the Superlift counterweight
evenly and without risk even if there are malfunctions during
driving! If required, the ground must be levelled accordingly.
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18/25 043−1060−056
6.4.2 Driving With Load on Horizontal, Even Terrain

( 0.35 Slope)
Boom in longitudinal crawler axis
When driving with load, boom in the longitudinal crawler axis, the
following must be observed:
− The load must be in the line of vision of the driver.
− During driving, no additional crane movements are permitted.
Equipment perm. Condition / limitation
slope
All lengths HA 0.3° − No limitation of the driving
distance
All lengths HA + HiA − max. 0.5 km/h (0.31 mph)
driving speed
Legend:
HA = Main boom
HiA = Fly jib
Boom 3605
When driving with load, boom not in the crawler’s longitudinal

axis, the following must be observed:
− The load must be held near to the ground.
− The driving movement can, if absolutely necessary, be sup-
plemented with an additional crane movement.
Acceleration and braking movements must be carried out

carefully and smoothly.

slope
All lengths HA 0.3° − for positioning loads of up to
a maximum of 20 m (65.62 ft)
driving distance
All lengths HA + HiA
− max. 0.5 km/h (0.31 mph)
driving speed
Legend:
HA = Main boom
HiA = Fly jib
043−1060−056 19/25
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20
Z 64 234
20/25 043−1060−056
fied in the table.
tal is displayed.
faces.
When driving on hills and inclines the angles specified in the table
can be maintained.
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22/25 043−1060−056
6.4.3 Driving With Load on Inclined, Even Territory

(u 0.35 Incline)
Boom not in crawler longitudinal axis

(Positioning of loads)
When driving with load, boom not in the crawler’s longitudinal
axis, the following must be observed:
− The load must be held near to the ground.
− The driving movement can, if absolutely necessary, be sup-
plemented with an additional crane movement.
Acceleration and braking movements must be carried out
carefully and smoothly.
Main boom 3605

slope
HA 72 m 1° − max. 0.5 km/h (0.31 mph) driving speed
(236.23 ft)
− 20% reduction in lifting capacity
2° − 30% reduction in lifting capacity
HA u 72 m 1° − 30 % reduction in lifting capacity
(236.23 ft) − max. 0.5 km/h (0.31 mph) driving speed
Main boom and fly jib 3605

slope
HA + HiA 72 m 1° − max. 0.5 km/h (0.31 mph) driving speed
(236.23 ft)
− 30% reduction in lifting capacity
2° − 40 % reduction in lifting capacity
(236.23 ft) − 30% reduction in lifting capacity
2° − 40% reduction in lifting capacity
(354.35 ft) − 40 % reduction in lifting capacity
HA + HiA u 108 m 1° − max. 0.5 km/h (0.31 mph) driving speed
(354.35 ft) − 50 % reduction in lifting capacity
Legend:
HA = Main boom
HiA = Fly jib
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20
Z 64 234
24/25 043−1060−056
fied in the table.
tal is displayed.
faces.
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Slewing and Braking the Superstructure 7
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C
C
18
Z 53 143 Z 53 141
73
62
59
Z 61 151
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7 Slewing and Braking the Superstructure
Each slew gear is driven using a hydraulic motor in a closed,

splash−lubricated planetary gear system.
Retaining brake
In every slew gear mechanism, a disc brake has been fitted for
free slewing of the superstructure; it is closed by spring resist-
ance, can be ventilated hydraulically and blocked mechanically
in the open position. This disc brake is a retaining brake, which
can also be used as a dynamic service brake.
The slewing movement is braked exclusively by actuating control

lever (3, Z 53 141).
7.1 Speed Control
The crane can be slewed in two speed ranges:

normal speed or high range.
High range can be switched on for the slewing gear by pressing
on the button (73, Z 61 151).
The slewing speed must be reduced for certain operating condi-

tions (depending on the height of the crane equipment and load
moment).
The maximum slewing speed in normal speed can be adjusted

using the rocker switch (18, Z 53 141). Control lever (3, Z 53 141)
always controls the slewing speed from zero through to the previ-
ously set max. slewing speed. The lower the max. slewing speed
the more precisely the slewing speed can be controlled.
In the display (59, Z 61 151) the set maximum value is indicated
by a red arrow.
The maximum possible slewing speed for high speed of the
superstructure corresponds to 1.4 min−1 (1.4 rpm) with the diesel
engine running at its rated speed.
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7
L R
19 8
18
3 2
Z 54 334 Z 58 035
61
73
62
59
Z 62 704
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7.2 Slewing
Normal operation
− Select the slewing gear by pressing on the button (62,

Z 62 704). The holding brake opens when the lever (3,
Z 58 035) is put out of position.
− Slew to the left (L, Z 54 334): Move lever (3, Z 58 035) to the
left.
− Slew to the right (R, Z 54 334): press lever (3, Z 58 035) to the
right.
Overdrive
− Select the slewing gear by pressing on the button (62,

Z 62 704). The retaining brake is opened when lever (3,
Z 58 035) is moved.
− Select overdrive by pressing on the button (73, Z 62 704).
− Slew to the left (L, Z 54 334): Move lever (3, Z 58 035) to the
left.
− Slew to the right (R, Z 54 334): press lever (3, Z 58 035) to the
right.
Switching on the slewing movement with “closing aid”:
Select the slewing gear by pressing on the button (62, Z 62 704).

Press pedal (19, Z 58 035) down.
Open slew gear retaining brake by moving control lever (3,
Z 58 035) in the desired direction.
Release pedal slowly.
The “closing aid ” function can be used at the precise beginning

of a swivelling or slewing movement, e.g. when turning against
the wind.
When the crane turns against strong wind or when it is standing

at a slight inclination within the tolerance range, a pressure in-
crease can be actuated which will increase the power of the slew
gear.
To accomplish this, press pushbutton 10 in control lever 3 (3, 10,
Z 58 036, page 6/9) or button (61, Z 62 704) and keep it pressed
down during the slewing sequence.
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19 8
18
2
3
Z 58 035
10
4 8
18
18 18
3 1 2
Z 58 036
6/9 043−1070−010c_en
Aligning the crane apparatus using the load
The slew gear’s retaining brake is released by pressing key (8,

Z 58 036) in the control lever (2, Z 58 036) or key (4, Z 58 036)
in the control lever (1, Z 58 036). The crane apparatus can be
aligned now using the slung load at the point where it is beginning
to be raised.
7.3 Braking the Superstructure

(Z 58 035)
− Move control lever (3) slowly to “O” position.
Do not brake the superstructure by switching on the move-

ment in the opposite direction.
The spring−loaded retaining brake is not to be used to brake

the superstructure.
Retaining brake
(Z 58 036)
The holding brake is always closed when no slewing movement

is being actuated.
The holding brake is opened by:
−Extend the control lever (3)

−By pressing one of the buttons (4 or 8) in the control lever (1 or
2).
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A A
Z 54 604
8/9 043−1070−010c_en
7.4 Mechanical Locking of the Holding Brake in Open

Position
− Before initiating this measure, check that there are no ob-

stacles within the slewing range!
The holding brake may not be locked in opened position ex-

cept when the crane is supported on outriggers or when it is
standing horizontally.
The holding brake is not permitted to be locked in opened

position when the Superlift is attached.
To ensure that the crane superstructure can independently move

itself into wind direction position when it is left by itself for longer
periods, the holding brake must be released, particularly when fly
jib is attached.
Working sequence
For this job there must be a second person at the slew gear He
or she must be able to speak to or have visual contact with the
crane operator.
1. Press pedal (19, Z 58 035, page 6/9) downwards.

2. Open the holding brake by pressing and continuing to hold
down one of the pushbuttons (4 or 8, Z 58 036, page 6/9) in
the control levers (1 or 2, Z 58 036, page 6/9).
3. Release pedal (19, Z 58 035, page 6/9).
4. Slide lever (A, Z 54 604) in while the brake is open.
5. Let go of button (4 or 8, Z 58 036, page 6/9) − the retaining
brake remains open even though the hydraulic pressure for
opening is switched off.
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Operating the Safety Equipment 8
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Z 58 907
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8 Operating the Safety Equipment
8.1 IC−1 Crane Control

(Z 58 907)
The crane control IC−1 (Intelligent Control System) combines

several devices which provide the crane driver with essential in-
formation for operating the crane within the parameters specified
by the manufacturer:
− Overload cut−off device (load limit device LLD)
− Display of numerous crane functions, for example, support-
ing force, tilt, crane configuration, lifting capacities etc.
− Warning (optical and acoustic) in case of prohibited condi-
tions
− Selection for remote control of crane assembly
(see section 14).
Entries are made by touching the monitor at the prescribed points

(touch screen).
The interaction between the “IC−1” crane controls and the

radio remote control is described in section 14 of this operating
manual.
The functions of the crane controls “IC−1” during operation with

the counterweight dolly are described in sections 16 and 20 of
this operating manual.
043−1080−056 3/145
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4/145 043−1080−056
8.1.1 Load Limit Device (LLD)
The load limit device is an operating aid. The load limit device
system used is an operating aid. It provides the crane operator
with important information on crane data, such as length and
angle of the boom, sheave head height, nominal carrying load,
total load suspended on the boom etc. and warns of an imminent
overload condition.
This safety device is not a replacement for the judgement

and experience of the crane operator, nor does it replace
safe procedures for operation of the crane.
The crane operator still carries the ultimate responsibility for
safe operation of the crane.
8.1.1.1 Function
If, when raising a load or lowering the boom, the permitted load
moment / the permitted load is exceeded, both the load−mo-
ment−increasing and the load−moment−reducing movements
and “raise load on hook” are shut down. “Lower load on hook” is
permitted.
Risk of accidents!
It is absolutely forbidden to override the load limit device
to overload the crane above its load bearing capacity!
Lifting a load with the load limit device bridged is pro-
hibited!
The load limit device should only be triggered in an emerg-

ency situation. Under no circumstances may it be used as a
standard operating tool!
This means that the crane operator must be satisfied, before
hoisting the load, that the load bearing capacity of the crane
is not exceeded by the load to be lifted. Loads that are too
heavy and exceed the load bearing capacity of the crane
must not be accepted, even if there is a load limit device in-
stalled!
Even without a load, the crane apparatus may only be moved

in those ranges where load bearing capacities are specified.
Before a load is raised, its weight must be known. The safety de-
vice may not be used to determine the weight of the load (see
section 8.1.10).
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80
14
Z 58 921
6/145 043−1080−056
The load limit device must be set to the corresponding crane

configuration by the crane operator before starting work.
This means that the crane operator must also change the
load limit device when the crane configuration is changed.
This is set by selecting the operating mode (detailed de-

scription from page 8.1.5).
Only when the load limit device has been correctly set by the
crane operator in accordance with the current operating
mode/crane configuration, can it operate automatically.
The crane operator is responsible for the correct setting by
acknowledging the crane configuration.
Following the shutdown of an overload condition by the load limit

device, movements which reduce the load moment can be car-
ried out in order to be able to set down a load that is suspended
freely. In this case, button (80) and foot switch (14) must be
pressed. This load moment increasing movement may only be re-
leased if it does not cause a dangerous situation. Take this into
consideration before pressing the button (80) the foot switch (14).
Danger of accident − limits of the load limit device!

Despite a functional load limit device that is correctly set in
accordance with the crane configuration, the load limit de-
vice can become ineffective in particular cases / operating
errors:
− insufficient load bearing capacity on the ground used for
the set−up site of the crane
− support errors
− influence of the wind
− diagonal pull
− dynamic influences, e.g. by crane movements that are
too fast and end with an abrupt stop
− dismounting work, if loads are unscrewed/burnt off after
slinging, then hang loosely from the crane and prove to
be too heavy
− lifting overloads with the luffing gear
− co−operation of several cranes.
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8/145 043−1080−056
The crane operator must observe these system limits when

setting up and operating the crane!
The load may only be taken up using the hoist in hook oper-
ation.
If the load is still in contact with the ground and the function
for raising the hoist has been switched off, the load is too
heavy. The movement “Raise main boom or fly jib” may not
be activated in this case!
This movement is not to be used to lift the load under any

circumstances!
It is essential for the operational reliability of the crane that

the load limit device functions in its original condition.
Risk of crushing!
Despite using automatic safety devices, the load could still

swing out when switching the machine off!
It can only be prevented by adapting the acceleration/
speed of all crane movements!
To do so, also observe the constant display of the load mo-
ment with advanced warning at 90 % of the permitted load
moment before switch−off.
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10/145 043−1080−056
The risk of the load limit device being affected by high−fre-

quency radiation is minimised by state−of−the−art technol-
ogy (shielding). It cannot, however, be completely ex-
cluded − in particular under extreme conditions, for
example near powerful transmitters.
If loads are not lifted as usual – i. e. raised from the ground

and lifted into a certain height to be set down there – but are
picked up in a certain height and are then lowered to the
ground, you have to watch, that besides the weight of load
and lifting tackle also the weight of the hoist rope has to be
taken into consideration. For lifting operations close to ca-
pacity limits this might cause the LMI to shut off the actual
crane operation.
043−1080−056 11/145
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60 61
Z 55 342
12/145 043−1080−056
8.1.1.2 Bridging the Load Limit Device
8.1.1.2.1 Bridging the Shutoff Function for Movements Which

Reduce the Load Moment
If a prohibited overload condition has occurred, all movements
which reduce the load moment are also shut down by the load
limit device. Only lowering the load on the hook is now permitted.
Following the shutdown of an overload condition by the load limit

device, movements which reduce the load moment can be car-
ried out in order to move a freely suspended load out of the over-
load range back into the normal operating range. In this case but-
ton (61, Z 55 342) and pedal switch (14, Z 58 921, page 6/145)
must be pressed for general release.
The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.
Risk of accidents!
These movements which reduce the load moment are only
allowed if they are not dangerous in any way. Take this into
consideration before activating the button (61, Z 55 342).
If the load is still in contact with the ground and the function
for raising the hoist has been switched off, the load is too
heavy. The movement “Raise main boom or fly jib” may not
be activated in this case!
This movement is not to be used to lift the load under any

circumstances!
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60 61
Z 55 342
14/145 043−1080−056
8.1.1.2.2 Bridging the Shutdown Function for all Movements

To accomplish this, the button (60, Z 55 342) must be touched
and the foot switch (14, Z 58 921, page 6/145) stepped on.
The load limit device is bridged for operating mode “RG0”.

This may only be done by authorised personnel which are
trained in the operation of the crane!
Under no circumstances may the bridging of the load limit
device be used to increase the load moment.
Lifting a load with the load limit device bridged is pro-
hibited!
043−1080−056 15/145
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16/145 043−1080−056
8.1.1.3 LLD Error code table
Error code Error Cause Elimination

E01 Radius range not As a result of luffing up too far, Luff boom up to one of the ra-
achieved or angle the minimum radius specified in diuses specified in the load
range exceeded the relevant load capacity chart capacity chart or luff the angle
was not achieved or the maxi- down.
mum angle was exceeded.
E02 Radius range exceeded As a result of luffing down too Luff boom down to one of the
or angle range not far, the maximum radius speci- radiuses prescribed in the load
achieved fied in the relevant load capacity capacity chart or luff the angle
chart was exceeded or the mini- up.
mum angle was not achieved.
E04 Operating mode not Non−available operating mode Using the keyboard, enter the
confirmed or not pres- selected. operating mode for the operat-
ent ing condition correctly in ac-
cordance with the allocation.
The selected operating mode is Check programming in the

either not contained in the flash flash EPROM.
EPROM or is blocked.
E05 Boom length not avail- Non−available boom length se- Using the keyboard, enter the
able lected. longitudinal code for the oper-
ating condition correctly in ac-
cordance with the allocation.
The selected boom length is not Check programming in the

contained in the flash EPROM. flash EPROM.
E06 With luffing fly jibs: As a result of luffing the fly jib Luff fly jib down to one of the
Radius range exceeded down too far, the maximum radiuses prescribed in the load
or fly jib angle range radius specified in the relevant capacity chart or luff the angle
not achieved. load capacity chart was ex- up.
ceeded or the minimum angle
was not achieved.
043−1080−056 17/145
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18/145 043−1080−056

E07 Erroneous response Overload relay defective Replace LLD assembly
message from overload
relay on the LLD as- LLD assembly faulty
sembly.
Relay should be acti-

vated, 2nd contact is
registered however as
switched off or the 2nd
contact is registered as
switched on at a point
where the relay should
have dropped out.
E20 Lower or upper limit Cable of the central unit to the Check both cable and plug, re-
value in the measure- transducer faulty or water in the place as needed
ment channel “Force plugs.
heavy head on the left”
exceeded. Transducer faulty Replace transducer.
Switchoff, if only 1 load
cell available or lower Electronic component in the Replace iFlex5 supplementary
or upper limit value in measurement channel faulty. assembly.
both measuring chan-
nels “Force heavy head
on the left and right”
exceeded.
light head on the left”
exceeded Switchoff, if Transducer faulty Replace transducer.
only 1 load cell avail-
able or lower or upper Electronic component in the Replace iFlex5 supplementary
limit value in both measurement channel faulty. assembly.
measuring channels
“Force light head on
the left and right” ex-
ceeded.
043−1080−056 19/145
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20/145 043−1080−056

E23 Lower or upper limit Cable from the central unit to Check both cable and plug, re-
value in the measure- the pressure absorber faulty or place as needed
ment channel “Pres- water in the plug.
sure A−frame cylinder”
exceeded. Pressure contact faulty Replace pressure absorber.
Electronic component in the Replace iFlex5 supplementary

measurement channel faulty. assembly.
value in the measure- the transducer faulty or water in place as needed
ment channel “Force the plug.
derricking gear” ex-
ceeded. Transducer faulty Replace transducer.

value in the measure- the angle transmitter faulty or place as needed
ment channel “Angle water in the plug.
main boom foot sec-
tion” exceeded. Angle transmitter faulty Replace angle transmitter.
Electronic component in the Replace iFlex5 basic module.

measurement channel faulty.
value in the measure- the angle transmitter faulty or place as needed.
main boom foot sec-
tion” exceeded. Angle transmitter faulty Replace angle transmitter.
Electronic component in the Replace iFlex5 base assem-

measurement channel faulty. bly.
043−1080−056 21/145
8
22/145 043−1080−056

value in the measure- the length indicator faulty or place as needed
ment channel “Length water in the plug.
indicator SL cylinder”
exceeded. Length indicator faulty Replace length indicator.
Electronic component in the Replace iFlex5 basic module.

measurement channel faulty.
heavy head” exceeded.
Angle transmitter faulty Replace angle transmitter.

LF” exceeded.
Transducer faulty Replace tansducer.

E2A Lower or upper limit Cable from the central unit to Check both cable and plug, re-
light head” exceeded.

E2B Lower or upper limit Cable from the central unit to Check both cable and plug, re-
LF foot” exceeded.

043−1080−056 23/145
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24/145 043−1080−056

E2C Lower or upper limit Cable from the central unit to Check both cable and plug, re-
A−frame” exceeded.

E2D Lower or upper limit Cable from the central unit to Check both cable and plug, re-
value in the measure- the transducer faulty or water in place as needed
ment channel “Force the plug.
standard runner” ex-
ceeded. Transducer faulty Replace transducer.

E2E Lower or upper limit like E2D like E2D
value in the measure-
ment channel “Force
enhanced runner” ex-
ceeded.
E2F Lower or upper limit Cable from the central unit to Check both cable and plug, re-
SL mast foot” ex-
ceeded. Angle transmitter faulty Replace angle transmitter.

E31 Error in the system pro- The system program PROM is Reload system program.
gram faulty.
Flash EPROM faulty Replace central unit.

E37 Error in the logical pro- The system program PROM is Reload system program.
gram sequence faulty.
Flash EPROM faulty Replace central unit.

E38 System program and The system program in the LLD Replace system program or
data PROM do not go does not go with the program- data PROM file.
together. ming in the data PROM.
E39 System program and The system program in the LLD Replace system program
load curve EPROM do does not go with the program- PROM or load curve PROM
not go together. ming in the EPROM load file.
curves.
043−1080−056 25/145
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26/145 043−1080−056

E51 Error in the crane data Crane data PROM has no valid Load crane data PROM with
PROM data. valid data.
Flash PROM faulty Replace central unit.

E52 Error in the load curve Memory module incorrectly Load crane data PROM with
PROM. bridged valid data.

E53 Error in the crane data Memory module incorrectly Load crane data PROM with
PROM (Bank 2) bridged valid data

E56 Error in the crane data Crane data PROM has no valid Load crane data PROM with
PROM data during calibration. valid data

E57 Error in the serial crane Serial crane data PROM has no Describe crane data PROM
data PROM valid data. with data (with test program or
on−line function), then restart
LLD.

E61 Error in the crane data Selected crane data PROM Check crane data PROM
PROM bank has no valid data and/or
does not go with load curve
PROM.
E62 Error in the crane data Selected crane data range has Check crane data range
range no valid data.
Selected crane data range is in- Load crane data that goes
compatible with crane type. with crane type.
E63 Error in crane data With dynamic memory manage- Select 1st data range.
area 2nd data PROM ment 2nd data area is not sup-
ported.
E80 Maximum power der- Maximum power derricking gear Reduce power derricking gear.
ricking gear exceeded.
043−1080−056 27/145
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28/145 043−1080−056

E81 Excessive deviation of The angle to the horizontal on Check the angle transmitter
the angles on the main the main boom head is greater on the main boom head.
boom head and on the than the angle on the main
main boom foot sec- boom foot section by more than Check angle transmitter on
tion. 5 degrees. the main boom foot section.
E82 Excessive deviation of The angle to the horizontal on Check the angle transmitter
the angles on the fly jib the fly jib head is greater than on the fly jib head.
head and on the fly jib the angle on the fly jib foot by
foot. more than 5 degrees. Check angle transmitter on
the fly jib foot.
E83 Maximum power sus- Maximum power suspension Reduce power suspension
pension main boom main boomexceeded main boom.
E84 Faulty configuration The selected configuration is not Select different configuration.
contained in the data EPROM.
Check programming in the
data EPROM.
E86 Faulty position of the The SL counterweight is not in Place the Superlift counter-
SL Counterweight its prescribed radius range dur- weight in the permitted range.
ing SL operation.
Length measurement of the Check the length measure-

Superlift counterweight defective ment of the Superlift counter-
weight.
E87 Faulty position of the The SL mast is not in its pre- Luff the SL mast into the per-
SL mast scribed radius range during SL mitted range.
operation.
Angle measurement of the SL Check angle measurement of

mast is faulty. the SL mast.
043−1080−056 29/145
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30/145 043−1080−056

E88 Faulty main boom posi- The main boom is not in the pre- Luff main boom into the per-
tion during operation scribed angle range during oper- mitted range.
with luffing fly jib. ation with luffing fly jib.
Angle measurement of the main Check angle measurement of

boom faulty. the main boom.
E89 Faulty position of the fly The fly jib is not in the pre- Luff fly jib into the permitted
jib during operation with scribed angle range during oper- range.
fixed angle to the main ation with fixed angle to fly jib.
boom or duringconfi-
guring of the fly jib. The fly jib is not in the pre- Luff fly jib into the permitted
scribed angle range during con- range for configuration.
figuration of the fly jib.
Angle measurement of the fly jib Check angle measurement of

faulty. the fly jib.
E8A Maximum power sus- Maximum power suspension luf- Avoid suspension of luffing fly
pension luffing fly jib fing fly jib exceeded. jib.
E8B Lower or upper limit Cable of the central unit to the Check both cable and plug, re-
HA with load on two
hooks” exceeded. Transducer faulty Replace transducer.

E8C Lower or upper limit see E20 see E20
value in the measuring
channel “Force HA/HI
head right” exceeded.
E8D Lower or upper limit see E21 see E21
value in the measuring
channel “Force HA/HI
head right” exceeded.
E8E Limit value exceeded Limit value exceeded Reduce load on the LF
limit value load ind. LF
operation mode
E8F Value exceeded, con- Value exceeded in the fixed Recalibrate the configuration
centration on operating point calculation. with floating point calculation,
modes see data group 2.11.
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32/145 043−1080−056

E90 Incomplete data from Incomplete data from the moni- Check the data on the moni-
the monitor to the tor has been transferred. tor, e.g. number of load capac-
iFlex5−LMI ity tables.
E95 Data missing from the No data has been transferred Check data transfer from the
monitor to the from the monitor. monitor
iFlex5−LMI
The transmitted load capacity
chart is incompatible with the
selected configuration.
E96 Error in data transfer The data set on the monitor Check data set on the monitor
from the monitor to the contains faulty data (quantity,
iFlex5−LMI. CRC symbol).
E98 LLD watchdog acti- The processing time for the LLD Reset system by switching off
vated task was exceeded. and then back again on.
Connect terminal and monitor

system announcements.
E9F Value range exceeded Value range exceeded in the None
arctan function for cal- fixed point calculation, corrected
culation of lever arm with floating point calculation
force without switchoff
EB0 Redundancy error in The measuring channels “Force Replace defective transducer
the measurement left” and “Force right” show dif-
channels SH ferent values.
EB1 Redundancy error in The measuring channels “Force Replace defective transducer
the measurement left” and “Force right” show dif-
channels SH/LH (HI ferent values.
bracing for SW, SWSL,
SFSL, LFVL separated)
EB2 SH bracing for SW, LF The measuring channels “Force Replace defective transducer
redundancy error in the left” and “Force right” show dif-
measuring channels ferent values.
EB3 SSL The measuring channels “Force Replace defective transducer
Redundancy error in left” and “Force right” show dif-
the measurement ferent values.
channels
043−1080−056 33/145
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34/145 043−1080−056

EB4 SSL/LSL The measuring channels “Force Replace defective transducer
channels
EB5 SSL bracing for SWSL, The measuring channels “Force Replace defective transducer
LFSL, LFVL, SFVL. left” and “Force right” show dif-
Redundancy error in ferent values.
the measurement
channels
EB6 channels HI bracing for The measuring channels “Force Replace defective transducer
SW, SWSL, SFSL left” and “Force right” show dif-
Redundancy error in ferent values.
the measuring chan-
nels
EB7 HI bracing for LFVL The measuring channels “Force Replace defective transducer
channels
EB8 SH/LH for LF The measuring channels “Force Replace defective transducer.
channels
EB9 SSL/LSL for LF The measuring channels “Force Replace defective transducer
channels
SSL/LSL for LF
EFD Load limit device A function that is required for Message is automatically
Watchdog extension more than 0.5 s is active, e.g. reset after several seconds.
write Flash PROM
If an error message is displayed that is not included in the present

list, then please contact our customer service technicians.
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Z 47 418
Z 59 514
36/145 043−1080−056
8.1.2 Description of the Monitor Screens and Function

Keys
8.1.2.1 Opening Screen

(Z 47 418)
Menu screen 1 appears on the display after the ignition has been
switched on.
After approximately 10 seconds the display switches automati-

cally and the operating mode selection screen is shown.
8.1.2.2 Symbols “Main Menu of the Display and Operating

Console of the LLD System” (LLD Screen)
(Z 59 514)
The name of the screen “Main menu”, the current time of day and
the current program version are displayed in the heading.
Symbol Meaning
Switching over to the “System settings”
screen
Preselection:
Switch monitor background lighting on/off
− If the background lighting is switched off,
the invisible button for switching it back on
is active in the centre of the display.
Selection of the “Set up crane type” screen
− Selection of tables only visible for cranes
with different tabular records
Selection of the “Set up display”

− switch over 1 or 2−monitor operation (LMI
/ MOT monitor)
Switching over to the “LLD screen”
Switching over to the “Operating mode

selection” screen
Switching over to the “Error code” screen
043−1080−056 37/145
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Z 59 514
Z 56 842
38/145 043−1080−056
(Z 59 514)
Switching over to the “Operating range limit”
screen
Switching over to the screen “IParameters”

for setting the valve parameters
Switching over to the “INFO” screen

−Display of tables, construction numbers,
dates
Switching over to “CAN BUS” screen
Switching over to “Diagnosis” screen

− Limit switch function
− Analogue boards I/O
− Digital boards I/O
Switching over to the “Function diagnostics”

screen
Switching over to the “Data logger” screen
8.1.2.3 Symbol “Main Menu of the Display and Operating

Console of the Engine and Crane Operating System”
(MOT Screen)
(Z 56 842)
Symbol Meaning
Switching over to the “System settings”
screen
Preselection:
Switch monitor background lighting on/off
− If the background lighting is switched off,
the invisible button for switching it back on
is active in the centre of the display.
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Z 56 842
40/145 043−1080−056
(Z 56 842)
Switching over to the display of the “LLD
system” on the monitor of the “Engine and
Crane Operating System”
− If there is a failure of the display and op-
erating console for the LLD system
Switching over to the “INFO” screen
−Display of tables, construction numbers,
dates
Switching over to “CAN BUS” screen
043−1080−056 41/145
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2
Z 47 420
Z 56 843
42/145 043−1080−056
8.1.2.4 “System Settings” Screen

(Z 47 420)
In the “System settings” screen, some basic settings of the LLD

system are displayed.
The displayed settings can be changed by touching the framed
button.
You must save the changes by touching button (1) if the changes
should always be valid.
You exit the display “System settings” screen by touching button

(2).
8.1.2.5 “Set Crane Type” Screen

(Z 56 843)
The selection button in the Main menu for this screen can only be
selected when lifting capacity tabular records for several con-
struction numbers are stored in the system.
The crane type currently set, together with the most important in-
formation concerning the stored load capacity charts, is dis-
played In the “Set crane type” screen.
Touching the framed button (3) opens a selection menu from
which the type of crane can be selected.
One can save and exit the “Set crane type” menu by touching the
button (2). If nothing is to be saved, one can exit the menu by
touching the button (4).
043−1080−056 43/145
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1
3
2 4
Z 56 844
21 20
N
Z 56 845
44/145 043−1080−056
8.1.2.6 “Set Display” Screen

(Z 56 844)
The selection button in the Main menu for this screen can only be
selected when the crane is equipped with two monitors.
Legend:
1 1−monitor operation
2 2−monitor operation
3 LLD monitor
4 MOT monitor
If one monitor fails, one can switch over from 2−monitor operation
to 1−monitor operation in the “Set display” screen.
Switchover to 1−monitor operation occurs when the button (1) is
touched.
To ensure that no malfunctions occur during 1−monitor

operation after a monitor has failed, the mains plug (N,
Z 56 845) or the CAN bus plug (C) of the defective monitor
needs to be pulled out of its respective socket (20 or 21,
Z 56 845). Both are to be found on the underside of the re-
spective monitor.
The displays will then be presented in reduced form, because the

amount of space on a single monitor is not sufficient for showing
them in their usual dimensions. In addition, it may be necessary
to change the views. The crane can continue to be operated, al-
though with less handling ease.
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Z 59 517
46/145 043−1080−056
8.1.2.7 “LLD” Screen
Symbols in Area “B” − Signal bar

(Z 59 517)
Symbol Meaning
Error display LLD (see error code list in part 4)
This is only displayed is there is an actual error.
Switch: to switch menu range “K” on or over
Preselection “Bridging LLD” (lower boom, raise

hoist)
Preselection “Bridging LLD” (raise boom)
“Bridging hoist limit switch”
Switch: to switch off acoustic warning signal
Error display PLC

Background becomes red when the error status
has changed since the last time the list of errors
was opened.
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Z 59 518
48/145 043−1080−056
Symbols in Area “C” − Configuration display

(Z 59 518)
Symbol Meaning
Short description of the boom combination in fig-
ure, for example “SW”
Main boom length (HA) − SH
Fly jib length (HI) − SW
Fly jib length (HI) − LF
Angle of the fly jib for LF/SFSL/SFVL
Angle of the fly jib for LF
Central ballast
Counterweight on the superstructure
Switching over: Operation with Superlift counter-

weight dolly (WG) / Superlift counterweight frame
(TR)
Superlift counterweight
Radius of the Superlift mast point
Support base area
Reeving of the main hook
Number of roller sets fitted to the sheave head
043−1080−056 49/145
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Z 59 518
50/145 043−1080−056
Continued: Symbols in Area “C” − Configuration display

(Z 59 518)
Symbol Meaning
Reeving LF
Winch(es) in the main boom
Max. load on the runner
Reeving of the runner
Weight of the empty hook block on the main

boom for fly jib operation.
This is an option that needs to be enabled by
TEREX−DEMAG. It is switched on when the
crane has SH/LF load capacity tables.
Winch in the main boom not installed for crane
apparatus with 1 winch in the main boom.
Winches not installed for crane apparatuses with
2 winches in the main boom.
Winches installed for crane apparatuses with 2

winches in the main boom.
Winch in the main boom installed for crane appar-
atuses with 1 winch in the main boom.
1 winch in the main boom installed for crane ap-
paratuses with 2 winches in the main boom.
043−1080−056 51/145
8
K (RGO)
Z 59 515
52/145 043−1080−056
Symbols in Area “K”

(Z 59 515)
Symbol Designa- Meaning
tion
Switch Switching on the “Operating
mode selection” screen
Switch Switching on the display

“Slewing angle and gradient
level indicator” in the variable
display field “I”
Switch Switching on the “Main
menu” screen
Switch Activation of “Operating

range limits” screen, “small”
in the variable display field
“K”
During crane operation for
monitoring
Switch Activation of “Operating
range limits” screen, “large”
in the entire display
For setting the operating
range limits
Switch Switching on the “Ground
pressure” display
Switch Switching on the “Rope limit

switch override” display
Switch “Quit” back to previous dis-

play
If this switch is pressed, all
entries that have been made
but are not desired are dele-
ted.
043−1080−056 53/145
8
1 3
2
14 4
13
6
7
8
12
11 10 9
Z 53 149
54/145 043−1080−056
“Crane display” area
Legend:
(Z 53 149)
1 Reversing
2 Operating mode “Configuration active”
3 Balance indicator for operation with double hook block
4 Wind speed
5 Superlift mast radius
6 Max. force in the derricking rope
7 Force in the derricking rope
8 Ground contact display
9 Superlift counterweight radius
10 Load radius
11 Main boom angle
12 Operating range limit active
13 Sheave head height
14 Emergency control system active
043−1080−056 55/145
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Z 59 519
56/145 043−1080−056
8.1.2.8 “MOT” Screen
Symbols in Area “K”

(Z 59 519)
Symbol Designa- Meaning
tion
Switch Switching on the “Main
menu” screen
Switch Switching on the “Operating

hours” display
Switch Switching on the “Counter-

weight dolly” display
Switch Switching on the “Joystick

modes” display
Switch “Quit” back to previous dis-

play
If this switch is pressed, all
entries that have been made
but are not desired are de-
leted.
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Z 47 418
98
Z 59 547 Z 57 145
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8.1.3 Operating the LLD System
For this system, all functions are operated by “tapping” the keys
or buttons shown on the monitor (touch screen).
By tapping a key/active button, a selection window is opened for

parameter selection, or the display changes to another selection
window.
When opening a selection window, a list of selection options
(pull−down menu) appears in the selected area. A value must
then be selected from the selection list. If the set value is not to
be modified, then the previous value must be selected again from
the selection list.
In principle, the following applies:

“Save” symbol:
Floppy
selected setting is saved and the display is
disk
changed
“Exit” symbol:
Door the display is exited again without saving
the modified setting
The setting of the load limit device begins with the entering of the
crane configuration in the “Operating mode selection” screen. Af-
terwards, depending on the desired operating mode, additional
parameters can be set in the individual screens of the IC−1 crane
controls.
8.1.3.1 Switching on
1. Rotate the ignition key (98, Z 59 547) clockwise until it stops.

2. Menu screen 1 “opening screen” appears (Z 47 418).
After approximately 10 seconds, the display switches automati-

cally to the display of the “Operating mode selection menu”
(Z 57 145).
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8.1.3.2 Entering the Operating Mode
In order for the control system and the load limit device to function
properly, the crane configuration must be set after switching on
the ignition or before starting work.
Because the crane configuration that has already been set up is

still saved in the display, even after restarting, one must check to
see whether it is still valid before commencing work.
Select the screen “operating mode selection” to check and set

the crane configuration (see the following page) or the most re-
cently selected setting will automatically reappear before switch-
ing off the ignition.
− Even if the display and the crane configuration remain un-
changed, the crane configuration still needs to be adjusted
once again and the mask needs to be exited “operating mode
selection” with .
− When the crane configuration is changed, it must be reset by

the crane operator.
− After the new values have been entered in the “operating
mode selection” screen, it must be exited again with .
Only when the operating mode has been set correctly by the
crane operator in accordance with the individual crane con-
figuration can the load limit device operate automatically.
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Z 57 149
Z 57 150
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Selecting the “Operating mode selection” screen

(Z 57 149, Z 57 150)
This screen appears:

− after every restart, as soon as the IC−1 has run through the
starting procedure (Z 57 150).
− by actuating the button in the “Main menu” or in the

“Quick menu” screen (Z 57 149).
The single parameters which are relevant to the operating mode

/ crane configuration are listed in this screen.
Risk of accidents!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane. This responsibility lies with the crane operator
alone. It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation.
The load capacity table valid for the selected crane configuration
can be displayed in the “Table view” screen by pressing on button
(1).
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Z 57 146 Z 57 147
Z 57 148
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Setting the operating mode
− Behind each button marked with B are further details and nu-
merical values.
− If the number values are red, they must be confirmed by one
touch.
The following is an example of operating mode selection:
Risk of accidents!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane. This responsibility lies with the crane operator
alone. It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation.
1. You can see the display “RZ I” on the monitor (Z 57 146).

2. Enter the desired data one after the other by touching the
buttons.
The selected value appears on the button and after pressing the
buttons “Save and Exit” and “OK” in the “C” operating mode line
(Z 57 146).
3. By touching the button “RZ II” switch on the display on the

screen (Z 57 147).
buttons.
5. By touching the button “RZ III” switch on the display on the
screen (Z 57 148).
buttons.
7. Open the selection list of reevings by touching one of the
symbols B.
8. Select the desired reeving.
The selected value appears on the button and after pressing the
buttons “Save and Exit” and “OK” in the “C” operating mode line
(Z 57 148).
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1 Z 57 148
Z 53 701
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9. Touch the button
to switch to the display (Z 57 148).

10. Touch the button (1, Z 57 148)
to save the entered data.

11. If the set data are not to be accepted but changed, you can
press the symbol
to switch to the LLD display and from there back to the

screen.
“Operating mode selection”. In addition, the message
“E4” appears in the signal bar (see 8.1.1.3). This message
disappears again when the crane parameters are re−en-
tered and accepted.
The screen now switches to the display “LLD” (Z 53 701).
The “LLD” screen − and there specifically the “K” area, the field
“Quick menu” (see section 8.1.2.7), the “MOT” screen and the
screen “Main menu” (see section 8.1.2.2, from page 33) serve as
starting points for using the IC−1 functions.
The required functions can be selected from these screens by

calling up the corresponding submenus.
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1 2
Z 62 707
1 2
Z 62 708
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8.1.3.3 Setting the Configuration Programs for Crane Assem-

bly
Configuration program “RG 0 assembly”

Configuration with partially assembled crane (e.g. raise
frame; see section 8.3.3.1).
Configuration program “RG 0 − lower limit switch − bridging”

To change the ropes from H1, H2, H3, W1 and W2 the corre-
sponding lower limit switches are bridged.
Configuration Program “RGO”

1. Bring up “Operating mode selection” screen on the monitor.
2. Switch on the display on the monitor by touching the button
“RZ I” (1, Z 62 707).
3. Open the uppermost pull−down menu and select RGO.
4. Enter the desired data in sequence by touching the buttons
as is described under 3.
“Save & Exit” (2, Z 62 707).
6. By touching the button ”OK” save the entered data. The
monitor now changes automatically to the LMI screen.
All of the limit switches and sensors are non−functioning during

the “RGO” operating mode. The main power cables for the SL
mast and the main boom must remain in their parked positions
in order to avoid error messages caused by the equipment al-
ready mounted with pilot contacts. Plugs for the SL mast on blind
pedestal (1, Z 62 708) and plugs for the main boom on blind ped-
estal (2, Z 62 708).
Once the crane is assembled with its apparatus, the two afo-
rementioned plugs must be plugged into the corresponding ped-
estal in the SL mast foot section and main boom foot section.
Now the next step in the erection of the crane can be carried out.
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1 3 4
10 5
9 6
8
7
Z 53 702
1 3
Z 53 703
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Legend:
(Z 53 702)
1 Radio remote control on/off
2 −
3 Assembly of the carrier (for TC crane without function)
4 Assembling the winch frame
5 Assembling the Superlift telescopic tube
6 Cylinder of the quick release
7 Lift cylinder counterweight
8 Assembling main boom foot section
9 Assembling the Superlift counterweight vehicle
10 Swing over A−frame
Configuration program “SMAB1”

“RZ I”.
buttons.
“RZ Save & Exit”.
5. By touching the button “OK” save the entered data.
Legend:
(Z 53 703)
1. Radio remote control on / off

2. −
3. Assembly chassis (track frame)
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1 8
Z 53 704
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Configuration program “SMAB2”

“RZ I”.
buttons.
“RZ Save & Exit”.
5. By touching the button “OK” save the entered data.
Legend:
(Z 53 704)
1 Radio remote control on / off
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Z 54 610
Z 56 400
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8.1.3.4 Configuration Operation
For erecting and lowering the selected crane equipment, “Erec-

tion operation” must be switched on.
Switching on erection operation

1. Switch on “Operating mode selection” screen.
“Save & Exit” (Z 54 610).
3. Switch to “Erection operation” by touching button 2.
4. Save the entry by touching button “1 = OK” (Z 54 610).
5. The display on the monitor now changes to the “LLD figure”
in accordance with the preselected operating mode. In addi-
tion, the symbol 2 appears in the display area “A” (Z 56 400).
6. The LMI does not function in this operating mode. The valid
erection table must therefore be adhered to precisely.
Switch off configuration operation

1. Switch on “Operating mode selection” screen.
“Save & Exit” (Z 54 610).
3. Switch off erection operation by touching button “2”
(Z 54 610).
4. Save the entry by touching button “1 = OK” (Z 54 610).
5. The display on the monitor now changes to the “LLD figure”
in accordance with the preselected operating mode. Symbol
2 is removed from the display area “A” (Z 56 400).
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Z 57 150
11
2
10 3
9
4
8
7
6
5
Z 60 947
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8.1.4 “View Table” Screen
Switching on table view
Press button (1, Z 57 150) in the “Operating mode selection”

menu to switch To View tables.
View tables
(Z 60 947)
In the “Table view” screen, all stored lifting capacity tables for the
set crane configuration can be called up by pressing key
(9).
The following details can be found in these lifting capacity tables
stored in the system:
(1) − Load capacities

(2) − SL−counterweight radius
(3) − Main boom angle
(4) − Scroll bar
(5) − Reeving when the hook block does not reach the ground
(6) − Minimum reeving for maximum load
(7) − Minimum reeving for maximum load
(8) − Load radius
(9) − ID number of the load capacity table
(10) − DS code
(11) − Selection of additional stored load capacity tables for the
set crane configuration
Please refer to the lifting capacity tables, which you will receive
with the crane − either on paper or as CD−ROM − for more details
on lifting capacities.
Please observe the following page.
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B C
A
d
E
F
G
K
I
Z 57 302
78/145 043−1080−056
Lifting capacity table (on paper or CD)

(Z 57 302)
The following example shows where you can find the various de-
tails in the lifting capacity table.
The following load table is only a specimen. Only the lifting

capacity tables that are supplied with the crane may be used
for operation of the crane.
(A) − Crane type and construction no. of the crane

(B) − Lifting capacities on the main boom
(C) − Code for the operating mode (here: SH for main boom
operation)
The meanings of all codes is explained in section 2.5.
(D) −
Permissible slewing range: 0° − 360°
(E) −
Track width (here: 8.4 m)
(F) −
Counterweight (here: 160 t)
(G) −
Central ballast (here: 0 t)
(H) −
Main boom length (here: 36 m)
(I) −
Radius (here: 18 m)
(K) −
Lifting capacity (here: 105 t)
(L) −
Minimum reeving number of the hoist rope (here:
18−strand)
(M) − DS code (here: 0000000303)
(N) − Follow restrictions/warning instructions,
without fail (here: none)
(O) − Item no. of the load capacity table
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Z 53 705
10 3 4 5
13 6
12
11 2 9 8 Z 53 706
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8.1.5 “Operating Range Limit” Screen
8.1.5.1 Switching on
Press the button (1, Z 53 705) in the K area of the LLD display to
switch on the “Working area limitation” screen (Z 53 706).
The limits which are active when this occurs are shown in “green”.
Legend:
(Z 53 706)
1. Signal bar
2. Display operating range main boom angle
3. Display slewing angle
4. Display work load
5. Display working radius
6. Back to LLD display
7. Control area for main boom angle limit
8. Control pad for head height limit
9. Control pad for wall limit
10. Display operating range head height
11. Control pad for radius limit
12. Control area for slewing angle limit
13. Display operating range (top view)
This safety device is not a replacement for the judgement

and experience of the crane operator, nor does it replace
safe procedures for operation of the crane.
The crane operator still carries the ultimate responsibility
for safe operation of the crane.
Make sure that you deactivate the activated limits as soon as

work in a limited operating range has been completed.
Otherwise, accidental shutdown can result during subse-
quent crane operation without limits.
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1 2 3
Z 53 707
1 2 3 4
Z 53 708
82/145 043−1080−056
8.1.5.2 Setting up the Various Limits
Slewing angle limit

(Z 53 707)
As the previously stored limit values remain stored after switching

back on then a check must be made to ensure that these values
are still valid before recommencing with work.
1. Swing the crane to the left−hand slewing angle limit and this
value by pressing the switch (1).
2. Swing the crane to the right−hand slewing angle limit and
save this value by pressing the switch (3).
3. Activate slewing angle limit by pressing the switch (2).
The switches (1 and 3) for saving the limit values are shown in
“green”.
Please refer to the information in section 7 “Slewing and

Braking the Superstructure”.
In particular make sure that the selected angle limit (= shu-
toff point) really does ensure sufficient clearance to the haz-
ardous area (e.g. swinging out of the hook block after the
crane movement is shut down), even in extreme situations!
Always drive all crane movements at adapted speeds!
After setting the limit angles, first make sure in a “test run”
that the shutdown occurs at the intended positions.
Radius limit
(Z 53 708)

1. Steer boom to the maximum radius limit and save this value
by pressing the switch (2).
2. Activate outer radius limit by pressing the switch (1).
The switch for saving (2) the limit value is then shown in “green”.
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1 2 3 4
Z 53 708
1 2 3 4
Z 53 709
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Continued: Radius limit

(Z 53 708)
3. Steer boom to the minimum radius limit and save this value
4. Activate inner radius limit by pressing the switch (3).
Make sure that the radius range does actually ensure suffi-
cient distance to the danger zone even in extreme situations
(i.e. when the hook block swings out after the swinging mo-
vement has been switched off).
Limits by a wall
(Z 53 709)

1. Steer boom to the limit point (A) and save this value by press-
ing the switch (2).
2. Steer boom to the limit point (B) and save this value by press-
ing the switch (4).
3. Select whether the limitation “in front of the wall” or “behind
the wall” is to apply by pressing the switch (3). The field (5)
in the display is presented accordingly “in green”.
4. Activate “Limitation with reference to wall” by pressing the
switch (1).
The switches for saving (2 and 3) the limit values are shown in
“green”.
Make sure that the selected limit does actually ensure suffi-
cient distance to the danger zone even in extreme situations
(i.e. when the hook block swings out after the swinging
movement has been switched off).
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1 3
2 4 6
Z 53 710
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Head height limit

(Z 53 710)
1. Raise boom to the limit point and save this value by pressing
the switch (2).
2. Activate the head height limit by pressing the switch (1).
Make sure that the selected limit point does actually ensure
sufficient distance to the danger zone.
Main boom angle limit

(Z 53 710)
1. Raise boom to the top main boom angle and save this value
2. Activate top main boom angle by pressing the switch (3).

3. Lower boom to the lower main boom angle and save this
value by pressing the switch (6).
4. Activate lower main boom angle by pressing the switch (5).
Make sure that the selected limit does actually ensure suffi-
cient distance to the danger zone even in extreme situations.
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20
Z 55 450
20
4
Z 55 451
88/145 043−1080−056
8.1.6 Display of the Ground Pressure
This display shows the relative distribution of the ground pres-

sure along both track carriers on the ground.
Determination of the ground pressure is not based on

measured data. − The display is only for the purpose of ap-
proximate estimation of the load on the ground.
Display selection
The display selection is possible under the following conditions:

− An operating mode needs to be selected.
− The operating mode RGO or SMAB may not be selected.
− No “LLD error” is permitted to be displayed.
− The “Configuring” function may not be selected.
− Press the button (1, Z 55 450) in the display (20, Z 55 450)
in the Quick Menu.
− Now the display of the ground pressure appears in the display
(20, Z 55 451) in the Quick Menu.
Legend:
(Z 55 451)
1. −
2. Display of the distribution of the ground pressure
3. Maximum ground pressure in t/m2
4. Selection of the track width
5. Display of the selected track width
Check to see whether the displayed track with (5, Z 55 451)

matches the track width on the crane. Correct this setting as
necessary by pressing the button (4, Z 55 451).
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1 2
Z 63 670
3 4 5
Z 63 671
90/145 043−1080−056
8.1.7 Logger (Optional)
A logger is a recorder, which automatically logs the data. The

data is saved on the computer. The saved data can be shown on
the display or they can be read out on a USB stick for further pro-
cessing.
Read out data are no longer saved on the computer.
Two loggers are saved in the crane control.

− Datalogger
− Windlogger
8.1.7.1 Calling up the Screens
Screen “Datalogger”
1. Call up the “Overload logger” screen by touching button (2,
Z 63 670) in the main menu of the LLD display.
2. Call up the display of the “Datalogger” screen by touching
button (5, Z 63 671).
“Windlogger” Screen
1. Call up the “Overload logger” screen by touching button (2,
2. Call up the display of the “Windlogger” screen by touching
button (4, Z 63 671).
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SP1SP2 SP3SP4SP5 SP6 SP7SP8SP9 SP102
1
A
C
B
Z 57 141
92/145 043−1080−056
8.1.8 “Data Logger” Screen (Data Recorder)
The data logger is a recorder that automatically writes down the

data when events or configurations occur that contain a potential
for danger. The current data record is then saved in the computer.
In the current version, 56 values (referred to as “Standard va-
lues”) are thus recorded.
Because of the large size of the data quantity, only an extract of
the most important data can be displayed on the monitor.
Description of the monitor display

(Z 57 141)
Header with the two−line column headings displayed for the

standard values.
SP1 = Date, time of day
SP2 = Trigger (abbreviations for the triggering events and
configurations. For meaning of the abbreviation,
see the following table)
SP3 = Main boom angle, fly jib angle
SP4 = Superlift mast radius, radius of the Superlift
counterweight
SP5 = Slewing angle, derricking rope force
SP6 = Working radius 1, working radius load 2
SP7 = Load 1, load 2
SP8 = Max. load 1, max. load 2
SP9 = Radius load 1, radius load 2
SP10 = Head height load 1, head height load 2
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SP1 SP2 SP3 SP4 SP5 SP6 SP7 SP8 SP9 SP10 2
C
B
Z 57 142
94/145 043−1080−056
Continued: Description of the monitor display

(Z 57 142)
Display field for the standard values, the software status, the
configuration and the system information.
A = Information concerning the software status

1st line = Date, time of day
2nd line = Trigger,
Type of crane,
Construction number,
Creation date of the load capacity chart
B = Configuration
1st line = Date, time of day
2nd line = Configuration chain of characters:
Operating mode_
Main boom length_
Fly jib length1_
Fly jib length2_
Fly jib angle1_
Fly jib angle2_
Central ballast_
Counterweight_
TR_or WG_ (TR = frame, WG = counter−
weight dolly)
SL counterweight_
Mast radius_
Outrigger support area_
VarioSL active (1 = on)
C = Example for saved standard values
D = Time and date change

One line = chain of characters:
Date
Time of day
Text “SW_DATECHANGE”
Old date with time of day
New date with time of day
E = Software version change

One line = chain of characters:
Date
Time of day
Text “SW_Version”
Current version number
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SP1SP2 SP3SP4SP5 SP6 SP7SP8SP9 SP102
1
A
C
B
Z 57 141
96/145 043−1080−056
Description of the abbreviations for “Trigger”
Abbreviation Description of the triggering configuration

for trigger
AUSL1 Work load Load1 in 10% increments when 100% is
exceeded
AUSL2 Work load Load2 in 10% increments when 100% is
exceeded
CANSTOP CAN bus error
LMI_DST LLD malfunction
LLD_WRN LLD advance warning
LLD_ERR LLD error
LLD_OVL LLD overload
NOT Emergency control system on or off
UEBHES Bridging HES (hoist limit switch)
UEBVERK Reducing override M
UEBVERKGR Bridging M enlarge
E703 PLC error A703: No. 26, 27
E707 PLC error A707: No. 2, 4, 37, 47, 48
UEBHZYL Bridging crosshead lift cylinder
MAX_L1 Maximum achieved in the overload range between ex-
ceeding and failing to meet the 10% limit for Load1
MAX_L2 Maximum achieved in the overload range between ex-
ceeding and failing to meet the 10% limit for Load2
Description of other abbreviations
Abbreviations Description
SW_START Software start
SW_START Exit the operation mode preselection screen
with Save & Exit
SW_DATACHANGE Date change
SW_VERSION Version change of the application
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SP1 SP2 SP3 SP4 SP5 SP6 SP7
1
A
B
C
Z 63 673
98/145 043−1080−056
8.1.9 “Windlogger” Screen

A windlogger is a recorder which − every ten minutes − deter-
mines an average of the wind speeds of the last ten minutes and
automatically logs the maximum wind speed. The current data re-
cord is then saved in the computer.
Description of the monitor display

(Z 63 673)
Header with the two−line column headings displayed for the

standard values.
SP1 = Date, time of day
SP2 = Trigger (abbreviations for the triggering events and
configurations. For meaning of the abbreviations,
see the following table)
SP3 = Measurement time period (10 min)
SP4 = Average of the wind speeds during the
measurement time period
SP5 = Maximum wind speed
SP6 = Measurement point main boom head L1
SP7 = Measurement point fly jib head L2
Display field for the standard values, the software status, the
configuration and the system information.
A = Information on software status

1st line = Date, time
2nd line = Triggers,
Crane type,
Construction number,
Date of creation of the load table
B = Configuration
Date
Time
Text “SW_Version”
Current version number
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SP1 SP2 SP3 SP4 SP5 SP6 SP7
1
A
B
C
Z 63 673
100/145 043−1080−056
Continued: Description of the monitor display

(Z 63 673)
C = Example of saved values
D = Selection of saved files

Date
Text “dl_wind”
Construction number
Number of saved file
Description of the abbreviations for “Trigger”
Abbreviation Description of the triggering configuration

for trigger
possible Event (Trigger)
Description of other abbreviations
Abbreviations Description
SW_START Software start
SW_START Exit the operation mode preselection screen
with Save & Exit
SW_DATACHANGE Date change
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1 2 3 4 5
Z 63 670 Z 63 671
Z 63 675
102/145 043−1080−056
8.1.9.1 Reading out the Log Files
Calling up “USB stick” screen

1. Call up the “Overload recorder” screen by touching button (2,
2. Call up display of the “USB stick” screen (Z 63 675) by touch-
ing button (3, Z 63 671).
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Z 63 676
Z 63 677 Z 63 678
104/145 043−1080−056
Reading out data
All logger files will always be extracted. No selection is possible

on the data, wind or hub loggers.
1. Plug in the USB stick in the LLD screen (Z 63 676). The sym-
bol in the display (Z 63 677) changes to display “USB stick
plugged in” and the “Copy” button becomes black.
2. Reading out of data is started by touching the black “Copy”
button.
3. If all data is read out, the “Copy” button becomes grey. The
symbol in the display (Z 63 378) changes to the display “Pull
out USB stick”.
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Z 59 520
1 2
11
3
10
9 5
8 7 6 Z 59 521
106/145 043−1080−056
8.1.10 “Parameters” Screen

(Z 59 520, Z 59 521)
It may not be possible to call up this screen, because it can be

blocked at customer request.
Pressing the button key in the Main menu causes the

“Parameters” screen (Z 59 520) to be called up.
This is where the proportional valve data for the control systems
of the individual hydraulic pumps are displayed and adjusted in
relation to the movement of the corresponding control lever. As
a result, the reaction of the crane to control lever movements can
be modified to accommodate the individual movements.
As crane movements can also be carried out when setting the

parameters for test purposes, the load utilisation display (2,
Z 59 521) of the load limit device is also displayed in this screen.
The crane operator is therefore continually informed of the cur-
rent load range of the crane.
Legend:
(Z 51 521)
1. Signal bar
2. Load utilisation display
3. Selection of hydraulic pump
4. Graphics display (alternately current curve or time response
behaviour)
5. Switching the graphics display (X(t)/I (X)
6. Status display of the values for output current in mA
7. Status display of the values for the movement of the control
lever of the selected hydraulic pump.
8. Status display of the current parameter set
9. Menu call−up
10. Current curve I (X)
The values X1, X2 and X4 in the left−hand column cannot be

modified
11. Time response behaviour X (t)
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8.1 8 8.2 7 6 Z 59 522
3.1 3.2 3.3
Z 59 524
108/145 043−1080−056
Status display “Current parameter set”

(Z 59 522)
Check the Status display (8) before you modify any parameters
(8).
2 conditions are displayed in the Status display:

− (8.1) Parameter set with which the control system is currently
working
− (8.2) Parameter set that is currently being displayed on the
screen.
Under normal circumstances, the designations 1, 2, 3 and D are

displayed for this purpose. If the parameter set with which the
control system works does not match any of the four data sets
stored in the monitor, then a 0 is displayed as the parameter set
designation.
This can be the case when the monitor or a control system

(A 0703) is replaced.
Hydraulic pump selection

(Z 59 524)
The crane movement to be controlled can be selected by means

of the hydraulic pump selection.
− (3.1) Designation of the hydraulic pump
− (3.2) Direction of movement of the control lever
− (3.3) Crane movements which are supplied by the selected
hydraulic pump.
Direction of movement: Raising or driving in reverse
Direction of movement: Lowering or driving forward
Left−hand control lever: Lowering or turning to the left
Left−hand control lever: Raising or turning to the right
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1.2
1.1
Z 59 525
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Time response behaviour X (t)

(Z 59 525)
In field (1) the following parameters are displayed and can be set:
1.1 Behaviour while increasing and/or accelerating the

movement (red in the graphics display)
1.2 Behaviour while decreasing and/or slowing down the

movement (yellow in the graphics display)
The current set values of the parameters are displayed graphi-
cally in field (4). Use button (5) to select between the display of
the current curve (Z 59 526, y−axis [mA]) or the time response
behaviour (Z 59 525, y−axis [ms]).
Red curve
− T1 [ms] (here: 500):
The time that passes when the control lever is fully activated
for the control lever movement from zero up to the defined
value X1 for the movement (point P1, see graphics display).
− T2 [ms] (here: 500):
The time that passes when the control lever is fully activated
for the control lever movement from the defined value X1
(point P1, see graphics display) up to the end point (P2, see
graphics display).
Yellow curve
− Value X1 [%] (here: 50):
Specification of the control lever movement for point (P1, see
graphics display).
− T1 [ms] (here: 500):
The time that passes when the control lever is suddenly re-
turned to neutral for the control lever movement from the end
point (P2, see graphics display) to the defined value X1 (point
P1, see graphics display).
− T2 [ms] (here: 500):
The time that passes when the control lever is suddenly re-
turned to neutral for the control lever movement from the de-
fined value X1 (point P1, see graphics display) to zero.
− Value X1 [%] (here: 50):
Specification of the control lever movement for point (P1, see
graphics display).
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2.2
2.1 4.1
4
2
Z 59 526
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Current curve I (X)

(Z 59 526)
In field (2) the following parameters are displayed and can be set:
2.1 Steering (red in the graphics display)

The values X1, X2 and X4 cannot be modified.
2.2 Output current

4.1 Definition area for point (X3, I3) is yellow in the graphics
display.
This is the area in which point (X3, I3) can be changed.
The current set values of the parameters are displayed graphi-
cally in field (4). Use button (5) to select between the display of
the current curve (Z 59 526, y−axis [mA]) or the time response
behaviour (Z 59 525, y−axis [ms]).
− I1 [mA] (here: 200):
Current slightly below the current for movement start I2,
which serves to ensure a gentle start of the movement when
I2 is reached.
− I2 [mA] (here: 300):
Current at which the selected movement starts.
The values of I1 and I2 were optimised ex works and should gen-

erally remain unchanged.
− X 3 [%] (here: 50):

Value for the movement of the control lever for a defined cur-
rent I3 (between the current for the start of the movement I2
and the final current I4).
− I3 [mA] (here: 650):
Current between the current for movement start I2 and max.
current I4.
If I3 is defined as such that − as in the example shown − the

straight line between I2 and I3 is very flat, the corresponding
crane movement can be influenced very precisely in this move-
ment range of the control lever.
− I4 [mA] (here: 1000):

Max. current to the solenoid valve.
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Z 59 527
9.1
9.2
9.3
9.4
9.5
9.7.1
9.6
9.7.2
9.7
9.7.3
9.8
Z 59 528
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Selecting a stored data set

(Z 59 527, Z 59 528)
Press key (9) “Menu” to open the selection window (Z 59 528).

(9.1) − View parameter set 1
(9.4) − View parameter set D (Demag default setting)
The default setting cannot be modified.
(9.5) − View the parameter set currently used in the crane con-
trols
(9.6) − Save the parameter set displayed in the view and activate
the crane controls.
(9.7) − Call up a submenu
(9.7.1) Save the parameter set displayed in the view

under “1” and activate the crane controls.
(9.7.2) Save the parameter set displayed in the view

under “2” and activate the crane controls.
(9.7.3) Save the parameter set shown in the display

under “3” and activate in the crane control system
(9.8) − Exit “Parameters” menu
This is where different parameter sets can be loaded or saved.

Actuating causes the “Parameters” menu to be finished and
exited.
If a new parameter set is loaded by the computer, then it must be

saved with . The parameter set is transmitted to the crane
control system.
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Z 59 529
Z 59 530
116/145 043−1080−056
Entering/changing a parameter
(Z 59 529)
Tap the entry field that belongs to the desired parameter (here:
200 mA).
A numerical pad appears on which the desired value − within the

limits specified at the top of the block − can be entered. If the entry
is outside the permissible range, it will be shown in red.
By pressing , the previously entered character can be de-
leted.
The modified values will be displayed in white (Z 59 530).
Then either reject the entry by pressing the reject entry key
or save by pressing the save entry key and activating directly
in the crane controls.
The modification of the numerical values can be monitored in the

graphics display if the corresponding graphics display has been
activated by pressing on key 5.
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8
9.4
9.7
Z 59 531
9.1
9.2
9.3
9.4
9.5
9.7.1
9.6
9.7.2
9.7
9.7.3
9.8
Z 59 528
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Copying a data set

(Z 59 528, Z 59 531)
If, for example, you want to assign the “Demag default setting”
parameter set to parameter set 1, then proceed as follows:
1. Open the “Menu” selection window by actuating key (9,
Z 59 531) and press key to load parameter set D.
Selection window (Z 59 528) closes.
2. Press the “Menu” key once again and save the selection pre-
viously made (parameter set D) in the selection window
(Z 59 531) via
in the submenu under Parametersatz1 [Parameter set 1]

(9.7.1). Selection window (Z 59 528) closes. The crane con-
trols now work with parameter set D under the new parame-
ter set − code 1.
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8
E F G
Z 53 714
120/145 043−1080−056
8.1.11 Load Monitoring Assembly

(Z 53 714)
With the help of the load limit device computer it is possible to

check the weight of the raised load (net load).
The load monitoring assembly may not be used to calculate

the weight of the load, rather it is used to check the weights
of loads which have been previously and independently
calculated. This helps to estimate the load hoist and to avoid
possibly hazardous situations.
Before the load is raised, the maximum load corresponding to the

operating condition must be specified. It is displayed on the
“MAX” screen (G) in relation to the selected operating mode.
Load monitoring
1. Press down button “E” when there is a suspended hook
block (without load, with load−handling device). The lifting
tackle is tared, in order to display the net load.
2. Release the button again after a short period of time.
3. Raise the load with the hoist.
The display NET (E) now shows the net load (actual load on
the hook without load−handling device).
4. The “F” display always shows the gross load.
Taring is automatically switched off if the position of the boom is

moved by 2.5° or the ignition is switched off/on, and the gross
load displayed again on the load display (E).
The gross load consists of the weight of the hook block, of the
hoist rope and all load−handling devices as well as the load
weight. The net load is the actual load on the hook block without
the load−handling devices. Display errors are possible because
of outside factors, e.g. wind, which have an effect on both the
crane and the load.
The load may only be raised using the hoist. Raising the load
by luffing up the fly jib or derricking the main boom is pro-
hibited.
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2 3
3.1
3.2
Z 59 533
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8.1.12 Gradient and Slewing Angle Display

Before all crane work, the ground surface must be prepared in
such a way that the crane is standing horizontally and evenly.
Legend:
(Z 59 533)
− 1 Button for selecting the gradient and slewing angle display
− 2 Slewing angle display
− 3 Spirit level for the gradient display
− 3.1 Numerical value of the cross gradient (x−axis) of the
crane
− 3.2 Numerical value of the longitudinal gradient (y−axis) of
the crane
You can always check the current gradient of the crane in the LLD
diagram on the screen if you have turned on the gradient and
slewing angle display by touching the button “1”:
The maximum permitted angles of inclination are:
− 0.3° for operation of the crane
− 2.5° for driving the crane
Risk of tilting!!
If the permitted tilt is exceeded you must:
1. Set down the load.
2. Level out surface, i.e. road surface for the crane.
You can always check the current position of the superstructure

relative to the carrier in the LLD diagram on the screen if you have
turned on the gradient and slewing angle display by touching the
button “1” (here 330.5 degrees).
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Z 57 303
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8.1.13 Troubleshooting
(Z 57 303)
The “LLD system” also supplies information concerning occurring

errors in the transmission system between the measuring
members (sensors, pressure contacts, angle transmitters) and
the central unit.
Errors occurring in the measuring and transmission areas of the

load limit device are displayed directly in the status display “B” of
the monitor using the corresponding error codes.
The error codes start with the letter “E”.

Example:
Touching the button with the error code will cause the current
error with the source of the error and its elimination to be dis-
played.
For the list of the possible error codes, see section 8.1.1.3.
The malfunctions can, in some cases, be rectified by the

measures suggested. If this is not successful and if repairs or the
replacement of defective components is required, trained service
personnel must be used.
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B 1
Z 59 748
Z 62 709
126/145 043−1080−056
8.1.13.1 “Error Messages” Screen

(Z 59 748, Z 62 709)
Calling up the “Error messages” screen from the “LLD”

screen
As well as displaying error codes in the area of the load limit de-
vice, checks of the remaining parameters can also be carried out.
Errors which occur in the “SPS” control system are displayed di-
rectly in monitor status display “B”. In addition, the possibility also
exists of calling up the “Error messages” screen from the “Main
menu” screen or from the Signal bar.
The colour of the symbol is white when the number of error mess-
ages has not changes since the display was last called up.
The colour of the symbol is red if the error status changes.
The symbol is not displayed if no error is present.
Example:
If there are transmission errors an acoustic signal will sound and

a button appears in the status display “B” of the monitor reading
“Switch off acoustic warning signal” (1, Z 59 748).
Touching the button (B) with the question mark will cause a list of
errors to be displayed (Z 62 709).
The malfunctions can, in some cases, be rectified by the

measures suggested. If this is not successful and if repairs or the
replacement of defective components is required, trained service
personnel must be used.
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Z 57 306
Z 62 709
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Calling up the “Error messages” screen from the “Main

menu” screen
Pressing the button / (Z 57 306), the list of the ex-

isting SPS errors (Z 62 709) is called up.
In any case, all error messages are retained until they have been
viewed. This is especially useful for identifying errors which only
occur for a short time, and then disappear automatically.
The corresponding symbol can − except in the “Main menu”

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

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

errors are cancelled − or both at the same time
Risk of accidents!
As soon as a error is displayed, stop operation and identify
error immediately; have it rectified by qualified personnel!
Providing the update key is white in the “Error messages”

(Z 62 709) screen , the list shows the current situation of
the error messages.
If red, must be updated by tapping the key. This can again
be necessary should the symbol stay red.
If − for opened “Error messages” screen − new errors occur, or

are cancelled, or both at the same time, the update key
is red. It must then be tapped, if necessary, repeatedly − until it
is white again.
Only after this is the list of displayed errors complete, and the
screen can be exited via .
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Z 57 307
Z 57 308
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8.1.14 “CAN” Screen
Touch the button “2” in the “Main menu” screen (Z 57 307) to dis-
play all devices connected to the CAN data bus and their statuses
on the CAN screen (Z 57 308).
B1 B2 Description
0 0 Node not available
0 1 Node preoperational
1 0 Stopped
1 1 Operational
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Z 57 309
1 3
2 Z 53 720
3
1
2 Z 53 721
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8.1.15 “I/O” Screen
Bring up the diagnosis screen in the main menu by touching the

button “3” (Z 57 309).
Legend:
(Z 53 720)
1 Version of the control software
2 Selection switch for the I/O card that is to be displayed
3 Shut down, return to main menu
Current I/O values of the individual control systems can be dis-

played in the diagnosis screen “I/O” (Z 53 720, Z 53 721). To do
so, you must select the required control system.
If for example the value of a particular sensor such as pressure,
angle, power or Length is being sought on one of the I/O cards,
then both the designation and the function (and possibly also the
location) of the sensor must be determined ahead of time on the
basis of the electrical diagrams supplied.
The individual entries are either digital inputs or outputs (value:

0 or 1) or analogue input and outputs. Among other things, a
validity status can be shown for the analogue values. If the values
are invalid, then the numerical value will be displayed in red letter-
ing; the same is true with overloaded analogue inlets, e.g.
through the connecting of a 24 V voltage.
In the diagnosis screen “I/O” (Z 53 720), the I/O values are dis-
played as a digital value.
In the diagnosis mask “I/O” (Z 53 721), the I/O values are dis-
played partially as analogue or digital values.
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4 “O”
Z 57 310 Z 60 948
2
3
4
3 4
Z 53 723 Z 53 724
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8.1.16 “Function Diagnostics” Screen
The function diagnostics screen is displayed by touching the but-

ton “4” (Z 57 310) in the main menu of the load limit device mask.
In order to work with the function diagnostics screen, the joystick

mode “O” must be activated in the MOT screen (Z 60 948) and
the function that is to be checked is selected by pressing the
corresponding button.
Legend:
(Z 53 723 and Z 53 724):
1. Directional contact
2. Steering of the joystick
3. Selection switch
4. Shut down, return to main menu
The joystick selected for diagnostic purposes is shown in the

right−hand section of the “Function diagnostics” screen. Actuat-
ing the joystick with the dead man’s handle pressed down will
cause the directional contact and the signal output of the joystick
to be displayed in green in accordance with the actuation, one
after the other.
The green coloration indicates that both the directional contact
and the signal output are OK.
Coloured boxes can be found in the left−hand section for the

dead man’s switch, general enabling by the IC−1 and the sole-
noid valves in the hydraulics required for the selected function.
They change the colour from red to green when the correspon-
ding valves are actuated by the IC−1 with the joystick is steered
Included among these are nominal/actual values for the actua-
tion of the hydraulic pumps and Trimot setting as well as values
concerning control pressure, pump pressure and load pressure.
The solenoid valves actuated can be determined and checked

with the aid of the hydraulics diagrams contained in the crane
documentation.
In addition, the pressure required can be measured by means of

pressure measurement at the corresponding measuring points.
The value that is outputted at “Counter” indicates the signals of

the rotation indicator of the hoists and winches.
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Z 57 311 Z 57 312
Z 57 313
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8.1.17 Malfunction Procedure
8.1.17.1 Error−free Operation/Malfunction

(Z 57 311, Z 57 312, Z 57 313)
Individual display fields are aligned on the monitors in the “LLD

and MOT” screens. For error−free operation the spaces between
the individual fields are separated with a grey background colour.
In the case of an error, the background colour changes to red.
In the main menu and in other submenus, the top line is displayed
in blue for error−free operation.
In the case of error, the colour of the top line changes to red.
8.1.17.2 Failure of the Crane Control (CAN Stop)
In the event of crane control failure all crane movements are

stopped within one second.
Before continuing operation of the crane, the error must first be

rectified.
In emergency situations, the load must be lowered with the

emergency control system and the crane itself may poss-
ibly also have to undergo emergency lowering.
No LMI monitoring is activated with the emergency control
system is activated. Corresponding caution is called for.
The erection tables must be adhered to without fail when
the crane is set down with the emergency control system.
8.1.17.3 Failure of a Monitor
The functioning of the load limit device is ensured in the event

that the LLD monitor fails. A switchover to “single monitor oper-
ation” may be made as described in section 8.1.2.6.
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Z 57 314
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8.2 Limit Switches
8.2.1 Hoist Limit Switch
8.2.1.1 Function
(Z 57 314)
Hoist limit switches are safety features that limit the upward
movement of hoist ropes and/or hook blocks.
As a result, collisions between hook block and boom head are
avoided and with them possible damage to these parts or to the
hoist rope, which could possibly cause the load to fall.
Crane operation is therefore permitted only with functioning

hoist limit switches that have not been triggered.
Risk of accidents!
The hoist limit switch must be triggered and checked for
functionality on a daily basis!
If a hoist limit switch is triggered (and not bridged), then the sym-
bol (1) will appear in grey on the LLD display. The following crane
movements are shut down:
− Raise hoists
− Lower derricking gear
− Lower and raise luffing gear 1
− Lower luffing gear 2
Then lower luffing gear in order to end this prohibited configur-

ation.
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Z 57 314
14
Z 57 315
140/145 043−1080−056
8.2.1.2 Bridging the Hoist Limit Switch

Switch on the bridging preselection by touching the button (1,
Z 57 314). Press the pedal (14, Z 57 315) to activate the hoist limit
switch.
The button (1, Z 57 314) is illuminated in red when the limit
switches are bridged.
The override can only be initiated if the control levers are in

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

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

prohibited. RISK OF ACCIDENTS!
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Z 57 317
Z 57 318
142/145 043−1080−056
8.2.2 Lower Limit Switch
8.2.2.1 Function
Lower limit switches are safety features that switch off the reeling
out of the hoist rope once it has been reeled out by up to 3 wind-
ings. This prevents the rope from winding on in the opposite
direction, among other things.
If a lower limit switch is triggered (and not bridged), then “Lower

hoist” is switched off. Only “Raise hoist” is possible.
8.2.2.2 Bridging the Lower Limit Switch
It is only in the operating mode “RGO” that the switch for selecting
the lower limit switch bridging is displayed in the quick menu.
Switch on bridging:
1. Select the “RGO” operating mode in the “Operating mode
selection” screen.
2. Switch on the menu for the lower limit switch by touching the
button (1, Z 57 317).
3. Touching one of the buttons (H1, H2, H3, W1, W2, Z 57 318)
will cause the corresponding lower limit switch to be bridged.
The colour of the button changes to red.
The bridging of the lower limit switch is only active for as long as
the finger continues to touch the button.
The lower limit switches are not permitted to be bridged ex-

cept in extraordinary circumstances (e.g. when replacing
and/or laying ropes).
043−1080−056 143/145
8
6 6 6
3 1 2
A
A A
D C
B B B
Z 57 316
144/145 043−1080−056
8.3 Dead Man’s Handle

(Z 57 316)
In order to prevent accidental initiation of crane movements, both

control levers are equipped with an additional button (6, dead
man’s handle). The crane movement can only be carried out as
long as one of these buttons is pressed.
For example, a movement can be made with the left−hand control
lever while the dead man’s switch is actuated in the right−hand
control lever.
You may only activate (press as well as release) a dead man’s
switch if the corresponding control lever is in the “neutral position”
and/or the initiated working movement has been completed.
Risk of accidents!
All crane movements must always be carried out and accel-
erated at suitable speeds so as to avoid sudden move-
ments of the load or swinging of the hook block and the
subsequent risk of collision or crushing when the motion
is switched off.
Control levers (1, 2 and 3) may not be switched directly to the

opposite slewing direction, but must first remain in neutral
position until the movement has stopped. Movement in the
opposite direction cannot be initiated until the superstruc-
ture and/or the winches have come to a standstill.
043−1080−056 145/145
Working With the Crane Equipment 9
043−1090−056 1/51
9
2/51 043−1090−056
9 Working With the Crane Equipment
9.1 Preparations
The loads specified in the load tables are valid under the follow-
ing conditions:
− The crane is standing on horizontal, even ground ( 0.5%).
− The ground must have sufficient load−bearing capacity for
the surface pressures that occur.
9.1.1 Positioning the Crane
Before starting work with the crane, you must make sure that the
ground has the required load−bearing capacity. For crawler−
mounted cranes, the ground must also be flat and horizontal, and
it must be well compressed.
043−1090−056 3/51
9
2 4
Z 59 728
4/51 043−1090−056
Visual check:
Use the unloaded hook block as a free−swinging pendulum. This

must be positioned in the centre of the boom when the crane is
correctly positioned, as seen from the front of the crane.
− With a short main boom (42 m / 137.8 ft) there must be no vis-
ible lateral deviation from the centre of the system (deviation
of less than 0.1 m / 0.3 ft).
− With a long main boom and fly jib the hook block is allowed
to deviate from the central position by half the boom width, in-
cluding the effect of a side wind.
The precise value of the steep position can be determined with

the aid of the spirit level (4, Z 59 728) in the LMI monitor. In addi-
tion to the graphics display, the steep position in X and Y direction
are also specified as absolute values in angle degrees. The maxi-
mum value is 0.3°.
The spirit level fitted on the carrier is used solely for aligning the
carrier centre section during configuring the crane. Its settings
must be checked at regular intervals with the aid of a spirit level
which is, for example, placed on the slew ring connection.
043−1090−056 5/51
9
20
Z 64 234
6/51 043−1090−056
9.1.2 Working Instructions
− All crane movements must be carried out at a suitable speed

without sudden jerking and in accordance with the configur-
ation and the load case.
− The weight of the hook blocks and the load−handling devices
is part of the rated load and must be deducted from the pay-
load.
− The maximum required reeving is programmed in the LLD
system. If a low reeving is selected then this reeving is to be
set at the display (20, Z 64 234) of the LLD system.
− Handle the slew gear and slew brake carefully, particularly
when operating the crane with the fly jib fitted.
Select a low slewing speed.
Brake carefully.
− It is only permitted to simultaneously raise loads on the
main boom and fly jib (two−hook operation) after the per-
mission of the crane manufacturer has been given!
You must avoid oblique pull and non−permitted increase
of the working radius at all costs!
− Due to the risk of collisions, simultaneous raising of
loads on the runner and main boom is not permitted.
9.1.3 Wind Speeds − Dynamic Pressure
If wind speeds are anticipated which are higher than the safe per-
mitted level for parking the crane, the boom system must be low-
ered and secured in good time.
Accordingly, the crane operator must request the expected wind

conditions from the competent met office before commencing as-
sembly of the crane and before starting work with the crane, and
must monitor the weather conditions using an anemometer.
043−1090−056 7/51
9
8/51 043−1090−056
The anemometers fitted on the crane must be checked with a

calibrated anemometer during the crane inspection, or at least
once a year.
Since the stability and strength limits of the crane are all−import-
ant when lowering certain boom combinations, information about
the wind direction is an equally important aspect.
Wind conditions which exceed the permitted limit values can lead
to hazardous situations due to the additional static loads, swing-
ing of the load and/or dynamic influences (e.g. wind−induced
vibration of crane components). Therefore the (peak) maximum
wind speed must be taken as the limit value. This wind limit is the
average value of a gust of wind over the duration of three sec-
onds or the maximum value recorded on the anemometer.
If vibrations are detected on crane components at prohibited high

winds, an examination must be carried out by the crane manufac-
turer.
9.1.3.1 Permitted Wind Speeds With Crane Operation
For wind speeds of 9.8 m/s (21.9 mph) listed in the load capacity
table (corresponds with a dynamic pressure of 60 N/m2 / 1.2 psf),
a wind surface area of the load of 1.2 m2/t (12.9 ft2/2.2 kip) is
calculated (including form factor 1.2).
Higher or lower permitted wind speeds (dynamic pressure levels)

apply for other wind surface areas, however the maximum per-
mitted wind speeds and dynamic pressures listed in the tables
may not be exceeded.
Crane operation with Main boom:
Main boom length Permitted wind speed Permitted dynamic pres-

sure
(m) (ft) (m/s) (mph) (N/m2) (psf)
up to 36 up to 118.1 15.0 33.6 140 2.9
42 − 66 137.8−216.5 13.8 30.9 120 2.5
72 − 84 236.2−275.6 11.3 25.3 80 1.8
above 84 above 275.6 9.8 21.9 60 1.2
043−1090−056 9/51
9
10/51 043−1090−056
Crane operation with Fly jib:
Main boom length/ Permitted wind Permitted

fly jib length speed dynamic pressure
(m) (ft) (m/s) (mph) (N/m2) (psf)
up to 48/ up to 157.5/ 13.8 30.9 120 2.5
up to 42 up to 137.8
up to 48/ up to 157.5/ 11.3 25.2 80 1.8
48 up to 72 157.5 to 236.2
54 up to 84/ 177.2 to 275.6/ 10.6 23.7 70 1.4
up to 42 up to 137.8
greater than 54/ greater than 177.2/ 9.8 21.9 60 1.2
greater than 48 greater than 157.5
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12/51 043−1090−056
In the following examples, the permitted wind surface area

of the load with a dynamic pressure of 60 N/m2 (1.2 psf) is as-
sumed to be 1.0 m2/t (10.8 ft2/2.2 kip) for safety reasons.
Example 1:
given: load 200 t (440.9 kip),
dynamic pressure 145 N/m2 (3.0 psf)
wanted: permitted wind surface area AWperm.
permitted wind surface area in accordance with DIN for 60 N/m2

(1.2 psf) is 200 m2 (2152.8 ft2).
200m2 x 60 N/m2 = 82.7 m2
AWperm.
145 N/m2 (890.2 ft2)
If loads with an area exposed to wind which is greater than

1.2 m2/t (12.9 ft2/2.2 kip) are to be raised, the load moment must
be reduced while utilising the permitted wind speed (9.8 m/s /
21.9 mph), or the load must be raised when the wind is not as
strong.
To evaluate and authorise individual load cases, precise
data is required. This must be made available to TEREX−
Demag before operation of the crane.
For special cases the permitted minimum and maximum wind

speeds are to be taken from the special load tables.
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3 1 2
21
Z 64 235
14/51 043−1090−056
9.2 Selection of the Functions for Crane Operation

9.2.1 Allocation of the Control Levers
(Z 64 235)
After commissioning of the crane and after setting the IC−1, the
selectable functions for crane operation will appear on the screen
(21).
The allocation of the control levers to the selectable functions is
always the same.
043−1090−056 15/51
9
53
67
O
60
Z 64 236
6 6 6
10 11 45 89
18
18 18
7 7
97
3 1 2
Z 58 003 Z 51 224
16/51 043−1090−056
9.2.2 Selection of Functions

Normal speed
− Switch the joystick display (Z 64 236) to joystick mode “O”.
The edge of the button is depicted in green.
− Switch on the desired function, e.g. hoist H1 (67, Z 64 236),
by touching the associated button. The colour of the button
changes to green.
− Switch the toggle switch (97, Z 64 236) to “Automatic”, the in-
stalled indicator light lights up.
The winch rotation indicator (7, Z 51 224) indicates whether the
rope drum of the selected winch is turning.
Overdrive
The system must be switched to high speed with the drum
at a standstill before the load is raised.
− Switch on the desired function, e.g. hoist H1 (67, Z 64 236)
actuated with control lever 1, by touching the associated but-
ton. The colour of the button changes to green.
The symbol for overdrive will appear at one of the positions
(53, Z 64 236) depending on the control lever selected.
− The overdrive can be activated in two ways:
∗ by pressing one of the pushbuttons (5, 9, 11, Z 51 224) in
the control levers.
∗ by pressing the symbol “Overdrive” (53, Z 64 236).
The symbol (53, Z 64 236) is green when overdrive is activated.
− Switch the toggle switch (97, Z 58 003) to “Automatic”, the in-

stalled indicator light lights up.
The winch rotation indicator (7, Z 51 224) indicates whether the
rope drum of the selected winch is turning.
To exploit the maximum rope speed with the hoists, however, the
high speed should only be selected for a loading of up to 60 kN
(13488.54 lbf) per rope line.
The rope end speed for normal and overdrive is variable and can
be set using the rocker switch (18, Z 51 224). The maximum angle
position of the control lever (1, Z 51 224) thereby always
corresponds to the ultimate rope speed. Use of this switch
enables individual precision control of the hoist in the preselected
rope speed range.
The range up to the ultimate value that has been set is shown as
a green bar in the display (60, Z 64 236).
043−1090−056 17/51
9
3 1 2
Z 58 033
18/51 043−1090−056
9.3 Configuring the Crane Equipment

Luffing Gear 1 (W1)
(Z 58 033)
This switch position is used to erect and lower the boom combina-
tion SW.
Operation of the derricking gear (E) is only possible at normal

speed.
For configuration operation, the derricking gear (E) is actuated

using control lever (2).
Erecting and Lowering the Main Boom
The luffing gear 1 (W1) is activated for rigged operation using

control lever (3).
Erecting and Lowering the Fly Jib

Luffing Gear (W2)
This use of the switch is used to raise and lower the boom com-
binations SSL, SSL/LSL and SWSL.
For configuration operation, the derricking gear (E) is actuated

using control lever (2).
Erecting and lowering the SL mast
The luffing gear 2 (W2) is activated for erection operation using

control lever (1).
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3 1 2
Z 58 033
20/51 043−1090−056
9.3.3 Simultaneous Operation of Luffing Gear 1 (W1) and

Luffing Gear 2 (W2)
(Z 58 033)
This switch position is used to erect and lower the boom combina-
tion SWSL.
The luffing gear 1 (W1) is activated for rigged operation using

control lever (3).
Erecting and Lowering the Fly Jib
The luffing gear 2 (W2) is activated for erection operation using

control lever (1).
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9
Z 54 476
2
1
Z 16 288
22/51 043−1090−056
9.4 Operating the Reeving Winch
9.4.1 General
The reeving winch (Z 54 476) is used for assembling the crane

to reeve the ropes of hoist 1, hoist 2, hoist 3, luffing gear 1 and
luffing gear 2.
The hydraulic system of the reeving winch is coupled with the hy-
draulic system of the slew gear. You can switch between the two
by alternately releasing the brakes.
The auxiliary reeving rope of the reeving winch must be reeved
in accordance with the reeving diagrams, however in the reverse
order, i.e.
− with the hoist ropes between the sheaves in the boom head
and the sheaves of the hook block,
− with luffing rope W1 between the sheaves of the two luffing
masts,
− with luffing rope W2 between the sheaves of the luffing lifting
beam and the sheaves of the mast point.
If the reeving rope is connected with the hoist rope or the luffing
rope in order reeve the hoist rope or luffing rope with the aid of
the reeving rope, then under no circumstances is the hoist rope
or luffing rope to be reeled in against the resistance of the reeving
rope.
Similarly, the pressure increase of the slew gear may also not be
switched on as well.
It is recommended that one watch the hoist or luffing rope, re-

spectively, through the monitoring camera of the hoist or luffing
gear, respectively, and always to reel out as much as required to
ensure that the rope remains slack and does not become taut.
The rope of the auxiliary winch can be unreeled manually or hy-

draulically.
The mechanical free switching device (1) on the drive side of the
winch can be used to reel off the rope more quickly (1, Z 54 476).
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9
Z 54 476
6 6 6
10 11 45 8 9
18
18 18
7 7
3 1 2
75
Z 64 212 Z 51 224
24/51 043−1090−056
The free switching device may only be actuated when the

gears are at a standstill and without load.
If the reeving rope is connected with the hoist or luffing rope,
then the hoist or luffing rope can only be reeled in and, in
order that the reeving rope is reeled out, in enabled position
of the free switching device.
In the coupled position the free−switching device (1, Z 54 476)

is inserted and secured. The rope can be reeled on and off hy-
draulically.
The free−switching device (1, Z 54 476) is pulled out and secured

in the enabled position. The rope can be drawn off manually.
9.4.2 Operation
− Preselect the reeving winch by touching button (75,

Z 64 212).
Auxiliary reeving rope “REEL IN”:
− Move control lever (3, Z 51 224) to the right, at the same time
button (6, Z 51 224) must be pressed for the dead man’s
handle switching.
Auxiliary reeving rope “REEL OUT”:
− Move control lever (3, Z 51 224) to the left, at the same time
button (6, Z 51 224) must be pressed for the dead man’s
handle switching.
If the rope drum is moved in the direction “Raise” by the

hoist or the luffing gear, the coupling (1, Z 54 476) at the reev-
ing winch must be locked in the enabled position.
If the ropes of the hoists and luffing gear are not reeved, they
have to be secured during transportation with a rope clamp (1,
Z 16 288, page 22/51) on the edge of the drum (2, Z 16 288, page
22/51). This helps to protect the rope ends (3, Z 16 288, page
22/51) against damage as a result of uncontrolled movement of
the winches.
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9
3 1 2
Z 58 033
26/51 043−1090−056
9.5 Operation of the Crane
9.5.1 Winch Selection for Crane Operation
9.5.1.1 Operating the Derricking Gear (E)

(Z 58 033)
This use of the switch is for crane operation with the boom vari-
ants SH, SH/LH and SW.
The derricking gear is actuated with control lever 3 during crane
operation.
Raising and Lowering the Main Boom
9.5.1.2 Simultaneous Operation of Derricking Gear (E) and

Hoist 1 (H1)
Using this switch position, a load can be raised and set down at
a different point following a change in radius (for boom variant SH
= load on main boom).
The derricking gear (E) is actuated with control lever 3 during
crane operation.
Operation of the derricking gear (E) possible at normal speed and

high speed.
The hoist (H1) is actuated with control lever 1 during crane oper-
ation.
Raising and Lowering the Load
9.5.1.3 Operating Range of the Main Boom
Steepest position:
−85° to the horizontal (observe load tables).
Lowest position:
−Radius in accordance with the load table
043−1090−056 27/51
9
3 1 2
Z 58 033
28/51 043−1090−056
9.5.2 Luffing Gear 1 (W1) Operation

(Z 58 033)
The winch in the main boom is used for boom variants SW and
SWSL as luffing gear 1 (W1) for adjusting the fly jib.
The luffing gear 1 (W1) is activated for crane operation using con-
trol lever (3).
Raising and Lowering the Fly Jib

Hoist 2 (H2)
Using this switch a load can be raised and set down at a different
point following a change in the radius of the fly jib (for boom vari-
ant SW and SWSL).
trol lever (3).
Raising and Lowering the Fly Jib
Hoist 2 (H2) is activated with control lever (2) during crane oper-
ation.
9.5.2.2 Operating Range of the Fly Jib
Steepest position:
−Radius in accordance with the load table.
Lowest position:
9.5.2.3 Luffing Gear 1 as Hoist 3 (Optional)
The winch in the main boom is used as a hoist for the hook block
on the runner with the boom variants SW and SWSL.
If the luffing gear 1 is used as hoist 3, the luffing rope must

be replaced with a hoist rope without fail.
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9
3 1 2
Z 58 033
30/51 043−1090−056
9.5.3 Operation of the Luffing Gear 2 (W2)

(Z 58 033)
The winch in the Superlift mast is used for adjusting the main
boom in the boom variants SSL, SSL/LSL and SWSL as luffing
gear 2 (W2).
trol lever (3).

Hoist Gear 1 (H1)
Using this switch a load can be raised and set down at a different
point following a change in the radius of the main boom (for boom
variants SSL, SSL/LSL).
trol lever (3).
Hoist 1 (H1) is activated with control lever (1) during crane oper-
ation.
9.5.3.2 Operating Range of the Main Boom
Steepest position:
−85° to the horizontal radius (consider load table).
Lowest position:
During operation with luffing fly jib (hook block on the fly jib), the
main boom can be moved into any position of the permitted oper-
ating range.
The IC−1 crane controls automatically calculate the permitted
load for every position of the main boom and fly jib.
043−1090−056 31/51
9
68
67
61
O
60
Z 55 347
S A
Z 59 722 Z 59 723
32/51 043−1090−056
9.5.4 Crane Operation With Double Hook Block, Hoist 1 and

Hoist 2 in Combined Operation
The crane is equipped with two control systems which are inde-
pendent of each other for monitoring the inclination of the double
hook block − the synchronous display and the radio−trans-
mitted inclination monitoring system.
9.5.4.1 Preparing for Operation

− Switch on hoist 1 by touching the button (67, Z 55 347). The
colour of the button changes to green.
− Switch on the hoist 2 by touching the button (68, Z 55 347).
The colour of the button changes to green.
− Switch on the transmitter (S, Z 59 722) of the radio inclination
monitoring system on the double hook block.
Check that the batteries are charged every time before beginning
work, charge battery if required. We recommend having a
charged battery at the ready.
− Program the crane control system for the synchronous dis-
play.
The synchronous display is based on the measurements of

the rope drum rotation of hoist 1 (H1) and hoist 2’s (H2)
winches, this is why it only works precisely if crane control
has the following values:
− the rope turns
− the number of windings
− the rope length
− Determine rope turns and number of windings at hoist 1 and

2’s rope drums (Z 59 723).
A = current position in which the rope is wound
B = current number of windings in the uppermost position
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Z 59 724
2 7 6 3
8
5 4
Z 59 725 Z 59 726
34/51 043−1090−056
− Call up the main menu (Z 59 724).

− Display the mask “Entry rope length” by pressing button (1).
− In order to enter the value measured at rope drum H1 for the
current number of windings in the uppermost position, press
button (2, Z 59 725). A number field (3, Z 59 726) appears for
input.
− After input has been completed the value must be saved by
pressing the symbol (4, Z 59 726).
− By pressing symbol (5, Z 59 726) the input is taken over into
the mask “Input of the rope length”.
− In order top enter the value measured at rope drum H1 for the
current position in which the rope is reeled, press button (2,
Z 59 725). A number field (3, Z 59 726) appears for input.
− After input has been completed the value must be saved by
pressing the symbol (4, Z 59 726).
− By pressing symbol (5, Z 59 726) the input is taken over into
the mask “Input of the rope length”.
− The values for hoist 1 are saved by pressing symbol (7,
Z 59 725).
− The current rope length (6, Z 59 725) of hoist 1’s rope then
appears in the mask “Input of the rope length”.
The values for hoist 2 are entered as described previously one

after the other.
After the values for hoist have been entered as well, you exit the
mask “Input of the rope length” by pressing symbol (8, Z 59 725)
and you return to the main menu.
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9
Z 59 727
2
1
Z 56 401 Z 56 402
36/51 043−1090−056
Switching on the Synchronous Display
1. In the main menu, call up the display “operating mode pres-

election” by pressing button (1, Z 59 727).
2. Select the reeving for double hook block (1, Z 56 401) in the
“operating mode selection” display.
3. On the monitor of the LLD systems, the corresponding syn-
chronous display in the “confirmation mode” appears (2,
Z 56 402).
4. Switch to the display “calibration mode” by pressing the but-
ton (2, Z 56 402).
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9
3 4 5
Z 56 403 Z 56 404
Z 56 405
38/51 043−1090−056
5. On the monitor of the LLD systems, the corresponding syn-

chronous display in the “calibration mode” appears (3,
Z 56 403).
Only now can the double hook block be moved by actuating the
control lever (1 and/or 2).
6. Bring the double hook block into the horizontal position by
activating the control levers (1 and/or 2).
If the double hook block is not in precise horizontal align-

ment, then damage can ensue during crane operation. The
synchronous display does not show the correct position of
the double hook block.
7. If the double hook block is in the horizontal position, the but-

ton (3, Z 56 403) must be pressed for calibration.
If double hook blocks are used which were not supplied

and/or released by Terex−Demag, then it is absolutely im-
perative that a determination be made during the calibration
process as to whether or not there is sufficient space be-
tween for any eventual steep position.
It is expedient to accomplish this by alternately lowering or
raising the right−hand or left−hand half of the hook block,
while at the same time being sure to observe whether there
is sufficient space available between.
8. After calibration, the display switches to “Surveillance mode”

(Z 56 404). When switching over to “Surveillance mode”, the
winch synchronisation is simultaneously activated (button 5,
Z 56 404 lights “green”) both winches are actuated by control
lever.1 The synchronous display is then switched on for
crane operation with double hook block.
On once more pressing the button (5, Z 56 404), the winch syn-
chronisation can be switched off (the button 5, Z 56 405 then no
longer lights).
043−1090−056 39/51
9
Z 59 728
40/51 043−1090−056
9.5.4.2 Crane Operation With Inclination Surveillance of the

Double Hook Block
The synchronous display must be in “Surveillance mode”.

The radio−transmitted inclination surveillance must be function-
ing and switched on.
The position of the double hook block can be monitored in the

LLD mask.
Legend:
(Z 59 728)
1. −
2. Display of the inclination
3. Display of the rope lengths which are currently on the rope

drums.
Both inclination surveillance systems − independent of each

other − can switch the hoists off when the max. inclination of the
double hook block has been reached.
When the radio−transmitted inclination surveillance fails,

the hoists are only switched off by monitoring the winches’
positions or rotations.
In this case, a constant visual check of the inclination of the
double hook block is required.
Due to the fact that the inclination surveillance system − with the
help of the winch positions or rotations − is based on theoretical
rope reeling behaviour, there can be deviations in practise.
These deviations can lead to a slight inclination of the double
hook block, which, however, cannot be shown in the synchron-
ous display.
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9
9 6
Z 56 409 Z 56 406
6 8
Z 56 407 Z 56 408
42/51 043−1090−056
Display of the inclination using the synchronous display
The bar (9, Z 56 409) for the display of the deviation from the de-
sired value goes to the left if hoist 1 is lowered more quickly than
hoist 2 and it goes to the right if hoist 2 is lowered more quickly
than hoist 1.
When an inclination of 70% of the maximum permitted inclination

has been reached, the scale background (6, Z 56 406) turns
orange.
If the maximum permitted inclination is exceeded, the hoists are

shut down. The scale background (6, Z 56 407) is coloured red
and the entire scale is framed in red.
After shut down, surveillance can be switched off by pressing the

bridging switch (8, Z 56 408). When activated, the button turns
red and an inclination is no longer displayed. On pressing the
switch once more, the synchronous display is switched to “ca-
libration mode” (Z 56 409).
043−1090−056 43/51
9
6 5
6
18
7
3 1 2
60 68
67
61
Z 64 237
Z 53 729
44/51 043−1090−056
9.5.4.3 Operation at Normal Speed

(Z 64 237)
“RAISE” load:
− Push control lever (1) backwards, at the same time pressing

button (6) for the dead man’s handle.
“LOWER” load:
− Push control lever (1) forwards, at the same time pressing

button (6) for the dead man’s handle.
The winch rotation indicator (7) shows whether the drum of hoist
H1 is rotating.
In the LLD display (2, Z 53 729) the position of the double hook
block can be monitored constantly.
9.5.4.4 Operation at High Speed

(Z 64 237)
The system must be switched to high speed with the drum

at a standstill before the load is raised.
“RAISE” load:
− Move control lever (1) backwards: at the same time pushbut-

ton (6) must be pressed for the dead man’s handle and rocker
switch (5) for high speed.
“LOWER” load:
− Push control lever (1) forwards, at the same time button (6)
must be pressed for the dead man’s switch and push button
(5) for the high speed.
The winch rotation indicator (7) shows whether the drum of hoist
H1 is rotating.
In the LLD display (2, Z 53 729) the position of the double hook
block can be monitored constantly.
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9
Z 59 729
Z 57 305
46/51 043−1090−056
9.5.4.5 Error Messages during Operation of the Radio−trans-

mitted Inclination Surveillance
See also section 8.1.11 and subsequent sections in these oper-

ating instructions.
Symbol (B, Z 59 729) shows that a new error has occurred in the
SPS control system by switching from white to red.
When button (B) is touched, a list with the cause of the error is
displayed (Z 57 305).
In connection with the radio−transmitted inclination surveillance
system the following error messages can be displayed:
Error code Text of the error message
E7_61 Radio−transmitted inclination surveillance of
the hook block is not active
E7_62 Switchoff of the radio−transmitted surveillance
of the hook block
E7_63 Battery warning of the radio−transmitted in-
clination surveillance
Error E7_61 appears when the double hook block is selected in

the mask “Operating mode preselection”.
043−1090−056 47/51
9
Z 53 711
1
2
4
Z 53 712
3 2
Z 53 713
48/51 043−1090−056
9.5.5 Operation with 2 Reeved Hook Blocks

All operating modes with the fixed fly jib 12m, 24 m, 36 m (39.4 ft,
78.7 ft, 118.1 ft), type “LF” in position 10°−15°, 20°, 30° can be
operated with 2 reeved hook blocks.
The load limit device (LLD) is programmed internally so that only
certain operating modes are enabled for “operation with two hook
blocks”. When the operating mode is enabled, the display is also
activated.
Operation with crane equipment LF

(Z 53 711)
1. Switch on operating mode selection menu.
2. Set operating mode.
If operation with two reeved hook blocks is possible for this se-
lected operating mode, switch (1) as well as entry field (2) for the
second reeving are displayed in the operating mode selection
menu RZ III (Z 53 711).
3. Enter reeving in the entry field (2). Reeving appears in the

LLD display (Z 53 713) after switchover.
Operation with runner

(Z 53 711)
The operating mode “runner” is not an “operating mode with two

reeved hook blocks”, however, in this case the second reeving
must also be entered in entry field (2).
2. Enter reeving in the entry field (2). Reeving appears in the

LLD display (Z 53 713) after switchover.
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9
Z 53 711
1
2
4
Z 53 712
3 2
Z 53 713
50/51 043−1090−056
Operation with crane equipment LF without load on the hook

block of the main boom
(Z 53 712)
2. Enter reeving in the entry field (2).
3. Enter weight of the empty hook block on the main boom into
entry field (4).
In the case of all operating modes with 2 reeved hook blocks

as described above, all hoist limit switches must be active,
i.e. their shift weights may not be suspended high and the
hoist limit switches thus relieved of load.
043−1090−056 51/51
Working With the Superlift 10
043−1100−054_en 1/55
10
8
7 17 18
5 3
Z 63 659
18.1
18.1
7 8
7 8
18 18
17 17
6
6
3 5.2
5.1 3
Z 63 660 Z 61 777
2/55 043−1100−054_en
10 Working With the Superlift Equipment
10.1 Description of the Superlift

The function of the standard Superlift apparatus is described on
the following pages.
The function of the Tele−Superlift (Tele−SL) is described in this
Section under 10.5.2.
The function of the Vario−Superlift (Vario−SL) is described in this
Section under 10.5.3.
The function of the Superlift apparatus with counterweight ve-
hicle is described in Part 1, Section 20.
Lattice boom cranes of the type CC 2400 −1 can be equipped

with Superlift equipment (in the following referred to as SL equip-
ment) in addition to the standard crane equipment.
The Superlift comprises:

3 Frame
5 Connecting ropes (Option “Standard SL”, Z 63 659)
5.1 Adjustment winch (Option “Vario SL”, Z 66 660)
5.2 Telescopic connection (Option “Tele SL”, Z 61 777)
6 A−frame
8 Superlift mast (SL−mast)
17 Bracing rods
18 Support rods
18.1 Support frame lift cylinder (optional for Vario SL and Tele
SL)
The frame (3) and the weights form the Superlift counterweight
(SLC).
The support frame is connected to the SL−mast (8) by means of

the rods (18). The A−frame (6) is connected by means of bracing
rods (17) with mast (8).
The Superlift counterweight is connected with the superstructure

by means of either the telescopic connection (5.2), the adjust-
ment winch ropes (5.1) or the horizontally aligned connecting
ropes (5).
The connecting ropes (5) must be taut when the crane is under
load and the Superlift counterweight is raised so that the Superlift
counterweight cannot swing backwards.
043−1100−054_en 3/55
10
1 2 3
Z 62 725
4/55 043−1100−054_en
As a result of the larger radius of the mast point compared with

the radius of the Superlift counterweight, the Superlift counter-
weight is pulled inward in the direction of the centre of rotation,
creating tension in the connecting ropes (5.1). The difference be-
tween the radius of the mast point and the SL counterweight is
0.5 m (1.64 ft).
If a telescopic connection is installed instead of the connecting
ropes (optional Tele SL), the mast point will remain constantly at
the same radius, but the SL counterweight will be moved with the
aid of the telescopic connection within a specified and LMI−moni-
tored range.
When the Superlift is fitted the crane can also be operated with-
out the SLC (= 0 t / 0 kip SLC).
No electrical system for frames or telescopic connections may be

connected in such cases. A dummy plug must then be plugged
onto the plug (1, Z 62 725). Otherwise an error message will occur
and a switching off of the movements under certain circum-
stances.
The above−referenced plug is located inside at the rear left−hand
area of the superstructure.
Risk of overturning the boom system to the rear when the

SLC has been set on the ground!
It is for that reason that depressions in excess of 0.5 m
(1.64 ft) are not permitted in the slewing area of the SLC.
043−1100−054_en 5/55
10
17
L SLC
A B
Z 54 335
6/55 043−1100−054_en
10.2 Modus Operandi

(Z 54 335)
The permitted load moment of the crane L x A (load x working

radius) is increased by the counter moment SL CWT x B (SL CWT
x Superlift counterweight Radius).
The equipment acts like a balance arm, whereby the load mo-
ment (L x A) is greater.
The difference in overall balance is taken up by the mast bracing
(17). The required force in the derricking gear stabilises the sys-
tem.
To maintain the balanced state, the size of the Superlift counter-

weight must be co−ordinated with the load moment. The distance
(B) of the SLC can be selected based on various possibilities.
Small changes in the working radius are possible when the cor-
rectly sized SLC is selected.
Operation of the crane with the Superlift fitted is also possible

without the SLC, in accordance with the lifting capacity for 0 t
(0 kip) SLC (see load table).
If a load is to be raised and slewed, the Superlift counterweight

must be raised with sufficient ground clearance (greater than
100 mm / 3.94 inches).
It is not possible to swing the SLC without load on the boom as

the SLC does not lift off the ground even with a large working
radius and a long boom within the range of the load tables (de-
pendent on the size of the SLC).
043−1100−054_en 7/55
10
4.3
4.2
4.3 4.10
4.2
4.11 4.10
4.10 4.1
Z 63 661
4.10
20
1
Z 62 662
8/55 043−1100−054_en
10.3 Safety Instructions for Working With the Superlift

Equipment
Working with the SL equipment requires special attentive-

ness on the part of the crane operating crew with respect to
function and danger.
− When the Superlift equipment is fitted, the crane must be

standing on even, horizontal and sufficiently stable ground.
Please observe all regulations for setting up and supporting the

crane on outriggers in sections 9.9.2 and 12.
− For work with the Superlift, special load tables are assigned
to the crane. Additional specifications (e.g. E−min. and E−
max.; 1, Z 62 662) appear on the LMI display (20, Z 62 662).
− The crane can work with the Superlift and also without the
Superlift counterweight. In this case, the load capacity tables
with “0 t” (0 kip) SLC must be used.
No electrical system for frames or telescopic connections may be

connected in such cases. A dummy plug must then be plugged
onto the plug (1, Z 62 725, page 4/55). Otherwise an error mess-
age will occur and a switching off of the movements under certain
circumstances.
− To enable the SLC to be lifted clearly and therefore the super-

structure to be slewed, the values specified in the load tables
must be adhered to.
− When the working radius is reduced, the force in the der-

ricking gear is reduced, which can lead to accidental
lowering of the SLC and to tilting of the boom system to
the rear!
− Observe the final position of the main boom to the rear!
− The main boom support cylinders and main boom foot
section can be damaged!
− The ultrasound sensors (4.10, Z 63 661) on the left−hand
and right−hand sides must be fitted on the support frame.
043−1100−054_en 9/55
10
10/55 043−1100−054_en
− No Superlift counterweight can be used with loads which, ac-

cording to the Superlift load capacity table, can be raised
without Superlift counterweight (= 0 t / 0 kip SLC).
− Slewing with a suspended SLC is only permitted when the re-
quired ground clearance and the maximum permitted de-
pression in ground level is ensured.
− Using the derricking gear, the SL mast is placed at its operat-
ing radius before crane operations begin.
− The working radius may only be changed when the Superlift
counterweight can be set down.
− The change in the working radius on the main boom

and/or on the fixed fly jib may only be made using “luffing
gear 2”.
− The operating radius on the luffing fly jib may be changed
only using “luffing gear 1” when the SL counterweight is
raised and the load freely suspended.
A person who is in visual and verbal contact with the
crane operator must watch the SLC from outside the cab.
043−1100−054_en 11/55
10
18
Z 53 732
12/55 043−1100−054_en
10.4 Working With the Crane Without Superlift Counter-

weight (SLC)
(Z 53 732)
When working without the SLC, the rods (18) on the support
frame (3, Z 63 659, page 2/55) must be released and the connect-
ing ropes and/or the telescopic connection must be removed.
− Release the support rods (18) on the support frame (3,
Z 63 659, page 2/55).
− Remove connecting ropes/telescopic connection from the
support frame.
− Disconnect the electric cable between the superstructure
and support frame.
− Insert the dummy plug in the socket.
If the dummy plug is not plugged in, then an error message will
appear and movements will be switched off under certain circum-
stances.
For working with the SL equipment without SLC, refer to the

corresponding load capacity charts for an SLC of 0 t (0 kip).
043−1100−054_en 13/55
10
Z 53 738
4 3 2 5 1 6
Z 62 728
14/55 043−1100−054_en
10.5 Working With the Crane With Superlift Counterweight

(SLC)
10.5.1 With Standard Superlift Equipment
(Z 53 738)
The Superlift mast radius can be modified in three defined stages
with the standard Superlift equipment.
Mast radius 11.5 m (12.67 ft) 13.5 m (14.88 ft) 15.5 m (48.21 ft)
SGR 11.0 m (36.09 ft) 13.0 m (42.65 ft) 15.0 m (49.21 ft)
SCR = Superlift counterweight radius
Preparations for Raising the Load
− Fitting the Superlift (see Part 3, Sects. 3 to 10)
− Selection of the SLC
The size of the SLC can be obtained from the respective load
capacity table.
In order to ensure the required force equilibrium and the rais-

ing of the Superlift counterweight for swivelling, the values
are permitted to deviate only slightly from those contained in
the maximum load capacity tables.
Setting the support frame down on the selected SCR.
The weights (4, Z 53 738) must be stacked symmetrically and

secured in place using stops on each plate or by inserting
wooden wedges to prevent them from slipping.
− In order to lower or stack the SLC, the ground must be level
and have load−bearing capacity (maximum 0.55 slope).
− If set down on just one side, the support frame is loaded un-
evenly. In extreme cases, this can lead to a system overload.
− Entering the operating mode (see section 8.1.3.2 and subse-
quent sections)
After entering the operating mode,

− the maximum derricking rope force (1, Z 62 728)
− the actual derricking rope force (2, Z 62 728)
− the SGR (3, Z 62 728)
− the radius of the load (4, Z 62 728)
− the status of the counterweight crossbar frame, raised/not
raised (5, Z 62 728)
− the mast radius (6, Z 62 728)
will be shown on the LLD display.
043−1100−054_en 15/55
10
3 1 2
18
6
4
5 Z 62 724 Z 53 734
5.1
8
7 17 18
3
6
5.1 3
Z 55 989
16/55 043−1100−054_en
Attachment of the connecting ropes
(Z 62 724, Z 53 734, Z 55 989)

− Connecting the Superlift counterweight (3, Z 55 989) with the
crane. Position the SL mast (8, Z 55 989) above the SCR (3,
Z 55 989) by pressing the button (4, Z 62 724) and pulling the
control lever (3, Z 62 724) to the rear in such a way that the
support rods (18, Z 53 734) on the SCR can be fastened.
If the Superlift counterweight can then still not be connected with

the rods, the crane or the Superlift counterweight must be reposi-
tioned and/or the assembly of the Superlift equipment must be
checked.
− Fit the connecting ropes (5.1, Z 55 989) between the crane
superstructure and the Superlift counterweight.
After the connection ropes have been assembled, the actual

mast radius must be back in the permitted tolerance range again.
It is restricted to 0.3 m (11.8 inch) to the front and 0.9 m (35.4 inch)
to the rear.
043−1100−054_en 17/55
10
18
13
22
3 Z 61 779
2
Z 62 730
18/55 043−1100−054_en
Raising the load

(Z 61 779)
Following preparations for raising the load, as described in sec-

tion 10.5.1, the load can be raised as follows.
− For adjusting the SL−mast (8), unroll the derricking rope (22)
from the rope drum by moving the lever (3) forward until
actual derricking rope force of (2, Z 62 730) 4 t − 5 t (8.8 kip
− 11 kip) is shown on the load limit device display in the crane
cab.
The dead weight of the main boom (7) causes the rods (18)
on the SLC (4) to be tensioned.
− Set the Superlift mast (8) to the preselected mast radius by

actuating lever (3).
The mast radius may only be changed during operation of the

crane within the permitted tolerance range of the derricking force
(EZW) (E−min % E−maximum). The exception being cranes that
are equipped with “variable mast radius” (see section 10.6).
− Position the hook block above the load.

To do so, reel in or unreel the luffing rope W2 by activating
the control lever 2 until the boom with the hook block is di-
rectly over the load.
043−1100−054_en 19/55
10
7
8
24.1
17
18
4
22
Z 61 778
20/55 043−1100−054_en
− Raising the load (Z 61 778)
Reel hoist rope H1 or H2 (24.1) onto the rope drum by mov-

ing lever (1 or 2) to the rear. If the hoist rope H1, H2 (24.1)
is tensioned, it raises the SLC (4) off the ground approx.
20 cm (7.87 inches) to 50 cm (19.69 inches).
In addition, by reeling the hoist rope H1, H2 (24.1) onto the

rope drum, the bracing rods (17) of the SL mast (8) and the
derricking ropes (22) are tensioned for adjusting the SL mast
(8).
While raising the load, observe the display of the maximum der-
ricking rope force on the load limit device display. If the actual
value of the derricking rope force approaches the value for the
maximum derricking rope force
1) interrupt the raising of the load
2) reduce the derricking rope force by unreeling by approximately
10 − 20 %.
3) observe the load radius!
4) continue to pick up the load with hoist 1 and hoist 2.
If, with the SLC hanging free, “E−max.” is reached when the
load is raised, the SLC is too small. Stop the lifting operation
and raise the SLC or mast radius to the next level.
− Reel in the hoist rope (24.1) further to raise the load.

The condition is now reached where the superstructure of
the crane can be slewed.
043−1100−054_en 21/55
10
7
8
24.1
17
18
4
22
Z 61 778
22/55 043−1100−054_en
Setting the Load Down
(Z 61 778)
− The load is set down on the ground by pushing lever (1 or 2)

forwards.
The load can only be set down if there is sufficient level

ground with load−bearing capacity available for the SLC (4)
being lowered at the same time.
If the SLC is reduced in order to set down the load, the set value
for “E−min” could be reached when setting down the load. The
background colour changes from white to orange (<3 t / 6.6 kip)
to red (<2 t / 4.4 kip).
In this case, you must proceed as follows with a suspended load:

− Reel in derricking rope − the force in the derricking gear is in-
creased. (set value to 4t − 5 t / 8.8 kip − 11 kip). Observe the
radius, if required, correct with luffing gear W2.
− Switch on luffing gear 2 (see section 9.7).
− Raise the main boom (7) by moving the lever (3) backwards
until the working radius has achieved the desired value.
− The load is set down on the ground by moving the lever (1 or
2) forwards.

− Pull the SL mast (8) by extending the lever (1) to the rear to
such an extent that the support rods (18) can be released
from the SLC (4).
− Detach the rods (18) from the SLC (4).
043−1100−054_en 23/55
10
18.1
7 8
18
17
5.2
3
Z 61 777
4 3 2 5 1 6
Z 62 728
24/55 043−1100−054_en
10.4.1 With the Tele Superlift

(Z 61 777)
The mast radius of the telescoping SL equipment is always
13 m (42.65 ft).
Mast radius 13.0 m (42.65 ft)
SGR 11.0 m (36.09 ft) − 15.0 m (49.21 ft)
SCR = Superlift counterweight radius
Preparations for Raising the Load

− Selection of the SLC
The size of the SLC can be obtained from the respective load
capacity table.
In order to ensure the required force equilibrium and the rais-

ing of the Superlift counterweight for swivelling, the values
are permitted to deviate only slightly from those contained in
the maximum load capacity tables.
Setting the support frame down on the selected SCR.
The weights must be stacked symmetrically and secured in

place using stops on each plate or by inserting wooden
wedges to prevent them from slipping.
− Entering the operating mode (see section 8.1.3.2 and subse-

quent sections)
After entering the operating mode,

− the maximum derricking rope force (1, Z 62 728)
− the actual derricking rope force (2, Z 62 728)
− the SGR (3, Z 62 728)
− the radius of the load (4, Z 62 728)
− the status of the counterweight crossbar frame, raised/not
raised (5, Z 62 728)
− the mast radius (6, Z 62 728)
will be shown on the LLD display.
043−1100−054_en 25/55
10
18
Z 53 734
5.2
18.17
8
5.5
5.6
18.19
5.7
5.8 5.1
5.9
ÍÍ
ÍÍ
ÍÍ Z 53 735
26/55 043−1100−054_en
Fitting the support frame to the crane with telescopic con-

nection
The support frame of the SLC must be set to the rear of the tele-
scopic connection in such a way that the support frame and the
telescopic connection can be connected.
− Fitting the telescopic connection(see part 3, section 6.3.5.)

− Luff the SL mast (8, Z 53 735) as far up or down as required
for the support rods (18.17, Z 53 735) to be in position above
the receptacles of the suspension attachment (5.2, Z 53 735)
and for the bolts to be able to be inserted. If it should be
necessary to retract or extend the telescoping cylinder, then
this can be accomplished by remote control, as described in
Sect. 14. The use of the control lever to move the telescopic
connection does not function in this configuration, because
the SL base frame is still on the ground and no enablement
is forthcoming from the IC−1 for that reason.
− If the cylinders (18.19, Z 53 735) of the Vario−Superlift are in-
stalled in the SL support rods, then these can be extended
and/or retracted as an aid for facilitating the threading of the
SL support rods into the suspension attachment of the tele-
scopic connection.
It is expedient to have the extension and retraction of the
above−referenced cylinders take place by remote control.
See in this connection Section 14.
043−1100−054_en 27/55
10
18
13
22
3 Z 54 336
3 1 2
4
5
Z 62 724
28/55 043−1100−054_en
Raising the load

(Z 54 336)

− Set the correct mast radius of 13 m (42.65 ft) by pressing the
button (4, Z 62 724) and moving the lever (3, Z 62 724) along
the Y axis. The frame must at the same time be moved to the
correct value in accordance with the respective load capacity
charts. Press the button (5, Z 62 724) and move the control
lever (3, Z 62 724) along the X axis for this purpose.
Take into consideration the fact that altering the mast radius with
the derricking gear will also result in a change in the main boom
angle. This must then be corrected with winch 2, which is used
for adjusting the main boom. To accomplish this, press the button
(6, Z 62 724) and adjust the main boom accordingly by actuating
the control lever (3, Z 62 724).

043−1100−054_en 29/55
10
1 3 4
10 5
9 6
8
7
Z 53 702 Z 54 343
130.1 130.2
130.7
Z 63 249
30/55 043−1100−054_en
Adjusting the Superlift counterweight radius (SGR)
The modification of the SCR is accomplished with suspended

load and raised SL CWT.
There are two different ways to change the SLC:

− Using the radio remote control (only when attaching or de-
taching the counterweight vehicle)
− Using the control levers in the crane cab (during crane oper-
ation)
Using the radio remote control
4. Switch on the operating mode “RG0” on the display panel for

the LLD system (Z 53 702).
5. Press the “radio remote control” symbol (1) to activate it.
6. Press the symbol “assembly of SL telescopic tube” (5,

Z 53 702) to activate this function.
Risk of crushing
Before you start changing the SCR, make sure that there are
no persons or obstacles within the range of movement.
7. Simultaneously press the buttons (130.1 and 130.7,

Z 63 249) to increase the SCR.
8. Simultaneously press the buttons (130.2 and 130.7,

Z 63 249) to reduce the SCR.
The modification of the SCR can be viewed in the crane cab on

the display panel for the LLD system in the “LLD screen”.
Do not fail to watch the ground contact switch display (5,

Z 54 343) during modification of the SLR. The SLC may not
be set down on the ground, due to unevenness in the ground,
for example, as this causes switchoff of the movement.
043−1100−054_en 31/55
10
Z 63 250 Z 54 343
3
Z 63 651
32/55 043−1100−054_en
Using the control levers in the crane cab

− Press the symbol “assembly of SL telescopic tube” (3,
Risk of crushing
no persons or obstacles within the range of movement. It is
imperative that a banksman be positioned at the counter-
weight dolly who is in visual or radio contact with the crane
operator in the crane cab.
− Press the control lever (3, Z 63 250) to the left to increase the
SCR.
− Press the control lever (3, Z 63 250) to the right to decrease
the SCR.
The modification of the SCR can be viewed on the display panel

for the LLD system in the “LLD screen”.
Do not fail to watch the ground contact switch display (5,

Z 54 343) during modification of the SLR. The SLC may not
be set down on the ground, due to unevenness in the ground,
for example, as this causes switchoff of the movement.
043−1100−054_en 33/55
10
7 8
18
13
22
4
Z 54 336
34/55 043−1100−054_en
(Z 54 336)

forwards.

If the radius is reduced in order to set down the load, the set value
to red (<2 t / 4.4 kip).

− Switch on luffing gear 2 (see section 9.7)
2) forwards.

from the SLC (4).
043−1100−054_en 35/55
10
4
1 2 3
Z 62 735 Z 62 733
Z 62 734
36/55 043−1100−054_en
10.4.2 With variable Superlift apparatus

(Z 62 735)
When working with the variable Superlift equipment, you can
modify the Superlift mast radius and thus also the SCR to any
value within a range from 9 m − 15 m (29.5 − 49 ft).
The advantage of this variable Superlift apparatus is that is poss-
ible to change the working radius of the load without restacking
the Superlift counterweight.
To operate the variable SL equipment it is necessary to reset the
guying in the horizontal direction and to adjust the height of the
SL CWT counterweight.
This is accomplished by a rope winch which alters the length of
the guying and 2 lift cylinders in the SL support rods, which alter
then length of the support rods.
Preparations for Raising a Load

− Selecting the Superlift counterweight (SL−CWT)
The size of the SL−CWT is to be taken from the correspon-

ding load capacity table.
Set down the basic frame on the selected beginning radius.
The weights (4, Z 62 735) must be stacked symmetrically and

secured with lashing straps against sliding out of position.

− Entering the operating mode

Select the operating mode “variable Superlift (Vario SL)” by
pressing the button (1. Z 62 733).
− After the button is pressed (1, Z 62 733) the displays for the
possible SL mast radii (2, Z 62 733) will appear, together with
the Selection button for the outrigger span (only active on TC
cranes; with CC cranes value “0.0”).
Switch over to the “Save & Exit” display of the Operating

mode preselection (Z 62 734).
End the operating mode entry by pressing the button “OK” (4,
Z 62 734).
043−1100−054_en 37/55
10
4 3 2 5 1
Z 62 731 Z 54 340
2 3
7 6 5 4
Z 62 736 Z 54 342
38/55 043−1100−054_en
− After you have finished entering the operating mode, the LLD
system display shows the main menu (Z 62 731).
Legend:
(Z 62 731)
1 Maximum derricking rope force
2 Actual current derricking rope force
3 Radius of the load
5 ultrasound sensors fitted (green = SL CWT is raised off the

ground, red = SL CWT is not raised off the ground)
− The other presettings must be made on the display/control
panel for engine and crane operation.
Press button (1, Z 54 340) to call up the “Quick Menu”.
Activate the displays for operation with Vario−SL by pressing

the buttons (2 and 3, Z 62 736).
Legend:
(Z 54 342)
3 Radius of the SL mast top section
4 Radius of the SLC
5 Bar display for the tolerance range of the radius of the SL

CWT.
90% of tolerance range reached = bar display orange
100% of tolerance range reached = bar display red.
6 Selection of “manual adjustment” of the guying of the SLC

(horizontal) via radio remote control. If the button (6) is
green, “manual tracking” is activated.
7 Selection of “automatic adjustment” of the guying of the SL

CWT (horizontal). If the button (7) is green, “automatic
tracking” has been switched on.
043−1100−054_en 39/55
10
18
Z 66 763
18
5
18.1
18 5.3
5
Z 57 524
40/55 043−1100−054_en
Fitting the adjustment winch
(Z 66 763, Z 57 524)
− Fitting the adjustment winch (see part 3, section 6.3.4.)

− Connecting the SLC (3) with the crane. Position the Superlift
mast (8) over the SLC (3) by pulling the control lever (3) back-
wards so that the rods (18) can be secured on the SLC.
043−1100−054_en 41/55
10
18
13
22
3 Z 61 779
2
Z 62 737
42/55 043−1100−054_en
Raising the load

(Z 61 779)

− For adjusting the SL−mast (8), unroll the derricking rope (22)
from the rope drum by moving the lever (3) forward until
actual derricking rope force of (2, Z 53 737) 4 t − 5 t (8.8 kip
− 11 kip) is shown on the load limit device display in the crane
cab.
The dead weight of the main boom (7) causes the stay ropes
(18) on the SL CWT (4) to be tensioned.
− Set the Superlift mast (8) to the preselected mast radius by

actuating lever (3).

043−1100−054_en 43/55
10
Z 54 348 Z 54 340
13
8 9 9 10 11 12
Z 62 738 Z 55 464
44/55 043−1100−054_en
Changing the Superlift mast radius
Changes are only made to the SL mast radius when the load is
raised.
− Modify the Superlift mast radius by actuating the control

lever (3, Z 54 348).
To keep the connecting rope taut between the support frame and
the superstructure, it must be correspondingly adjusted when the
mast radius is changed. This can be done using the adjustment
winch, triggered either automatically, or manually with the aid of
the radio remote control.
Selection of the adjustment winch
The selection is made at the display and operating console for

engine and crane operation.
1. Press button (1, Z 54 340) to access the “Quick Menu”.

2. Call up the displays for operating the adjustment winch and
the lift cylinder by pressing the button (8 and 9, Z 62 738).
Legend:
(Z 55 464)
9 Button for automatic adjustment of the SLC
10 Button for manual adjustment of the SLC
11 Bar display: Tolerance range of the SGR
When the tolerance limits are reached, the bar display first turns
orange (90%) then red (100%).
12 Display of the SGR
13 Display of the SL mast radius
043−1100−054_en 45/55
10
13
9 10 11 12 1
Z 55 464 Z 62 739
130.4
130.5
3
130.16
Z 54 348 Z 55 465
46/55 043−1100−054_en
Automatic adjustment of the SL CWT
Prior to activation of the automatic adjustment, check to see

whether both the length indicator is connected to the support
frame and the connecting ropes are attached.
1 Preselect the automatic adjustment of the adjustment

winch by pressing the button (9, Z 55 464).
2 Check whether the control lever is switched to mode “O” (1,

Z 62 739).
3 Now the adjustment winch will be controlled together with

SL mast radius modification by means of the control lever
(3, Z 54 348).
Manual adjustment of the SL CWT
The manual adjustment is intended for the construction and sus-

pension of the support frame and for the correction of the radius
of the SL counterweight during crane operation.
It can happen that a non−permitted deviation, i.e. a too−small dif-
ference between the mast radius and the SL counterweight
radius will be shown on the tolerance display (11, Z 55 464) dur-
ing crane operation. The SL counterweight radius is to be cor-
rected as follows in such cases:
1 Preselect the manual adjustment of the adjustment winch

by pressing the button (10, Z 55 464).
2 Simultaneously press the buttons (130.4 and 130.16,

Z 55 465) on the wireless remote control to reel in the con-
necting ropes (reducing the SGR). The indicator in the toler-
ance display (11, Z 55 464) moves on the display.
3 Unreel the connecting ropes (increasing SGR) by pressing

the keys (130.5 and 130.16, Z 55 465) on the radio remote
control at the same time.
4 Reel the Vario winch in or out as far as necessary for the tol-
erance display indicator to move into middle position.
043−1100−054_en 47/55
10
Z 62 740 Z 54 340
2 7 6 5 4 3
Z 54 344 Z 54 345
48/55 043−1100−054_en
Do not fail to watch the ultrasound sensor display (5,

Z 62 740) during modification of the SL mast radius. It is not
permitted to set the SL CWT on the ground.
If the display switches from green to red, then the crane
movement will be switched off. By activating the frame’s lift
cylinders, raise the frame until the display of the ground con-
tact switch changes to green again.
Selecting the support frame lift cylinders

− The selection is made at the display and operating console
for engine and crane operation.
Press button (1, Z 54 340) to call up the “Quick Menu”.
Call up the displays for operating the support frame lift cylin-
ders by pressing the button (2, Z 54 344).
Legend:
(Z 54 345)
3 bar display for the ground clearance of the SLC in 2 variants

0.5 m − (1.64 ft) mode (standard range)
2.0 m − (6.56 ft) mode (expanded range)
4 Button for preselection of the right−hand lifting cylinder
5 Pressure in the right and left lift cylinder, respectively
6 Extension length of the right or the left lift cylinder
7 Button for preselection of left lift cylinder
043−1100−054_en 49/55
10
7 4 8
Z 54 346 Z 54 347
130.1 130.2
130.4
130.5
Z 54 348 Z 54 349
50/55 043−1100−054_en
Operating the support frame lift cylinders
The support frame lift cylinders can be used in all variants with
Superlift support frame, with SL apparatus with 0−ton (0 kip) SLC
and in operating mode RG0.
1 Preselect the operation of the support frame lift cylinder by

pressing the buttons (7 and 4, Z 54 346).
2 Check whether the control lever is switched to mode “O” (8,

Z 54 347).
3 The support frame lift cylinders can now be extended or re-

tracted with the control lever (3, Z 54 348).
If the wireless remote control is used (for activation of the

radio remote wireless control, see Sect. 14), then
−the left support frame lift cylinder can be extended by sim-
ultaneously pressing the pushbuttons (130.1 and 130.4,
Z 54 349) or retracted by simultaneously pushing the push-
buttons (130.2 and 130.4, Z 54 349).
−the right support frame lift cylinder can be extended by
simultaneously pressing the pushbuttons (130.1 and
130.5, Z 54 349) or retracted by simultaneously pushing the
pushbuttons (130.2 and 130.5, Z 54 349).
The support frame may not be raised further with the support
frame lift cylinders unless it is already in its raised state. If the sup-
port frame has been set down on the ground, then no running−in
operation of the support frame lift cylinders is possible. If the sup-
port frame lifting cylinders are nevertheless to be retracted, then
the jumper switch (9, Z 54 600, page 52/55) must be pressed.
043−1100−054_en 51/55
10
9 6 9 10
Z 54 600 Z 54 601
11
Z 54 602
52/55 043−1100−054_en
4 When the ground clearance reaches the preselected max.

value of 0.5 m (1.64 ft), the jumper switch (9, Z 54 600) will
appear. Except for the operation of the slew gear, no further
control operations are possible.
The jumper switch also appears if:
∗ the height measurement of the support frame is not
possible due to failure of the sensors
∗ when monitoring of the support frame inclination is no
longer possible due to failure of the position−measuring
systems in the support frame lift cylinders.
∗ the clearance between the support frame and the
ground is less than the minimum clearance.
5 If the jumper switch (9, Z 54 601) is now pressed (becomes

red), then the bar display switches over to the 2 m (6.56 ft)
mode. Now all movements are enabled for a greater lifting
height. The lifting height display still shows the previous en-
abled range in green, but now with a lower resolution. The
expanded height range is shown in yellow in the bar display
(10, Z 54 601).
6 Monitoring of support frame inclination.

If the maximum length difference of the support frame lifting
cylinders is reached, the “raise direction” is disabled for the
support frame lifting cylinder that is retracted the most; on
the other one the “lower direction” is disabled. The disabling
will be automatically cancelled again when both support
frame lift cylinders have the same extension length.
No interruption of the actuated movement on the part of the crane

operator is required.
The disable status is indicated by length sensor values (6,
Z 54 601) flashing red and black at intervals of one second.
During Superlift operation with 0 t (0 kip) SLCW, the lifting height

of the frame lift cylinder is not monitored. Similarly, there is only
limited monitoring of the tilt.
If the support frame lift cylinders are activated individually, then
no automatic monitoring of the inclination will take place.
7 If the warning light is illuminated (11, Z 54 602), then retrac-

tion of the support frame lift cylinders is not permitted. (e.g.
there is still not enough ground clearance of the support
frame to the rotation of the superstructure)
043−1100−054_en 53/55
10
7
8
24.1
17
18
4
22
Z 61 778
54/55 043−1100−054_en
(Z 61 778)

forwards.

If the SLC is reduced in order to set down the load, the set value
to red (<2 t / 4.4 kip).

− Switch on luffing gear 2 (see section 9.7)
2) forwards.

from the SLC (4).
043−1100−054_en 55/55
Operating the Heating and Ventilation 11
043−1110−054_en 1/25
11
102
112
111
114
Z 57 541
2/25 043−1110−054_en
11 Operating the Heating and Ventilation
11.1 Operating the Heating
In addition, the operating instructions of the manufacturer in

part 4 of these documents must be observed.
The crawler−mounted crane is equipped with an engine−inde-

pendent heater. The heating is switched on with the timer (102,
Z 57 541).
The fuel tank for the heating is in the back of the crane cab.
The heating warms up automatically. Depending on the ambient

temperature, warming−up can take up to a minute.
After switching off the heating the heater fan continues to cool off
the system for 130 seconds. This is why the battery switch may
only be switched off after the heating has come to a standstill.
The heater assembly may only be used for the purpose

specified by the manufacturer in the operating instructions
supplied.
Operation is not permitted:
− where combustible exhausts or fumes can form (e.g. near
fuel, coal dust, sawdust, wheat storage etc.).
− in enclosed spaces (e.g. garages) due to the risk of
poisoning.
− during refuelling.
During electric welding work on the vehicle, to protect the

control unit the + pole of the battery should be disconnected
and connected to ground.
043−1110−054_en 3/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
4/25 043−1110−054_en
11.1.1 Controls
(Z 36 772)
(1) − Time
(2) − Selection
(3) − Heating
(4) − Backwards
(5) − Forwards
Display of the timer
(6) − Memory
(7) − Symbol for radio remote control
(8) − Day of week/selected day
(9) − Current time/selected time
(10) − Temperature
(11) − Service indicator light
Switch on the heater assembly briefly (approx. 10 s) outside

of the regular heating period as well approx. once a month.
This prevents the water pump and burner motor seizing up.
Before the heating period a test run must be carried out

using the heater assembly. If heavy smoke or unusual
burner noises or a heavy smell of fuel develops, the heating
must be switched off and the fuse removed to place it out of
operation. The heating may only be restarted once an in-
spection has been carried out by authorised service person-
nel.
If there are malfunctions, we recommend:
∗ Switching the system off and on again (not more than twice).
∗ Checking the main fuse.
∗ Checking the air duct for blockages.
∗ Seek help at a garage.
043−1110−054_en 5/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
6/25 043−1110−054_en
11.2 Heating Operation
11.2.1 Setting the Timer

(Z 36 772)
After the power supply has been switched on, all signals flash in
the display (6), the timer must be set. The heating system cannot
be switched on in this status.
To set the timer, proceed as follows:
To call up the time of day:
− Press button (1).
Setting the time:
− Simultaneously press pushbutton (1) and pushbutton (4) or

(5).
To set the day of the week:
− Simultaneously press pushbutton (1) and pushbutton (2),

more than once if necessary.
To call up time of day and day of week:
− Press button (1).
After the timer has been adjusted, the time of day (9) and the day
of the week (8) are shown on the display.
043−1110−054_en 7/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
8/25 043−1110−054_en
11.2.2 Heating Operation Without Preselection With Ignition

“OFF”
(Z 36 772)
Switch on heating system:

− Switch on the heating system using the pushbutton (3) on the
timer (the heating time is set ex works to 120 minutes. It can
be changed on a one−time basis or permanently).
Display:
Duration of heating time, heating symbol = operating indicator
Changing the duration of heating time on a one−time basis:
After switching on:

∗ Shortening the duration of heating time: Press button (4).
∗ Lengthening the duration of heating time: Press button (5).
Changing the duration of heating time permanently:
Press pushbutton (3) and keep it pushed down while at the same
time shortening the duration of heating time with pushbutton (4)
or lengthening it with pushbutton (5). (When the pushbutton (3)
is released, the original duration of heating time appears on the
display. To call up the modified duration of heating time, press
pushbutton (3) twice, i.e. switch it off and then back on again).
Switching off the heating system:
Press button (3). The heating system continues to run automati-

cally for 2−3 minutes for cooling purposes.
043−1110−054_en 9/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
10/25 043−1110−054_en
11.2.3 Heating Operation Without Preselection With Ignition

“ON”
(Z 36 772)
Switch on heating system:

− Switch on the heating system with the pushbutton (3) on the
timer. The heating system remains in operation for as long as
the ignition is switched on. If the ignition is switched off, there
are still 5 minutes remaining heating time. It can be increased
to a maximum of 4 hours by pressing the button (5).
Display:
Time of day, day of week, heating symbol = operating display
Switching off the heating system:
Press button (3). The heating system continues to run automati-

cally for 2−3 minutes for cooling purposes.
043−1110−054_en 11/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
12/25 043−1110−054_en
11.2.4 Heating Operation With Preselection

(Z 36 772)
Up to 3 switch−on times within the next 24 hours or one

switch−on time up to 7 days can be preselected.
No more than one switch−on time can be activated at a time.
Select memory:
Select memory and thus activate (starting from neutral position,

for as long as the display is visible).
Press but- Display Basic setting
ton (2)
First memory 1x A 111
Second memory 2x B 222
Third memory 3x C 333
Neutral position 4x
The display of the time in the memory goes out after 10 seconds.
Recall:
− Press pushbutton (2) once.
11.2.4.1 Heating to Begin Within 24 Hours
To set preselection day:
Generated automatically, no adjustment necessary.
Set the preselected time:

− Select desired memory with pushbutton (2).
− Release pushbutton (2).
− Setting time with pushbuttons (4) or (5).
Adjustment is only possible for as long as the display is visible.
Recall:
− Press pushbutton (2) once.
043−1110−054_en 13/25
11
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
14/25 043−1110−054_en
11.2.4.2 Heating to Begin More Than 24 Hours Later (up to 7

Days)
(Z 36 772)
If the switch−on time is established for a weekday outside of the

next 24 hours, then it must remain activated after the adjustment
has been made, i.e. this memory may not be abandoned again
(that means that in the meantime, heating can be started only for
the present moment “3” or the time of day “1” is displayed). If a
different memory or the neutral setting is nevertheless selected,
even if only for control purposes, then there is an automatic reset-
ting back to the next setting opportunity (within 24 hours).
To set preselection day:

− Select desired memory with pushbutton (2).
− Keep pushbutton (2) pressed down and set preselection day
with pushbutton (5).
Set the preselected time:

− Release pushbutton (2).
− Set time with pushbuttons (4) or (5).
Checking the activated memory:

The preselection time of the selected memory is displayed for ap-
proximately 10 seconds, after which it disappears or the time of
day is shown when ignition is “ON”. The display of the pres-
elected time with the preselected day can be called up again by
pressing button (2) once (for 10 seconds, as previously de-
scribed).
043−1110−054_en 15/25
11
Z 58 919
16/25 043−1110−054_en
11.2.5 Safety Equipment

(Z 58 919)
The flame is monitored by the flame probe (6), the maximum per-
missible temperature by the temperature sensor (7), or one can
choose to use the overheat cut−out sensor (8) instead. Both of
these influence the control unit (9) which switches off the heating
system in the event of malfunctions.
1. If the heating system does not ignite within 90 seconds after

the fuel supply starts flowing, then the start is repeated.
If however the heating system fails again after a further 90
seconds of fuel supply flow, then the malfunction switch−off
goes into effect.
2. If the flame goes out of its own accord during operation, a

new start is first carried out.
If the heating system does not ignite within 90 seconds after
the switch−on of the flow of fuel or if it ignites but then goes
out again within 3 minutes, then the malfunction switchoff
goes into effect.
The malfunction switch−off can be reversed by switching
briefly off and on again.
Do not switch on more often than twice. If the heating system

does not then ignite, then have the malfunction corrected in
a workshop.
043−1110−054_en 17/25
11
A B C 4
3
Z 63 244
B
1.2
Z 59 556
18/25 043−1110−054_en
11.3 Liquid Gas Heating System (Optional)

(Z 63 244, Z 59 556)
11.3.1 Important Notes
− Check before each commissioning whether the wall
chimney for exhaust gas ventilation is unblocked. Do
not fail to remove or open the cover cap from the wall
chimney!
− The cover cap for the wall chimney is always to be
mounted and/or closed when the heating system is not
in operation. This applies in particular to the washing of
the crane
− Have the exhaust gas ventilation checked by a specialist
after each deflagration (backfire).
− The device is not permitted to be operated during refuel-
ling or while in the garage.
− The spray cans and gas cartridges which are taken into
the crane are not permitted to be exposed to the flow of
hot air.
− The following is to be observed in cases of gas system
leaks and/or gas odour:
∗ Close the gas bottle at once
∗ extinguish all open flames
∗ do not smoke.
∗ switch off auxiliary heating system
∗ open windows
∗ do not actuate any electrical switches
∗ have the entire installation checked by service per-
sonnel
∗ at a suitable specialist workshop.
11.3.2 Heating
Switch on the heating as follows:
1. If necessary, remove the flue cover.
2. Open the bottle valve and quick release valve in the gas line.
3. Set desired room temperature using the control knob.
Operating part with sliding switch
(Z 63 244)
Set switch (3) to “heat” (position “A”) and switch (2) to the desired
output (“FULL, high flame” or “1/2, low flame”). At low ambient
temperatures, start the heating running at “FULL”.
043−1110−054_en 19/25
11
A B C 4
3
Z 63 244
B
1.2
Z 59 556
20/25 043−1110−054_en
Operating part with combination rotary switch
(Z 59 556)
Set rotary switch (1.2) to desired heating stage “A” (“FULL, large
flame” or “1/2, small flame”). At low ambient temperatures, start
the heating running at “FULL”.
11.3.3 Ventilation
Switch on the fan as follows:
Operating part with sliding switch
(Z 63244)
− Set the switch (3) to “Ventilation” (position “C”).

− Set switch (2) to the desired output (“FULL” or “1/2”).
Operating part with combination rotary switch
(Z 59 556)
− Set rotary switch (1.2) to the desired air output (C).
11.3.4 Shutting off
(Z 63 244, Z 59 556)
− Set sliding switch (3) or rotary switch (1.2) to the middle (B).
If the heating system is switched off after a heating phase, then

the blower can continue to run afterwards to utilise any residual
warmth.
− During prolonged down times, put the chimney cover in place

and close the valve on the gas tank.
043−1110−054_en 21/25
11
A B C 4
3
Z 63 244
B
1.2
Z 59 556
22/25 043−1110−054_en
11.3.5 Notes on Heating Operation

(Z 63 244, Z 59 556)
If the switch (3) or the rotary switch (1.2) is set to “Heating” (posi-
tion “A”) or “Ventilation” (position “C”), the green control lamp
under the rotary knob (4) must light up. The fan is in operation.
If the control lamp does not light up, then the fuse in the electronic
control unit is to be replaced (see Lubrication and Maintenance
Instructions).
If the heating is switched off following a heating phase, the green

light means that the fan is still running to use up the residual
warmth. The ignition switch may therefore only be switched off
once the fan comes to a standstill.
If the red indicator lamp (1) lights up continually, there may be a

fuel shortage, air in the gas line, heavily clogged blower or a de-
fective fuse.
The error is unlocked / deactivated by switching the heating off
and on again.
If the red indicator lamp flashes there is insufficient operating volt-

age for the heating.
Make sure that the flue for the exhaust line and the combustion
air intake is always kept free of obstacles (sludge, foliage etc.).
Make sure that the wall chimney for the exhaust line is al-
ways kept free of obstacles (sludge, foliage, etc.).
Always put on the cover cap of the wall chimney when the
heater is not in operation.
This cover cap must be removed before each time the appar-
atus is put into operation.
The device is not permitted to be operated during refuelling
or while in the garage.
The positive terminal is to be disconnected from the battery
and to be grounded during electric welding work on the
crane chassis or on the superstructure for the protection of
the heating system control units.
Do not fail to observe in addition the “Trumatic E 2400” oper-

ating instructions published by the device manufacturer for
the operation and servicing of your heating system.
043−1110−054_en 23/25
11
102
112
111
114
Z 57 541
24/25 043−1110−054_en
11.4 Operating the Air Conditioning System

The crawler−mounted crane is equipped with an air conditioning
system. The control knobs (111, 112, Z 57 541) and the toggle
switch (114, Z 57 541) are used to operate the air−conditioning.
The air conditioning equipment must be switched on at least once

a month for a short period of time. Operation is required to lubri-
cate the compressor.
11.4.1 Controls
(Z 57 541)
111 Blower switch
112 Thermostat − warm air
114 Toggle switch (air conditioning on − cold)
043−1110−054_en 25/25
Parking the Crane 12
043−1120−010a_en 1/7
12
2/7 043−1120−010a_en
12 Parking the Crane
12.1 Wind Speeds
If the crane is parked with the erected boom after crane oper-
ation, the maximum expected wind speed for the crane (when
parked) must be taken into consideration.
Main boom − crane without load

e.g. SH, SH/LH, SH+LF, SH/LH+LF
Crane Track Main boom HA max. wind speed

type (Superlift) (
CC (°)
(m) (ft) (m) (ft) (m/s) (mph)
2400−1 7.25 23.79 up to up to 75 15 33.54
144 472.46
Main boom and fly jib − crane without load

e.g. SW
Crane Track Total length HA HI max. wind

type ( ( speed
CC (°) (°)
(m) (ft) (m) (ft) (m/s) (mph)
2400−1 7.25 23.79 up to up to 85 65 15 33.54
168 551.21
Check to make sure that the slewing range is free of ob-

stacles before releasing the slew brake (see Sect. 7 in Part
1 of the crane documentation).
Possible only with rigging variations without Superlift.
− The crane equipment must be slewed so that the wind hits the
crane along its length from behind. The slew brake must be
applied (closed). The Superlift counterweight must be fitted
and lowered in accordance with the erecting regulations (part
3 of the “Assembly Instructions”, section 10). The stay ropes
of the Superlift counterweight must be tensioned.
043−1120−010a_en 3/7
12
4/7 043−1120−010a_en
− If higher winds are expected than are permitted (following

consultation with the weather authorities) the boom system
must be lowered in good time.
The wind speeds apply in accordance with the main boom table
if the following conditions are met−the fly jib lowered
− jib top section lying on the ground
− boom system positioned against the wind
− the slew brake applied.
Wind direction
If the crane is to be taken out of operation for a longer period of
time (e.g. on the weekend), the crane superstructure and boom
must be turned in a direction which would mean that possible
storms would approach the crane from behind.
Boom position
The crane is at its most stable against the effects of wind from all
directions when the centre of gravity of the entire crane is near
the centre of the undercarriage (rotating axis). The position of the
centre of gravity can be affected by the angle of the main boom
and fly jib.
Back stroke safety devices
Two hydraulic cylinders prevent both the main boom and fly jib
from sagging reverse. When the crane is out of operation, the
boom must be tilted so far forwards that it cannot be pushed from
the front to the back, even under heavy storm conditions, thus
avoiding sudden and abrupt activation of the mechanical stops.
Counterweight dolly (optional):
If the counterweight vehicle loaded with the Superlift counter-
weight is stopped after completion of work, then the outrigger cyl-
inders are to be extended as far out as necessary to relieve the
tyres.
043−1120−010a_en 5/7
12
6/7 043−1120−010a_en
12.2 Lowering the Boom System
If the wind conditions could possibly exceed the limit values for
parking of the crane, the boom must be lowered to the ground in
good time.
If local conditions allow, the boom system should be lowered
against the wind direction (oncoming wind). Therefore the boom
must be turned into the wind, to reduce the wind loads when
lowering the boom. The parking brake of the slew gear may not
be locked in open position (see Sect. 7, Part 1 of the crane docu-
mentation).
Changing wind strengths and wind direction must be taken into
consideration early enough; relevant information must be col-
lected in good time and with foresight in mind.
043−1120−010a_en 7/7
Emergency Operation 13
043−1130−054 1/7
13
140.1 3 140.2 1 2
140.7 140.10 140.5 140.4 140.13 140.16
Z 57 120
2/7 043−1130−054
13. Emergency Operation
13.1. Emergency Control System with the Mobile Control

Panel
(Z 57 120)
If the IC −1 control fails, the momentary crane movement can be
ended by the mobile control panel for the emergency control sys-
tem and the crane can be moved into a safe position. The IC −1
control should then be repaired immediately.
During operation with the emergency control system, all
safety circuits such as limit switches and load limit devices
do not function. The crane movements must therefore be
carried out with great care.
The crane operator is solely responsible for the safe oper-
ation of the crane.
− The control levers (1 − 3) in the crane cabs do not function dur-
ing crane operation with the emergency control system.
The mobile control panel for emergency operation is made up of
the following components:
1 S 2472 Control lever Hoist 1 raise/lower
Left crawler forwards/backwards
2 S2476 Control lever Hoist H2 raise/lower
Hoist H3 raise/lower
Right crawler forwards/reverse
3 S 2482 Control lever Derricking gear “E” raise / lower
3 S2486 Control lever Slew slew gear right / left
140.1 Mobile control panel
140.2 Switch STOP
140.3 − − −
140.4 S 2495 Switch Operation counterweight dolly
140.5 R2495 Governor Speed control counterweight dolly
140.7 S 2481 Selector switch Derricking gear E / luffing gear W1 /
Luffing gear W2
140.10 S 2485 Switch Operation “slew gear”
140.13 S2471 Selector switch Hoist 1/left crawler
140.16 S 2475 Selector switch Hoist H2/hoist H3/right−hand crawler
043−1130−054 3/7
13
140.1 3 140.2 1 2 140.17
R1
R2
140.7 140.10 140.5 140.4 140.13 140.16 140.18
Z 59 294
4/7 043−1130−054
Continued: The mobile control panel for emergency oper-

ation is made up of the following components:
(Z 59 294)

140.17 S Key switch Position “0”: Two−engine operation
Position “R1”: One−engine operation Engine 1
Position “R2”: One−engine operation Engine 2
This switch in present only on cranes that
have 2 engines!
140.18 S Pin The mobile control panel is disabled when the
pin is pulled out. This is a security feature
against use by unauthorised persons.
During operation with emergency control and fitted counter-

weight dolly, you must ensure that the reversing function for
driving is not used.
This means that driving with the counterweight dolly is only
possible when the chassis is in 0° position to the superstruc-
ture.
Driving is not possible if the chassis is in the 180° position
to the superstructure as the wheels of the counterweight
dolly turn in the opposite of the crawlers in this condition.
043−1130−054 5/7
13
A
B
Z 63 956
Z 63 957
6/7 043−1130−054
Caution: the load limit device of the crane is non−functional

when the mobile emergency control system is being used.
For this reason it may only be used to set a load on the
ground when crane control IC−1 has failed.
A crane may only ever be activated from a driver’s cab/con-

trol console.
As both the assembly remote control as well as emergency
control is viewed as a control panel, it is prohibited to work
with the assembly remote control and emergency control
at the same time.
Activating the emergency control system

(Z 63 956, Z 63 957)
Emergency control is activated by turning the key switch (A) in the

receiver (B) by 90° to the right.
LED (C) is illuminated.
Symbol D continues to be displayed in the LLD monitor.
Emergency control is deactivated by turning the key switch (A) in

the receiver (B) by 90° to the left.
043−1130−054 7/7
Radio Remote Control 14
043−1140−056 1/21
14
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4 130.6
130.8
130.7 130.9
130.11
130.10 130.12
130.14
130.13 130.15
130.16 130.18
130.17
Z 49 294
2/21 043−1140−056
14 Radio Remote Control
14.1 General
The radio remote control can be used to operate remotely all as-
sembly procedures.
If the radio remote control fails, the valves for the assembly pro-
cedures must be actuated manually (see section 14.4).
14.2 Preparations for Assembly Using the Radio Remote

Control
(Z 49 294)
1. Switch on the power supply of the crane.
2. Start the drive motor.
3. Place the transmitter (130, Z 49 294) ready for operation, i.e.

− insert the rechargeable battery in the battery unit.
The rechargeable battery is used at the same time as a key.

When the system is shut down, remove the battery and protect
against unauthorised access.
− Switch on the power supply by pulling out the EMERG-

ENCY OFF switch (130.19). The red LED (130.20) must
light up when the transmitter is switched on.
If the red LED (130.20) flashes or remains completely shut off,

then the rechargeable battery must be charged.
The radio remote control transmitter and receiver automatically

seek a frequency every time they are switched back on.
043−1140−056 3/21
14
1 3 4
10 5
9 6
8
7
Z 53 702
1 3
Z 53 703
4/21 043−1140−056
Legend:
(Z 53 702)
1 Radio remote control on/off
2 −
3 Assembling chassis
4 Assembling the winch frame
5 Assembling the SuperLift telescopic tube
6 Cylinder of the quick release
7 Lift cylinder counterweight
9 Assembling SuperLift counterweight dolly
10 Swing over A−frame
4. Set operating mode “RG0 (Z 53 702) or SMAB1” (Z 53 703)

in the LLD display.
5. Touch button (1, Z 53 702 or Z 53 703).
6. Then the selection for the assembly function in the LLD dis-
play is shown.
7. The desired assembly function can be activated by pressing

one of the buttons.
Ending the assembly with the radio remote control

− When the button (1, Z 53 702 or Z 53 703) is pressed again,
switching off the remote control, all assembly functions are
deactivated and the display for assembly selection in the LLD
display is deleted.
− With the selection of a new operating mode for the load limit
device system, all functions of the remote control are deleted.
043−1140−056 5/21
14
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4 130.6
130.8
130.7 130.9
130.11
130.10 130.12
130.14
130.13 130.15
130.16 130.18
130.17
Z 49 294
6/21 043−1140−056
14.3 Tabular Collation of the Assembly Procedures
14.3.1 Assembly Procedures on the Superstructure

(Z 49 294)
Desired function Button Operation
Assemble the winch frame H1
Unpin frame 130.2+130.10
Pin the frame 130.1+130.10
Assembling the winch frame H2
Unpin frame 130.2+130.11
Pin the frame 130.1+130.11
Swing over A−frame
Extend the A−frame 130.1+130.8
Retract A−frame cylinder 130.2+130.8
Assembling main boom foot section
Unpin the boom foot 130.2+130.10
Pin the boom foot 130.1+130.10
14.3.2 Assembly Procedures on the Chassis

(Z 49 294)
Unpin track frame on the left 130.2+130.10
Pin track frame left 130.1+130.10
Unpin track frame right 130.2+130.11
Pin track frame right 130.1+130.11
Completely extend the outriggers 130.1+130.3
Completely retract outriggers 130.2+130.3
Retract outriggers front left 130.1+130.6
Extend outriggers front left 130.2+130.6
Retract outriggers front right 130.1+130.12
Extend outriggers front right 130.2+130.12
Retract outriggers rear left 130.1+130.9
Extend outriggers rear left 130.2+130.9
Retract outriggers rear right 130.1+130.15
Extend outriggers rear right 130.2+130.15
Extend the clamping cylinder slewing connection 130.1+130.7
Retract the tensioner slewing rim 130.2+130.7
Retract the position cylinder slewing rim 130.1+130.8
Retract the position cylinder slewing rim 130.2+130.8
043−1140−056 7/21
14
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4 130.6
130.8
130.7 130.9
130.11
130.10 130.12
130.14
130.13 130.15
130.16 130.18
130.17
Z 49 294
8/21 043−1140−056
14.3.3 Assembly Procedures on the Counterweight Dolly

(Z 49 294)

Slew swivelling bolster 1 to the left 130.4+130.13
Slew swivelling bolster 1 to the right 130.5+130.13
Slew the swivelling bolster 2 to the left 130.4+130.14
Slew swivelling bolster 2 to the right 130.5+130.14
Extend SuperLift telescopic tube 130.1+130.7
Retract SuperLift telescopic tube 130.2+130.7
Completely extend the outriggers 130.1+130.3
Completely retract outriggers 130.2+130.3
Extend front outriggers 130.1 + 130.6 or
130.1 + 130.12
Retract outriggers front 130.2 + 130.6 or
130.2 + 130.12
Extend outriggers rear 130.1 + 130.9 or
130.1 + 130.15
Retract outriggers rear 130.2 + 130.9 or
130.2 + 130.15
14.3.4 Assembling the Counterweight (CWT)

(Z 49 294)

Extend left counterweight hoist cylinder 130.1+130.7
Retract left counterweight hoist cylinder 130.2+130.7
Extend right counterweight hoist cylinder 130.1+130.8
Retract right counterweight hoist cylinder 130.2+130.8
Extend left & right counterweight hoist cylinders 130.1130.16
Retract left & right counterweight hoist cylinders 130.2+130.16
Pin counterweight 130.1+130.10
Unpin counterweight 130.2+130.10
043−1140−056 9/21
14
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4 130.6
130.8
130.7 130.9
130.11
130.10 130.12
130.14
130.13 130.15
130.16 130.18
130.17
Z 49 294
10/21 043−1140−056
14.3.5 Adjustment of Crossbar Hoist Cylinder (SuperLift)

(Z 49 294)

Raise left crossbar / retract left cylinder 130.1+130.7
Lower left crossbar / extend left cylinder 130.2+130.7
Raise right crossbar / retract right cylinder 130.1+130.8
Lower right crossbar / extend right cylinder 130.2+130.8
Raise left and right crossbar 130.1130.16
Lower left and right crossbar 130.2+130.16
14.3.6 Adjustment of the Winch for Vario SuperLift

(Z 49 294)

Reel in winch 130.4130.16
Unreel winch 130.5130.16
043−1140−056 11/21
14
Z 59 746
130.8
130.6
130.7 130.12
130.10
2
130.5
130.4 130.15
130.1
130.2
130.9
130.13 130.16 130.17 130.11 Z 59 747
12/21 043−1140−056
14.4 Assembly Procedures in Case of Radio Remote Con-

trol Failure
At operating sites where radio−controlled operation is not per-

mitted or if there is a failure of the radio remote control, the as-
sembly procedures can be carried out by means of the following:
− Virtual radio remote control on the monitor of the IC−1

− Actuating the individual valves by hand
14.5 Virtual Radio Remote Control
The “Virtual radio remote control” dialogue is called from the

“Quick Menu” of the MOT screen by pressing the button (1,
Z 59 746).
The button (2, Z 59 747) of the virtual radio remote control is pro-
vided in the MOT screen.
No. Element Designation Function
130.1 Button Direction: Extending
130.2 Button Direction: Retracting
130.4 Button Direction: Turn to the left
130.5 Button Direction: turning to the right
130.6 Button Preselection: Outriggers: front, left
130.7 Button Preselection: Pinning
130.8 Button Preselection: Pinning
130.9 Button Preselection: Outriggers: rear, left
130.10 Button Preselection: Assembly cylinder
130.11 Button Preselection: Assembly cylinder
130.12 Button Preselection: Outriggers: Front, right
130.13 Button Preselection: Swivelling bolster 1: left
130.15 Button Preselection:outriggers: rear right
130.16 Button Preselection:counterweight assembly
130.17 Button Preselection: Swivelling bolster 2:
right
043−1140−056 13/21
14
14/21 043−1140−056
14.6 Manual Control of Assembly Procedures
During all assembly procedures to the superstructure, chas-

sis, and counterweight dolly the solenoid valve Y 3178 (high
pressure pump P3.2) must be activated!
The valve Y 3178 is attached on the assembly frame. Connecting

a 24 V voltage to the valve will cause the hydraulics equipment
to be switched to the high−pressure stage. This is necessary in
order to make available the required hydraulic power for the pin-
ning and unpinning functions.
However, after assembly the valve Y 3178 must be returned to
the initial position!
043−1140−056 15/21
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16/21 043−1140−056
14.7 Tabular Collation of the Assembly Procedures in

Case of Radio Remote Control Failure
14.7.1 Assembly Procedures on the Superstructure
Desired function Valve (Fitting) location of the
valve
Pin the frame Y9341 Assembly frame
Unpin frame Y9342 Assembly frame
Pin the frame Y9344 Assembly frame
Unpin frame Y9343 Assembly frame
A−frame
Lower the A−frame (8° shutdown) Y9411 Assembly frame
Assembling main boom foot section
Pin the boom foot Y9362 Proximity slew gear engine
Unpin right−hand side of boom foot Y260D Proximity slew gear engine
14.7.2 Assembly Procedures on the Chassis (CR)

Desired function Valve (Fitting) location of the valve
Pin track frame left Y9762 Chassis intermediate section
Unpin track frame on the left Y9761 Chassis intermediate section
Pin track frame right Y9766 Chassis intermediate section
Unpin track frame right Y9797 Chassis intermediate section
Completely extend outriggers Diverse Opening on the chassis intermediate section
Completely retract outriggers Diverse Opening on the chassis intermediate section
Extend outriggers rear left Y9723 Opening on the chassis intermediate section
Retract outriggers rear left Y9722 Opening on the chassis intermediate section
Extend outriggers front left Y9713 Opening on the chassis intermediate section
Retract outriggers front left Y9712 Opening on the chassis intermediate section
Extend outriggers rear right Y9725 Opening on the chassis intermediate section
Retract outriggers rear right Y9724 Opening on the chassis intermediate section
Extend outriggers front right Y9716 Opening on the chassis intermediate section
Retract outriggers front right Y9715 Opening on the chassis intermediate section
Extend clamping cylinder slewing rim Y9792 Chassis intermediate section
Retract tensioner slewing rim Y9791 Chassis intermediate section
Extend position cylinder slewing rim Y9794 Chassis intermediate section
Retract position cylinder slewing rim Y9793 Chassis intermediate section
043−1140−056 17/21
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18/21 043−1140−056
14.7.3 Assembly Procedures on the Counterweight Dolly

(GW)
During all assembly procedures on the counterweight dolly,

the solenoid valve Y 9855 must be activated!
The valve Y9855 is fastened to the control block on the bottom

of the counterweight dolly.
Manual fitting can be made easier by applying 24 V voltage to
both valves.
However, after fitting both valves must be brought back to their
original state!
Desired function Valve (Fitting) location of the valve

Slew swivelling bolster 1 to the left Diverse valve strip on the bottom of the
GW
Slew swivelling bolster 1 to the right Diverse valve strip on the bottom of the
GW
Slew the swivelling bolster 2 to the left Diverse valve strip on the bottom of the
GW
Slew swivelling bolster 2 to the right Diverse valve strip on the bottom of the
GW
Completely extend the outriggers Diverse Control block bottom GW
Completely retract outriggers Diverse Control block bottom GW
Extend SuperLift telescopic tube Diverse valve strip on the bottom of the
GW
Retract SuperLift telescopic tube Diverse valve strip on the bottom of the
GW
Extend front outriggers Y9815, Y9811 Control block bottom GW
Retract outriggers front Y9815, Y9812 Control block bottom GW
Extend outriggers rear Y9828, Y9811 Control block bottom GW
Retract outriggers rear Y9828, Y9812 Control block bottom GW
043−1140−056 19/21
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20/21 043−1140−056
14.7.4 Assembling the Counterweight (CWT)

valve
Extend left counterweight hoist cylinder Y9392, Valve strip front bridge
Y9399
Retract left counterweight hoist cylinder Y9391 Valve strip front bridge
Extend right counterweight hoist cylinder Y9394, Valve strip front bridge
Y9399
Retract right counterweight hoist cylinder Y9393 Valve strip front bridge
Extend left & right counterweight hoist cylin- Y9392, Valve strip front bridge
ders Y9394,
Y9399
Retract left & right counterweight hoist cylin- Y9391, Valve strip front bridge
ders Y9393
Pin counterweight Y9372 Valve bank rear bridge
Unpin counterweight Y9371 Valve bank rear bridge
14.7.5 Adjustment of Crossbar Hoist Cylinder (Superlift)

valve
Raise crossbar left Y9426
Lower crossbar left Y9425
Raise crossbar right Y9426
Lower crossbar right Y9425
Raise left and right crossbar Y9426
Lower crossbar left and right Y9425
14.7.6 Adjustment of the Winch for Vario Superlift

valve
Reel in winch Y9442
Unreel winch Y9441
043−1140−056 21/21
Driving With the Counterweight Dolly 16
043−1160−056 1/35
16
B
1524
200
ø700
7
4 5 7 6 2
Z 54 333
2/35 043−1160−056
16 Driving With the Counterweight Dolly
16.1 General
The CC 2400 −1 can be operated with a counterweight dolly.
Legend:
(Z 54 333)
1 Frame
2 Swivelling bolster
3 Support cylinder
4 Support plate
5 Drive axle
6 Wheel
7 Slew gear
The operation with the counterweight dolly is monitored by the

display and operating console for engine and crane operation.
The steering of the counterweight vehicle is comprised of 2 swi-
velling bolsters, each equipped with one that is power−driven.
Both swivelling bolster have one hydraulic rotary transmission.
The swivelling bolsters can be rotated as needed for the different
operating modes.
The operation of the outrigger of the counterweight vehicle as
well as the rotation of the swivelling bolster is undertaken by re-
mote control after activation of the radio remote control (see sec-
tion 14).
A rotational angle sensor in the superstructure of the crane re-
cords the angle position of the superstructure relative to the chas-
sis. For each swivelling bolster, a rotational angle sensor records
the angle.
The forward direction of the frame support is specified by the con-
trol levers in the cab.
The crane operator is responsible for the correct alignment

of the wheels! If the wheel position is incorrect, damage can
be caused to the counterweight dolly!
The following operating modes apply to the counterweight dolly:

−Circular travel
−Driving behind (including cornering)
−Parallel travel (including “crab walk”)
The individual operating modes are described in the following
separate descriptions.
043−1160−056 3/35
16
4/35 043−1160−056
When operating with the counterweight dolly, the following

should be observed:
When operating with the counterweight dolly, it must be ensured

that the counterweight dolly never lifts off the ground. This can be
achieved with the help of the derricking gear.
The crane operator must make sure that the derricking force is
always between the minimum and maximum limit values.
The prerequisite for this is that the Superlift counterweight re-

quired by the load capacity tables is lying on the counterweight
dolly.
Derricking force too low:
If the counterweight dolly threatens to be lifted up when the load

is raised even though the correct Superlift counterweight is fitted,
the derricking force is set too low and must be increased by actu-
ating the derricking gear (retract derricking rope).
When the minimum derricking force is observed, the derricking

rope is held under preliminary tension. This ensures that the
ropes do not work loose on the winch.
Derricking force too high:
If, when raising the load, the maximum derricking force is re-
ached, the preliminary tension of the derricking rope was too high
in the unloaded condition and must be reduced by actuating the
derricking gear (let out derricking rope).
If the maximum permitted derricking force is reached when the

load is raised and the counterweight dolly lifts up, there is insuffi-
cient weight on the counterweight dolly. In this case, the weight
must be increased in 10 t (22 kip) steps.
043−1160−056 5/35
16
130.20 130
130.19 130.2
130.1 130.3
130.5
130.4
130.6
130.9
130.12
130.14
130.13 130.15
130.18
130.17
Z 54 622
6/35 043−1160−056
16.2 Radio Remote Control

(Z 54 622)
To activate the radio remote control, see section 14.

130 B 290 Radio Remote − Control of stabiliser on
Control counterweight dolly
− Control of swivelling bolster on
counterweight dolly
130.1 Button Direction: extending/left
130.2 Button Direction: retracting/right
130.3 Button Selection:
Outriggers: General
130.4 Button Direction: Turning to the left
130.5 Button Direction: Turn to the right
Outriggers: front, left
Outriggers rear, left
Outriggers front, right
Rotating swivelling bolster 1
Rotating swivelling bolster 2
Outriggers rear, right
130.17 Button Pushbutton not assigned
130.18 Button Pushbutton not assigned
130.19 Button STOP (switches off remote control)
130.20 Display Service display
Two buttons must always be pushed in order to implement a func-

tion with the remote control unit. One button is used to describe
the direction and another to select the function.
Example: Rotate swivelling bolster 1, left: Press the keys 130.4
and 130.13 simultaneously.
043−1160−056 7/35
16
Z 41 115
Z 41 116
8/35 043−1160−056
16.3 Description of Mechanics

16.3.1 Basic Position and Angle Functions
(Z 41 115)
The basic position is defined as the crane configuration shown
in the diagram.
The crane has the following specifications:
− Top view of crane
− The travel gear of the crane and the swivelling bolsters of the
counterweight dolly are arranged in such a way that the frame
support moves forward when the control lever for the travel
gear is moved forward.
− The angle of the superstructure is now defined as being 0 de-
grees. Rotation of the superstructure to the right means a
change in angle of 0 degrees to 360 degrees.
The value 360 degrees does not exist and is treated as 0 de-
grees.
− The swivelling bolsters of the counterweight dolly are defined
as shown in the illustration. Rotation to the right means a
change in angle of 0 degrees to 360 degrees. Here too, 360
degrees is treated as 0 degrees.
16.3.2 Reversing (Definition)
(Z 41 116)
Reversing is defined as a change in the effective direction of the
control levers for the travel gear.
Within the superstructure angle ranges of 0 degrees to 90 de-
grees and from 271 degrees to 0 degrees, moving the control
lever forwards will result in forward driving and moving it back will
result in driving in reverse.
In the superstructure range of 91 degrees to 270 degrees, the
IC−1 switches automatically into reverse, for both the crane and
the counterweight vehicle.
This means that even when the superstructure angle setting is
between 91 degrees and 270 degrees, the control lever must be
pushed forward in order to drive in the direction that the driver is
looking. The slewing direction of the crawlers changes automati-
cally.
The slewing direction of the wheels of the counterweight dolly is
automatically adapted to the crawlers’ slewing direction.
There is no reversing function when the IC−1 crane control
fails and emergency control is used.
This means that driving with the counterweight dolly is only
possible if the chassis is in the position 0° to the superstruc-
ture.
043−1160−056 9/35
16
158 21
G
151
152
153
154
150 155 156 157
Z 63 975
10/35 043−1160−056
16.4 Description of Software
16.4.1 Counterweight Dolly Menu

(Z 63 975)
The menu “Counterweight dolly” (CWT dolly) is opened by pres-

sing the “Quick menu key” (158) in the display (21) of the MOT
screen.
The “Quick Menu” (Q) opens. Press button (G) in the quick menu
(Q). The sub−menu for the counterweight dolly is opened in the
display of the MOT screen.
The operating modes are selected in the menu.

Item Element Designa- Function
tion
150 Switch Driving behind 0 degrees and 180 de-
grees
151 Switch Parallel travel
152 Switch Circular travel
153 Switch High range counterweight dolly
(only possible for circular travel)
154 Display Current pressure in the pump circuit
2.2
155 Display Angle between superstructure and
carrier
156 Switch Selection: Angle adjustment for swi-
velling bolsters
157 Display Error angle between superstructure
and chassis
158 Switch Selection and display of the Quick
Menu in the display range “K”
156 Switch Switch on/off radio remote control
G Switch Selection and display of the “counter-
weight vehicle” function
043−1160−056 11/35
16
Z 54 625 Z 58 924
1 2 3
14 4
5
13 6
7
12 8
11 9
Z 54 626
12/35 043−1160−056
16.5 Setting the Operating Modes
The counterweight dolly (CWT dolly) can be activated from every

operating mode from which it is possible to work with the Superlift,
if the option “Dolly or crossbar” is activated in the IC−1 crane con-
trol.
16.5.1 Selection “Operation with Counterweight Dolly” (CWT

Dolly)
8. In the “Operating mode preselection” menu, switch on the

display on the screen (Z 54 625) by touching the button
“RZ II”.
9. Make the selection by touching the “WG” = CWT button (1,

Z 54 625).
10. Touch the button twice
to confirm the entry (Z 58 924).

At the same time, a valid DS code selection appears for the
chosen operating mode (configuration of the crane).
11. Touch the “OK” button to save and exit the “Operating mode
preselection” (Z 58 924).
12. The LLD figure (Z 54 626) with the counterweight dolly ap-
pears in the display.
043−1160−056 13/35
16
158
Z 54 627
153
150 151 152

Z 54 628
14/35 043−1160−056
16.5.2 Selection of the “Counterweight Dolly” (CWT Dolly)

Menu
1. Call up the Quick menu in the display (21, Z 54 627) by pres-

sing the button (158, Z 54 627) and call up the menu area
(“K”, Z 54 628) by pressing the “Counterweight vehicle” sym-
bol button.
2. Now you can press one of the buttons (150 − 152, Z 54 628)
to select the operating mode for moving with the CWT dolly.
Button 150 = Trailing
Button 151 = Parallel travel
Button 152 = Circular travel
Button (153, Z 54 628) serves to activate the high range during

circular travel.
It is only displayed and can only be activated if the symbol for
circular travel (152, Z 54 628) was pressed first.
043−1160−056 15/35
16
16/35 043−1160−056
16.5.3 Procedure When Changing Operating Mode
RISK O F OVERLOADING for the derricking gear!

To make sure that the derricking gear is not overloaded, it is
strictly prohibited to support the counterweight dolly when
a load is hanging on the hook.
If it is necessary to switch to a different operating mode while tra-

velling with attached load, the load must be set down prior to
stabilisation.
If it is not possible to set down the load, the “lower derricking gear”
function must be activated at the same time as the counterweight
dolly is supported.
In this case, the company operating the crane must make sure
that there is a clear line of communication between the crane op-
erator and operator of the counterweight dolly.
− Stabilise the counterweight dolly.
− Call up the corresponding menu.
− Position swivelling bolsters using the radio remote control.

of the wheels!
If the wheel position is incorrect, damage can be caused to
the counterweight dolly!
16.5.4 Shutoff Criteria
If a prohibited differential angle is reached on an axle, the travel

gear of the counterweight dolly and the travel gear of the crawler−
mounted crane will be shut down.
Shut−down remains in effect until the next release (e.g. accept-

ance of another operating mode or correction of the angle at the
swivelling bolster using the radio remote control).
043−1160−056 17/35
16
164 156 162 164
150 155 156 157 154 160
Z 56 239
2 3
1
14 4
13
6
7
8
12
11 10 9 Z 53 149
18/35 043−1160−056
16.5.5 Operating Mode “Trailing”

(Z 56 239)
Switch on the operating mode by pressing the button (150).
After touching the push button (156) the current angle positions
of the swivelling bolsters (160) are displayed.
For “Drive behind”, the swivelling bolsters must be as shown in
position 0°.
− If the frame support is in the wrong position for the selected

operating mode, button 157 lights up red.
− For information on changing the position of the swivelling
bolster, see section 16.5.8.

The LEDs (162) are green when the nominal angle (164) of the
swivelling bolsters equals the current angle settings of the swivel-
ling bolsters (160).
After touching button (156) again, the bar graph (157) with the
angle monitoring is once more displayed.
For the operating mode “Trailing”, it is not possible to switch on

the high speed for the chassis.
Displays for the operating mode “Trailing”
Operating mode Angle indicator Reversing the

superstructure travel gears
155
Trailing 0° ($90° error tolerance) 270...0...90 No
Tailing 180 ° ($90 ° error tolerance) 90...180...270 Yes
− In the operating mode “Drive behind” 1805, within the angle

range 905...1805...2705, the reversing position is displayed in
the LMI display by the symbol (1, Z 53 149).
− Error display by bar diagram 157
If the maximum error angle of +90 degrees is reached, then
the colour of button 157 will first change to yellow and become
red at precisely 90 degrees.
No switchoff results from the angle of error, the angle of error
of 90° may not however be exceeded.
043−1160−056 19/35
16
161
150
156
155
157
Z 55 471 Z 55 472
Z 55 473 Z 55 474
Z 55 475
20/35 043−1160−056
Cornering
Cornering is a special function when trailing. It makes it possible

to drive with the frame support in narrow circular arcs between 1
degrees to a maximum of 89 degrees.
If the track travel gear is rotated by more than 90 degrees, then

it will automatically switch over to ”Reversing”. The forward direc-
tion of the frame support changes. The control levers (1 and 2 or
3) must be pushed forward in order to carry out cornering of the
counterweight dolly.
− Set the swivelling bolster of the counterweight dolly by means

of radio remote control to the differential angle between the
superstructure and the chassis of the crane (displayed under
item 155, Z 55 471).
The counterweight vehicle can be steered thus onto a circular

path to the left or the right from out of “Trailing”:
− Rotate the track travel gear, with the crane standing in posi-
tion, more than 1 degree to the left or right. This means that
the circular path is preset (Z 55 473).
− Select “Cornering” by touching the button (161, Z 55 471).
− Set the swivelling bolster of the counterweight dolly by means
of radio remote control to the differential angle between the
superstructure and the chassis of the crane (displayed under
item 155, Z 55 471).
− Move the vehicle combination in the desired forward or back-
ward direction by moving the control levers (1 and 2 or 3) for-
wards or backwards (Z 55 474).
043−1160−056 21/35
16
158
21
151
152
153
154
150 155 156 159 157
Z 55 469
22/35 043−1160−056
If the vehicle combination is in position as shown in Illustration

Z 55 474 (page 20/35), then travel in reverse direction (Z 55 475)
is also possible.
− Select “Cornering” by touching the button (161, Z 55 471,
page 20/35).
− Check the position of the swivelling bolster of the counter-
weight dolly.
− Move the frame support in the desired backwards direction
by moving the control levers (1 and 2 or 3) backwards.
If the superstructure angle reaches 90 degrees or 270 degrees,

the crane travel drive will switch off.
With this operating mode, no switching on of the overdrive is

possible while using control levers 1 and 2 or 3 for the track travel
gear.
When cornering, the carrier may only be moved in a straight−

ahead direction.
043−1160−056 23/35
16
164 156 162 164
156 155 152 153 160

Z 56 240
24/35 043−1160−056
16.5.6 Operating Mode “Circular Travel”

(Z 56 240)
Switch on the operating mode by pressing button “152”.
After touching the push button (156) the current angle positions
of the swivelling bolsters (160) are displayed.

The LEDs (162) are green when the nominal angle (164) of the
swivelling bolsters equals the current angle settings of the swivel-
ling bolsters (160).
After retouching the button (156), the angle display of the super-
structure is once more displayed (155).
Displays for the operating mode “Circular travel”

Operating mode Angle indicator superstructure 155
Circular travel 0 degrees...359 degrees
High Range − Travel Gear
The counterweight dolly can be moved at high range in the oper-

ating mode “Circular travel”.
Only in this operating mode, a corresponding button (153) is of-
fered to the operator. When the Circular travel mode is exited (re-
positioning of wheels), the overdrive is automatically locked.
For safety reasons, however, you should press the button (153)
to turn off the overdrive.
043−1160−056 25/35
16
164 156 162 164
156 155 151 157 160

Z 56 241
26/35 043−1160−056
16.5.7 Operating Mode “Parallel Travel”

(Z 56 241)
Switch on the operating mode by pressing the button (151).
− If the frame support is in the wrong position for the selected

operating mode, button (156) lights up red.

In the operating mode “Parallel travel”, the angle of the swivelling

bolsters on the counterweight dolly is the same as the angle of
the superstructure (155). During driving, the swivelling bolsters
are automatically adapted when there is a small change of the
superstructure angle. The drives of the counterweight dolly and
of the track travel gear are switched off only when the automatic
swivelling bolster adjustment reacts too slowly or is insufficient.
To leave the switch−off position, the position of the carrier to the

superstructure needs to be corrected by actuating control lever
1 and/or 2.
− Error display by means of bar graphics

The bar display (157) is used to give information to the crane
operator. If the final position is reached, then the travel drive
of the crane and the counterweight dolly does not switch off.
The high range function for the travel gear of the crawler−
mounted crane and the counterweight dolly cannot be selected.
043−1160−056 27/35
16
156 155 151 157

Z 55 477
2 3
1
14 4
13
6
7
8
12
11 10 9
Z 53 149
28/35 043−1160−056
Diagonal travel
Diagonal travel is a special function during parallel travel. This

makes it possible to drive sideways with the frame support diag-
onally, the so−called “Crab walk”.
Diagonal travel can be carried out in any superstructure position.
During diagonal travel, as during all operations with the

Superlift, an additional person must make sure that tyre dis-
tortion is kept as low as possible during driving which is too
fast or too slow.
− Reversing is required for parallel travel in the range between

91 and 269 degrees! This takes place automatically.
In the LMI display, the symbol (1, Z 53 149) indicates that the
reversing is switched on.
Quit switch off position
If the drives of the counterweight dolly and of the crawler are

switched off because the automatic swivelling bolster adjustment
reacted too slowly or was insufficient, the swivelling bolster posi-
tion must be corrected.
This procedure is described in section 16.5.8.
043−1160−056 29/35
16
156
2
3
Hh
K
Z 58 925
30/35 043−1160−056
16.5.8 Changing the Swivelling Bolster Positions
Before the swivelling bolster position is changed, the load

must be set down and the counterweight dolly must be stabi-
lised.
Legend:
(Z 58 925)
Hh Display with correction mode “Trailing”
K Display with correction mode “Circular travel”
P Display with correction mode “Parallel travel”
156 “Correction” button
1 Display of actual current swivelling bolster angle
2 Indicator light for release of swivelling bolster angle (green

= permitted, red = blocked)
3 Display of nominal current swivelling bolster angle
To switch over and/or to correct the swivelling bolster position, the

button (156) must be touched to switch over to the “Correction
mode”.
043−1160−056 31/35
16
130.2
130.3
130.1
130.5
130.4
130.14
130.13
Z 54 633
156
Z 55 478
32/35 043−1160−056
To turn the swivelling bolster into a valid range:
1. Activate the radio remote control (Z 54 633) (see section 14).
2. Touch the button (156, Z 55 478). The button turns green.
3. Stabilise the counterweight dolly by simultaneously pressing

the buttons (130.2 and 130.3, Z 54 633) on the radio remote
control.
4. Rotate the swivelling bolster into the new position by simulta-

neously pressing the buttons (130.13 or 130.14 together
with one of the buttons 130.4 or 130.5, Z 54 633).
5. Retract the stabiliser by simultaneously pressing the buttons

(130.1 and 130.3, Z 54 633) on the radio remote control.
6. Touch the button (156, Z 54 478) again to end the adjusting

process.
− If the swivelling bolsters are adjusted, they only have to be

turned in the corresponding direction without observing the
exact angle.
The turning movement stops automatically, when the swivel-
ling bolsters have assumed the correct angle position.
043−1160−056 33/35
16
158
Z 55 679
Z 55 480
34/35 043−1160−056
16.5.9 Leaving the Operating Mode “Counterweight Dolly”

In the display (Z 55 679) switch over the menu area (K, Z 55 679)
to e.g. “joystick display” (Z 55 480) or select a new operating
mode by pressing the button (158, Z 55 479).
043−1160−056 35/35
Working With the Superlift Equipment (Counterweight Dolly) 20
043−1200−010a_en 1/27
20
(13 m)
18
17
6
5 9
13000
4
Z 54 636
2/27 043−1200−010a_en
20 Working With the Superlift
20.1 General Instructions

(Z 54 636)
Lattice boom cranes of the type CC 2400 −1 can be equipped

with Superlift equipment (in the following referred to as SL equip-
ment) in addition to the standard crane equipment.
The Superlift comprises:

4 Counterweight dolly
9 Weights
5 Telescopic connection
8 Mast
17 Bracing rods
18 Rods
The counterweight dolly (4) and the weights (9) combine to form
the Superlift counterweight.
The counterweight dolly (9) is connected to the mast (8) by

means of the support rods (18). The boom support (6) is con-
nected to the mast (8) by means of the bracing rods (17) and the
derricking rope.
The counterweight dolly (4) is connected to the superstructure by

means of a telescopic connection (5).
When the Superlift is fitted, it is possible to operate the crane also

without the Superlift counterweight (= 0 t / 0 kip) Superlift counter-
weight) and without the counterweight dolly.
If the crane is in a tilted position or positioned on a floating

base, use of the Superlift is prohibited.
043−1200−010a_en 3/27
20
17
SLG
A B
Z 54 637
4/27 043−1200−010a_en
20.2 Modus Operandi

(Z 54 637)
The permitted load moment of the crane L x WR (load x working

radius) is increased by the load moment of the Superlift counter-
weight (SLC x B).
The equipment acts like a balance arm, whereby the load mo-
ment (L x A) is greater.
The difference in overall balance is taken up by the mast bracing
(17). The required force in the derricking gear stabilises the sys-
tem.
To maintain the balanced state, the size of the Superlift counter-

weight must be co−ordinated against the load moment. The dis-
tance (B) of the Superlift counterweight can be selected based
on various possibilities.
Small changes in the working radius are possible when the cor-
rectly sized Superlift counterweight is selected.
Work with the crane with a fitted Superlift is also possible without
the Superlift counterweight, in accordance with the lifting capac-
ity for the 0 t (0 kip) counterweight (see load table).
043−1200−010a_en 5/27
20
6/27 043−1200−010a_en
20.3 Safety Instructions for Working With Superlift Equip-

ment with Counterweight Dolly
Special care is required by the crane personnel when work-

ing with the Superlift due to the different functions and in-
creased dangers involved.
− The vehicle combination must stand on an even, horizontal

surface that is able to support the crane when the Superlift
equipment is attached.
Please observe all regulations for setting up and supporting the

crane on outriggers in sections 12 and 20.4.
− For work with the Superlift, special load tables are assigned
to the crane. Additional specifications (such as D−min. and
D−max.) are shown in the LLD display.
− For loads that, according to the Superlift load capacity chart,
can be raised without Superlift counterweight (0 t / 0 kip), no
Superlift counterweight and no counterweight dolly must be
used.
− Using the derricking gear, the SL mast is placed at its operat-
ing radius before crane operations begin.
The outreach of the main boom or the rigid fly jib may only
be changed using the “luffing gear 2”.
The outreach of the luffing fly jib may only be changed using
the “luffing gear 1”.
A person who is in visual and verbal contact with the crane
operator must watch the counterweight dolly from outside
the cab.
When the working radius is reduced, the force in the derrick-

ing gear is reduced which, in extreme cases, can result in the
boom system swinging backwards!
043−1200−010a_en 7/27
20
8/27 043−1200−010a_en
− When the crane is moved or turned with the counterweight

dolly attached, the crane operator must be in visual and in
verbal contact with a banksman.
− Prior to commencing any driving or slewing movement, crane
operators and banksmen must make sure that there are no
persons or obstacles within the entire driving range of the
chassis and the counterweight dolly.
It is strictly forbidden to stand directly next to the counter-

weight dolly’s tracks and tyres!
D A N G E R T O L I F E!
It is only permitted to stand under the counterweight dolly

after it has been stabilised and the tyres have been visibly
relieved.
043−1200−010a_en 9/27
20
11 m −15 m
36 ft − 49 ft
Z 54 638
10/27 043−1200−010a_en
20.4 Requirements Regarding the Ground Conditions at

the Operating Site
The crane itself must stand on a level, horizontal and load−bear-

ing ground. The required load−bearing capacity of the ground de-
pends on the ground pressures that actually occur for the individ-
ual loading case.
If the crane is in a tilted position or positioned on a floating

base, use of the Superlift is prohibited.
For jobs where the crane is to be turned with the counterweight

dolly, a fixed ring area is required for the counterweight dolly that
has the following dimensions (Z 54 638).
Example for a 15 m radius:
Inside diameter of the torus area: D1 = 25.0 m (82.02 ft) (maxi-
mum)
Outermost diameter of the torus area: D2 = 34.0 m (111.55 ft)
(min.)
The maximum pressure that the tyres of the counterweight dolly

exert on the ground is 90 N/cm2 (0.013 psi). The maximum
ground pressure of 90 N/m2 (0.013 psi) does always apply, re-
gardless of the crane’s load, as long as the counterweight dolly
is in contact with the ground.
The fixed ring area must be able to support so much weight that
the wheels of the counterweight dolly do not sink into the ground.
Furthermore, the fixed ring area must be largely level and hori-
zontal. The permissible deviations between the levels of the ring
area and the site where the crane is standing are specified in il-
lustration Z 54 638. Measurement “A” may be a maximum of
200 mm (7.8 in). Unevenness within the ring area itself must not
exceed +/− 50 mm (1.95 in).
For travel with the crane with the counterweight dolly, a solid road
surface with a width of about 9.5 m (31.17 ft) is required; other-
wise, the same requirements apply to the road surface as to the
ring area.
043−1200−010a_en 11/27
20
18
4
Z 54 639
12/27 043−1200−010a_en
20.5 Operating the Crane Without the Superlift Counter-

weight
(Z 54 639)
When working without the Superlift counterweight, you must first

support the counterweight dolly and then disconnect it from the
crane.
A Superlift counterweight (9) of at least 20 t (44 kip) must be

stacked on the counterweight dolly before disconnecting it
from the crane.
− For information on attaching and removing the counterweight

dolly, see section 16 in part 3, “Assembly instructions”.
− When working with the Superlift without the Superlift counter-
weight, the corresponding load tables for the 0 t (0 kip) Super-
lift counterweight must be used.
043−1200−010a_en 13/27
20
18
9
5
4
Z 54 642 Z 54 640
13 m20
18
5 9
4
13000
Z 54 641
14/27 043−1200−010a_en
20.6 Operating the Crane With the Superlift Counterweight
20.6.1 With Variable Superlift Equipment

(Z 54 642)
When working with the variable Superlift equipment, you can

modify the Superlift counterweight radius to any value within a
range from 11 m (36.09 ft) to 15 m (49.22 ft).
The advantage of this variable Superlift equipment is that it allows
you to change the load’s outreach without requiring you to re-
stack the Superlift counterweight.
In order to enable the operation of the variable Superlift equip-
ment, it is necessary to reset the guying in the horizontal direction
of the Superlift counterweight dolly.
20.6.1.1 Preparations for Raising a Load
− Fitting the Superlift (see part 3, sections 3 to 10)

− Fitting the counterweight vehicle (see part 3, section 6)
(Z 54 640, Z 54 641)
− Selection of the Superlift counterweight (SL CWT)
For the size of the SL CWT, refer to the corresponding load
capacity table.
The counterweight dolly is unevenly loaded if the weights are

placed one−sided in position. In extreme cases, this can lead to
a system overload.
043−1200−010a_en 15/27
20
3 2
Z 54 644 Z 54 645
130.2
130.1
130.11
Z 54 646
16/27 043−1200−010a_en
20.6.1.2 Adjusting the Superlift Counterweight Radius (SCR)
There are two different ways to change the SCR:

− Using the radio remote control (e.g., when attaching the
counterweight dolly)
− Using the control levers in the crane cab (e. g., during crane
operation)
Using the radio remote control

− Switch on the operating mode “RGO” on the display panel for
the LLD system (Z 54 644).
− Press the “radio remote control” symbol (1, Z 54 644) to acti-
vate it.
− Switch on the operating mode “RGO” on the display panel for
monitoring the engine and for crane operation (Z 54 645).
− Press the symbol “counterweight dolly − trailing” (2, Z 54 645)
to activate this function.
Risk of crushing
no persons or obstacles within the range of movement.
− Press simultaneously the buttons 130.11 and 130.1 on the

radio remote control (Z 54 646) to increase the SCR.
− Press simultaneously the buttons 130.11 and 130.2 on the
radio remote control (Z 54 646) to reduce the SCR.
The modification of the SCR can be viewed in the crane cab on

the display panel for the LLD system in the “LLD screen”.
043−1200−010a_en 17/27
20
3 2
Z 54 647
Z 54 648
18/27 043−1200−010a_en
Using the control levers in the crane cab

− Press the symbol “counterweight dolly − trailing” (2, Z 54 647)
to activate this function.
Risk of crushing
no persons or obstacles within the range of movement. It is
imperative that a banksman be positioned at the counter-
weight dolly who is in visual or radio contact with the crane
operator in the crane cab.
− Press the control lever (3, Z 54 648) to the left to increase the
SCR.
− Press the control lever (3, Z 54 648) to the right to decrease
the SCR.
The modification of the SCR can be viewed on the display panel

for the LLD system in the “LLD screen”.
043−1200−010a_en 19/27
20
2 1 4
Z 54 337 Z 54 338
1 2 3 4
Z 54 643
20/27 043−1200−010a_en
20.6.1.3 Entering the Operating Mode
7. Selection of “Counterweight vehicle” by pressing the button

(1, Z 54 337).
8. Selection of Superlift mast radius by pressing the button (2,

Z 54 337).
9. Switch over to the “Save & Exit” display of the Operating

mode preselection (Z 54 338).
10. End the operating mode entry by pressing the button “OK”
(4, Z 54 338).
11. After you have finished entering the operating mode, the
LLD system display shows the main menu (Z 54 643).
Legend:
(Z 54 643)
1 Radius of the load
3 Actual force in the derricking rope
4 Maximum force in the derricking rope
043−1200−010a_en 21/27
20
W2
8
24.1
7 18
13
22
L 4
Z 54 648
3
Z 54 639
22/27 043−1200−010a_en
20.6.1.4 Raising the Load

tion 20.6.1.1, the load can be raised as follows.
1. Unreel the derricking ropes (22, Z 54 648) for adjusting the

Superlift mast (8, Z 54 648) from the rope drum by moving
the lever (3) forward until the LLD display (Z 54 639) in the
crane cab shows an actual derricking rope force (2, Z 54 639)
of 2 t − 3 t (4.4 kip − 6.6 kip).
The dead weight of the main boom (7, Z 54 648) causes the
rods (18, Z 54 648) on the Superlift counterweight dolly (4,
Z 54 648) to be tensioned.
2. Set the Superlift mast (8, Z 54 648) to the preselected mast

radius by actuating the lever (3).
The mast radius may only be changed during operation of the

crane in the permitted tolerance range of the derricking force
(EZW) (E−min % E−max.).
3. Position the hook block (13, Z 54 648) above the load.

To do so, move the control lever 2 to wind the luffing rope W2
on or off until the boom (7, Z 54 648) with the hook block is
positioned directly above the load.
043−1200−010a_en 23/27
20
W2
8
24.1
17
7
18
13
22
L 4
Z 66 764
24/27 043−1200−010a_en
4. Raise the load (Z 66 764).
Wind the hoist ropes H1, H2 (24.1) onto the rope drum to ten-
sion the guy ropes (17) of the SL mast (8) and the derricking
ropes (22) for adjusting the SL mast (8).
While raising the load, observe the display of the maximum der-
ricking rope force on the load limit device display. If the actual
value of the derricking rope force approaches the value for the
maximum derricking rope force
1) interrupt the raising of the load.
2) reduce the derricking rope force by unreeling by approximately
10 − 20 %.
3) observe the load radius!
4) take up the load further with hoist 1 and hoist 2.
5. The load is raised by reeling in hoist rope (24.1) further.
043−1200−010a_en 25/27
20
W2
8
24.1
7
18
13
22
L 4
Z 54 648
26/27 043−1200−010a_en
20.6.1.5 Setting the Load Down
1. The load is set down on the ground by pushing lever (1 or 2)

forwards.
If the radius is reduced in order to set down the load, D−min may
be reached.
The following must then be carried out:
− Do not activate luffing gear 2 any more.
− Pull the control lever (3) backwards to wind the derricking
rope onto the rope drum − the force in the derricking rope in-
creases.
− Switch on luffing gear 2 (see section 9.5.3).
− Push lever (3) to the rear to raise the main boom (7, Z 54 648)
until the working radius has reached the desired value.
2) forwards.
043−1200−010a_en 27/27

Manufacturer Specifications for Crawler-Mounted Crane

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043−0000−001 1/1

2 Structure of the Crawler−Mounted Crane . . . . . . . . . . . . . . . . . . 3

4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 Engine and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6 Driving the Crawler−Mounted Crane . . . . . . . . . . . . . . . . . . . . . . . 3

7 Slewing and Braking the Superstructure . . . . . . . . . . . . . . . . . . 3

8 Operating the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9 Working With the Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . 3

10 Working With the Superlift Equipment . . . . . . . . . . . . . . . . . . . . 3

11 Operating the Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . 3

12 Parking the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

13. Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Driving With the Counterweight Dolly . . . . . . . . . . . . . . . . . . . . . 3

20 Working With the Superlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The operating, lubricating and maintenance instructions included

Crane classification Crawler−mounted crane

Crane type CC 2400−1

Construction number ___________________

Maximum load 400 t / 881 kip (DIN 15019.2)

Manufacturer Terex−Demag GmbH

This documentation is comprised of these operating instructions,

The operating instructions for this crane consist of 4 parts:

At a minimum, the operating manual (Part 1) must be perma-

Please note that the information given in this documentation cor-

In such cases, we make every effort to update your documents

Pass on these documents to your crane operator and all spe-

Periodic, preventative inspections and maintenance are the saf-

If you find any mistakes while reading these documents or have

“Putting practice into practice”.

Delivery of the crane

The preserving material can be removed by:

cleaning thinners, e.g. Conrad thinner RV 5339 E 45430

Before operating for the first time

Please contact our service department if you have any questions

From inside Germany

or contact your nearest Terex−Demag associate.

Changes to the crane

Following modifications and/or repairs to parts that affect the

Therefore please inform us immediately of any modifications car-

WHAT do I want to know?

I would like to know, for example, which control elements are

WHERE can I find the desired information?

The complete documentation is made up of 4 parts:

Part 1 − Operating manual

These parts are divided up by index cards.

As the load limit device is described in the operating instructions,

2. I glance through the headings in bold for the chapters, until

3. In this section 8, I find as item 8.1.2 the “Description of

HOW can I find the specified page in section 8?

1. I take hold of the pages of part 1 as shown in (Z 26 350) and

2. I then check the number of the page at the bottom right−hand

The number of the page in the section is located at the bottom

Please note that this possibility of acquiring specific and tar-

In these operating instructions the titles and the corresponding

“Danger” is used if failure to follow an operating procedure,

“Caution” is used if failure to follow an operating procedure,

“Note” is used to designate an important operating or assembly

Specifications such as “left” or “right” always relate to the crane

This section on “Safety Instructions” gives a concise and general

The safety instructions for assembling the crane are contained in

1.2 Intended Use