LTM 1070 - 1

LIEBHERR
TELESCOPIC BOOM MOBILE CRANE
LTM 1070/1
as of series 034
Operating instructions
BAL >No. 09505>02>02
pages : 1 up to 655
Crane number
Date
The operating instructions are part of the crane!
Always keep on hand!
Comply with road travel and crane operating

regulations!
LIEBHERR>WERK EHINGEN GmbH, Postfach 1361, D>89582 Ehingen / Donau

Tel. (07391) 502>0, Telex 71763>0 le d, Telefax (07391) 502>399
1
PREFACE 021643>02
These operating instructions should enable you to operate the crane safely and utilize its capabilities to the
fullest extent possible. They also provide notes on how important sub>assemblies and systems function.
Certain terms are used in these operating instructions, and in order to avoid misunderstandings while
operating, these terms should be used consistently.
DANGER: Only qualified and especially trained personnel may work on this crane!
If this is not assured, the change of causing a serious accident is greatly increased!
All regulations and guidelines applicable to the job site, such as accident prevention regulations and all
guidelines and regulations stated in the Operation Manual must be strictly adhered to.
All accident prevention and operating guidelines and regulations, etc. assume that the crane is strictly used for
lifting and transporting of loads, which are not stuck. Any other application or use does not constitute ∫specified
and proper use∫.
C A U T I O N: Pile driving and pulling tasks with vibration machinery, for example pulling pile
plankings, may only be carried out in connection with attenuator pads and may
only be performed after consultation with the crane manufacturer.
Any risks associated with unspecified or improper use are the sole responsibility of the crane's owner, operator
or user.
Using these instructions
> makes it easier to become familiar with the crane

> avoids malfunctions due to improper operation
Observing these instructions
> increases reliability in operations

> increases the operating life of the crane
> reduces repair costs and down>time
Always keep these operating instructions handy in the driver's and crane cab > they are an integral part of the
crane!
Operate this crane only with a thorough knowledge of its capabilities and limitations and in strict observance of
these instructions.
If you receive further information on the crane from us, e.g. in the form of technical information letters, this
must be observed and filed with the operating instructions.
If there are parts of these instructions or individual chapters that you do not understand, please do not hesitate
to ask us before you begin operation > we are glad to answer any inquiries you may have.
No part of these operating instructions may be circulated, nor may they be used for the purposes of competition.
All rights expressly reserved according to copyright law.
2
PREFACE 021643>02
These operating instructions are to be read and the information in them is to be observed by all persons
operating, maintaining, or otherwise working in any capacity on this crane.
Notes
Throughout these instructions, the terms "Note", " C A U T I O N " and " D A N G E R " occur > these refer
any persons working with the crane to IMPORTANT OPERATING METHODS that must be observed.
Note: The term "Note" is used whenever the observance of certain instructions or notes is
economically meaningful to the utilization of the crane.
CAUTION: The term " C A U T I O N " is used whenever damage to the crane can occur if the
operating instruction(s) is not observed and adhered to.
DANGER: The term " D A N G E R " is used whenever the nonobservance of the warning given
may injure or lead to the death of persons and damage to the crane.
Safety devices
The safety devices integrated into the crane system deserve your special attention. They must always be
checked to see that they are functioning properly. If they do not function or function incorrectly, the crane may
not be operated. Your motto should always be:
"SAFETY FIRST"
3
CONTENTS
183216
4
CONTENTS
1.00 DESCRIPTION OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.01 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.02 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.03 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.01 ROAD TRAFFIC REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.02 INSTRUCTIONS ON RUNNING>IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.03 OPERATIONAL PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.04 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.01 CONTROLS AND INSTRUMENTS > VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.02 BEFORE VEHICLE START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.03 AXLE SUSPENSION / LOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.04 DRIVING ON PUBLIC ROADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.05 THE CRANE AT THE JOBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

4.01 CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE . . . . . . . . . . . 174
4.03 STARTING THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.04 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.05 CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.06 REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.07 COUNTERWEIGHT .................................................................... 280
4.08 WORKING WITH A LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.09 DRIVING WITH ATTACHMENT IN PLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
4.10 DRIVING FROM THE CRANE OPERATORπS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4.11 CRANE OPERATION ∫FREESTANDING∫ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.12 TWO>HOOK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5
CONTENTS
6
CONTENTS
5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

5.01 SAFETY>TECHNICAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
5.02 FOLDING JIB > TK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

6.01 HEATER / ENGINE PREHEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
6.02 EMERGENCY CRANE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
6.03 RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
6.04 SLIDING ARM MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

7.01 SERVICING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . 514
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE ............................. 518
7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . 554
7.06 LUBRICATION CHART AND FILLING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
7.07 SCHMIERSTOFFTABELLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588

8.01 REPEAT CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
8.04 INSPECTION OF CRANE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646

9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES . . . . . . . . . . . . 648
9.02 GUIDELINES TO PREVENT FIRES IN THE ENGINE AREA
AND IMPORTANT SERVICE WORK TO BE PERFORMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
7
1.00 DESCRIPTION OF THE CRANE 021672>00
8
021672>00
Chapter 1
Description of the Crane
9
1.01 TERMINOLOGY 022529>00
183214
10
Abbreviation of boom systems
T = Telescopic boom
TK = Telescopic boom with folding jib 0∞, 15∞ or 30∞
Boom combinations
T > Boom combination T =10.6 m to 40.0 m

K = 8.4 m to 15.8 m
TK > Boom combination T =34.3 m to 40.0 m

K = 8.4 m to 15.8 m
11
183217
12
1 Crane chassis
1.1 4>axle chassis
1.2 Tires, axles 1>4, with single wheels
1.3 Diesel engine with automatic transmission
1.4 Driverπs cab
1.5 Sliding arms with outrigger cylinders n
1.6 Support pads
2 Crane superstructure
¡ Winch 1 Hoist gear at T, TK operation
¬ Winch 2 Hoist gear T, TK operation
2.1 Diesel engine with pump distributor gear

2.2 Crane operatorπs cab
2.3 Counterweight
2.4 Telescopic boom control > luffing cylinder
13
183215
14
3 Telescopic boom
3.1 Pivot section
3.2 Telescopic section 1
4 Folding jib
4.1 Adapter for installation of folding jib below an angle of 0∞, 15∞ or 30∞
4.2 Folding jib 8.4 m
4.3 End section 7.4 m
15
1.02 PRODUCT DESCRIPTION 023400>00
16
The crane carrier
Frame Liebherr designed and manufactured box type, torsion resistant construction made of
high tensile structural steel.
Outriggers 4> point (front and rear) outriggers, full hydraulic extension in horizontal and verti>
cal direction .
Engine 6>cylinder Diesel engine, made by LIEBHERR Type D 9406 TI>E, watercooled,
Output:
Per EG Norm (EURO 2) 300 kW (408 PS) at 2100 min>1,
max. torque 1700Nm at 1500 min>1.
Fuel tank capacity: 400 l.
Transmission Automatic transmission, made by Allision type HD 4560, with torque converter and
lock>up coupling, 6 forward speeds, 1 reverse speeds.
Transfer gearbox with off road gear .
Axles All 4 axles are steerable

Axles 1, 3 and 4 are planetary axles with differential locks.
Gear shafts All gear shafts with 70∞ cross gears.
Suspension All axles are provided with hydro>pneumatic suspension with automatic leveling.
Axle suspension can be locked hydraulically .
Tires 8 wheels, all axles provided with single tires.

Tire size 14.00 R 25.
Steering Hydro steering with dual circuit and additional auxiliary steering pump.
Mechanical control from the driverπs cab, hydrostatic control from the crane opera>
torπs cab .
Brakes Service brake: All wheel servo assisted air brakes, dual circuit.
Eddy current brake : Telma type Eddy current brake (wear free constant
brake )
Manual brake : Spring loaded, acting on wheels of axles 2, 3 and 4.
Driverπs cab 1>man all > steel cab with resilient mountings, safety glass windows, full range of
control instruments .
Electrical system: 24 V DC,

2 batteries
(4 battery installations available if desired ).
17
18
The crane superstructure

Frame: Liebherr > made torsion resistant, welded construction of high tensile structural steel.
Linked to crane carrier by a triple roller slewing ring .
Crane engine 4 cylinder Diesel, made by LIEBHERR, Type D 924 T>E, watercooled
Output:
per EG Norm (EURO 2) 120 kW (163 PS) at 1800 min>1,
max. torque 720 Nm at 1200 min>1.
Fuel tank capacity 300 l.
Crane drive Diesel, hydraulic with axial piston double pump and automatic regulation, one gear double
pump, regulated, open hydraulic circuits.
Crane control Electronic / electric control via two 4>way self centering manual control levers .
Hoist gear Axial piston, fixed displacement motor, hoist drum with integrated planetary gear and
spring loaded retaining brake.
Luffing gear 1 differential cylinder with pilot controlled brake valve.
Slewing gear Axial piston, fixed displacement motor, planetary gear and spring loaded retaining brake.
Crane cab All > steel construction with safety glass windows, heater, controls and instruments.
Safety devices ∫LICCON∫ overload system, hoist limit, safety valves to protect hydraulic system against
pipe and hose ruptures.
Telescopic boom 1pivot section and 4 telescopic sections, hydraulically extension under partial load.
Telescopic section 1 and 2 can be extended hydraulically independent of each other.
Telescopic sections 3 and 4 can be extended synchronous.
Boom length: 10.6 m > 40 m.
Electr. system 24 Volt DC, 2 batteries.
Additional equipment
Folding jib : 8.4 m to 15.8 m long, can be installed below 0∞, 15∞ or 30∞ to the telescopic boom .
2nd hoist gear: For two hook operation or with folding jib operation, if the main hoist cable is to remain in
place.
Tires: 8 tires, all axles with individual tires . Tire size : 16.00 R 25
Drive 8¥8: Additional 2nd axle drive .
Steering: Hydrostatically from the crane operatorπs cab *
* Optional
19
1.03 TECHNICAL DATA 023401>00
Measurements
Weights
$ Axle loads
$ Lifting tackle
Working speeds
$ Travel speeds
$ Crane speeds
Lifting heights
$ Telescopic boom
$ Lattice jib
Tires
Tire pressure for travel on Tire pressure for crane

Tire size Tire weight [kg] public highways operation
[bar] ª free on tires ´ [bar]
according to load capacity

14.00 > 25 245 10 chart
ª free on tires ´
according to load capacity

16.00 > 25 * 300 9 chart
ª free on tires ´
Emission values at the work place
Stationary sound LpAeq [db(A)]

Sound levels at nominal
engine RPM
left ear right ear
Driver's cab, driver's side 74 73
Driver's cab, co>driver's side 73 73
Crane operator's cab 76 76
* optional
20
183211
21
185761
22
183213
23
2.00 SAFETY 021673>00
24
021673>00
Chapter 2
Safety
25
2.01 ROAD TRAFFIC REGULATIONS 021178>04
26
Traffic regulations
The crane is approved for on>road travel if it is operated according to local and regional traffic regulations.
Before driving on public roads and highways, bring the crane to the appropriate condition to conform to local
and regional traffic regulations.
It must be assured that the weight, axle loads and dimensions remain as they are noted in the vehicle license
and that they are not exceeded.
For axle loads you must differentiate between technically possible and permissible loads, according to traffic
regulations.
In countries with EEC regulations, axles loads may not exceed 12 tons when driving on a public road or
highway.
If the crane operator drives on a road with an axle load which is higher than 12 tons, then he alone must take
the responsibility for this action.
DANGER: If axle loads or total weight exceed the permissible limit, then the braking power of
the vehicle will be reduced in proportion to the excess weight.
Brake pad wear and the danger that the brakes overheat will increase.
The steering system, the service brake, parking brake and retarder will then no
longer conform to regulations!
The life of the brakes, axles, wheel hubs, suspension cylinders and bearings will be
reduced.
A hook block may only be carried on the front if:
> it is reeved not more than 4 times,

> if it has been marked by the manufacturer on the data tag with he letter ∫E∫ for ∫entschßrft (defused)∫ and
> if the cable was attached to the front towing eyes and if the hook is held with an auxiliary cable and
attached to the towing coupling .
DANGER: When moving the crane on public highwathen the field of vision of the driver may
not be obstructed by the hook block.
Mast tip*
If a mast tip is installed, then > to prevent obstruction of the driverπs field of vision > it should be turned from the
working position to the transport position and secured in this position with pins and spring retainers.
* Optional
27
28
Travel with the crane according to the national road traffic regulations.
Carrying passengers in the crane cab is not permitted.
29
2.02 INSTRUCTIONS ON RUNNING>IN 021617>02
30
2.02 INSTRUCTIONS ON RUNNING>IN 021617>02
Instructions on running>in
CAUTION: The crane is not yet running>in
For this reason, the following instructions must be followed:
1.) During the first 2000 km (1,240 miles), the mobile crane must not be driven at more than 3/4 of its maxi>
mum speed in each gear (engine speed = max. 1900 rpm)
> Full throttle is permitted only briefly when driving or traffic conditions demand.
> At the end of the running>in period, gradually increase to full power operation.
2.) The oil pressure and temperature gauges must be monitored constantly while driving!
> If either gauge shows an excessive reading, stop operation immediately.
3.) Carry out the following service operations after the first 50 and the first 100 kilometres (30and the first 60
miles) of operation.
> Check that wheel nuts are tightened securely.
CAUTION: Do not overtighten wheel nuts!

(max. permitted tightening torque = 600 Nm; 445 ft>lb).
> Check coolant and oil levels in the engine.

> Check oil level in power>shift (Hi>Lo) or automatic transmission.
> Check engine, transmission and axle mountings for secure seating and for leaks (visual check).
> Check drive shafts for secure connection.
> Check all other chassis components for secure mounting.
> Check air pressure and conditions of the tyres (visual check).
Breaking in the brake pads
In order to obtain optimum braking acting, new brake pads must be activated or broken in. Brake in the new
pads by applying the brakes in intervals in low to medium speed range, do not brake forcefully! The braking in
route > preferably at least 500 km (310 miles) depends on the vehicle. In this phase, the maximum brake drum
or brake disk temperature of 200 ∞C (392 ∞F) may not be exceeded. The increase in temperature resulting from
each individual braking action may not exceed 15% of the maximum value.
CAUTION: DO NOT break in new brake pads through one or more continuous braking actions
over a longer period of time or by applying the brakes forefully while driving at
high speed.
DANGER: If this point is not strictly observed, you could cause a serious accident!
31
2.03 OPERATIONAL PLANNING 021674>00
32
2.03 OPERATIONAL PLANNING 021674>00
Operational planning
As well as a fully functioning crane and well>qualified personnel, operational planning is an important
precondition for safe and reliable crane operation.
The crane operator must be in possession of or procure all the necessary information before starting the crane
operation, especially:
> Nature of work
> Site location (journey distance)
> Route to be driven
> Height and side clearances
> Electrical overhead wires (complete with voltage data)
> Space requirements at the operating sites
> Movement restrictions due to surrounding structures
> Weight and dimensions of load(s) to be lifted
> Required lifting height and radius
> Load>bearing capacity of soil or surface to be operated upon
The crane operator can then use this information to decide on the correct crane operating equipment:
> Hook blocks/load blocks
> Auxiliary telescopic boom
> Lifting / slinging tackle
> Counterweight
> Underlay material for support pads
DANGER: If the crane operator does not possess all necessary and required information, it
may prove impossible to carry out the intended work, or he may be tempted to
improvise > and accidents may be the result!
33
2.04 SAFETY>TECHNICAL NOTES 021675>03
34
Requirements of the crane operator

The most important requirement of the crane operator is to control, operate and adjust the crane so that there is
no danger to the crane crew and/or third parties.
In order to fulfil this requirement, we would like to give you in the following a few important safety notes.
65% of all accidents involving vehicle cranes is due to improper crane operation.
Improper operating procedures most often carried out are:
Not paying careful attention while working in the case of, for example:
> slewing too quickly,
> quick braking of the load,
> cross pulling,
> loose cable formations
Overloading
Driving too fast with a load, or setting up and loading on an uneven surface.
Improperly slinging a load.
Operating in unsuitable conditions, especially pulling at an angle or fixed loads coming loose.
Wind on suspended load.
Improperly driving on public roads without a load, for example, engine or transmission overloaded.
Collision with bridges, ceilings, high>voltage wires.
Insufficient support; support base beneath the supports not sufficient in capacity.
Improper assembly/disassembly of telescopic booms.
20% of all accidents involving cranes are due to improper maintenance:

> Lack of oil, grease or antifreeze
> Accumulation of too much dirt
> Broken cables, defective tires, worn parts
> Emergency limit switch or load torque limiter not operational
> Brake and/or transmission failure
> Defects in the hydraulic systems; for example, tears in hoses
> Loose screws
DANGER: In your interest and in the interest of others, please learn to command your crane
thoroughly and familiarize yourself with all the dangers associated with the work to
be carried out.
35
180000
36
Selecting an operating site

To avoid accidents from the outset, the correct selection of an operating site is extremely important.
The operating site should be selected so that:
> the supports can be extended to the points prescribed in the load capacity tables.
> crane operations can be carried out within the smallest possible radius.
> no obstacles hinder necessary movements.
> the ground at the operating site is able to support expected loads.
DANGER: The most important requirement for safe crane operation is working on firm
ground with the capacity to support your loads.
Slopes and trenches

The crane must not be set up too close to slopes or trenches and depending on the type of soil, a safe distance
must always be kept from them.
Note: Safe distance is measured from the foot of the trench and is:
> soft or backfilled soil = 2 ¥ depth of trench (A2 = 2 ¥ T)
> hard or grown soil = 1 ¥ depth of trench (A1 = 1 ¥ T)
DANGER: If a safe distance can not be kept, the slope or trench must be firmly filled.
Otherwise, there is a danger that the edge of the slope or trench will give way.
37
38
Permissible ground>bearing load

When the crane is supported, the supports exert considerable pressure onto the ground. In certain cases,
individual supports must take up the weight of the crane as well as the weight of the load and this is transferred
to the ground.
The ground must always be able to stand up to the pressure exerted upon it. If the surface area of the support
pads are not sufficient, these must be fixed with a foundation corresponding to the load> bearing capacity of the
ground. The necessary supporting surface can be calculated from the load> bearing capacity of the ground and
the supporting pressure of the crane.
Support pressure
Required supporting surface = $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
Load>bearing capacity of the ground
Permissible ground>bearing load
[daN / cm2]
Type of Soil
[kg/cm2]
A) lled soil, not artificially sompacted 0>1
B) Natural soil, apparently undisturbed
1. sludge, peat, marshy earth 0
2. noncohesive, sufficiently firm soil:

fine to medium sand 1,5
course sand to gravel 2,0
3. cohesive soils:
loamy 0
soft 0,4
stiff 1,0
semi solid 2,0
hard 4,0
4. rock with a minimum of fissures, in healthy, unweathered

condition and favorably situated:
in densely packed strata 15
solid or column formation 30
C) Artificially compacted ground
1. asphalt 5 > 15
2. concrete concrete groupe B I 50 > 250

concrete groupe B II 350 > 550
If there is any doubt as to the load>bearing capacity of the ground at the operating site, the ground must be
investigated; for example, with a dynamic sounding rod.
CAUTION: Only stable materials, such as wood planks of sufficient strength and size, may be
used to make a foundation beneath the support pads. In order to achieve an even
distribution of pressure above the foundation surface, the supports must be
positioned in the middle of the foundation.
39
180001
40
Support pads
Strict adherence to the support base in reference to load>capacities as given in the load>capacity table is
absolutely essential to the safety of crane operations.
Equal distribution of pressure on the support pads of the sliding arms must be established so that the
transmission of transverse force between the sliding arms is guaranteed.
The outriggers may only be used when the sliding arms are extended in these positions!
DANGER: Intermediate adjustments between the prescribed support widths may not be made
as the transmission of transverse force is only possible above lateral support bases
and, because of the absence of a support base in intermediate positions, an
incorrect initiation of force is applied to the upper boom.
The sliding arms must be pinned securely to prevent any movement of the support
jacks, which could cause a serious accident!
The pins must be fully inserted and the handle must point downward, otherwise it
could caus a serious accident, causing the crane to topple over.
Always extend all 4 sliding arms and support jacks, including those on the side opposite the load. If only the
sliding arms and support jacks on the load side are extended, the results could be dangerous as:
DANGER: 1. The load hanging on the hook tensions the hoist cable and the telescopic boom
and also the lattice fly jib if used and the guy cables) and also deforms them. If, in
this situation, the load were to drop out of the lifting tackle cables, or if the lifting
tackle cable or hoist cable were to break, the load on the boom would be suddenly
lifted and the boom would jerk up violently.
Therefore the crane may topple over.
2. Despite what has been assumed before commencing operations, it may prove
necessary to slew the load to the opposite side.
Therefore the crane may topple over.
3. When turning form longitudinal direction, the crane can tip over due to the
momentum of the boom or counterweight.
Aligning the crane

Besides the proper foundation beneath the supports, horizontal alignment of the crane is essential to
operational safety.
DANGER: If the crane is set up unevenly and the boom is swung toward a downhill grade, the
result is an extension of the boom radius, which in extreme cases can cause the
crane to topple over.
Example: At a boom length of 50 m, uneven adjustment of the crane by only 5∞ will cause an boom
radius of 10 m to be increased by a = 4 m.
41
42
Checking safety measures
Crane supported
> Is axle suspension blocked?
> Is the load>bearing capacity of the ground sufficient?
> Are all 4 sliding arms and support jacks extended to the support base as given in the load>capacity tables?
> Are the sliding arms secured with bolts?
> Are the support pads secured?
> Is the crane horizontally aligned?
> Is there sufficiently safe distance from slopes and trenches?
> Have the axles been relieved of loads, i.e., is there no longer contact between the ground and the tires?
> Has it been established that the crane is not in the vicinity of electrical overhead wires?
> Has the operating site been selected so that the crane may operate within the smallest possible boom
radius?
> Are there any obstacles in the area that will hinder necessary crane movements?
43
Crane operation with a load

Before beginning any work, the crane operator must be convinced that the crane is in safe operating condition.
The safety devices, such as load torque limiter, hoist limit switch, brakes, and so forth, must all be operational.
> The load torque limiter must be set to the current operating status of the crane.
> The load capacities as given in the load capacity tables must be adhered to. The crane must never be
operated with a load exceeding the permissible load capacities.
> Before beginning any operations, the crane operator must know the weight and dimensions of the load.
> All hoisting and slinging tackle must meet the requirements of the work to be carried out.
> It must be ensured that the weights of the hoisting, slinging and staying tackle are taken from the load
capacity table.
Example:
Highest permissible load capacity according to table 30.000 kg 30.000 kg
Weight of the hook block 370 kg . /. 370 kg
Weight of the slinging rope 40 kg . /. 40 kg
Actual useful load of the crane Table value = 29.590 kg
In this case, the load to be lifted may not exceed 29,590 kg.
Ballast
The required ballast is dependent on the load to be lifted and necessary boom radius for operating with that
load. Data in the corresponding load capacity table is decisive in selecting ballast.
DANGER: If ballast is not mounted according to the load capacity table, there is danger of the
crane toppling over.
Hoisting gear, hoisting cable

The lifting capacity of the crane depends on the tensile force, or pull, of the hoisting cable and the number of
possible hoist reeving cables. When working with a single cable, the crane can only lift as much as the hoisting
gear pulls.
If the load to be lifted is greater than the pull of the hoisting gear, the hoisting cable must be reeved between
the pulley head on the boom and the hook block as many times as necessary according to the principle of a block
and pulley.
When reeving, ensure that the data given in the load capacity table book and operating instructions are
observed and adhered to.
DANGER: If the maximum tensile force is exceeded, there is the danger that the cable(s) may
snap or that the hoisting gear and/or drive motor may be damaged.
44
Crane operation
D A N G E R exists if:
1. The load torque limiter is not set to the actual equipment status of the crane, and as a result, cannot
fulfil its function as a safety device.
2. The load torque limiter is defective or put out of operation.
3. The sliding arms of the hydraulic supports are not extended to the points specified in the load capacity
table.
4. The support pads are not supported with stable base material sufficiently large for the soil conditions.
5. If the load is pulled at an angle. It is particularly dangerous when pulling to the side since the telescopic
boom has a lower torque resistance to the side. The load may not be pulled at an angle.
6. An excessive load is attached to the hook during dismantling work, which then hangs freely on the
crane when it is detached.
7. If loads which have become stuck are pulled free with the hook block. Even if the weight of the load
which is stuck is no greater than the permissible lifting load, the crane may topple over backwards if the
load is suddenly freed since the tension created in the boom can cause it to jerk back violently.
8. Work is carried out in strong winds. Refer to the data given in the load capacity table.
9. The crane is not aligned horizontally and the load is slewed toward the slope.
10. The hook load begins swinging because the crane operator has not properly controlled the movements.
11. The loads and radii contained in the load capacity tables are exceeded.
12. When working in the vicinity of power cables, these are not isolated by electricity engineers or if the
hazardous area is not covered of fenced off. If it is not possible to take such measures, a sufficient safety
clearance must be maintained:
Minimum distance
Rated Voltage
[m] [ft]
up to 1 kV (1000 V) 1 3
above 1 kV up to 110 kV 3 9
if rated voltage is unknown 5 16
Note: If, despite all precautions having been taken, a flashover occurs, carry out the following
procedure:
> Keep calm.
> Do not leave the crane cab.
> Warn those around the crane not to move and not to touch the crane.
> Move the crane away from the danger area.
DANGER: Not observing the above points can lead to (fatal) accidents and damage!
45
180003
46
A suspended load is always a risk

When performing any movement, the crane operator must always keep his eye on the load, and when moving
the crane without a load, he should observe the crane hook or the lifting tackle. If this is not possible, he must
only operate the crane according to instructions given to him by a signaller. These instructions may be given in
the form of hand signals or over a two>way radio. Whatever method is used, precautions must be taken to
eliminate the risk of misunderstandings.
DANGER: Hand signals must first be discussed and agreed upon and then clearly given.
Misunderstandings can lead to serious accidents.
The hand signals illustrated on the opposite page are given as recommendations for safe working.
When operating in foreign countries, always observe NATIONAL TRAFFIC REGULATIONS.
Explanation of hand signs
1 = Raise boom
2 = Lower boom
3 = Lift load slowly
4 = Lower load slowly
5 = Raise boom slowly
6 = Lower boom slowly
7 = Raise boom and hold load
8 = Lower boom and hold load
9 = Extend boom
10 = Retract boom
11 = Raise boom and lower load
12 = Lower boom and raise load
13 = Raise load
14 = Lower load
15 = Slew load this way
16 = Shut down all systems
17 = Stop!
47
48
Observing wind conditions

It is essential to adhere to the information given in the load capacity tables regarding the maximum
permissible wind speed.
Crane operations must be stopped and the boom lowered as soon as the maximum wind speed is exceeded.
Wind Force Wind Speed

Effects of Wind
in the inland
Beaufort degree Description [m/s] [km/h]
0 Calm 0 > 0,2 1 No wind, smoke rises straight up
1 Slight air 0,3 > 1,5 1>5 Wind direction is shown only by
(draft) observing the trail of smoke, not by the
wind sock
2 Light breeze 1,6 > 3,3 6 > 11 Wind can be felt on the face, the leaves
rustle, wind sock moves slightly
3 Gentle breeze 3,4 > 5,4 12 > 19 Leaves and thin twigs move
Wind extends a small breeze flag
4 Moderate 5,5 > 7,9 20 > 28 Swirls up dust and loose paper, moves
breeze twigs and thin branches
5 Fresh breeze 8 > 10,7 29 > 38 Small deciduous trees begin to sway,
foam forms at sea
6 Strong wind 10,8 > 13,8 39 > 49 Thicker branches move

Telephone lines begin to whistle,
umbrellas are difficult to use
7 Stiff wind 13,9 > 17,1 50 > 61 Entire trees swaying; difficult to walk
into wind
8 Gale force wind 17,2 > 20,7 62 > 74 Breaks twigs off trees, walking becomes
difficult
9 Gale 20,8 > 24,4 75 > 88 Minor damage to property (chimney tops
and roofing tile are blown off)
10 Severe gale 24,5 > 28,4 89 > 102 Trees are uprooted, significant damage
to property
11 Violent sorm 28,5 > 32,6 103 > 117 Extensive, widespread storm damage
12 Hurricane 32,7 > 36,9 118 > 133 Major destruction
49
3.00 OPERATION OF THE CHASSIS 021676>00
50
021676>00
Chapter 3
Operation of the Chassis
51
3.01 CONTROLS AND INSTRUMENTS > VEHICLE 023402>00
185763
52
Pos.:
1 * Foot pedal > Service brake

2 Retaining lever > For adjustment of steering column tilt angle
3 Steering column switch for

> Turn signal indicator lights
> Windshield wipers
> Windshield wiper > intermittent operation
> Windshield washer system
> Change headlight from dim to high beam
> Horn
> Headlight flasher
4 Pedal > Service brake
5 Pedal > Engine regulation

6 * Steering column switch > (5>stage) for Eddy current brake
7 Acoustical warning > Engine overspeeding
8 Cigarette lighter
9 Interior light with switch
10 Container > Windshield washer fluid
11 Fuse and relay box
12 Slide control > Temperature selection

13 Slide control > Air inlet selector lever for air circulation / fresh air
14 Slide control > Change air flow upward or downward
15 Rotary switch > (3>stage) for blower
16 Reserved
17 Reserved
18 Reserved
19 Reserved
20 Lever > Release for horizontal seat adjustment

21 Lever > Adjustment of back rest angle
22 Button > Lower back support in upper area of back rest
23 Button > Lower back support in lower area of back rest
24 Lever > Adjustment of seat angle
25 Battery master switch > crane chassis
* Optional
53
185764
54
Pos.:
26 Display > Converter > oil temperature

27 Display > Converter > oil pressure
28 Duplex air pressure gauge for reservoir and brake pressure > brake circuit ¬
29 Duplex air pressure gauge for reservoir and brake pressure > brake circuit I
30 Trip log > Speedometer with trip odometer and clock

31 Warning light > Trip log problem ( pens do not register or diagram disk has not been in>
serted)
32 Warning light > Factory adjusted high speed has been exceeded
33 Gauge > Diesel engine RPM

34 Key > operated switch > Ignition , starter
35 Hour meter
36 * Rotary switch > Change over from chassis to superstructure operation

37 * Rotary switch > Temperature regulator for air conditioner
38 Gauge > Oil pressure > Diesel engine
39 Indicator light > Parking brake (hand brake)
40 Display > Fuel tank level
41 Display > Coolant temperature > Diesel engine
42 Electrical socket > 24 V DC
43 Indicator light > Preheat Diesel engine
44 Warning light > Alternator
45 Warning light > Air filter contaminated
46 Warning light > Engine oil pressure too low
47 Warning light > Error in the electronic control of the automatic transmission or oil
pressure in oil circuit > torque converter too low
48 Reserved
49 Display > Travel direction > vehicle
50 Warning light > Steering circuit I
51 Warning light > Air pressure supply > Brake circuit I
52 Warning light > Air pressure supply > Brake circuit ¬
53 Warning light > Air pressure supply > Brake circuit √
54 Reserved
55 Warning light > Rear axle steering lock / release is in intermediate position if this war>
ning light lights up
56 * Indicator light > Eddy current brake
57 Reserved
58 * Indicator light > Rear fog light
59 Indicator light > speed limit
60 * Indicator light > Air conditioner
61 Indicator light > Beacon (s)

62 Warning light > Fuel level is too low
63 Warning light > Coolant level > travel engine is too low
64 Warning light > Coolant temperature is too high
65 Reserved
* Optional
55
185764
56
Pos.:
66 Indicator light > Headlight > High beam

67 Display > Travel direction > for towing trailer
68 Warning light > Steering circuit ¬
69 Indicator light > Off road gear turned on
70 Indicator light > ∫All wheel drive∫, Drive of axle 1 (or 1 and 2 *) added
71 Indicator light > Transverse differential lock of driven axles is added
72 Reserved
73 Indicator light > Rear axle steering released
74 * Indicator light > Auxiliary heater
75 Reserved
76/77 Warning light > Automatic brake blocking prevention on the vehicle. (ABV)
This warning light must turn off at a travel speed of more than
10!km/h. If it does not turn off, then there is a problem with the electro>
nic ABV control for the vehicle.
78 Warning light > Automatic brake blocking prevention on the trailer. (ABV)
When a trailer is attached, this warning light must turn off at a travel
speed of more than 10 km/h. If it does not turn off, then there is a pro>
blem with the electronic ABV control for the trailer .
79 * Switch > Outside mirror heater

80 * Switch > Seat heater, left
81 * Switch > Seat heater, center
82 * Switch > Seat heater, right
83 * Switch > electric window control , driverπs side
84 * Switch > electric window control, passenger side
85 Reserved
86 * Switch > Air conditioner
87 Reserved
88 Reserved
89 Reserved
90 Reserved
91 Switch > Release / lock of rear axle steering
92 Switch > Neutral position > transfer gear box
93 Switch > Engage off road gear
94 Switch > Engage drive for 1st ( or for 1st and 2nd*) axle ,
∫All wheel drive ∫
95 Switch > Engage transverse differential lock for driven axles
96 Reserved
97 Reserved
98 Switch > Hazard warning blinker with indicator light
99 Light switch >(2stage) for parking lights, head lights and instrument lighting
100 Switch > Beacon with indicator light
101 * Switch > Rear fog light
102 * Switch > Auxiliary heater for cab and preheat system for Diesel engine*
103 * EMERGENCY OFF button> Shut off of travel motor and complete electrical system in chassis
104 Reserved
105 Reserved
106 Reserved
* Optional
57
185765
58
Pos.:
107 Reserved
108 Reserved
109 Reserved
110 Gear selector > Keyboard

Key D Travel range, forward
Key N Neutral
Key R Travel range, reverse
111 Monitor > Indicator SELECT selected gear

Indicator MONITOR just placed gear
112 Operating mode indicator

113 Key MODE > pushed, Travel program S 1 (for uphill driving)
not pushed, Travel program S 2 (Economy program)
114 Arrow key ≠ > Gear selection (increasing)

115 Arrow key Ø > Gear selection (decreasing)
116 Button > ªLEVEL´, automatic adjustment of axle suspension (travel height( for on road
travel
117 Indicator light > ªLEVEL´, lights up if the axle suspension for on road travel is set (with the but>
ton (112) held down)
118 Button > Rear axle steering control
119 Reserved
120 Switch > Turned off Axle suspension free ( suspended)
Turned on Axle suspension blocked

121 Reserved
122 Button > Raise / lower front left side of vehicle
123 Button > Raise / lower front right side of vehicle
124 Button > Raise / lower rear left side of vehicle
125 Button > Raise / lower rear right side of vehicle
126 Reserved
127 Reserved
128 Reserved
129 Reserved
130 Manual lever > Parking brake

131* Button > Emergency release valve for parking brake (hand brake)
132 Manual lever > Engine regulation (gas lever )
* Optional
59
3.02 BEFORE VEHICLE START UP 023403>00
60
Pre>checks before start up

Before starting the vehicle, the following pre>checks must be carried out:
Note: For a more complete description of the below listed pre>check procedures, refer to
Chapter 7.04, ™MAINTENANCE GUIDELINES > CRANE CHASSIS™.
Check oil levels and filters

> Oil level on travel and crane engine
> Oil level on automatic transmission
> Oil level on hydraulic tank for steering, outriggers, and axle suspension
> Filter on hydraulic oil tank for steering
Check fuel level

Check the fuel level on the fuel gauge in the driverπs cab.
Check the coolant level

Add enough coolant via the filler nozzle to fill the coolant reservoir to the rim .
DANGER: NEVER check the coolant level if the engine is still warm! Check the coolant level
ONLY when the engine is cold, hot coolant fluid can cause serious skin burns!
Check the tires

Check the condition of the tires, including the spare.
DANGER: There is an increased danger of accidents if the tires are damaged, the treads are
worn and/or the air pressure in the individual tires varies!
Check the mounting of the counterweight

Check the locking lips of the counterweight plates and the locking receptacles for the counterweight plates for
damage.
DANGER: If the locking lips are broken off or if there is any distortion on the mounting base,
then the tight seating of the counterweight plates is no longer assured.
As a result, the counterweight plates can fall off.
If there is any damage, the locking system or the counterweight plates must be replaced.
If one of the brackets is bent, the depository bracket must be aligned or replaced.
61
183221
62
General transport condition
For travel purposes, all loose parts must be securely attached to the mobile crane .
> The axle suspension system must be switched to ∫Suspended∫ (See chapter 3.03.)
> The rear axle steering must be locked in ∫straight forward position ∫ .
> The rotary switch (1) must be in ∫Chassis∫ position .
> The telescopic boom must be completely retracted and lowered in the boom receiver.
> The slewing brake must be applied.
> The telescopic boom must be secured to prevent it from running free by attaching the hook block (or the load
hook) in the eye hook on the front coupler, it must be attached with the two mounting cables and shackles in
such a way as not to restrict the view of the operator. The hoisting cable must be pulled until it is just tight.
> Check the two hinge locks (2) for the installation ladder* under the front bumper to assure that they are loc>
ked tightly.
> All windows and the door on the crane operatorπs cab must be closed .
> The four sliding arms in the hydraulic outriggers must be individually secured with pins (12) to prevent unin>
tentional extension and movement. The lever position of the pins must point downward.
> The four outrigger pads must be secured in their receptacles and pinned (13).
> The four wheel chocks (10) must always be carried and secured in their holders to prevent them from falling
out .
> The two control boxes (15) must be locked.
> Check all engine covers and secure them with rotary locks (5) and check all locks (4, 6 and 14) on doors and co>
vers on the crane superstructure to assure that they are locked securely.
> Check the mounting screws on the spare tire (7) to make sure they are secure.
> Check all pins and spring retainers to see if they are properly seated:
on the spare tire (7),
on the outrigger pad receptacle (13),
on the locking pins of the sliding arms ( 4¥ Pos. 11 and 4 ¥ Pos. 12 ).
Check the pins on the tow coupling (3) for the hoisting cable attachment.
> Check the locks for the counterweight (8), make sure that there are no foreign objects on the vehicle frame un>
der the counterweight or within the slewing range.
> Check if all locking pins used for the crane operation are present and secure them for transport,
such as the pins for the sliding arms (11 and 12) and locking pins for counterweight (8).
DANGER: All locks, spring retainers and locking pins must be fastened and secured in such a
way, that they do not come loose during transport, which could cause an accident
or damage.
If these safety, locking and securing measures mentioned in the above chapter ∫Ge>
neral transport conditions∫ are not adhered to, there is an increased risk of acci>
dents!
Note: When driving on public roads, the counterweight, the hook block and the double folding fly
jib must be transported separately in order to stay within the maximum axle pressure of 12
tons, as described in chapter 3.04 ™ DRIVING ON PUBLIC ROADS™.
A hook block (one or three sheaves) may only be transported on the front, if :
> it is, at a maximum, quadruple reeved,
> it has been marked by the manufacturer on the identification plate with the letter ∫E∫ for RENDERED SA>
FE and
> if it has been fastened to the front tow coupling (3) with the shackle provided for this purpose and it has been
pulled tightly.
* Optional
63
185171
64
Adjust the driverπs seat

The hydraulically suspended driverπs seat can be adjusted to fit any body size:
> Horizontal seat adjustment (20)

> Adjustment of back rest angle (21)
> Lower back support (22 and 23)
> Adjustment of seat surface angle (24).
The seat suspension is adjusted automatically.
Adjust the mirrors

Before travel, the outside mirrors must be cleaned and the mirrors must be properly adjusted by the driver:
Adjust the steering wheel

By releasing the steering wheel adjustment lever (2), the tilt angle of the steering wheel can be adjusted to suit
the driver.
CAUTION : To prevent possible knee injuries, after pulling the lever (2) ∫upward∫, the lever po>
sition must be aligned with the steering column .
DANGER: The steering wheel, the driverπs seat and the mirror may not be moved or adjusted
during travel.
Release the steering column incline lever only when the vehicle is at a standstill and
retighten it after adjustment is completed.
If this is not observed, there is a great danger of causing a serious accident.
65
185766
66
Check hazard warning flashers, blower, windshield wipers and horn

Turn on the battery master switch (25) to carry out these checks.
Before starting the engine, check the following :
a) Before the ignition is turned on,

> check the switch for indicator light / hazard warning flasher (98)
b) After the ignition is turned on,

(turn the ignition key in the key operated switch one notch to position ∫1∫ )
> check the rotary switch (15) for blower > heater, ventilation (air conditioner *)
> check the switch for the windshield wiper and washer system (3)
> check the fluid level in the windshield washer reservoir (10)
> check the horn (3)
DANGER: If the hazard warning flashers, or any of the other above mentioned functions are
defective, DO NOT start to travel. Make sure that these functions are repaired befo>
re operating the vehicle, otherwise there will be an increased risk of accidents!
Check fuses
Remove the cover on the fuse box (11) and check all fuses. If any of them are defective, they must be replaced.
C A U T I O N: NEVER repair or short circuit a fuse! NEVER use a different size or stronger fuse,
use only fuses for the same amperage! If you do not use the same amperage fuse,
the total electrical system can be damaged or you could cause an electrical fire.
*Optional
67
183223
68
Check the lights
Note: To check the lights, the battery master switch and the ignition must be turned on .
Check all lights before starting the vehicle:
> High beam / low beam head lights (1, 2)
> Parking lights / front and rear (3)
> Turn signals (4)
> Beacon (5)
> Brake lights (6)
> Back up light (7)
> Rear fog lights * (8)
> Boom head light * (9)
> License plate illumination (10)
> Side lights * (11)
> Fog light*
> Display and control panel illumination
D A N G E R: Missing or defective lights increase the risk of accidents.

Any defective lights must be repaired by qualified mechanics or changed before
starting the vehicle.
* Optional
69
3.03 AXLE SUSPENSION / LOCKING SYSTEM 023404>00
185765
70
3.03 AXLE SUSPENSIN / LOCKING SYSTEM 023404>00
Description
All axles are provided with hydro>pneumatic suspension with automatic leveling.
Each axle is connected with the frame via 2 hydraulic cylinders, which act as suspension and leveling elements.
Axles 1 and 2 as well as 3 and 4 form axle groups with 2 hydro accumulators each, axle blocking valves and
hydraulic cylinders.
The entire vehicle can be raised or lowered via this hydro>pneumatic suspension system, for example to reduce
the craneπs clearance height , or it can be raised to improve the vehicles fording power.
In addition, the entire vehicle can be raised or lowered either on the left and right front or on the left and right
rear .
The axles can be independently suspended with axle pressure compensation or locked.
To raise the vehicle: in suspended condition, push buttons (122, 123, 124 or 125 ) on the ∫rear∫ ,
To lower the vehicle: in suspended condition, push buttons (122, 123, 124 or 125 ) on the ∫front∫.
Controls and instruments

located in the driverπs cab, next to the operatorπs seat, on the center console
Pos.:
116 Button > automatic vehicle height adjustment, with the engine at low idle
If this button is pressed when the switch (116) is turned off (axle suspension is acti>
ve) then the vehicle will automatically align itself for to the correct travel height
for on road travel.
117 Indicator light > Travel height adjusted
When the correct ∫travel height∫ is reached, the indicator light stays on until the
button (116) is being released.
120 Switch > turned on axle suspension blocked

turned off axle suspension free (suspended)
Switch (120) turned off

122 Button > To raise / lower the vehicle on the left front side
123 Button > To raise / lower the vehicle on the right front side
124 Button > To raise / lower the vehicle on the left rear side
125 Button > To raise / lower the vehicle on the right front side
132 Manual lever > For engine regulation (gas lever)
Fig. 1 Suspended condition, on road travel

> Axle compensation for axles 1 + 2, 3 + 4,
> Manual leveling possible.
Fig. 2 Blocked condition

Crane supported, crane operation freestanding and driving with attachment in place
> Axle compensation for axles 1 . . . 2,
> Manual leveling not possible.
71
185765
72
1. Axle suspension ∫SUSPENDED∫

For driving on public roads, highways and off>road.
The switch (120) must be turned off, in this position, all axles are suspended.
CAUTION : The height of the crane can be regulated automatically or manually only in this
switch position .
1.1 Automatic travel height regulation
The adjustment must be made on level, horizontal ground with sufficient load carrying capacity.
To automatically regulate the travel height, push button (116) until the indicator light (117) lights up.
The crane is automatically returned into the correct travel height for on road travel by level switches, which
are installed on the suspension cylinders .
1.2 Manual travel height regulation

By actuating the button (122, 123, 124, 125), the pressure in the hydro>pneumatic system is either increased
or decreased , which allows the height of the vehicle to be adjusted as follows:
To raise / lower the vehicle on both sides:

> Push button (122 and 123) on the ∫rear∫, vehicle is being raised on front.
> Push button (122 and 123) on the ∫front∫ ,vehicle is being lowered on the front.
> Push button (124 and 125) on the ∫rear∫, vehicle is being raised on the rear.
> Push button (124 and 125) on the ∫front∫ ,vehicle is being lowered on the rear.
1.3 To raise / lower the vehicle on one side:

> Push button (122 ) on the ∫rear∫, vehicle is being raised on the left front.
> Push button (122 ) on the ∫front∫ , vehicle is being lowered on the left front.
> Push button (123) on the ∫rear∫, vehicle is being raised on the right front.
> Push button (123) on the ∫front∫ , vehicle is being lowered on the right front .
> Push button (124 ) on the ∫rear∫, vehicle is being raised on the left rear.
> Push button (124 ) on the ∫front∫ , vehicle is being lowered on the left rear.
> Push button (125) on the ∫rear∫, vehicle is being raised on the right rear.
> Push button (125) on the ∫front∫ , vehicle is being lowered on the right rear .
CAUTION : Never fully raise or lower the vehicle when driving on uneven roads, such as off
road!
There must always be some suspension path available.
The boom must always be positioned towards the front, in lengthwise direction
of the vehicle and it must be placed down in center position.
DANGER: When actuating the axle suspension / blocking system, make sure that there are
no persons within the danger range of the crane.
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2 Axle suspension ∫LOCKED∫

Release the switch (120) , push the symbol and turn on .
The hydro >pneumatic suspension of all axles is locked, axle equalization exists for axles 1 and 2.
The axles must be locked for :
2.1 Supporting the crane ,

2.2 the working mode ∫free standing on tires∫ and ∫driving the crane with a load∫.
2.3 Driving the crane with the attachment in place.
2.1.1 To support the crane

Before supporting the crane, ∫LOCK∫ the axle suspension by turning on the switch (120) .
When extending the outrigger cylinders, the axles are raised until all wheels are off the ground.
CAUTION: If this point is not observed, the axles can be damaged because the frame will
bend during crane operation.
When lowering the supported crane onto the wheels, the outrigger cylinders must be retracted far
enough until the wheels touch the ground again. Then turn the switch (120) to ∫SUSPENDED∫ .
CAUTION: DO NOT turn the switch (120) until the wheels touch the ground again.
If this point is not observed, the axle suspension will be damaged due to the
sudden release of the axle blocking system .
DANGER: It is prohibited to change the crane in supported condition from ªLOCKED ´

to ªSUSPENDED´ .
There is a danger of causing a serious accident because the axle may drop
down.
Special care must be taken if repairs must be made underneath the vehicle!
2.2.1 Driving the crane with a load

Before driving the crane with a load,
1) the automatic travel height must be adjusted (see paragraph 1.1).
2) the axle suspension must be ªLOCKED´ by turning on the switch !(120) .
The adjustment must be made on level, horizontal ground with sufficient load carrying capacity. The
travel route may not change by more than max. ± 0.15 m over a length of 10 m .
2.3.1 Driving the crane on the jobsite, with the attachment in place (see chapter 4.09)
Before driving the crane on the jobsite, the axle suspension must be ªLOCKED´ by turning on the
switch !(120) .
The adjustment must be made on level, horizontal ground with sufficient load carrying capacity. The
travel route may not change by more than max. ± 0.15 m over a length of 10 m .
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3.04 DRIVING ON PUBLIC ROADS 023405>00
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Travel condition of the crane for on road travel

Fig.: 1 Axle load 12 t / axle
Before driving the crane on public roads and highways, the counterweight must be distributed as shown in the
illustration, to retain an axle load of 12 tons per axle.
> Telescope the telescopic boom in all the way, lock it and place it in vehicle lengthwise direction to the front.
The plate placed on the vehicle frame is secured if the telescopic boom is placed in the transport receptacle, the
rubber pads on the luffing cylinder push onto the plate.
> Rig the hook block, as described in chapter 3.02, General transport conditions.
CAUTION: If hoist gear 2 is installed, the spare wheel must be removed.
With 14.00 R 25 tires, an additional counterweight of 0.8 t must be installed on the

vehicle frame behind the counterweight mount.
Equipment configuration of the crane
Required adjustment of axle suspension

system: ∫SUSPENDED∫ Boom length 40 m
Switch(120) turned off

Push button (116) until indicator light (117)
Width of vehicle 2.5 m Width of vehicle 2.7 m
lights up
Hook block
(3pulley, 400 kg) attached on the front ¥ ¥
tow coupling
2. Hoist gear [t] 1.0 (1.3) 1.0 (1.3)
or
replacement weight [t] 1.0 1.0
Counterweight
see fig. 1 see fig. 1
on crane superstructure [t]
Counterweight
on vehicle [t]
Counterweight
0.8 none
on vehicle [t]
Folding jib folded in ¥ ¥

Tires 14.00 R 25 16.00 R 25
Tire pressure [bar] 10 9
Axle load [t/axle] see fig. 1 see fig. 1
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Travel condition of crane

Fig.: 2 Axle load >12 t / axle
Equipment configuration of crane
DANGER: Due to the higher total weight, the brake path is longer!
The 2.1 ton counterweight must be attached with 2 screws M 30 ¥ 140 and nuts to
the counterweight frame.
CAUTION: If axle loads are of more than >12 t / axle, then the crane may not be driven on
public roads, on construction sites, or only in countries, which permit such axle
loads.
Even axle loads can only be obtained by distributing the ballast as shown.
Other ballast variations are not permitted for driving, since it would cause
increased loads.
With 14.00 R 25 tires, an additional counterweight of 0.8 t must be installed on the
vehicle frame behind the counterweight mount.
Required adjustment of axle suspension

Boom length 40 m
system: ∫SUSPENDED∫
Switch(120) turned off

Push button (116) until indicator light (117)
Width of vehicle 2.5 m Width of vehicle 2.7 m
lights up
Hook block
(3pulley, 400 kg) attached on the front ¥ ¥
tow coupling
2. Hoist gear [t] 1.0 (1.3) 1.0 (1.3)
or
replacement weight [t] 1.0 1.0
Counterweight
on crane superstructure [t]
Counterweight
on vehicle [t]
Counterweight
0.8 none
on vehicle [t]
Folding jib folded in ¥ ¥

Tires 14.00 R 25 16.00 R 25
Tire pressure [bar] 10 9
Axle load [t/axle] see fig. 2 see fig. 2
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Description of gear selector (110)
R (Reverse travel)
Changing from neutral to reverse, reverse to forward or vice versa may only be done when the vehicle is at a
standstill, the parking brake is applied and at low idle speed!
If the Reverse gear is turned on, the SELECT range selection indicator and the MONITOR show an "R" .
Wait for 1 to 2 seconds after changing gears before accelerating.
N (Neutral)
This position is used to start the engine, to control the vehicle components and if the engine is run at low idle
speed for a longer period.
On the SELECT range selection indicator and the MONITOR appears an "N", if the gear in in Neutral.
CAUTION : For safety reasons, apply the parking brake before starting the engine.
Do not let the vehicle run out in low idle (SELECT indicator on "N") , this eliminates
the engine braking action, and the gear lubrication is insufficient.
Note: Before changing from "N" to "D" or "R", it must be assured that the manual engine regula>
tion (manual gas lever 132) is on low idle (downward).
Changing from "N" to "D" or "R" is blocked as long as the engine RPM is higher than low
idle RPM. You must shift back to "N" and reduce the engine RPM before the gear can be
shifted.
If the shift procedure is blocked on "D" or "R" , then the SELECT number in the indicator
blinks.
D (Continuous driving in the S1 and S2 program)

In this gear selection, 6 forward gears are available.
At a certain RPM and speed, the torque converter is turned off (bypassed) in gears 2!.!.!.!.!6 and a simple mecha>
nical power transfer from the engine to the gear is established.
The return shift is done in reverse order.
In both programs, no ªlock>up´ occurs in 1st gear , the vehicle drives constantly via the converter.
Exception: In manual selection of the 1st gear, the converter bypass coupling !(WK) is closed.
The SELECT range selection indicator shows the highest usable gear and the MONITOR shows the actually pla>
ced gear.
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Description of gear selector, continuation
Travel stages 5, 4, 3, 2
There are times when road or traffic conditions require a limitation of the automatic shifting procedure to a lo>
wer range. These ranges also offer better engine braking action.
Push the arrow key ≠ (up) or Ø(down) to get to the desired gear. The SELECT indicator shows the selected and
the MONITOR indicator shows the just placed gear .
CAUTION : When selecting a lower gear, the gear might not shift back until the travel speed has
been reduced sufficiently.
"5" (Continuous travel with limited high speed)

In this gear selection, the gear between the 1st and 6th gear are shifted automatically, the 6th gear is locked.
Push the arrow Ø(down) until the number "5" appears in the SELECT window.
"4" (Continuous travel with limited high speed )

In this gear selection, the gear between the 1st and 4th gear are shifted automatically, the 5th and 6th gears
are locked.
This gear selection can be recommended for routes, where the automatic would continuously shift back and
forth between the 4th and 5th gear, or on a slight downhill route, to prevent that the automatic shifts up into
the 5th and 6the gear.
"3" (Slow driving, city driving)

The 4th and 5th gears are locked.
The starting procedure occurs in 2nd gear, then shifts up automatically to the 3rd gear. This gear selection
should also be used before driving downhill.
It assures the best possible engine braking action.
"2" (Slow driving)

In this travel stage, only the 2nd gear is shifted. Up shifts are suppressed .
Use this gear when driving uphill or downhill, preselect the 2nd gear in time.
"1" (Creeper gear)

All other gears are locked.
Use this gear when you must drive extremely slow (slush, snow) or when load and terrain dictate it (for example
when driving up or down a steep hill).
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Travel programs (S1) and (S2)

To drive the crane from the driverπs cab, 6 forward gears and 1 reverse gear and two travel programs (S1) and
(S2)are available.
The travel programs (S1) and (S2)are preselected with the MODE key (113) .
In both programs no ªlock>up´ occurs in 1st gear , the vehicle drives constantly via the converter.
Exception: In manual selection of the 1st gear, the converter bypass coupling !(WK) is closed.
Note: The change from (S1) to (S2) or reverse can be made during travel.
When using the rear axle steering, after actuating the switch (91), the up shift lock is acti>
vated, which means that only the 1st and 2nd forward gear as well as the reverse gear are
available.
Program MODE ON=> Power (S1)

MODE key (113) pressed, release of gears 1 . . . . 6
This travel program is a more powerful travel program (with higher fuel consumption) and should only be tur>
ned on before driving uphill.
Full load upshifts occur in all gears at and engine RPM of 2030 . . . . 2050>1.
Back shifts
The gear shifts back automatically only to the 2nd gear, the 1st gear must be selected manually by pressing the
arrow key Ø (down) three times.
Program MODE OFF=> Economy (S2)

MODE key (113) not pressed , release of gears 1 . . . . 6
This travel program has been designed as an economy travel program,
Full load upshifts occur in all gears at an engine RPM of approx. 1900>1.
Engine brake operation

The gear shifts only back into the 2nd gear in engine brake operation, the 1st gear must be selected manually.
Example:
SELECT MONITOR
I I
6 => 4 actual travel condition
I I
2 => 4 Display indicator when engine brake is actuated
In this case, to select the 1st gear, the arrow Ø (down ) must be pressed 5¥ or continuously until 1=>4 appe>
ars on the display.
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Up shift lock
When the rear axle steering is turned on, the up shift lock from 2nd gear or driving from the superstructure is
active in all travel conditions.
Indication in Display in program MODE ON=> Power (S1). (chassis and superstructure)
SELECT MONITOR
in 1st gear: 6 => 1
in 2nd gear: 2 => 2
Indication in Display in program MODE OFF=> Power (S2). (chassis and superstructure)
SELECT MONITOR
in 2nd gear: 2 => 2
Driving, shifting
The travel speed is regulated via the gas pedal (5) and the gear selector (110) of the automatic transmission.
To protect the engine from overspeeding, do not shift back until the highest speed of the next lower gear is rea>
ched. If necessary, slow down the crane with the service brake to obtain this speed.
CAUTION : When the vehicle is at a standstill, the engine must run on low idle and be in neutral
"N" , before shifting into another gear.
Do not give gas during or shortly before shifting from "N" into another gear, this eli>
minates the engine braking action, and the gear lubrication is insufficient.
Be aware that there is a delay when changing directions and shifting from !N (Neu>
tral) to !D (Drive) or!R (Reverse) if the gas pedal is pushed down to far. These shifting
procedures are blocked until a sufficiently reduced gas pedal position is obtained.
The travel direction change occurs when this position is reached.
Make sure to release the gas pedal if you shift from !N (Neutral) to !D (Drive) or!R (Re>
verse) , then this blocking function does not occur.
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Driving, shifting, continuation
Gas pedal (5)

The position of the gas pedal influences the automatic shift timing.
If the gas pedal is pressed down all the way, the system shifts up automatically if the engine RPMs are high,
while a partially pressed down gas pedal permits shift up at low engine RPMs.
An electronic signal informs the ECU about the position of the gas pedal .
When the gas pedal is pressed down too far, then it influences the travel direction changes (changes from !N
(Neutral) to !D (Drive) or!R (reverse)).
Up shifting occurs without engine speed limitation, while an engine speed limitation occurs when shifting back
or when shifting from !N (Neutral) into the forward gear range !D (Drive) or into the reverse gear range !R (rever>
ses) .
If back shifting or shifting from N (Neutral) into a travel range with an engine speed, which is too high, is selec>
ted, then the ECU prevents the shifting procedure, until N (Neutral) is set again and/ or a lower speed is rea>
ched.
If the Reverse gear is selected when driving forward or shifting from Neutral into another gear range, and the
engine speed is too high, then a continuous warning signal will be heard.
DANGER: The gear is equipped with a gear range lock, which prevents upshifting past the se>
lected gear.
To drive downhill, select a lower range.
However, if the regulating speed of the engine is exceeded in the highest selected
gear, then the gear can shift into the next higher gear anyway.
Actuate the service brake and /or the Eddy current brake to prevent exceeding of
the engine RPM in the highest selected gear.
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Read and delete diagnostic codes

via the selector keys
Each code consists of a two digit main code and a two digit sub code.
Maximum 5 codes with numbers (d1 . . . . d5) can be in the memory at the same time.
If a new one is added, the oldest non>active code disappears from the list.
If all codes are active, then the code with the lowest priority, which is not in the main severity list, is deleted
from the list.
If diagnostic operation is turned on, ( each indicator element takes two seconds), the first code (position d1) is
shown as follows:
d1, main code (two digits) Sub code (two digits)
Then the sequence is repeated.
Push the MODE key to show the codes for positions d2 . . . . d5. After a certain number of cycles, a code can be
deleted from the memory if it was not repeated.
The diagnostics operation, which was triggered by the selector keys, ends automatically after two minutes, if
nothing else is added.
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Indication of stored codes for gear oil indication
Prerequisite:
> Gear is at operating temperature
> Gear selection in in neutral N
> Engine runs at low idle speed
> Vehicle is in safe and horizontal position
> Parking brake is applied, the vehicle is secured with wedges to prevent it from rolling off.
> Simultaneously push both arrow keys (Ø≠) twice ,

> Watch the digital indicator and read the codes, the oil level indication is shown on the display within the next
two minutes, (the display blinks at 8, 7, . . . . 1 approx. 2 minutes)
After 2 minutes, the display shows the following:
Oil level sensor information
Code Cause
OL >OK Oil level ok.
LO >01 1 liter too low
LO >02 2 liters too low
HI >01 1 liter too much
HI >02 2 liters too much
CAUTION: Error in the above given parameter stops the 2 minute

sequence. One of the following codes appears on the display
and shows the reason for the interruption. If all parameters
have been taken care off, the countdown starts over again.
OL >50 Engine RPM too low
OL >59 Engine RPM too high
OL >65 Neutral is not selected
OL >70 Oil temperature too low
OL >79 Oil temperature too high
OL >89 Output shaft does not turn
OL >95 Error on sensor
CAUTION: Customer Service must fix this problem!
To end the oil level check

Push any desired key (R, N or D) 2 times.
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Indication of stored codes for diagnostics indication
Prerequisite:
> Gear selection in in neutral N
> Parking brake is applied.
I M P O R T A N T :The diagnostics can also be run when the engine is turned off and the ignition tur>
ned on.
Read the code

1. > Go to the diagnostics system, and simultaneously push the arrow keys (Ø≠) twice.
2. > Read the first of five code positions on the display

Example:
Code 25 11is in the 1st position.
The display changes the readout every 2 seconds , as follows:

a) Code position d 1
b) Main code 25
c) Sub code 11
d) The display repeats indication a, b, c.
3. > Push the MODE key quickly and read the code position d2 , as described in 2. .
4. > To read the code position d3, d4, d5, push the MODE key quickly each time.
5. > To read all code positions again, push after d5 the MODE key again and the display starts over with d1.
Evaluate code numbers

> see diagnostics indication automatic transmission
at the end of chapter 7.04 MAINTENANCE GUIDELINES CRANE CHASSIS.
End reading of diagnostics codes

To end the read mode and to return to the original indicator mode on the display, do the following:
1. Push the arrow keys (Ø≠) up and down at the same time.
2. Push any desired selector key R, N, D
(the gear is accepted if no active gear locking code is active.
3. Do nothing, after some time the diagnostics system will return automatically to the normal display indicator
mode .
Note : If a problem was shown, then the above error diagnostics must be carried out again as fol>
lows:
> Turn the travel motor off and turn the ignition off.
> Start the engine again, push the "R" (reverse gear) key, then push the !"N" key again.
CAUTION : If the problem message is not deleted after this procedure, then the indicated pro>
blem must be fixed by expert personnel.
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Establish travel readiness

The engine is running at low idle speed.
CAUTION : Before entering a travel stage, it must be assured that the gear box is NOT shifted in
neutral position.
The switch (92) must be OFF .
When the vehicle is at a standstill, before changing from "N" to another travel stage, always apply the service
brake or the parking brake to prevent the vehicle from "creeping away" .
> On the gear selector (110) push the appropriate key

"D" for forward or
"R" reverse.
> Release the parking brake, the manual brake lever points to the front when the brake is released.
The crane already starts to move off slowly.
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Turn on the battery master switch (25)
Apply the parking brake

When the brake is applied, the manual brake lever (130) points to the rear, indicator light (39) lights up.
Note: To apply the parking brake, pull the manual brake lever straight out and then move it to
the rear.
Changing to travel operation from the driverπs cab

Prerequisite:
> The crane is on level ground,
> the switch (120) is turned off, the axle suspension is active.
> The gear selector in the driverπs cab (110) and in the crane operatorπs cab (208) must be in neutral position.
> The parking brake in the driverπs cab and in the crane operatorπs cab must be applied.
> Turn off the travel motor and ignition.

> Change the switch (36) to the ∫Chassis∫ position.
CAUTION : The engine must be at a standstill and the ignition must be turned off before chan>
ging over .
Before changing over, the parking brake in the driverπs cab and in the crane opera>
torπs cab must be applied.
Note: If the switch (36) is actuated when the engine is running, the engine will turn off automati>
cally.
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Turn on the ignition > check instruments

>Insert the ignition key into the ignition (34) and turn it one notch in clockwise direction, to position ∫1∫.
The following indicator and warning lights will come on:

> Parking brake (30)
> Preglow indicator light (43)
> Battery charge (44)
> Engine oil pressure (46)
> Insufficient oil pressure in the torque converter / automatic transmission (47)
> Steering circuit ¡ (50)
> Steering circuit ¬ (68
> Selected travel range on gear selector switch (108)
If the pressure is too low:

> Brake circuit ¡ (51)
> Brake circuit ¬ (52)
> Brake circuit √ (53)
If the fluid level is too low:

> Fuel level (62)
> Coolant level (63)
Note : If the air pressure in the individual brake circuits has dropped below approx. 5 bar , war>
ning lights (51, 52, 53) will come on.
Fuel and coolant must be added before starting the engine, if warning lights (62 or 63) come
on .
Start the engine
CAUTION : For safety reasons, apply the parking brake before starting the engine.
When the vehicle is at a standstill, the engine must be at low idle before shifting
from neutral "N" into another gear.
Do not give any gas during or shortly before shifting from "N" into another gear.
> Push the neutral position key "N" on the gear selector (110) , the engine can only be started in this position.
When the "N" key is being pressed, a beeping sound can be heard, in the window (111) appears under SELECT
and MONITOR the indication "N".
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Starting the engine with the flame glow preheating system

The travel motor (engine) is equipped with a flame glow system and a flame start control unit.
Description of function
The flame start control unit supplies the current to the indicator light (43), the flame glow plugs in both intake
pipes and the solenoid valve for the fuel supply for the flame glow plugs.
At a lube oil temperature below the glow stop temperature (e+20∞C ), the preglow phase begins when the igni>
tion is turned on.
Preglow time
The preglow time depends on the system voltage .
When the ignition is turned on, the indicator light (43) lights up , the flame glow plugs are energized.
After completion of the preglow time, the indicator light (43) starts to blink (approx. 0.8 Hz), the STARTING
READINESS phase of the flame start system begins.
If the engine is not started during this time, the flame start control unit turns the flame glow plugs and the indi>
cator light (43) off.
If the engine is started during the starting readiness phase, then the flame start control unit opens the solenoid
valve for the fuel supply for the flame glow plugs.
After glow operation

The after glow operation starts when the starting procedure has been completed, the flame glow plugs continue
to be energized, the solenoid valve opens, the indicator light (43) turns off.
If the starting procedure was not successful, then the solenoid valve and the flame glow plugs are turned off.
> Return the ignition key to the stop before restarting the ignition.
At a lube oil temperature above the glow stop temperature (f+20∞C), the flame glow system is not functio>
ning, the indicator light !(43) blinks as soon as the ignition key is turned from the 1st notch and the engine is
ready to start.
Preglow time After glow time Glow stop
Volt sec ∞C sec ∞C
e19 35 +20 120 +25 (±5)

20 28 +10 120
21 26 0 120
22 24 $10 150
23 20 $20 180
32 10 $30 180
<$30 180
The flame start control unit recognizes errors on the flame start system and indicates the same, the indicator
light (43) will blink rapidly (approx. 1.6Hz) .
The following errors are recognized:

> Interruption of the flame glow plug > heating wire,
> Missing current supply on terminal 30,
> Defective fuse of flame start control uni t.
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Starting the engine at a lube oil temperature above the glow stop temperature (f+20∞ C)
CAUTION : The engine may only be started if:

> the alternator warning light (44) is on ,
> the flame start system indicator light (43) blinks.
If the engine does not start after max. 10 seconds, then wait for 1 minute.
The starter should only be cranked three times for 10 seconds per starting procedu>
re, with a 1 minute break in between.
At a lube oil temperature above the glow stop temperature (f+20∞C) , the flame glow system is not in opera>
tion, the indicator light !(43) blinks as soon as the ignition is turned on.
> Continue to turn the ignition key in clockwise direction to position "2" , slowly press down the gas pedal (5)
and start the engine.
Note: At every starting procedure, the starter will start to turn after about 1 second after the igni>
tion key is turned to position !"2"!.
This delay prevents a failure of the electric engine shut off system.
> Release the ignition key as soon as the engine turns over and release the gas pedal!(5) .
> If the engine does not start after approx. 5 seconds, slowly press down the gas pedal (5) and turn the starter
again.
> Return the ignition key all the way to the stop before restarting.
When the engine is warm, start the engine without pressing on the gas pedal (5) to prevent unnecessary ex>
haust emission.
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Starting the engine at a lube oil temperature below the glow stop temperature (e+20∞ C)
CAUTION : The engine may only be started if:

> the alternator warning light (44) is on ,
> the flame start system indicator light (43) blinks.
If the engine does not start after max. 10 seconds, then wait for 1 minute.
1. Preglow
> Turn the ignition key to (34) position ∫1∫ ,
the preglow time begins, the indicator light (43) will turn on.
If you try to start the engine during the preglow time, then the preglow phase is automatically interrupted. In
this case, return the ignition key to the stop and repeat the preglow phase.
2. Start the engine

The starting readiness starts as soon as the indicator light !(43) blinks.
> Turn the ignition key (34) to position ∫2∫ and start the crane engine without pressing down the gas pedal (5)
.
Note: The starter turns over after approx. 0.6 seconds after the ignition key is in position !∫2∫ .
If the engine is not started during the starting readiness time, then the starting readiness will automatically
stop.
In this case, repeat point 1. and 2.
> If the engine does not start after approx. 5 seconds, return the ignition key to the stop and repeat the preglow
phase.
> slowly press down the gas pedal (5) or pull the gas lever (132) lightly and start again, engine RPM max. 1000
RPM.
If the engine still does not start after max. 10 seconds, then wait for 1 minute. The starter should only be
cranked three times for 10 seconds per starting procedure, with a 1 minute break in between.
During the cold season, pay special attention to the batteries.

The starting capacity is significantly reduced during cold temperatures, for example at >10 ∞C, it is only about
66% of its normal capacity.
For that reason, after the engine has been turned off, the batteries should be removed and stored in a heated
room .
CAUTION : As long as the engine is running, DO NOT loosen either the cable on the alternator,
nor any one of the battery terminals, do not unplug the regulator or change any of
these item.
The alternator must be connected with the batteries during operation .
DO NOT turn the engine off by turning the battery master switch off !(25) !
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Starting procedure at ambient temperatures below >20 ∞C
To assure that the crane starts in extreme low temperatures, and that the engine is supplied with sufficient lu>
brication, the engine and the oil pan for the engine and the oil pan for the automatic transmission must be pre>
heated.
Preheating the engine *

Prerequisite: All components must be filled with service fluids for winter operation, according to the lu>
brication chart.
The preheat procedure * occurs via the coolant circuit through two* in>line, Diesel fuel operated heating units.
To preheat the oil pan for the engine*

The oil is preheated via the exhaust from the heating unit for engine preheating.
To preheat the oil pan for the automatic transmission *

The oil is preheated via the exhaust from the Diesel engine operated cab heater.
Preheat time
depends on ambient temperatures
Ambient temperature Preheat time

[∞C] [min]
> 40 to > 35 120

> 35 to > 30 90
> 30 to > 25 60
> 25 to > 20 30
> 20 and warmer no preheating required
Turn on the engine preheater

> Turn on the battery master switch (25) .
> Move the sliding regulator (12 > not shown) for the temperature selection to "cold" .
> Depending on the ambient temperature, turn on the two* heating units via switch (102) about 30 to 120 minu>
tes before starting the engine. It is functioning properly when the indicator light (74) turns on.
After about 15 seconds, the combustion procedure will start and the heating unit will run in automatic regula>
tion .
To turn the heaters off after the preheat time

Turn both* heaters off via switch (102) , the indicator lights (74 and 75*) will turn off.
The fuel supply is interrupted and the combustion procedure is ended.
The combustion blower and the heater pumps will continue to run to cool down the heating units and will turn
off after about 150 seconds.
*Optional
109
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The engine runs > check instruments

Observe the oil pressure gauge (38) and the oil pressure warning light (46) immediately after starting
the engine.
CAUTION: If no oil pressure is indicated or if the warning light (46) does not turn off, turn the
engine off immediately, to prevent engine damage due to insufficient lubrication .
The engine must must turned off immediately , if :

> the oil pressure drops or fluctuates strongly,
> the output and speed changes without changing the engine regulation lever,
> smoky exhaust fumes,
> increasing coolant and oil temperature,
> sudden abnormal noise in the engine or turbocharger .
Do not put a full load on the engine until it is at operating temperature.
The following indicator lights must turn off when the engine is running :
> Battery charge indicator (44)
> The oil pressure in the torque converter / automatic transmission is too low (47)
> Steering circuit ¡ (50)
> Steering circuit II (68)
Note : The indicator lights for the steering circuit II (68) will turn off after traveling at a
speed of about 10 km/hr.
> Brake circuit ¡ (51)

> Brake circuit ¬ (52)
> Brake circuit √ (53)
> Oil filter in automatic transmission (65*)
Note : The indicator lights in the brake circuits will turn off when the pressure in the brake system
has built up to approximately 5 bar .
The cut off pressure is approximately at 8.5 bar.
The parking brake (130) may be released once the air pressure in brake circuit III
has reached approximately 5.2 bar . At that point, indicator light (39) will turn off.
*Optional
111
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Turn the engine off

> Relieve the engine, slowly reduce the engine speed, then let the engine run for a short time in low idle, to give
the turbo charger time to run down .
The turbocharger,which runs at high speed, is supplied by the engine lubrication circuit and needs time to run
down .
If you turn the engine off suddenly, the turbocharger would run for a period of time without oil supply.
> Turn the engine off by turning the ignition key (34) to the left.
> Remove the ignition key.
CAUTION: If the engine is at a standstill and the ignition is left "on", the batteries may
discharge, depending on their current charge.
Low level discharge can cause the following damage:
> reduced capacity

> white layer on batteries and terminals
> short battery life expectancy
> defective batteries
To turn the engine off in an emergency*

In dangerous situations, the engine can be turned off by pushing the emergency ∫OFF∫ button (103*) .
> The engine will be shut down immediately by pushing the button (103), at the same time, the knob of the
button will lock down.
> To restart the engine, turn the ignition key (34) all the way to the left, then release the knob of the button
(103) by turning it to the ∫right∫ .
The engine may now be restarted.
CAUTION: The emergency "OFF" button (103 *) may only be used in absolute emergency
situations.
*Optional
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Adjust the axle suspension

The switch (120) must be turned off . In this position, all axles are suspended.
In this position all axles are suspended.
Note: For a description of the "AXLE SUSPENSION / LOCKING SYSTEM", refer to chapter
3.03.
Automatic travel height adjustment

The automatic and manual travel height adjustment must be made while the vehicle is parked on a level road
surface!
> Start the engine as described in paragraph 1. and 2.
D A N G E R: Before actuating the axle suspension / locking system, it must be assured that there
are no persons within the danger range of the crane.
> Push button (116) for the automatic leveling until the indicator light (117) lights up.
The crane will be automatically set to the correct level ( travel height) .
The indicator light (117) will light up as long as button (120) is depressed.
Manual travel height adjustment
C A U T I O N: When driving on public roads, manual level adjustment is only permissible under
special circumstances, for example if the crane must be lowered in order to
improve its vertical clearance, allowing it to pass under a bridge.
The manual travel height adjustment may only be made if the vehicle is at a
standstill.
Carry out the manual travel height adjustment as described in chapter 3.03, paragraph 1.2, "AXLE SUSPEN>
SION / LOCKING SYSTEM" .
Ready to travel > engine runs in low idle speed.

> On the gear selector switch (110) , push the button for the desired travel range (R, N or D ), a beeping sound can
be heard, in the window(111) appears the highest usable gear under SELECT and the placed gear appears un>
der MONITOR.
A slight reduction in engine speed signals, that the selected gear has been placed.
Release the parking brake

> Pull the manual brake lever (130) straight out and push it forward, indicator light (39) turns off.
C A U T I O N: As long as the necessary brake release pressure of approx. 5.2 bar is not available in
brake circuit III > and the warning light (53) is on > the parking brake will not relea>
se, even if the brake lever has been moved forward.
Move the manual brake lever (130) back again and recharge the brake circuit III
until the warning light (53) turns off.
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Check the function of the service brake system

> Slowly press down on the foot pedal for the service brake (4) , the red needle in the duplex air pressure gauges
(28, 29 must move in proportion to the pedal stroke, until it shows the same reading as the white needle (reser>
ve pressure).
Service brake (4)

>Increase the engine RPM by pressing the gas pedal (5) down , the crane will begin to move,
>Check the service brake by pressing down the brake pedal (4).
C A U T I O N: Check the brakes immediately after the crane starts to move.
Engine brake (1)

Use the foot button (1) to actuate the wear free engine brake.
DANGER: When going downhill, use only the engine brake.

If the braking action is insufficient, slow down the vehicle with the service brake
until the transmission can down shift to next lower gear.
Eddy current brake (6) *

The Eddy current brake can be applied with the 5>stage steering column switch (6) , its function is indicated by
indicator light (56) *.
CAUTION: The steering column switch must be shifted back to NULL (ZERO > to the front) as
soon as the vehicle is standing still or no addition decrease in speed is required.
Emergency release valve * (131) for parking brake (manual brake)

If the parking brake is blocked by some kind of defect in the air pressure system, then the parking brake can be
vented (released) by pushing the button (131)* to be able to move the vehicle from the danger zone.
DANGER: It is not permitted to continue driving with a defective air pressure system!
Driving downhill
Use the engine brake or the Eddy current brake * to slow the driving speed, in order to take it easy on the
service brake.
A simple rule of thumb:

Drive downhill in the same gear as you used to drive uphill.
C A U T I O N: If you go downhill too fast, the retarder can be overworked and it can no longer
hold a constant travel speed, at the same time, the oil temperature will exceed its
upper limit of 120∞C .
In this case, use the service brake to slow the vehicle and shift to the next lower
gear.
If the travel speed is adapted to down hill driving, as previously described, then the
engine retarder can slow the vehicle speed without the danger of overheating.
* Optional
117
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118
Keep an eye on the following important instruments while driving:
1. Warning light > steering circuit ¬ (68)

At a driving speed of approximately 10 km/h (6 miles per hour) , the warning light (68) for the hydraulic stee>
ring circuit II must turn off.
C A U T I O N: If the warning light does not turn off, then the steering circuit II is not functioning
properly. The crane must be stopped immediately and the cause must be found and
remedied.
2. Warning lights > brake circuit ¡, ¬, √ (51, 52, 53)
C A U T I O N: If one of these warning lights is on, then the brake circuit is not functioning pro>
perly. The crane must be stopped immediately and the cause must be found and re>
medied.
Warning lights
Automatic brake block preventer* vehicle (76, 77)
Automatic brake block preventer * trailer (78)
These warning lights must turn off at a speed of about 10 km/hr. (6 miles per hour) .
DANGER: If one of the two warning lights (76 or 77) or, when a trailer is used warning light
(78) does not turn off or lights up during travel, then there is a problem with the elec>
tronic ABV control.
The automatic brake block preventer is no longer functioning.
It is possible to continue driving, but it must be noted that the vehicle can only be slowed down ∫normally∫,
which means without ABV support.
Make sure to have the cause checked out as soon as possible by a trained expert.
3. Oil pressure gauge > engine (38)
CAUTION : If the oil pressure drops while traveling and does not increase if the engine speed is
increased, then the crane must be stopped immediately and the engine must be tur>
ned off.
If there is insufficient or no oil pressure, the engine is not lubricated, which can cau>
se serious engine damage.
4. Warning light > engine oil pressure (46), warning light > Coolant temperature (64)
C A U T I O N: If one of these two warning lights (46, 64) comes on during travel, then the crane
must be stopped immediately and the engine must be turned off.
Low engine oil pressure or high coolant temperature can cause serious engine
damage.
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5. Coolant temperature gauge (41)

If the temperature increases too much while driving, the coolant temperature gauge (41) rises.
Try to lower the temperature to a permissible range of 85∞C to 90∞C ( 185∞ F to 194∞ F) by decreasing the engine
load or by increasing the engine speed.
C A U T I O N: If the coolant temperature does not drop to within the permissible range, then the
crane must be stopped immediately and the engine must be turned off.
Increased engine coolant temperature can cause serious engine damage.
Increased temperatures can cause transmission damage.
Problem in the fan control , Fig. 1
— Thermostat > Sensor, charge air temperature

“ Shut off valve > Emergency control, fan ™on™
If the engine temperature indicator moves in the direction of the "red range", then there is the possibility that
there is a problem in the fan control .
This problem “can be remedied by closing the shut off valve —for a short time.
C A U T I O N: This emergency control may only be used to end travel!
Torque converter oil temperature gauge (26)

During normal travel operation, the needle of the temperature gauge (26) must be within the permissible ran>
ge.
C A U T I O N: If the needle goes into the red range, stop the crane immediately.
Shift the automatic transmission into neutral position "N" and let the engine run at
approximately 1500 RPM.
The oil temperature must drop to the permissible temperature range within a short
period of time.
If the oil temperature does not drop into the permissible temperature range, then
the crane must be stopped immediately and the engine must be turned off.
Torque converter oil pressure gauge (27)
CAUT I ON: If the torque converter oil pressure drops dramatically, turn the Diesel engine off
immediately.
Low oil pressure can cause transmission or torque converter damage.
*Optional
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122
8.DO NOT SHIFT>!(DNS>) indicator light in the digital indicator window!(111)

Every time the engine is started, the DO NOT SHIFT warning light lights up and turns off after a few seconds.
This short term signal means that the warning light control is functioning properly. If the DNS indicator light
does not light up after turning the ignition on, or remains on longer, than the system must be inspected imme>
diately.
ELECTRONIC CONTROL UNIT (ECU)

If the DNS indicator light lights up during travel (except when starting), in continuous operation, then the ECU
control has determined a diagnostic code. While it light up, short beeps can be heard for about 8 seconds from
the gear control unit. They are acoustical signals that the upshift and backshift functions are limited and no
changes in direction will occur. The SELECT field on the indicator is empty.
Note: Refer to the "Indication of stored codes for diagnostics indication" at the end of
chapter !7.04, MAINTENANCE GUIDELINES > CRANE CHASSIS
If the DNS indicator light turns on and the ignition is turned off, the gear remains in "N"
(Neutral), until the DNS indicator light is turned off.
If the warning light (47) and the DNS indicator light in the digital indicator window !(111) turn on at the same
time during travel, then operate the gear in the selected travel range only long enough to move to a rest stop or
service station.
CAUTION : If this problem occurs when driving on a highway or in traffic, do not change the
preselected gear but drive in the selected gear to the next parking area.
9. Warning light (47) for electronic gear control

When the engine is started, the warning light (47) lights up and turns off after a few seconds again. This short
term illumination shows that the warning light is functioning.
If the warning light (47) and the DNS indicator light in the digital indicator window !(111) turn on at the same
time during travel, then there is a problem in the electronic system of the gear control.
Fuel gauge (40)

The fuel gauge shows when it becomes necessary to add fuel.
C A U T I O N: Do not let the fuel tank get completely empty, because contaminants in the fuel tank
can be drawn into the fuel system and it will become necessary to clean and bleed
the entire fuel system .
Do not drive until the fuel level warning light (62) comes on, refuel before.
* Optional
123
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124
Off>road driving
Adjust the axle suspension for off road driving as described in
"AXLE SUSPENSION / LOCKING SYSTEM", chapter 3.03.
For off>road driving, driving on unpaved surfaces and during winter or cold weather conditions, additional ge>
ars are provided, which may only be selected when the vehicle is at standstill, and in the following order:
1. Off road gear

2. Front wheel drive, drive for 1st axle (for 8¥6 drive)
or 1st and 2nd* axle (for 8¥8* drive)
3. Transverse differential lock for the driven axles

The off road gear can be selected separately.
The front axle drive requires off road gear .
The transverse differential lock requires off road gear and front axle drive.
The Off>road gear reduces the travel speed of the individual gears and increases the drive power, which is
transferred by the wheels to the ground surface.
If the off road gear is selected and one or more wheels spin, then the drive for the 1st (or the 1st and 2nd)*
axle can be added via switch .
If the addition of the drive for the 1st (or 1st and 2nd)* axle is not enough to prevent the wheels from spin>
ning, then the transverse differential lock for the driven axles can be added via switch (95) .
CAUTION : When driving with locked transverse differential locks, the drive axles can be si>
gnificantly damaged.
For that reason, the following must be observed:

> Shift only while at a standstill.
> Drive carefully!
> Do not drive into curves.
> Turn on the differential locks only shortly before an obstacle and turn it off imme>
diately after passing it.
> Use the differential locks only to drive on loose or muddy ground, sand, slush, etc.
> never use it to drive on solid ground.
* Optional
125
185747
126
1.1 To add the off road gear :

> Bring the crane to a standstill,
> on the gear selector switch (110), push the "N" button,
> add the off road gear, via switch (93),
> on the gear selector switch (110) , push the button for the desired travel range.
> The off road gear is added as soon as the indicator light (69) is on.
If the indicator light (69) does not come on, return the gear selector stitch (110) to neutral position
again, and repeat procedure.
2.1 Add front axle drive:

> add the drive for the 1st (or 1st and 2nd*) axle via switch (94),
> Move off carefully.

The drive for the 1st (or the 1st and 2nd* axle ) is not added until the indicator light (70) turns on.
3.1 Turn on the transverse differential locks

> turn on the transverse differential locks for the driven axles via switch (95),

The transverse differential locks are not turned on until the indicator light (71) turns on.
To turn the added controls off

Turn the transverse differential locks as well as the front axle drive (s) off as soon as the ground becomes harder
and provides sufficient traction and they are no longer required to drive.
* Optional
127
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128
Rear axle steering *

The rear axle steering can be turned on via button (118). It makes it possible, independent from the front
wheels) to turn the wheels of the 3rd and 4th axle in for offset movement of the crane (for the so > called dog or
crab walk) and tight turning radii .
If the button (118) is pushed on the left side, then the wheel turns in to the left, if the button (118) is pushed on
the right, then the wheel turns in on the right.
When using the rear axle steering, after the switch (91) is turned on, the shift lock is actuated, which means
that only the 1st and 2nd forward gear and the reverse gear are available.
CAUTION : The rear axle steering may not be used while driving on public roads.
The functional warning lights (55 and 73) for the rear axle steering must be off for
on road travel.
Check the rear axles visually to make sure the tires are turned in the right direction.
To put the hydraulic rear axle steering in operation

> Bring the vehicle to a standstill on level ground.
> Apply the parking brake (130) .
> Shift the gear selector switch (110) to ∫N™neutral position,
> via switch (91), release (open) the steering lock for the 3rd and 4th axle .
It can be unlocked when the automatic transmission is in neutral position, in 1st and 2nd forward gear as well
as in reverse.
> Move the steering button (118) slightly to the left and right until the yellow indicator light (73) lights up.
If the red warning light (55) lights up instead of the yellow indicator light (73) , then the steering lock / release
is in an intermediate position .
In this case, turn the switch (91) on and off again and move the steering button (118) slightly to the left and
right until the yellow indicator light (73) lights up.
> Now the 3rd and 4th axles can be steered synchronous to the left or right, as desired, via the steering button
(118) .
To take the hydraulic rear axle steering out of operation
CAUTION: If the rear axle steering is no longer needed, then it must be locked again on level
ground in straight forward direction before continuing to drive!
> Bring the vehicle to a standstill on level ground.

> Turn the wheels for straight travel.
> Apply the parking brake .
> Via switch (91) , apply the steering lock for the 3rd and 4th axle.
> Move the steering button (118) for the rear axle steering slightly to the left and right until the yellow indica>
tor light (73) turns off.
C A U T I O N: The red warning light (55) MAY NOT LIGHT UP!
> Make sure that the rear axle steering is locked by actuating the steering button (118) again while watching
the wheels of the 3rd and 4th axle, these wheels may no longer steer to the right or left .
* Optional
129
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130
Towing
In case the mobile crane must be towed, a pressurized air supply coupling is provided on the right front
underneath the bumper. This connection must be coupled with the air pressure system of the tow truck to
maintain the pressurized air supply for the crane.
Towing regulations
For towing, the reserve pressure of the air pressure brake system of the vehicle to be towed must be at least 6
bar.
C A U T I O N: During the towing procedure, the parking brake must be released to prevent
damage to the operating system .
As a matter of principle, the towing speed may not exceed 10 km/h ( 6.2 miles per hour) .
To tow the crane, use the tow coupling with pins in the bumper.
The crane may only be towed with a tow bar.
1. In the event of Diesel engine and automatic transmission damage

> The towing distance may be no more than 10 km (6 miles).
> The towing speed may no exceed 10 km / hr (6.2 mph).
> The air pressure system of the vehicle to be towed must always be supplied with at least 6 bar air pressure via
an external air pressure system.
> Shift the transfer gear into neutral position , switch (92) is turned on.
CAUTION : If the transfer gear is in neutral position ( free run), then the Diesel engine may not
be started.
The automatic transmission may not be shifted from neutral position, which means
that no other gear may be selected.
2. In the event of transfer gear damage

> Flange off the gear shaft from the transfer gear to the drive axles and hold it up.
> Change the gear selector switch (110) to neutral position ∫N∫ and start the engine and let is run at low idle.
3. In the event of damage to the drive axles

> Remove the gear shaft to the defective axle.
> Remove the half shaft from the defective axle.
Note : Allow only trained personnel to carry out the towing procedures if there is any damage to
the drive axles.
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132
To stop the vehicle in traffic

> Bring the crane to a stillstand by applying the service brake.
> The travel range on the gear selector switch (110) can remain engaged.
To interrupt travel with the engine running

>Bring the crane to a stillstand by applying the service brake.
>Before leaving the driverπs seat, switch the gear selector switch (110) into neutral position ∫N∫ .
>Use the manual brake lever (130) to apply the parking brake, the indicator light (39) must turn on.
To end travel
Note: Always change back to "N" (Neutral) before turning the engine off .
>Bring the crane to a stillstand.

>Switch the gear selector switch (110) into neutral position ∫N∫ .
>Use the manual brake lever (130) to apply the parking brake.
> Relieve the engine load by slowly decreasing the engine RPM, let the engine run for a short time at idle speed
to give the turbocharger time to run out.
> Turn the ignition off with the ignition key (34) by turning it counterclockwise to position ∫0∫ and remove the
key.
> Turn the battery master switch (25) off by pulling the switch cam .
> Lock the cab.
> Place chocks under the wheels to prevent the crane from rolling away.
133
3.05 THE CRANE AT THE JOBSITE 023406>00
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134
SELECT THE SITE

Choose the site carefully to assure that the outriggers can be extended to the support base specified in the load
capacity chart and that the crane can be aligned horizontally.
DANGER: The safety guidelines in chapter 2.04 must be strictly observed and adhered to, as
they prevent personal injury or death to yourself and others and possible damage to
the crane and equipment!
Changing from driving to crane operation

> the manual brake lever in the driverπs cab and in the crane cab (130 and 263) is applied,
> the gear selector switch in the cab and in the crane cab ( 110 and 208) is in neutral position ∫N∫,
> the switch (36) is set to the vehicle symbol ,
> the switch (120) is turned off (in position ™Axles suspended∫,
> the engine is running,
Note: You should also refer to chapter 4.03, STARTING THE CRANE.
Lock the axle suspension

> Align the crane via the manual leveling control ( button 122, 123, 124, 125 ) as level as possible,
> turn the engine off by turning the ignition key (34) to the left and turn the ignition off.
> the switch (36) is set to the ∫left∫ to the crane operation symbol , the axle suspension is automatically loc>
ked.
In addition, for safety reasons, always turn switch (120) to AXLE SUSPENSION LOCKED.
CAUTION : The switch (36) may only be actuated when the engine is not running and the igni>
tion is turned off.
Note : If the switch (36) is actuated, the gear selector switch in the driverπs cab (110) as well as in
the crane operatorπs cab (208) must be in neutral position "N" .
If the switch (36) is actuated when the engine is running, the engine and ignition turns off
automatically .
The following functions are now changed over to superstructure operation:

Electrical system, steering, gear selection, engine regulation for travel motor, parking brake and operating
brake.
> Turn the ignition on again and start the engine as described in chapter 3.04 .
Support the crane

The crane can be supported from the chassis as well as from the crane operatorπs cab.
CAUTION : The crane operator is obligated to set the appropriate load capacity chart for the ac>
tual supporting width in the LICCON overload safety device.
The vertical support cylinders must be supported properly and may not be exten>
ded as far as the lower stop .
The crane operator must assure, by measuring, that the extended cylinder stroke is
less than the maximum cylinder stroke.
If there is any doubt, all vertical support cylinders must be retracted a couple of
millimeters (mm] .
135
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136
To change over to superstructure operation
CAUTION: The switch (36) may only be actuated when the engine is not running and the
ignition is turned off.
Note: When the switch (36) is actuated, the gear selector switch in the driverπs cab (110) as well as
in the crane operatorπs cab (208) must be in neutral position ∫N∫.
If this is not the case, the warning light (111) lights up in the driverπs cab in the display and
the warning light (209) lights up in the crane operatorπs cab in the display .
If the switch (36) is actuated when the engine is running, the engine and ignition turns off
automatically.
In addition, for safety reasons, always turn the switch (120) to ∫AXLE SUSPENSION
LOCKED∫.
> Turn the switch (36) to the crane symbol to automatically lock the axle suspension .

Steering, gear selection control, manual and foot brake, and the electrical system .
137
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138
Support the crane from the chassis

On both sides of the vehicle is a control box Fig. 1 with buttons, to control the outrigger support system.
Control box functions on the left side of the vehicle

a) Sliding arms left front > extend / retract
b) Outrigger cylinder left front > down / up
c) Outrigger cylinder right front > down / up
d) Outrigger cylinder right rear > down / up

e) Outrigger cylinder left rear > down / up
f ) Sliding arms left rear > extend / retract
Control box functions on the right side of the vehicle

a1) Sliding arms right front > extend / retract
b1) Outrigger cylinder right front > down / up
c1) Outrigger cylinder left front > down / up
d1) Outrigger cylinder left rear > down / up

e1) Outrigger cylinder right rear > down / up
f 1) Sliding arms right rear > extend / retract.
Bring the outrigger pads from transporting to operating position
Fig. 2 :
> Turn the handle of the retaining pin (C) ∫upward∫ and pull the pin from the bore (4) .
> Pull the outrigger pads on the handle until the stop (2) on the head of the outrigger cylinder (5).
> Insert the pin (C) into bore hole (3) .
Fig. 3 :
> Turn the handle of the pin (C) downward to secure it .
Fig. 4:
> Loosen the mechanical lock (pin A) on the four sliding arms and take them out,
> Open the control box for the outriggers, on the left or right hand side of the vehicle.
139
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140
Support the crane
Extend the sliding arms from the chassis
The sliding arms on the left side of the vehicle may only be controlled via the control box on that side of the ve>
hicle.
The sliding arms on the right side of the vehicle may only be controlled via the control box on that side of the
vehicle.
DANGER : The operator must carefully observe the sliding arms while he extends or retracts
them.
While the sliding arms are extended or retracted, the operator must make sure that
there are no persons or objects within the danger zone.
> Increase the engine RPM with the manual control lever (132) to max. 1500 RPM, otherwise let it run at low id>
le speed.
> Extend all four sliding arms to the support base specified on the load capacity chart .
> Check if support surfaces (E1 or E2) match.

E1= wide support base
E2= reduced support base
Check marks (F) can be used by the crane operator to check the extension, if the extension is correct, they are
located just before the edge of the outer part of the sliding arm (D + G).
> Secure all 4 sliding arms with 2 pins (A+B) per arm .
DANGER: The sliding arms MUST be secured with pins to prevent any subsequent movement
of the support surface. If this is not done, it could cause a serious a c c i d e n t !
The pins (A and B ) must be completely inserted and the handle must point
downward. If this point is not adhered to, the crane could topple or tip over and
cause a serious
a c c i d e n t.
Check the outriggers
Note: At this point, make sure to check the site again to assure that the outriggers can be placed
properly and securely and assure that all safety regulation and guidelines are strictly ad>
hered to, otherwise there is a serious risk of accidental injury or death!
DANGER: All 4 sliding arms for the outriggers must be extended, including those on the oppo>
site side of the load.
If only the sliding arms on the load side are extended, it can have serious
consequences, because :
1. Due to the load hanging on the hook, the hoist cable and the telescopic boom (this
also applies to the auxiliary boom and the guy ropes, if they are used) are under
great tension and stress.
If, in this situation, the load were to drop from the lifting cables and tackle, or if
the hoisting cable were to break, the sudden loss of the load and resulting relief
would cause the boom to jerk up, which in turn might cause the crane to topple
over.
2. Despite previous assumption, it might become necessary to swing the load to the
opposite side. If this happens, it could cause the crane to topple over.
3. When slewing from the lengthwise or longitudinal direction, the center of gravity
changes due to the boom or counterweight momentum, which might be sufficient
for the crane to topple over.
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Supports
The outrigger pads must be set on a foundation or base, its size depends on the ground conditions, the
foundation must be made of strong material, such as wood, steel or concrete slabs.
Note: Read and observe the safety guidelines and observe the permissible ground bearing load (
chapter 2.04 ) .
Outrigger pad area = 2500 cm2
DANGER: Use only suitable material for making the foundation.

The foundation must be placed in the center beneath the outrigger pads.
If this point is not observed, there is a serious risk of accidents.
To extend and / or retract the outrigger cylinders from the chassis
C A U T I O N: To assure proper operation of the LICCON supporting force monitor, the support
cylinders may not extended either to ∫ lower stop∫ nor to ∫ upper stop∫ .
> Go to one of the control boxes and extend the outrigger cylinders and raise the crane until the wheels are off
the ground.
DANGER: If this point is not observed, the axles may be damaged , because the vehicle frame
might bend during crane operation.
When you move the outrigger cylinders from the control box, move only those
outrigger cylinders you can see directly !
When the outrigger cylinders are extended or retracted, the operator must make
sure that there are no persons or objects within the danger zone.
Align the crane horizontally

On both sides of the vehicle and in the crane operatorπs cab are sight gauges to level the crane.
> Align the crane horizontally by extending or retracting the individual outrigger cylinders.
This is achieved when the air bubbles in the sight gauges are between the innermost rings.
DANGER: If the crane is not aligned horizontally, there is an increased risk of causing a
serious accident.
Note : The maximum permissible deviation from the horizontal crane position is ± 0,5% (± 0.3∞ ).
The air bubble in the sight gauges must be between the innermost ring (in the center).
The crane is aligned

> Once the crane is aligned, reduce the engine speed via the engine regulation (132) to low idle speed and turn
the engine off by turning the ignition key (34) to the ∫left∫.
> Turn the ignition off and remove the ignition key.
To put the crane into service

Refer to chapter 4.03, STARTING THE CRANE.
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To retract the outrigger cylinders from the crane chassis

> Start the travel and crane engine, as described in chapter 3.04 and move the throttle control lever (132) to in>
crease the engine RPM to about 1500 RPM , otherwise let it run at low idle.
Retract the outrigger cylinders, Fig. 1

> Open the control box on the left or right hand side of the vehicle,
> Evenly retract the outrigger cylinders by pressing the buttons (b / c / d / e or b1 / c1 / d1 / e1) and lower the crane
until the wheels touch the ground.
> Retract all four outrigger cylinders all the way.
> Turn the switch (120) to the position for ∫Axles suspended∫.
>
CAUTION : Make sure all wheels touch the ground before turning off the switch for the axle sus>
pension (120) .
If this point is not observed, it can cause damage to the axle suspension due to the
sudden release of the axle lock.
Bring the outrigger pads from operating to transport position
Fig. 2 :
> Move the handle of pin (C) ∫upward∫ and pull the pin from bore (3) ,
> Push the outrigger pad into the retainer (1) and push it in on the handle in direction of the large arrow until
the stop on the head of the outrigger cylinder (5).
Fig. 3 :
> Insert the pins (C) into the bore hole (4) and turn the handle downward to secure them .
CAUTION: Before retracting the sliding arms, bring the outrigger pads into transport position
and secure them.
When you push the outrigger pads into the retainer , push back with your hand to
create some counterpressure to prevent the outrigger pads from dropping!
Retract the sliding arms
DANGER: The operator may only move those sliding arms he can see directly.
Fig. 4
> Release and remove the mechanical lock >pins (A + B ) on all four sliding arms.
Fig. 1 +5 :
> Fully retract the sliding arms by pressing the button (a + f or a1 + f1 ) and secure them with the four pins (A)
to prevent them from falling out.
> Insert the four pins (B) into the transport receptacle.
> Return the engine speed to low idle speed and turn the engine off by turning the ignition key to the left ,
> turn the ignition off and remove the key.
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Prerequisites
on the crane:
> The parking brake is applied,
> the crane is parked on level ground of sufficient load carrying capacity and has been aligned horizontally via
the manual leveling system.
> the safety pins on all four sliding arms are pulled out ,
> the outrigger pads are in operating position and secured,
> the battery master switch is turned on .
In the driverπs cab:

> The parking brake is applied,
> the axle suspension is locked, which means
the switch (36) is set to ∫crane operation∫ ,
the switch (120) is turned on, (in position axle suspension ∫locked∫).
> The travel and crane engine is turned off, the ignition key has been pulled.
Change over
> In the driverπs cab, start the travel and crane engine, as described in chapter 3.04.
> Align the crane via the manual leveling (button 122, 123, 124, 125) as horizontally as possible.
> Turn off the travel motor (engine) and turn the ignition off.
> Change the switch (36) to the ∫crane operation∫ symbol, the axle suspension is automatically locked.
> Pull the ignition key.
CAUTION : The switch (36) may only be actuated when the engine is not running and the
ignition is turned off.
Note: If the switch (36) is actuated, the gear selector switch in the driverπs cab (110) as well as in
the crane operatorπs cab (208) must be in neutral position ∫N∫.
If the switch (36) is actuated when the engine is running, the engine will turn off
automatically.
In addition, for safety reasons, always turn the switch (120) to ∫AXLE SUSPENSION
LOCKED∫.

steering, gear selection control, parking and service brake, and the electrical system.
To put the crane into service

Refer to chapter 4.03, STARTING THE CRANE.
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To support the crane from the crane operatorπs cab
CAUTION: All guidelines and preventative measures already given in the chapter describing
the crane supporting procedure from the chassis must be observed.
If the crane is to be supported from the crane operatorπs cab, the desired movement (sliding arm or outrigger
cylinder) must be preselected via the preselector switch (319).
The control release button (316) must always be held down, when one of the buttons (295, 296, 308, 309) is
actuated. This safety measure is installed to prevent that the crane gets into a dangerous incline position due to
inadvertent actuation of one of the support function buttons. Always give a warning signal (horn) before
extending or retracting the sliding arms.
DANGER: The operator must carefully observe the sliding arms while he extends or retracts
them.
If he must extend or retract outriggers without visually being able to seem the
outrigger cylinder or sliding arm, then he must use an assistant to guide him.
there no persons or objects within the danger zone.
If the crane is not properly horizontally aligned, there is a danger of accidents.
All 4 sliding arms and outrigger cylinders must be extended, even those on the
opposite side of the load.
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Support the crane from the crane operatorπs cab (continuation)

> In the crane cab, insert the ignition key into the key operated switch (283), and start the travel engine as
described in chapter 4.10.
During the support procedure, the Diesel engine speed may be increased from idle to max. 1500$1 via the
throttle control lever (132) in the driverπs cab.
Return the lever (132) to ZERO position as soon as the increased engine is speed is no longer needed.
> Via the control release preselector button(319), preselect the desired movement (either sliding arm or
outrigger cylinder).
The buttons (295, 296, 308, 309) have four functions each, depending on the symbols.
Extend the sliding arms from the crane operatorπs cab
DANGER: All 4 sliding arms on the outriggers must be extended, including the sliding arms on
the side opposite the load.
> Button (319) hold the button in ∫bottom∫ position and at the same time
> Button (295) push ∫down∫ > left front sliding arm extends,
> Button (296) push ∫down∫ > right front sliding arm extends,
> Button (308) push ∫down∫ > left rear sliding arm extends,
> Button (309) push ∫down∫ > right rear sliding arm extends.
Extend the outrigger cylinders from the crane operatorπs cab :

> Button (319) hold the button in ∫top∫ position and at the same time
> Button (295) push ∫down∫ > left front outrigger cylinder extends,
> Button (296) push ∫down∫ > right front outrigger cylinder extends,
> Button (308) push ∫down∫ > left rear outrigger cylinder extends,
> Button (309) push ∫down∫ > right rear outrigger cylinder extends.
Align the crane horizontally

> Align the crane horizontally by extending or retracting the individual outrigger cylinders.
This is achieved when the air bubbles of both sight gauges (206) are between the innermost rings.
The maximum permissible deviation from the horizontal crane position is ± 0.5% (± 0.3∞ ).
DANGER: If the crane is not aligned horizontally, there is an increased risk of causing a
serious accident.
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To retract the outrigger cylinders from the crane operatorπs cab :

> Push button ( 295, 296, 308, 309 ) to evenly retract all outrigger cylinders and lower the crane until the wheels
touch the ground.
> Retract all four outrigger cylinders fully.
> Change over the switch for the axle suspension (120)
CAUTION: Make sure all wheels touch the ground before changing the switch for the axle
suspension (120) .
If this point is not observed, it can cause damage to the axle suspension due to the
sudden release of the axle lock.
Retract the outrigger cylinders

> Button (319) hold the button in ∫top∫ position and at the same time
> Button (295) push ∫up∫ > left front outrigger cylinder retracts,
> Button (296) push ∫up∫ > right front outrigger cylinder retracts,
> Button (308) push ∫up∫ > left rear outrigger cylinder retracts,
> Button (309) push ∫up∫ > right rear outrigger cylinder retracts.
Bring the outrigger pads to transport position and secure them.
Retract the sliding arms
CAUTION: Before retracting the sliding arms, return the outrigger pads to transport position
and secure them.
When you push the outrigger pads into the retainer, create a counterpressure to
prevent the outrigger pads from dropping!
> Button (319) hold the button in ∫down∫ position and at the same time
> Button (295) push ∫up∫ > left front sliding arm retracts,
> Button (296) push ∫up∫ > right front sliding arm retracts,
> Button (308) push ∫up∫ > left rear sliding arm retracts,
> Button (309) push ∫up∫ > right rear sliding arm retracts.
DANGER : The operator may only move those sliding arms he can see directly.
If he is not able to observe any of the outrigger cylinders or sliding arms, then he
must be guided by another person.
Turn the travel engine off from the crane operatorπs cab.
> Let the engine run for a short time at low idle speed, then turn the engine off via the engine Stop button (320).
> Turn the ignition off with the ignition key (283) by turning the key counterclockwise to ∫0∫ and then pull it off.
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Changing over from crane operation to travel operation
Prerequisites on the crane

> The crane is supported and the crane is aligned horizontally by the outrigger cylinders on the outrigger pads ,
> the wheels are off the ground.
> The telescopic sections are retracted and locked,
> The telescopic boom is placed to the front in the boom receptacle and is secured to prevent it from running out
by itself.
> The hook block is secured, as described in chapter 3.04 .
> The counterweight plates are distributed as described in chapter 3.04.
> The battery master switch (25) is turned on .
C A U T I O N: For transport on public roads transport the counterweight plates and the hook
block as described in chapter 3.04 DRIVING ON PUBLIC ROADS.
Prerequisites in the crane operatorπs cab

> The parking brake is applied ,
> the gear selector switch is in neutral position ∫N∫ ,
> the ignition for the travel motor is turned off, the key has been pulled.
Prerequisites in the driverπs cab:

> The travel motor has been turned off,
> the ignition is turned off, the ignition key has been pulled,
> the battery master switch (25) is turned on,
> the parking brake is applied,
> the gear selector switch is in neutral position "N",
> the axle suspension is locked, which means switch (120) is turned on ,
> the switch (36) is turned ∫to the left∫ (to the crane symbol) .
Changeover
In the driverπs cab turn the switch (36) to the ™vehicle™ symbol.
CAUTION: The switch (36) may only be turned if the engine is not running and the ignition is
off.
> Insert the ignition key into the keyed switch (34) and turn it one notch in clockwise direction and start the
travel engine as described in chapter 3.04.
> Move the throttle control lever (132) to increase engine speed to max. 1500 RPM.
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Retract the outrigger cylinders and sliding arms
Proceed as described in this chapter in paragraph Retract outriggers from the crane chassis,
> lower the crane until all wheels are again in contact with the ground,
> retract outrigger cylinders and secure the outrigger pads with pins in transport position,
> retract the sliding arms and secure with pins.
Turn the travel motor off

> Let the engine run for a short time at low idle, then turn the engine off by turning the ignition key (34) to the
"left" .
> Turn the ignition off.
Actuate the axle suspension

> Turn the switch (120) off, the axle suspension is automatically activated.
CAUTION : Do not turn the switch (120) off until the crane is lowered all the way.
If this is not observed, the axle suspensions can be damaged due to sudden release
of the axle blocking system.
> Turn off the ignition key.
Changing from crane to travel operation

> Turn the switch (36) to the vehicle symbol, the axle suspension is activated.
Before moving the switch (36), make sure that the gear selector switch in the driverπs cab (110) as well as in
the crane operatorπs cab (208) is in neutral position "N" .
If this is not the case, the warning light in the display (111) lights up in the driverπs cab and the warning light
in the display!(209) lights up in the crane operatorπs cab.
If the switch (36) is actuated when the engine is running, the engine and the ignition will turn off automati>
cally.
CAUTION : The switch (36) may only be actuated when the engine is at a standstill and the igni>
tion is turned off.
The steering, gear selector control, hand and foot brake, and electrical system functions are now changed over
to superstructure operation.
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Check the following items before leaving the jobsite :
In the crane operatorπs cab

> Is the crane superstructure locked to the crane chassis?
> Is the gear selector switch in position ∫N∫?
> Is the parking brake applied?
> Is the rear axle steering locked in ™straight position∫?
> Are the windows and doors closed?
In the driverπs cab:

> Is the rear axle steering locked in ™straight position∫?
> Is the switch ∫axle suspension locked∫ turned off?
On the crane
> Are the sliding arms fully retracted and secured with pins?
> Are the outrigger cylinders fully retracted?
> Are the outrigger pads inserted and secured?
> Are the lock pins secured, with the handle pointing downward?
> Are the lock pins in their retainers and secured so they cannot fall out?
> Is the installation ladder* secured (under the front bumper)?

> Are the travel motor and the converter box covered ?
> Is the mounting cover for the removal and installation of the transfer gearbox tightly secured?
> Are the locks and retainer bars of the covers on the crane superstructure closed?
> Are the wheel chocks in their retainers and secured so they cannot fall out?
> Are the control boxes on both sides of the vehicle closed and locked?
> Is the spare tire mounted properly and is it secured with a retaining pin?
> Is the telescopic boom fully retracted and secured in its retainer?
> Is the hoist cable fastened on the pin of the towing coupling?
> Are the counterweight plates distributed and secured as described in chapter 3.04?
DANGER: All locks, spring retainers and pins must be attached and secured in such a way,
that they cannot loosen up by themselves and thus cause damage.
If these checks and measures are not performed, chances of having an accident will
increase.
Note: After an extended period on a jobsite, before driving off, make sure to complete all checks
described in chapter 3.02 ∫BEFORE VEHICLE START UP ∫.
* Optional
159
4.00 OPERATION OF THE SUPERSTRUCTURE 021677>00
160
021677>00
Chapter 4
Operation of the Superstructure
161
4.01 CONTROLS AND INSTRUMENTS 023407>00
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162
Pos.:
200 Pedal > Engine regulation > crane engine

201 Pedal > Engine regulation > travel engine
202 Pedal > Service brake
203 Pedal > Slewing gear > apply slewing brake
203.1 Button > Slewing gear > rotation (release brake)
204 Button > Horn
205 Switch > Travel direction indicator
206 Sight gauge > To check horizontal leveling of crane
207 Dome light with switch
208 Gear selector
209 Monitor > Screen
210 * Switch > Beacon
211 * Switch > Beacon
212 * Switch > Seat heater
213 Not installed
214 Not installed
215 Not installed
216 Not installed
217 * Switch > Working floodlight, roof or boom head
218 Not installed
219 Switch > Illumination of hoist gears
220 * Switch > Windshield washer > roof window,
221 Switch > Windshield wiper > roof window > 2 stage,
Stage 1 > intermittent, Stage 2 > wipe
222 * Switch > Windshield washer system > front window,
223 Switch > Windshield wiper > front window, 2stage
Stage 1 > intermittent, Stage 2 > wipe
224 * Switch > Air conditioner system
225 * Indicator light > Air conditioner system
225 * Indicator light > Air conditioner system
226 * Indicator light > Auxiliary heater
227 * Switch > Auxiliary heater
228 Reserved
229 Reserved
230 Reserved
231 Reserved
232 Reserved
233 * Digital clock with the following indicators:
> Time of day and day of the week,
> problem in auxiliary heater,
> air temperature,
> Preselection of heater operation with 3 preselection times,
every preselection time can be preprogrammed up to 7 days in advance.
234 Gauge > Tank level, fuel for travel and crane engine
235 Hour meter > Crane operating hours
* Optional
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Pos.:
236 * Keyed switch > Working platform

237 * Indicator light > (red) lights up if the keyed switch (236) is set to ∫crane operation∫
238 * Indicator light > (green) lights up if the keyed switch (236) is set to ∫working platform∫
239 Switch > Working floodlights
240 * Switch > Working floodlights, roof or boom head
241 Reserved
242 Reserved
243 Reserved
244 Reserved
245 Reserved
246 Control box > Emergency control
248 Rotary knob > To change armrest incline

249 Manual lever > To change armrest and control panel incline
250 Manual lever > To release lock for horizontal seat adjustment
251 Rotary switch > Fan (3> stage)
252 Turn regulator > Temperature > cab heat
253 Sliding regulator > Change between recirculated air /ventilation, air flow
254 Turn regulator > Temperature > air conditioning system
255 Air vents > Control > air flow ∫up∫ or ∫down∫
256 Turn regulator > Adjustment of seat height and suspension (set the operatorπs weight on the
window)
257 Button > Back support in the upper area of the backrest
258 Button > Back support in the lower area of the backrest
259 Manual lever > Change of seat surface incline
260 Reserved
261 Manual lever > Mechanical crane superstructure lock
262 Seat contact switch
263 Manual lever > Parking brake
264 Reserved
265 Reserved
Trumatic>e Gas heater *
247 * Control unit with thermostat for gas heater

— Indicator light > (red), lights up in case of problem
“Sliding switch > for full power (large flame symbol), for half power (small flame symbol)
” Sliding switch > Heater > OFF > Ventilation
‘ Rotary knob > Temperature selection with green indicator light
* Optional
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183228
166
Machines with one hoist gear
Pos.:
266 * Button > ∫Deadman ∫ > bypass of seat contact switch (262)
267 Manual control lever > Slewing gear and telescoping gear
268 Button > Shut off bypass when telescoping out
269 Button > Rapid gear cut in for hoist gear, luffing gear and telescoping gear
270 Button > Rear axle steering
271 Button > Bypass of LICCON Overload safety device, to luff up at overload
DANGER: The bypass may only be made if the overload was triggered by luffing
down, with freely suspended load, and the crane operator is absolutely
sure that the overload condition will be eliminated by luffing down.
In addition, it is also not permitted to bypass the LICCON safe load indi>
cator system in working radii of !e3.5 m .
272 Switch > Slewing brake ∫open / closed∫

273 Restrictor > Restrictor closed
The slewing movement follows the manual control lever (267) , which means
the slewing movement is slowed by the manual control lever and stops as soon
as the manual control lever it set to zero position.
Restrictor open
The slewing movement follows the load (free run) and must be slowed down via
the pedal!(203) .
274 Reserved
275 Reserved
276 * Button > ∫Deadman∫ > bypass of seat contact switch (262)
277 Manual control lever > Hoist gear and luffing gear
278 Button > Rapid gear cut in for hoist gear
279 Button > Rapid gear cut in for hoist gear, luffing gear and telescoping gear
280 Rotary switch > Preselection of operating mode

Switch position (Fig. 1) Tele 1 telescope out / in
Switch position (Fig. 2) Tele 2 telescope ou t / in
Switch position (Fig. 3) Tele 3 and 4 synchronized telescope ou t / in
* Optional
167
183227
168
Machines with two hoist gears
Pos.:
266 * Button > ∫Deadman∫/ bypass of seat contact switch (262)
267 Manual control lever> Slewing gear and hoist gear 2
268 Button > Shut off bypass when telescoping out
269 Button > Rapid gear for hoist gear 2
270 Button > Rear axle steering
271 Button > Bypass of LICCON safe load indicator to luff up at overload
DANGER: The bypass may only be made if the overload was triggered by luffing
down, with freely suspended load, and the crane operator is absolutely
sure that the overload condition will be eliminated by luffing down.
In addition, it is also not permitted to bypass the LICCON safe load indi>
cator system in working radii of !e3.5 m .
272 Switch > Slewing brake ∫open / closed∫ ( on / off)

273 Restrictor > Restrictor closed
The slewing movement follows the manual control lever (267) , which means
the slewing movement is slowed by the manual control lever and stops as soon
as the manual control lever it set to zero position.
Restrictor open
The slewing movement follows the load (free run) and must be slowed down via
the pedal!(203) .
274 Reserved
275 Reserved
276 * Button > ∫Deadman∫/ bypass of seat contact switch (262) (262)
277 Manual control lever > Hoist gear 1 and luffing gear and telescoping gear, depending on position of
switch (280)
278 Button > Rapid gear for hoist gear 1
279 Taster > Rapid gear for luffing and telescoping gear, depending on position of switch
(280)
280 Rotary switch > Preselection of operating mode

Switch position (Fig. 1) Tele 1 telescope out / in
Switch position (Fig. 2) Tele 2 telescope ou t / in
Switch position (Fig. 3) Tele 3 and 4 synchronized telescope ou t / in
Switch position (Fig. 4) Luffing gear
Switch position (Fig. 5) Hoist gear 1 and 2
Special installation ∫Three movements∫ *
280 Switch position (Fig. 6) Hoist gear 1 and 2 and luffing gear
CAUTION : In this switch position, the slewing gear is locked.

If the slewing crane movement is needed, the switch (280) must be mo>
ved into one of the other switch positions (Fig. 1 to 5) .
* Optional
169
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170
Pos.:
281 EMERGENCY OFF button> To turn the crane engine and the complete electrical system off
282 Keyed switch > Ignition / starter switch for crane engine
283 Keyed switch > Ignition / starter switch for travel engine
284 Reserved
285 Reserved
286 Warning light > Insufficient oil pressure in crane engine
287 Indicator light > Crane superstructure position to the front
288 Indicator light > Travel direction indicator > crane
289 Warning light > Fuel level / travel engine
290 Warning light > Insufficient oil pressure in travel engine
291 Indicator light > Preglow travel engine
292 Reserved
293 Warning light > Alternator , crane engine
294 Warning light > Increased coolant temperature, crane engine
295 Button > Sliding arm or outrigger cylinder, left front extended / retracted
296 Button > Sliding arm or outrigger cylinder, right front extended / retracted
297 Indicator light > Crane superstructure position to the rear
298 Warning light > Parking brake (manual brake lever) applied
299 Warning light > Oil pressure in travel engine
300 Warning light > Increased coolant temperature, travel engine
301 Warning light > This warning light combines warning lights on the crane chassis::
1. Insufficient oil pressure in the oil circuit torque converter / automatic trans>
mission , or
2. Error in electronic gear control, or
3. Increased oil temperature in oil circuit torque converter / automatic trans>
mission
302 Reserved
303 Reserved
304 Indicator light > Preglow crane engine
305 Reserved
306 Indicator light > Crane superstructure locked to crane chassis
307 Warning light > Air filter > crane engine
308 Button > Sliding arm or outrigger cylinder, left rear extended / retracted
309 Button > Sliding arm or outrigger cylinder, right rear extended / retracted
310 Switch > Low beam
311 Switch > Emergency blinker system
312 Switch > Release / lock rear axle steering
313 Switch > All wheel drive for 1st (or 1st and 2nd* ) axle
314 Reserved
315 Switch > Instrument panel illumination
316 Button > Take on / place down counterweight
317 Button > Lock / release counterweight
318 Reserved
319 Button > Preselection: extend / retract sliding arms or outrigger cylinders
320 Button > Engine Stop button / travel engine
* Optional
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172
Pos.:
321 Reserved
322 Reserved
323 Reserved
324 Reserved
325 Reserved
326 Control and indicator unit of ∫LICCON∫ safe load system

(please refer to more detailed ∫LICCON∫ operation manual)
A > Alpha numerical data input

B > Program keys
C > Input key to confirm changes
D > Keyed switch Bypassing the LICCON safe load indicator system
E > Function keys > > Page forward

< > Page backward
{ > Brightness adjustment
F > Function keys Screen program
327 * High voltage warning device
328 Battery master switch > Electrical system for crane superstructure
* Koptional
173
4.02 CONTROL + INDICATOR UNIT FOR ∫LICCON∫ OVERLOAD SAFETY DEVICE 022634>00
183589
174
Operation:
See separately issued Operating Manual.
The LICCON overload safety device can be operated with the following control elements:
A $ Alpha numerical keyboard

With the alpha numerical keyboard (A), numerical values can be entered and a coded equipment
configuration view (load capacity chart) can be recalled on the screen.
The equipment configuration views are marked with a two digit number code.
If the entered code is confirmed with the button (C) ENTER, then the equipment configuration view (load
capacity chart) appears on the monitor.
If the equipment configuration view is confirmed with button (F8) O.K., then it is taken on by the
LICCON overload safety device and transferred to the ™OPERATION∫ program. The operating view
appears on the monitor .
B $ Program keys
With the program keys (B), various LICCON programs can be recalled.
By pushing program key (B1), for example, the equipment configuration view can be called up, and with
program key (B2), the operating view can be chosen.
During crane operation, various programs can be called up on the screen.
However, the crane operator is also able to view different equipment configurations, but he may not
confirm them with the key (F8) O.K.
By pushing the program key (B2), the operating view returns to the view, with which the crane works.
The equipment configuration view may only be selected if no crane movements are initiated.
F $ Function keys
With the function keys, operating conditions and functions, which are visible in the lower part of the
screen as symbols, can be changed.
The function keys (F1 to F8) are always to be viewed in connection with the symbols above, since they
have different meanings in different LICCON programs.
C $ The (C) ENTER key is an input confirmation key.

If there is a function in the operating mode and / or the equipment configuration is being changed, than
this change can only be confirmed with the key (C) ENTER and the load capacity chart can be called up
on the screen.
If the change in operating mode and / or the equipment configuration is confirmed with the key (C)
ENTER and an acoustical signal sounds, then the change has not been accepted. This means that the
chosen operating mode or the chosen equipment configuration has not been programmed into the
system.
D $ The installation key (D) is used to bypass either the LICCON overload safety device or the hoist top
limit switch.
On some cranes, the functions of this switch have been replaced by a switch on the instrument panel.
E $ The keys (E1) and (E2) < > are used for horizontal paging and are needed when a load capacity chart
is too wide to be viewed on one screen .
If keys (E1) and (E3) are pushed at the same time, the screen changes from light to dark.
When keys (E2) and (E3) are pushed at the same time, you can choose between 4 light levels.
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Description
The LICCON safe load indicator or overload safety device (Liebherr Computed Controlling) consists of an
electronic module with power pack and micro processor central unit, the monitor with controls, pressure
sensors, incline angle and length sensors.
As an overload safety device, the LICCON works according to the principle of a comparison of ∫should be∫ and
∫actual∫ values.
The ∫actual∫ values coming from length,angle and pressure sensors are compared with the ∫should be∫ values,
which are stored in the central data processor, and then are calculated by the microprocessor.
The crane data values, such as the load capacity charts, boom weights, center of gravity and measurements,
have been stored on data chips in the central data bank. This data is the reference information used to calculate
any overload conditions.
The system functions are either controlled by automatic components such as boom length and angle sensors or
by direct input into the dialogue functions on the monitor .
The prewarning symbol blinks when the load on the crane is 90 % or higher than the maximum load carrying
capacity.
If the overload safety device recognizes a sensor problem, for example, which could lead to a dangerous
situation, then it shuts down and displays a STOP symbol, even though the maximum permissible load carrying
capacity has not been exceeded. The STOP symbol remains on and blinks as soon as the load on the crane
exceeds the maximum permissible load carrying capacity.
An acoustical signal sounds with the blinking prewarning and STOP symbol.
If the crane shuts off due to overload, movements must be carried out which will reduce the load momentum,
such as:
> setting the load down
> retracting the telescope
> luffing up while pushing the button ™Luffing up at overload∫
Load momentum increasing movements are:

> luffing down
> telescoping out
> taking on a load by luffing up.
The central unit recognizes ground problems, broken lines and short circuits after (+).
When the hoist top limit switch is triggered, the overload safety device is also triggered.
The movement ∫hoist gear up∫ and all load momentum increasing movements are shut off, the warning symbol
hoist limit switch and the STOP symbol appear and blink on the monitor.
DANGER: The proper function of the load moment limiter is only assured if the adjusted
operating mode, the equipment configuration and the hoist cable reeving actually
match the condition of the crane.
If this is not observed, it can cause a serious accident!
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To weigh a load
The overload safety device makes it possible to determine the weight of a raised load (net load). This
calculation, however, is only permitted if the approximate weight of the load is known and it can be assured
that the crane is not overload.
With a free hanging hook block (with tackle), press the Tare button (F7) in the operating view. The ∫actual load
capacity∫ is automatically reset to zero.
In the ∫actual load carrying capacity indicator symbol∫, the NET description will appear in addition.
If the load is now being raised via the hoist gear, then the net weight of the load will be indicated.
If the working radius is being changed, the indicator returns to indicate the gross weight.
Functions check for control and indicator unit

The status of the monitor and the controller is shown via four luminous diodes, which are located on the front
behind the front windshield.
LED 1 (yellow) 24 V power supply available

LED 2 (red) Error in controller (watchdog error)
LED 3 (green) Self test of controller (Self test o.k.)
LED 4 (yellow) Power supply for controller available
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4.03 STARTING THE CRANE 023408>00
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Checks before starting crane operation

Before operation, complete the following checks:
Note: For detailed description of the below listed checks,

refer to chapter 7.05, ™MAINTENANCE GUIDELINES , CRANE SUPERSTRUCTURE™ .
Check on the crane engine

Check the coolant level (Fig. 1 )
> The coolant reservoir must be filled to the rim on the filler neck.
DANGER: NEVER check the coolant level if the engine is still warm! Check the coolant level
ONLY when the engine is cold, hot coolant fluid can cause serious skin burns!
Check the oil level (Fig. 2)

> The oil level must be between the minimum and maximum ( MIN and MAX) mark on the dipstick.
Check the air filter (Fig. 10)

> If the warning light lights up when the engine is running, then clean or replace the air filter insert.
Check the fuel level (Fig. 9)

> Check how much fuel is remaining in the tank by checking the fuel gauge in the craneπs cab.
CAUTION : Do not wait until the fuel tank is completely empty before adding fuel, otherwise
contaminants and particles in the fuel will be drawn into the fuel system, making it
necessary to flush and bleed the system.
Checks on the hydraulic tank for the crane hydraulic

Breather filter (Fig. 4)
> Open the rotary cover and visually check the filter for contamination.
Oil filter (Fig. 5)

> Service the two filters according to guidelines in chapter 7.02 and 7.03.
> One of the two filters is equipped with a maintenance indicator*.
If it is contaminated, a red area will appear in the indicator.
Oil level (Fig. 6)

> The oil level must be in the center of the center sight gauge.
CAUTION: Check the oil level:

> with the vehicle in level position,
> with the telescopic boom placed down,
> with the folding jib folded in.
Central lubrication system (Fig. 7 )

> Make sure that the grease containers is always filled with grease, as specified to the lubrication chart.
*Optional
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Check the general crane condition

Before operating the crane, the crane operator must ensure that the following conditions are met:
> The crane must be properly supported and aligned horizontally,

> The slewing gear of the slewing ring must be clean and greased,
> The air supply for the oil cooler and radiator must be clear and unobstructed,
> The side covers must be closed and locked,
> There are no other persons or objects within the craneπs slewing range or danger range ,
> The cable and rope drums as well as the limit switch are free of snow and ice,
> There are no loose parts and objects on the crane superstructure, telescopic boom and folding jib*.
Make sure to observe all safety guidelines and danger warnings in chapter 5.02 FOLDING JIB .
DANGER: Before lifting the boom, it must be assured that there are no loose parts on the
boom, such as pins, spring retainers, etc. and that is is free and clear of any ice for>
mation.
If this point is not observed, there is an increased risk of accidents and severe
injuries due to falling objects, which might strike persons or objects and equipment
on the ground.
Before telescoping or luffing up the telescopic boom, you must check that the
folding jib* is pinned in both transport retainers on the telescopic boom pivot
section!
*Optional
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Crane operatorπs seat

The two unlocked control consoles can be tilted upward, the crane operatorπs seat can be adjusted to any body
size.
When adjusting the seat, move the seat with your body (seat and back) .
Seat adjustment
> Adjustment of arm rest height
Lever (248)
> Adjustment of back rest incline, including the two control consoles
Lever (249)
> Release for horizontal seat adjustment

Bracket (250).
Adjustment of seat suspension

> Set the approximate weight of the operator on the sight gauge of the regulator (256).
> Adjustment of pneumatic back rest support in the upper area of the backrest
Button (257).
> Adjustment of pneumatic back rest support in the lower area of the backrest
Button (258).
To raise and lower the seat surface on the front as well as adjusting the complete seat surface incline including
the two control consoles
> Turn the lever (259) in direction — and set the desired position by moving your body weight around until
comfortable.
> Release the lever (259) .
To raise and lower the seat surface on the rear as well as adjusting the complete seat surface incline including
the two control consoles
> Turn the lever (259) in direction “ and set the desired position by moving your body weight around until
comfortable.
Adjusting the seat height

> Turn the lever (259) alternately in direction —+“ and set the desired position by moving your body weight
around until comfortable.
Seat heater *
The seat can be heated by turning on the switch (242, not shown).
*Optional
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Heater / ventilation / air conditioner *

Also refer to chapter 6.01, HEATER.
The crane operatorπs cab can be heated, ventilated or cooled as ambient temperatures require.
The controls for the heater , ventilation and air conditioner are located below the crane operatorπ seat.
To heat the cab with the engine dependent heater

> Preselect the air distribution by closing or opening the air vents (255) to distribute the air to the front, upward
or downward,
> Turn the pull switch (253) to air circulation ,
> Turn on the blower with the knob (251) ,
> Regulate the temperature with the regulator (252) .
To heat the cab with the engine independent, Diesel fuel operated heater*
> Set the correct time to turn the heater on and the time of duration on the digital clock (233).
> Turn switch (227) to turn on the heater, the heater is operational, as soon as the indicator light (226) lights
up.
> Close / open the top/bottom air vents (255) to choose air distribution ,
> turn the pull switch (253) to ventilation,
> turn on the rotary switch (251) to turn on the blower,
> regulate the temperature via the regulator (252) .
To heat the cab with the engine independent, gas operated Trumatic>e 2800 * heater
Also refer to the enclosed, more detailed manufacturerπs operating manual and chapter 6.01 HEATER.
> Set the desired room temperature on the thermostat ( rotary knob ‘ of the control unit (247). and set the
temperature vale (252) to WARM´, (open it all the way).
> Close the pull switch for fresh air /ventilation (253).
> On the control unit (247), set the switch ” to ªHEAT´ and set the switch “ to the desired power. In low
ambient temperatures, let the heater run at full power.
or downward,
> Turn the pull switch (253) to air circulation ,
> Turn on the blower with the knob (251) ,
> Regulate the temperature with the regulator (252) .
* Optional
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To ventilate the cab

or downward,
> Turn the pull switch (253) to fresh air ,
> Turn on the blower with the knob (251) .
Air conditioner *
Also refer to the enclosed, more detailed manufacturerπs operating manual .
> Turn the air conditioner on via switch (224), the system is operational as soon as the indicator light (225)
lights up.
> Close / open the top / bottom air vents (255) to choose air distribution ,
> Change the pull knob (253) to recirculate the air ,
> turn the rotary switch (251) to turn on the blower .
> Regulate the temperature with the regulator (254).
Sun screen
The front windshield and the roof window are quipped with a sun screen.
> If necessary, move both screens to provide the best possible protection from glare and sun.
* Optional
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Windshield wiper
The windshield wipers on the front window as well as on the overhead roof window can be operated with the 2
stage switch (223, 221) .
Windshield wiper on front window > switch (223)

Windshield wiper on roof window > switch (221).
1. Stage > intermittent operation
2. Stage > standard wipe operation
Windshield washer (to clean the windows) *

The windshield wipers on the front window as well as on the roof window can be supported in their function by a
windshield washer system * .
Add commercially available antifreeze fluid suitable for windshield washer systems to the reservoir before the
start of the cold season.
Button (222) Front window

Button (220) Roof window.
Front window
The front window may be opened from the inside by simply pushing on it. A pair of nitrogen cylinders helps to
raise the window.
If you want to open the window only partially, you can secured the window on the perforated belt at any angle.
DANGER: Be very careful when you close the front window, make sure that your HANDS ARE
OUT OF THE WAY so you donπt jam them in the window and injure yourself!
Horn
Before you start working, make sure to check the horn by pressing down the foot operated button (204) to check
its function.
D A N G E R: The horn should be used ONLY in dangerous situations to warn others, to preserve
its warning effectiveness.
Lighting
The air plane warning light * is actuated with switch (211) .
The winch illumination * and the heater for the external mirror * is turned on with switch (219) .
The working floodlights on the front and rear* on the crane operatorπs cab are turned on with switch (239) .
The working floodlights on the roof of the cab * and on the boom head * are turned on with switch (240) .
The interior of the cab is illuminated by a dome light with switch (207) .
The instrument panel illumination can be turned on or off with switch (315) .
The headlights on the vehicle are turned on with switch!(310).
The emergency blinker system is turned on with switch (311) .
* Optional
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Preheat the crane hydraulic *

Version to >40∞ C.
Before the crane hydraulic system can be preheated, the crane engine must be warm and running.
In order to assure proper function of the crane hydraulics in extremely low temperatures, the engine and the hy>
draulic system must be preheated before using the crane., switch (305)
CAUTION : The engine must be preheated and the hydraulic system must be ∫run to warm up∫.
The cylinders, which are especially stressed in crane operation, such as those for
> vertical support,
> boom luffing cylinders and
> boom telescoping cylinders,
must be controlled in such a way that the cold oil in the cylinders is displaced and
replaced with warm oil.
Refer to the end of this chapter for preheating the engine and the crane hydraulic > Crane operation at am>
bient temperatures below >20∞ C .
*Optional
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Turn on the crane ignition > check the instruments

> Turn on the battery master switch (behind the crane cab on the battery box).
> Insert the key into the ignition (282) and turn it one notch in clockwise direction to position!"1" .
The following indicator and warning lights come on when the crane ignition is turned on:
> Oil pressure warning light > crane engine (286)
> Preglow indicator light > crane engine (304)
> Battery charge indicator light > crane engine (293)
The indicator light (304) turns on for approx. 50 seconds ( =preglow time) and then blinks for 30 seconds
(=starting period ).
DANGER: NEVER operate the crane with defective warning lights. Any defective lights and
bulbs MUST BE REPLACED before operating the crane.
If the crane is operated without a functioning warning system, it can cause serious
accidents, injury and death.
Fuel gauge
> Check the fuel gauge for the crane engine
CAUTION: Do not operate the crane until the fuel tank is empty, as residue and contaminants
from the bottom of the tank are then drawn into the fuel system. If the fuel system
becomes contaminated, it must be cleaned and bled before continued operation.
DO NOT WAIT until the warning light lights up before adding fuel!
Starting the craneπs engine and turning it off

> Continue to turn the ignition key to position !"2", slowly depress the gas pedal for the crane engine!(200) and
start the crane engine.
> As soon as the crane engine has started, release the ignition key and release the pressure on the gas pedal
(200) .
Note : In every starting procedure, it will take the starter approximately 1 second before it starts
to turn, after the ignition key has been moved to position!"2"!.
This delay prevents problems for the electric engine shut off.
If the engine does not start after 5 seconds, slowly press down the gas pedal for the crane engine !(200) and crank
the starter again.
CAUTION : The crane engine may only be started if:

> the warning light (293) for the alternator is on.
> the indicator light (304) for the flame glow system blinks.
If the engine does not start after max. 10 seconds, wait for one minute before restar>
ting.
> Before restarting, return the ignition key all the way to stop.
If the engine is warm, start the engine without pressing on the gas pedal (200) to prevent unnecessary exhaust
emission.
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Winter operation
To start the engine with the integrated flame glow system
CAUTION: The engine may only be started if:

> the warning light (293) for the alternator is on .
> the indicator light (304) for the flame glow system blinks .
If temperatures are below freezing, always start the engine with the flame glow system , note the longer
preglow time.
It not only reduces the starter limit temperature, but also simplifies starting the engine at temperatures, which
actually do not yet require a starting aid.
It is also possible to reduce exhaust emission during the starting procedure, if the vehicle is being started by
using the flame glow system (∫preheat∫) .
The flame glow system is not operating if the engine is started immediately.
Note: > At a coolant temperature of more than +20 ∞C, the flame glow system is turned off
(automatically)!
> A problem in the flame glow system is indicated if the preglow indicator light (304) does
not turn off or if it lights up when the engine is running.
At a coolant temperature of <15∞C , the flame glow system is automatically turned on, the current dependent
PREGLOW TIME begins, it lasts about 45 bis 50 seconds and the indicator light !(304) is on.
If the engine is started during this time, the system shuts off.
> Turn the ignition key back to the stop before restarting.
After a preglow time, the STARTING READINESS starts, it lasts about 30 seconds.
The indicator light !(304) blinks, the engine must now be started without pressing the pedal for engine
regulation (200) down.
If the engine is not being started during this time, the system shuts off.
> Release the ignition key after the engine starts.
The flame glow system shuts off automatically if :

> the engine is not being started within 30 seconds, when the indicator light (304) blinks,
> the engine is started as long as the indicator light (304) is on,
> the warning light > alternator (293) does not turn off when the engine is running,
> the coolant temperature reaches approx. 25∞C when the engine is running.
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Starting procedure at ambient temperatures of less than 0 ∞C
1. Preglow
The charge indicator light (293) must be on.
> The preglow time of about 40 >50 seconds starts when the ignition key (282) is being turned to position ∫1∫
(travel), which is indicated by indicator light (319) , which is ∫on∫.
If the engine is started during this preglow time, then the preglow procedure is automatically interrupted.
In this case, return the ignition key to the stop and repeat the preglow procedure.
2. Start the engine

After the preglow time, the starting readiness period of approx. 30 seconds begins, the indictor light (304)
blinks.
CAUTION: The engine may only be started if

> the indicator light (304) flame glow system blinks.
> Turn the ignition key (282) to position ∫2∫ and start the engine without pressing down on the gas pedal (200).
If you do not start the engine within this starting readiness period, the starting readiness period
automatically drops off.
In this case, repeat point 1 and 2.
During the cold season, pay special attention to the batteries. The starting capacity is greatly reduced during
cold temperatures; at >10 ∞C it is only 66% of its normal capacity.
For that reason, the batteries should be kept in a heated area when the engine is turned off .
CAUTION : As long as the engine is running, DO NOT loosen, remove or change the cable of the
alternator,on of the battery terminals nor the regulator plug.
During operation,the alternator must always be connected with the batteries .
DO NOT turn the engine off by turning the battery master switch off (328, not
shown)!
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3. Starting procedure at ambient temperatures of less than >20 ∞C
At extreme temperatures, to make sure the engine starts properly and is supplied with sufficient lubrication,
the engine and the oil pan should be preheated.
Preheating the engine *

Prerequisite: All components must be filled with service fluids for winter operation, as specified in the
lubrication chart.
The engine is preheated* via the coolant circuit with a Diesel fuel operated heater.
To preheat the engine oil in the oil pan*

The oil is preheated by the engine heater exhaust.
Preheat time
depends on ambient temperatures
Ambient temperature Preheat time

[∞C] [min]
> 40 to > 35 120
> 35 to > 30 90
> 30 to > 25 60
> 25 to > 20 30
> 20 and above no preheating
Preheating
> Turn on the battery master switch (on the battery box, behind the crane operatorπs cab) ,
> Turn the temperature regulator (252) to ∫cold∫.
> Depending on the ambient temperature, turn the heater for the preheat system on via switch (227) about 30 to
120 minutes before starting the engine , the indicator light (226) will light up to indicate proper function .
After about 15 seconds, the heater will turn on and will run automatically.
To turn the heater off after the preheat time

> Turn the heater off via switch (227) , the indicator lights (226) turn off.
This interrupts the flow of fuel and the combustion stops.
The fan and the heater pump will continue to run to cool the heater off and both will turn off after about 150
seconds.
*Optional
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The engine runs > check instruments

Observe the oil pressure warning light (286) immediately after starting the engine.
CAUTION : If if the warning light (286) does not turn off, or if it comes on during crane
operation, turn the engine off immediately, to prevent engine damage due to lack of
oil pressure .
The engine must must turned off immediately , in case of :

> the output and speed changes without changing the engine regulation lever,
Do not put a full load on the engine until it is at operating temperature.
The following indicator lights must turn off when the engine is running :
> Battery charge indicator (293)
The following instruments should be monitored during cane operation:

> Coolant temperature (294)
> Battery change indicator light (293)
> Air filter on crane engine (307).
CAUTION : If the warning light for the engine coolant (294) lights up during operation,
turn the engine off immediately.
Increased coolant temperature can cause serious engine damage.
Turn the crane engine off by pushing the EMERGENCY OFF BUTTON (281).
In case of an emergency, the travel and crane engine can be turned off by pushing the emergency OFF button
(281) . As soon as the button (281) is pushed, the engine shuts off, the alternator does not supply current, which
causes the relay to fall off and the electric crane control turns off. At the same time, the knob locks down.
In order to restart the engine, the ignition key (282) must be turned to the left stop, then the knob of the button
(281) can be released by turning it to the ∫right∫ . Now the crane engine can be restarted.
CAUTION : The emergency ∫OFF∫ button (281) may only be used in absolute emergency situa>
tions.
It is not permitted to use the emergency ∫OFF∫ button (281) during regular opera>
tion!
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The engine runs

As soon as the batteries are charged by the alternator, and the voltage is stable, the electric crane control and
the ∫LICCON∫ overload system turn on automatically.
The micro processor system will run through a self test.
Do not move any one of the two manual control levers during this run > up period.
CAUTION : If one of the two manual control levers has been moved during run up, the error
message ∫ERROR 013∫ will appear, but this does not mean that the crane is out of
service.
To delete this error message, turn the crane engine off and turn the ignition off.
The error message ∫ERROR 013∫will disappear as soon as the engine is restarted.
If no error was found, the EQUIPMENT CONFIGURATION VIEW will appear after a few seconds.
The EQUIPMENT CONFIGURATION VIEW will appear, which was used last.
If the symbol ªINSTALLATION (!)´ (Fig. 5) blinks, do NOT operate the crane, because the LICCON!overload
warning device is bypassed by keyed switch (17) .
During crane operation, the keyed switch (17) must be turned OFF, the switch must be positioned
™VERTICALLY∫ and the key must be pulled off.
DANGER: If the switch (17) is in position ∫ON∫

> the working speeds cannot be controlled by the manual control lever,
> the LICCON overload warning system is no longer effective,
> the hoist limit switch is bypassed.
Crane operation with the switch (17) ∫ON∫ is strictly prohibited.

This could cause a serious ACCIDENT, causing injury or D E A T H !
The actual equipment configuration must be entered. After checking the equipment configuration, press the
F8 key to confirm, at the same time, the OPERATING VIEW will appear.
The battery voltage may be checked on the ∫LICCON∫ monitor (326) by pressing the F3 key.
Refer to the LICCON operation manual for more details.
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Crane operation at ambient temperatures of less than >20 ∞C
Preheat the hydraulic system *
CAUTION : The preheat time takes max. 30 minutes.
Prerequisite:
> The crane engine, has been preheated and turned off, as described at the beginning of this chapter.
> Insert the ignition key into the ignition (282) and start the crane engine, as described at the beginning of this
chapter.
> Turn on switch (305 *) , the green indicator light in the switch must light up.
> After 30 minutes preheat time, turn the switch (305) off again.
Note : By turning on the switch (305) the hydraulic system is switched to ∫Block∫ , and the hy>
draulic system is warmed up within about 3 0 minutes from > 40 ∞C to +10 ∞C.
> Actuate the boom luffing cylinders and the boom telescoping cylinders for about 10 minutes (extend/ retract) to
displace the cold oil in the cylinders , replacing it with warm oil.
Turn the crane engine off

> Turn the crane engine off by turning the ignition key (282) to the left.
> Remove the ignition key.
CAUTION: If the engine is at a standstill and the ignition is left "on", the batteries may
discharge, depending on their current charge.
Low level discharge can cause the following damage:
> reduced capacity

> white layer on batteries and terminals
> short battery life expectancy
> defective batteries
*Optional
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4.04 SAFETY DEVICES 022540>02
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Check the safety devices

The crane operator MUST CHECK EVERY TIME before he operates the crane, that all safety devices function
properly.
DANGER: DO NOT OPERATE THE CRANE WITH DEFECTIVE WARNING DEVICES , this
can lead to serious accidents, causing injury or death.
LIEBHERR COMPUTED CONTROLLING ( LICCON )
Safe load indicator (load moment limiter)

The electronic safe load indicator turns all load moment increasing crane movement off as soon as the permis>
sible load moment is exceeded.
Only load moment decreasing movements can then still be carried out.
However, the fact that the crane is equipped with this load moment limiter does not free the operator from his
responsibility with regard to operating safety.
For that reason, before lifting a load, he must know the approximate weight of the load and decide, by checking
the load capacity table, if the crane is able to lift such a load.
DANGER: The load moment limiter is a safety device, it may not be used as an operational shut
off control when extending the boom or luffing it with a suspended load .
Before operating the crane, the load moment limiter must be adjusted to the actual
equipment configuration according to the load capacity chart, only this way will it
be able to fulfill its protective duty.
If the crane operator does not observe this safety obligation, then there is a great
danger that the crane overturns and is damaged beyond repair, despite a
functioning load moment limiter.
The load moment limiter cannot monitor and control all possible operating
conditions, this is still primarily the responsibility of the operator.
The safe load indicator registers but does not monitor, for example the incline.
The safe load indicator registers but does not monitor, for example the wind speed.
Leveling instruments
(sight gauges)
In order to assure the safety while working with the crane, the crane must be horizontally aligned.
DANGER: If the crane is not aligned horizontally, there is an increased risk of accidents.
On both sides of the vehicle is a sight gauge, as well as in the crane operatorπs cab, the air bubbles must always
be within the inner rings (center).
The maximum permissible deviation from the horizontal line is ± 0.5% (± 0.3∞ ).
If the sight gauges have been damaged by external forces and become maladjusted, then they must be recali>
brated.
To do so, place a level on the slewing ring onto the frame of the vehicle, and align the crane horizontally in a
longitudinal and lateral direction.
Then reset the sight gauges by adjusting the adjustment screws and secure them in this position with lock nuts.
During normal travel and crane operation, the adjustment of the sight gauges should remain unchanged.
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Emergency "OFF" button (281)

If actuated, the Diesel engine and the electric crane control is turned off. Any initiated movement can be
stopped immediately.
DANGER: The emergency "OFF" button may only be used in actual emergency situations. It
is not permitted to use this emergency "OFF" button for normal operation!
"Control Release" knob* (266/276 )

If the crane operator works standing up, he must hold down one of the two knobs.
If he works in seated position, the two knobs (266/276) are bypassed by the seat contact switch (262) .
Note: This safety control is installed in order to prevent any unintentional crane movement which
may be accidentally caused if the manual control levers (267 / 277) are touched when
entering or exiting the cab.
Seat contact switch (262)

When working while seated, the control release for the crane operation is enabled by the depressed seat contact
switch (262).
Knob ∫Luffing at overload∫ (271)

In overload, the ∫luffing" crane movement is also turned off, even though it is a load reducing crane movement
with a freely suspended load.
If the knob (271) "luffing at overload" is held down and the manual control lever (277) is moved in ∫luffing up∫
direction, then this crane movement can be carried out.
DANGER: IT IS NOT PERMITTED to lift a load with the hoist gear by ∫luffing the boom ™,
when it has already triggered the load moment limiter and therefore shut off the
crane movement.
This could lead to overload and cause the crane to topple over.
Bypassing this function in the limit range may only be done, if the LICCON safe load
indicator does not report overload of the freely suspended load.
It is also not permitted to bypass the LICCON system at working radii of e3,5 m .
Contact switch * on the crane superstructure > locking mechanism

During crane operation ∫only to the rear∫ , the superstructure must be mechanically locked to the chassis.
The lever (261) must be ∫down∫.
CAUTION : The indicator light (306) must be on.
Due to a contact switch on the locking mechanism, the LICCON is released in locked condition so that the load
capacity chart "to the rear" (increased load capacities) can be released.
* Optional
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Bypass key (D )
The key operated button (D) on the monitor of the LICCON control has two different functions.
It can be used to bypass:

1. the LICCON safe load indicator and / >or
2. the shut off for the hoist ∫top∫ limit.
Hold the keyed switch (D) to the ™right™ position to bypass the LICCON safe load indicator.
CAUTION: The bypass is only permitted and necessary for installation purposes.
Select the shut off cause to be bypassed with function key F 5,

> push the key for the next shut off cause to appear in the symbol >
and then hold the key in this position to the ∫right∫ .
The symbol begins to blink.
Two different shut off causes can be selected for bypass:

1.1 Shut off of LICCON (100%)
In the symbol, the text ∫100%∫ is crossed out.
2.1 Shut off of hoist ∫top∫ limit

In the symbol appears a crossed out load hook with arrow on ∫upper stop∫.
1.1.1 Bypassing the LICCON safe load indicator
DANGER: The LICCON safe load indicator system is not effective as long as the keyed button
is operated.
2.1.1 Bypass of the ∫upper™ hoist limit switch
DANGER: The hoist limit > hoist ∫top∫ is bypassed as long as the keyed button is operated.
The hoist limit switch may only be bypassed during crane operation, if another
person carefully observes the distance between the hook block and the boom pulley
head.
The observer must be in direct contact with the crane operator.
The hoist movement must be carried out with utmost care and at the lowest possible
speed.
Bypassing the hoist limit switch is only permitted in an emergency by authorized
personnel only!
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Sliding arms monitor*

For detailed description refer to chapter 6.04 SLIDING ARM MONITOR.
The LICCON sliding arm monitor checks the data of the crane operator, who has set it according to the
supporting width to select the load capacity chart on the LICCON panel **.
CAUTION: It does not monitor proper crane support and if the sliding arms are pinned
properly on the intended positions.
Support force monitor *, Fig. 1

See also chapter 6.04 SLIDING ARM MONITOR.
The support force is monitored via the LICCON safe load indicator **.
During crane operation, he LICCON support force monitor constantly determines the support force in all 4
outrigger cylinders.
The maximum and minimum values , when the alarm is triggered have been entered at the factory, depending
on crane type.
In equipment configuration crane supported, these support forces are automatically shown, either on crane
operator request or when a critical situation occurs.
CAUTION: Blinking question marks ( ??? ) instead of a value, with the error number !062/063 in
the ERROR symbol FK6 indicate an error in the corresponding pressure sensor or
in the connection.
1. Indication of current support force **

With function key F3, the symbol support force monitor, Fig. 1 is shown next to the crane symbol, the
support force for every support is shown in tons [t].
The symbol appears automatically, including the alarm signal ªSHORT HORN´, if a support has reached or
exceeded the maximum force or if it has reached or fallen below the minimum force. However, the crane
movements are NOT shut off.
The value (s), which trigger the warning are shown blinking.
DANGER: The crane movements are NOT shut off if the permissible support force is being
exceeded / fallen below. Under no circumstances may the LICCON support force
monitor be used to utilize the crane to the tipping limit!
If this is not observed, it can result in a serious accident.
2. Programming maximum and minimum support forces **

The same maximum and minimum support force values for each support have been entered at the factory,
depending on crane type.
The operator can change these 5 values in the SUPPORT FORCE LIMIT VALUE MODIFICATION program,
depending on the situation at hand.
* Optional
** Refer to the more detailed, separately issued ∫LICCON∫ operating manual for the operational guidelines for
the LICCON safe load indicator.
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Limitation of slewing speed , Fig. 2

In order to prevent a slewing movement which is inadvertently carried out to quickly, the slewing speed must
be limited via the LICCON safe load indicator system * in the CONTROL program.
> When starting the program via the B2 program key, preprogrammed percentage values are shown under the
∫Vmax >Symbol∫ .
> Use function key F8 (or program key B2) to return to the CRANE OPERATING VIEW.
Actuate a slewing movement (restrictor 273)

The control of the slewing movement can be made in two ways.
Before beginning crane operation the crane operator must determine how he wants to carry out the slewing
movement by opening or closing the restrictor (273) .
1. Restrictor (273) open

The slewing movement follows the load (after>run), which means the slewing movement must always be slo>
wed down by countering with the manual control lever or with the slewing brake (pedal 203) .
2. Restrictor (273) closed

The slewing movement follows the manual control lever (267), which means the slewing movement is slowed
down and stops as soon as the manual control lever is moved to zero position.
By pressing the foot button (203.1) , the slewing brake can be opened and the boom can be positioned with the
hoist gear over the load by sensitively deflecting the corresponding manual control lever .
Lock hoist gear *, Fig. 3

In order to prevent an unintended movement of the cable winch, which is not needed in crane operation with
only one cable winch by inadvertently touching the manual control lever, this cable winch can be turned off via
the !CONTROL program.
Push function key F4 to bring the cursor to the symbol for the cable winch, which is to be turned off, then push
function key F5 to turn the cable winch off .
The winch symbol changes to ∫cable winch is crossed out ".
Wind velocity warning device * Fig. 1

The wind velocity warning device is integrated into the ∫LICCON∫ system. *
As soon as the max. permissible wind speed is exceeded, the wind velocity warning light blinks and an
acoustical signal ªSHORT HORN´ sounds, but the crane movements are NOT shut off.
DANGER: If the permissible wind speed is exceeded, shut down is NOT carried out
automatically. This is only a warning system!
YOU YOURSELF MUST cease crane operation and lower the boom.
If you do not adhere to this rule, the risk of causing a serious accident is
significantly increased.
CAUTION: When operating the crane with the folding jib, the removable wind sensor must
always be installed and properly connected and fully functional, otherwise the
∫LICCON∫ safe load indicator will indicate a malfunction.
* Refer to the more detailed, separately issued ∫LICCON∫ operating manual for the operational guidelines for
the LICCON safe load indicator.
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Indication of direction of rotation of w inch and hook path

Is integrated into the ∫LICCON∫ system *
Via this symbol on the ∫LICCON∫crane operating view, the direction of rotation of the winch is shown, if the
winch spools in or out, even even if the actual movement of the hook block is hard to detect due to multiple ree>
ving or due to slow speed.
CAUTION: When the cable is spooled in /out, keep watching the winch to make sure that there
is no excess loose cable spooling up on the winch.
Loose cable can damage the winch cable.
Hoist limit switch > winch spooled in / out

A cam limit switch is installed in the hoist winch and turns off the ™down / lower™ crane movement, if there are
at least 3 safety loops remaining on the drum.
This switch also stops the movement when the winch is full.
DANGER: If the hoist cable is spooled up during installation, make sure that the end of the ca>
ble still remains in front of the winch and is not spooled up over the winch, because
if the end of the cable is then pulled over the winch by another turn, the shut off
could no longer be guaranteed when the cable gets to the three safety loops.
In this case, the cam limit switch must be reset.
In addition, if the hoist cable is replaced with a new one, then the cam limit switch
must be reset, so it shuts off when it gets to the point when there are still three
safety loops on the drum.
If this point is not observed, the cable mount can be torn out, causing the load to
fall.
Hoist limit switch > Hoist top

The hoist limit switch monitors the distance of the hook block to the boom pulley head, it is installed to prevent
the hook block from hitting the boom pulley head.
It must be checked before every crane operation by running the hook block up to the top weight to check the
switch function.
The ∫hoist∫, ∫luffing out∫ and ∫telescoping out∫ crane movements must shut off if the switch is functioning
properly.
DANGER: The hoist limit switch may only be bypassed during crane operation with the keyed
button (D), if another person carefully observes the distance between the hook
block and the boom pulley head.
The observer must be in direct contact with the crane operator.
The hoist movement must be carried out with utmost care and at the lowest possible
speed.
The limit switch may not be used as a regular shut off system .
If this point is not observed, in case of malfunction, various crane components can
be severely damaged or the crane can topple over.
Bypassing the hoist limit switch is only permitted in an emergency by authorized

personnel only!
Hydraulic safety valves

Pressure relief valves against broken pipes and hoses.
Shut off valves in luffing, telescopic and outrigger cylinders.
* Refer to the more detailed, separately issued ∫LICCON∫ operating manual for the operational guideli>
nes for the LICCON safe load indicator.
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High voltage warning device * HSW 40

The high voltage warning device* (327) monitors the safety distance between the boom and the overhead wires,
as long as they are high voltage (AC current) wires.
CAUTION: This unit is not effective for overhead wires of trolley or streetcar systems.
DANGER: This is only a warning device, it does not SHUT OFF operation.
Safe crane operation is only assured, if all adjustments,as described in chapter 4.08 ∫Working near overhead
electrical wires ∫ have been made.
A test unit on the boom sends test values via a cable to the high voltage warning device in the crane cab.
The monitoring range is limited, no warning will occur outside the monitoring range.
Note: Please also refer to chapter 2.04 SAFETY TECHNICAL NOTES.
If the voltage in the wires is known :

Set the voltage value on the high voltage warning device.
As soon as a minimum distance is exceeded, a warning will sound.
If the voltage in the wires is unknown :

The high voltage warning device * must be adjusted.
* Optional
221
4.05 CRANE OPERATION 022541>03
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222
Prerequisites:
> The crane is properly supported as noted in the load capacity chart and horizontally aligned,
> the counterweight is installed and secured, as noted on the load capacity chart ,
> the crane engine is running,
> the hook block is properly reeved according to the reeving chart ,
> all safety devices are set in accordance with the load capacity chart,
> the danger zone is free of personnel and objects.
CAUTION: Always operate the manual control levers slowly and carefully.
This not only ensures longer crane life, but also helps to avoid accidents.
DANGER: Any time there is any crane movement, you must make sure that there are no obsta>
cles within the working range and no persons within the danger zone.
Before initiating any crane movement, you must give a warning signal (horn. foot
button 204).
The crane engine is running

As soon as the batteries are charged by the alternator, and a stable, constant voltage is available, the electric
crane control and the ∫LICCON∫ safe load indicator will automatically turn on.
The micro processor will turn through a self test.
Do not move the two control levers (267, 277) during the run up period.
If n error was found, then then the "EQUIPMENT CONFIGURATION PRE>SELECTION" view will appear af>
ter a few seconds on the monitor.
The crane control is released

when the seat contact switch (262) is pushed down.
Not e: In order to prevent any unintentional crane movement when entering or exiting the cab by
inadvertently moving the manual control levers (267, 277) , the crane control is shut off by
the seat contact switch (262), as soon as the crane operator gets up from his seat.
If the crane operator must work while standing up, the seat contact switch can be bypassed
via one of the two buttons (266, 276) .
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224
Before starting to work

> the slewing movement control must be set by opening or closing the restrictor (273) and
> the telescopic boom must be extended to the noted extension length, according to the currently valid load capa>
city chart.
Extension length of telescopic sections
without folding jib

Telescopic boom : T=10.6 m to 40.0 m
Boom length [m]
10.6 14.0 17.4 20.7 24.1 27.5 30.9 34.3 37.6 40.0
Extension condition of telescopic sections [ % ]
Tele 1 0 46 0 92 0 92 92 0 92 92 0 92 92 100
Tele 2 0 0 46 0 92 46 92 92 92 92 92 92 92 100
Tele 3 0 0 0 0 0 0 0 46 23 46 92 69 92 100
Tele 4 0 0 0 0 0 0 0 46 23 46 92 69 92 100
Code No.:
See current load z z z z z z z z z z
capacity chart
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Extension length of telescopic sections
with folding jib

Telescopic boom : T= 34,3 m bis 40,0 m
Folding jib: K= 8,4 m bis 15,8 m
Boom length [m]
T= 34,3 T= 37,6 T= 40,0 T=30,9 T=37,6 T=40,0

K= 8,4 K= 8,4 K= 8,4 K=15,8 K=15,8 K=15,8
Extension condition of telescopic sections [ % ]
Tele 1 92 92 100 0 92 100
Tele 2 92 92 100 92 92 100
Tele 3 69 92 100 92 92 100
Tele 4 69 92 100 92 92 100
Code No.:
See current load z z z z z z
capacity chart
DANGER: For steep boom positions, for which no load capacities are noted on the load capa>
city chart, there is a danger of tipping backward , to the counterweight side, when
slewing the crane superstructure.
This danger exists especially
> if the support base has been reduced,
> if the crane is supported, but the sliding arms are retracted or
> if it is standing unsupported on the tires.
Before luffing up the boom with side mounted folding jib*, it must be assured that
the folding jib is attached to the telescopic boom pivot section for transport.
If this is not observed, then the folding jib can fall down when the boom is luffed up.
This can cause a serious accident.
Note: Transport retainer of folding jib, see chapter 5.02 FOLDING JIB.
* Optional
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VERSION WITH TWO HOIST GEARS*

Control of crane movements
Operating mode switch (280)

When telescoping telescopic sections 1, 2 and 3 out, when a programmed telescoping length is reached the te>
lescopic movement is shut off automatically and the symbol ∫ STOP Telescoping∫ appears on the monitor.
The shut off points are for :

Telescopic
[%] [%] [%] [%] [%]
section
1 46 92 100
2 46 92 100
3+4 23 46 69 92 100
To bypass the shut off

> Hold button (268) down, while simultaneously deflecting the manual control lever (277)!"to the right" until
the symbol!"STOP Telescoping " turns off.
> Release the button (268) and telescope the corresponding telescopic section out to the length given on the load
capacity chart.
Fig. 1 In this position, only telescopic section 1 is telescoped in or out via the manual control lever (277) , hoist
gear 1 or hoist gear 2 and the slewing gear are operational.
The rapid gear can be added for telescoping out or hoist gear 1 or hoist gear 2.
Fig. 2 In this position, only telescopic section 2 is telescoped in or out via the manual control lever (277) , hoist
Note: For design reasons, it is possible that telescopic sections 3 + 4 run along when telescoping
telescopic section 2 in our out.
For that reason, when triggering the shut off points for telescopic sections 2, 3 and 4, al>
ways position telescopic section 2 first.
Fig. 3 In this position, telescopic sections 3 + 4 are telescoped in or out synchronously via the manual control
lever (277) , hoist gear 1 or hoist gear 2 and the slewing gear are operational.
Fig. 4 In this position, the telescopic boom can be luffed up / down with the manual control lever (277) , hoist
The rapid gear can be added for luffing up or hoist gear 1 or hoist gear 2.
Fig. 5 In this position, only hoist gear 1 or hoist gear 2 and the slewing gear are operational.
The rapid gear can be added for hoist gear 1 or hoist gear 2 .
Fig. 6 Switch position ∫THREE MOVEMENTS∫ *

In this position, three crane movements
hoist gear 1 and hoist gear 2 and luffing the telescopic boom can be carried out at the same time.
The rapid gear can be added for hoist gear 1 or hoist gear 2
The slewing gear is automatically locked.
If the ∫slewing∫ movement is desired, then the operating mode switch (280) must be switched to posi>
tion (Fig. 5) .
Note: To be able to place the two hookblock reeved onto the chassis in 2 winch operation or to be
able to luff up the telescopic boom with reeved hookblocks, the operating mode switch (280)
is set to switch position (Fig. 6) t.
*Optional
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230
Version with two hoist gears

Crane movement ªLifting /lower (up / down) ´
DANGER: At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (button 269, 278,
279), if the crane is loaded with more than 50% of its maximum permissible load car>
rying capacity at the corresponding reach.
CAUTION: When spooling the cable of hoist gear 1 or 2 out, keep watching the winch to make
sure that there is no excess loose cable on the winch. Keep an eye on the winch!
> With program key B2 , turn on the OPERATING VIEW.

See also >Chapter 4.02 LICCON SAFE LOAD INDICATOR SYSTEM
>Chapter 5.10 MAST STUB*
>the more detailed LICCON Operating manual.
Hoist gear 1 up / down

> Move the manual control lever (277) to the front = hoist down (lowering)
> Move the manual control lever (277) to the rear = hoist up (lifting)
Hoist gear 2 up / down

The speed of the crane movement is regulated via the deflection of the corresponding manual control lever and
the gas pedal.
The ªhoist´ speed can be further increased by adding the rapid gear:
Turn the rapid gear on, hoist gear 1 and hoist gear 2
> Push the button (269 or!278) once, the ªrapid gear´ symbol appears on the monitor.
The rapid gear remains operational until the button (269 or 278) is pushed again or the manual control lever
(267 or 277) is returned to zero position and the ªrapid gear´ symbol turns off.
> Initiate the hoist or lowering movement be deflecting the corresponding manual control lever.
Note: On the crane operating view of the LICCON is shown that the winch turns, even if no hook
movement is visible due to multiple reeving and slow speed.
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232

Control of crane movement ªLuffing´ the telescopic boom
DANGER: It is not permitted to lift a load by luffing the telescopic boom if the LICCON safe lo>
ad indicator system has shut off when the load had been lifted via the hoist gear.
This will overload the crane and can cause the crane to topple over.
A bypass in the limit range may only be done if the LICCON safe load indicator sy>
stem does not report overload when the load is freely suspended.
In addition, it is also not permitted to use the bypass of the LICCON safe load indi>
cator system in working radii of more than 3.5 m.
> Switch the operating mode switch (280) to ªluffing´ the telescopic boom (fig. 4).
> Deflect the manual control lever (277) to the left = to luff up the telescopic boom.
> Deflect the manual control lever (277) to the right = to luff down the telescopic boom .
The speed of the ™luffing™ crane movement is regulated via the deflection of the corresponding manual control
lever (277) and the gas pedal for the crane engine.
A further increase of the luffing up movement can be obtained by adding the rapid gear:
Turn the rapid gear on

> Push the button (279) once, the ªrapid gear´ symbol appears on the monitor.
The rapid gear remains operational until the button (279) is pushed again or the manual control lever (277) is
returned to zero position and the ªrapid gear´ symbol turns off.
> Initiate the hoist or lowering movement be deflecting the corresponding manual control lever (277),
Luffing up with folding jib* installed on the side on the telescopic boom pivot section
DANGER: Before luffing up the boom with side mounted folding jib*, it must be assured that
*Optional
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234
Operating mode ªTHREE MOVEMENTS´ *
DANGER: The operating mode ∫THREE MOVEMENTS∫ is an installation operating mode and
may only be used for this purpose.
It may not be used for crane operation.
It is strictly prohibited to lift a load in this operating mode, because the LICCON sy>
stem does not monitor or shut off in this mode!
In order to place the hook blocks in 2 winch operation onto the chassis or to luff up the telescopic boom with ree>
ved hook block, the operating mode switch (280) is switched to switch position ∫THREE MOVEMENTS∫ (fig. 6).
The three crane movements hoist gear 1 +2 and luffing the telescopic boom can now be carried out at the
same time.
CAUTION : The slewing gear is automatically locked.

If the ∫slewing∫ movement is selected, the operating mode switch (280) must be set
to the position shown in fig. 5.
> Set the operating mode switch (280) to hoist gear 1 + hoist gear 2 + luffing (fig. 6).
> Initiate the luffing movement of the telescopic boom by deflecting the manual control lever (277)
> Actuate the hoist gear 1 by deflecting the manual control lever (277) .
> Actuate the hoist gear 2 by deflecting the manual control lever (267) .
* Optional
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236
Control of crane movement ªtelescoping´ the telescopic boom
Description
The telescopic sections 1 and 2 are hydraulically pushed in or out individually, after pre>selection via the ope>
rating mode switch (280), by moving the manual control lever (277).
The telescopic sections 3 and 4 are hydraulically pushed in or out synchronously, after pre>selection via the
operating mode switch (280), by moving the manual control lever (277).
Every extension condition has been given a 2 digit code number.

This code number is noted on the current load capacity chart and must be entered into the system via the LIC>
CON keyboard .
The telescoping procedure is shown optically on the monitor of the LICCON system.
The current extension condition of the various telescopic sections is shown in percentages [%], the individual
values are separated by diagonal lines.
Note: Please refer to more detailed LICCON operating manual for operational instructions.
CAUTION : The telescopic boom should generally be telescoped out to the required length wit>
hout a load and then the load should be attached.
However, it is possible to telescope the telescopic boom under partial load.
This partial load depends on the lubrication of the bearing shoes as well as on the
existing telescopic lengths.
The permissible partial load is matched via the pressure relief valves to the corre>
sponding length condition.
DANGER: When telescoping loads in or out, it is imperative that the equipment configurations,
radii and guidelines given in the load capacity charts are strictly adhered to!
* Optional
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Control of crane movement ªTelescoping out´

The speed of the telescoping crane movement is controlled by the deflection of the manual control lever (277)
and via the engine regulation (200).
Further increase of telescoping out speed can be reached by adding the rapid gear:

The rapid gear is now retained until the button (279) is pushed again and the ªrapid gear´ symbol turns off.
Telescoping telescopic section 1 out

> Turn the operating mode switch (280) to telescopic section 1 (Fig. 1).
> Move the manual control lever (277) to the right and telescope the telescopic section 1 out to the first shut off
(=46 %) .
If extension condition 46 % is not needed, but 92 % or 100%, then press the bypass button (268) in the manual
control lever (267) momentarily after shut off!
> Continue to deflect the manual control lever (277) to the right and telescope the telescopic section 1 out to the
desired extension length.
N o t e: Telescopic section 2 should be telescoped out before telescopic section 3+4 .
> Move the manual control lever (277) to the right and telescope the telescopic section 2 out to the first shut off
(=46 %) .
If extension condition 46 % is not needed, but 92% or 100 %, then press the bypass button (268) in the manual
> Continue to deflect the manual control lever (277) to the right and telescope the telescopic section 2 out to the
Telescoping telescopic section 3 and 4 out

> Move the manual control lever (277) to the right and telescope the telescopic section 3 (with 4) out to the first
shut off (=23 %) .
If extension condition 23 % is not needed, but 46%, 69%, 92% or 100 %, then press the bypass button (268) in
the manual control lever (267) momentarily after shut off!
> Continue to deflect the manual control lever (277) to the right and telescope the telescopic section 3 (with 4)
out to the desired extension length.
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Control of crane movement ªTelescoping in ´

The speed of the telescoping movement is controlled by the deflection of the manual control lever (277) and via
the engine regulation (200).
Note: Telescopic section 2 should be positioned before telescopic section 3+4 .

When telescoping the various telescopic sections in, no shut off occurs.
Rapid gear is not applicable.
To telescoping telescopic section 2 in

> Move the manual control lever (277) to the left and telescope the telescopic section 2 in.
To telescoping telescopic section 3 + 4 in

> Move the manual control lever (277) to the left and telescope the telescopic sections 3+4 in.

> Move the manual control lever (277) to the left and telescope the telescopic section 1 in.
CAUTION : As soon as the telescoping procedure has been completed, change over the opera>
ting mode switch (280) to luffing gear (Fig. 4) !
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Version with two hoist gears *
Control of ªslewing ´ crane movement

> Before initiating the crane movement, the mechanical slewing platform lock must be released. Move the ma>
nual lever (261) down, the indicator light (303) turns off.
> Release the slewing brake via switch (272) , switch position ∫up™.
> Set the control of the slewing movement by opening or closing the restrictor (273) .
Note: If the operating mode switch (280) is set to the ∫lower right∫position
to operating mode THREE MOVEMENTS *, then the slewing gear is locked.
Preselect the slewing speed

In the load capacity manual, the maximum permissible slewing speeds are given in percentages (%). These va>
lues, which depend on boom length and operating mode,may never be exceeded in crane operating with a load.
DANGER: A safe crane operation is only assured if all adjustments are made according to the
load capacity chart.
> Turn on the OPERATING VIEW via program key B2 .

> With program button ” , select the CONTROL program.
On the screen (326) appear from left to right the Vmax > symbol of the slewing gear, the symbol for hoist gear .
Under the Vmax > symbol of the slewing gear appear the preprogrammed slewing speed values in percentages
[%].
> With program key F1 and F2, the desired or maximum permissible slewing speed can be selected in percenta>
ges [%] depending on the values given in the load capacity chart.
> Confirm this speed entry by pressing the ENTER key. The new value is now shown in the chosen Vmax!> sym>
bol .
> Choose OPERATING VIEW via function key F8 (or the program key B2) .
> Press function key F3 to show the chosen slewing speed in the OPERATING VIEW.
DANGER: If the maximum slewing speed, as noted on the load capacity chart, is not preselec>
ted, the crane can be damaged severely.
Before initiating the ªslewing´ crane movement , the crane operator must assure
that there are no persons or obstacles within the slewing range.
If this point is not observed, there is an increased risk of accidents.
In addition, before any ªslewing´ crane movement, an audible warning signal must
be given by pressing the horn.
* Optional
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Control of ªslewing´ crane movement, continuation
The slewing movement can be controlled two different ways:

The crane operator must decide before starting to work, how he wants to control the slewing movement, by
opening or closing the restrictor (273) .
1. Restrictor (275)open
The slewing movement follows the load (after>run), i.e. the slewing movement must always slowed down by
countering the manual control lever or with the slewing brake (pedal 203) .
2. Restrictor (275) closed

The slewing movement follows the manual control lever (267), i. e. the slewing movement is slowed down and
stops as soon as the manual control lever is moved to zero position.
By actuating the foot button (203.1), the slewing brake can be released and the boom can be positioned over a
load by carefully deflecting the manual control lever.
CAUTION : If the restrictor is closed,

> DO NOT actuate the foot button !(203.1) ,
> DO NOT counter the manual control lever
during a slewing movement.
The speed of the crane movement is controlled by the deflection of the manual control lever (267) and via the
engine regulation (200).
> Move the manual control lever (267) to the right = to turn to the right
> Move the manual control lever (267) to the left = to turn to the left.
* Optional
245
183232
246
Control of ªslewing ´ crane movement , continue
To slow down the slewing movement with open restrictor (275)

The slewing movement can be slowed down two ways:
1. by countering with the manual control lever (267)
or
2. by pressing the foot pedal (203).
Note : Normally, the movement should be slowed by countering with the lever, as this can be done
much more sensitively.
To slow down the slewing movement with closed restrictor (275)

Bring the manual control lever (267) slowly to zero position, and the slewing movement will stop.
CAUTION : If loads are carried with a large wind>exposed surface, and if there is any wind co>
ming from the side, then it can happen, that the slewing movement ªruns away´.
Even if loads are positioned exactly, then it can happen, if wind is coming from the
side, that the load ªruns sideways´ .
In order to prevent this, slow and hold the load movement down by pressing the
pedal (203).
If the load needs to be retained in a certain position for a longer period of time, then the slewing brake should be
applied via switch (272) .
In general, the following rule applies:
Longer boom
more load } slower speed
Geschwindigkeit
DANGER: When slewing with a load, initiate the slewing movement and /or braking move>
ment very carefully and very gently.
Jerky, irregular movements and braking the slewing movement too suddenly can
cause the load to swing.
A swinging load can cause the boom to break off and could cause the crane to
topple over.
247
183236
248
VERSION WITH ONE HOIST GEAR

Control of crane movements
Operating mode switch (280)

When telescoping telescopic sections 1, 2 and 3 with 4 out, when a programmed telescoping length is reached
the telescopic movement is shut off automatically and the symbol ∫ STOP Telescoping∫ appears on the monitor.
The shut off points are for :

Telescopic
[%] [%] [%] [%] [%]
section
1 46 92 100
2 46 92 100
3+4 23 46 69 92 100
To bypass the shut off

> Hold button (268) down, while simultaneously deflecting the manual control lever (267)!"to the front" until
the symbol!"STOP Telescoping " turns off.
> Release the button (268) and telescope the corresponding telescopic section out to the length given on the load
capacity chart.
Fig. 1 In this position, only telescopic section 1 is telescoped in or out via the manual control lever (267),
hoist gear 1 and slewing gear are operational.
The rapid gear can be added to telescope out or for hoist gear 1.
Fig. 2 In this position, telescopic section 2 is telescoped in or out via the manual control lever (267), hoist ge>
ar 1 and the slewing gear are operational.
The rapid gear can be added for telescoping out or hoist gear 1.
Note: Due to the design, it is possible that the telescopic sections 3 + 4 go along when exten>
ding or retracting telescopic section 2 .
For that reason, always position telescopic section 2 first when triggering the shut off
points of telescopic sections 2, 3 and 4.
Fig. 3 In this position, telescopic sections 3 + 4 are extended or retracted synchronously via the manual con>
trol lever (267) , hoist gear 1 and the slewing gear are operational.
The rapid gear can be added for telescoping out or hoist gear 1.
249
183236
250
Version with one hoist gear
Crane movement ªLifting /lower´
DANGER: At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (button 269, 278,
279), if the crane is loaded with more than 50% of its maximum permissible load car>
rying capacity at the corresponding reach.
CAUTION: When spooling the cable of hoist gear 1 or 2 in, keep watching the winch to make
sure that there is no excess loose cable on the winch. Keep an eye on the winch!
> With program key B2 , turn on the OPERATING VIEW.

See also >Chapter 4.02 LICCON SAFE LOAD INDICATOR SYSTEM
>Chapter 5.10 MAST STUB*
>the more detailed LICCON Operating manual.
Hoist gear up / down

The speed of the crane movement is regulated via the deflection of the corresponding manual control lever and
the gas pedal.
The ªhoist´ speed can be further increased by adding the rapid gear:
Turn the rapid gear on:

The rapid gear remains operational until the button (278) is pushed again or the manual control lever (277) is
returned to zero position and the ªrapid gear´ symbol turns off.
> Initiate the hoist or lowering movement be deflecting the corresponding manual control lever.
Note: On the crane operating view of the LICCON is shown that the winch turns, even if no hook
movement is visible due to multiple reeving and slow speed.
* Optional
251
183236
252
Control of crane movement ªLuffing´ the telescopic boom
DANGER: It is not permitted to lift a load by luffing the telescopic boom if the LICCON safe lo>
ad indicator system has shut off when the load had been lifted via the hoist gear.
This will overload the crane and can cause the crane to topple over.
A bypass in the limit range may only be done if the LICCON safe load indicator sy>
stem does not report overload when the load is freely suspended.
In addition, it is also not permitted to use the bypass of the LICCON safe load indi>
cator system in working radii of more than 3.5 m.
> Deflect the manual control lever (277) to the left = to luff up the telescopic boom.
> Deflect the manual control lever (277) to the right = to luff down the telescopic boom .
The speed of the ™luffing™ crane movement is regulated via the deflection of the corresponding manual control
lever (277) and the gas pedal for the crane engine.
A further increase of the luffing up movement can be obtained by adding the rapid gear:

> Push the button (269 or 279) once, the ªrapid gear´ symbol appears on the monitor.
(277) is returned to zero position and the ªrapid gear´ symbol turns off.
> Initiate the hoist or lowering movement be deflecting the corresponding manual control lever (277),
Luffing up with folding jib* installed on the side on the telescopic boom pivot section
DANGER: Before luffing up the boom with side mounted folding jib*, it must be assured that
* Optional
253
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254
Control of crane movement ªtelescoping out´

The speed of the ªtelescoping´ crane movement is controlled by the deflection of the manual control lever (267)
and via the engine regulation (200).
Further increase of telescoping out speed can be reached by adding the rapid gear:

> Push the button (269 or 279) once, the ªrapid gear´ symbol appears on the monitor.
(267) is returned to zero position and the ªrapid gear´ symbol turns off.

> Move the manual control lever (267) forward and telescope the telescopic section 1 out to the first shut off
(=46 %) .
If extension condition 46 % is not needed, but 92 % or 100%, then press the bypass button (268) in the manual
> Continue to deflect the manual control lever (267) to the front and telescope the telescopic section 1 out to the
N o t e: Telescopic section 2 should be telescoped out before telescopic section 3+4 .
> Move the manual control lever (267) to the front and telescope the telescopic section 2 out to the first shut off
(=46 %) .
If extension condition 46 % is not needed, but 92% or 100 %, then press the bypass button (268) in the manual
> Continue to deflect the manual control lever (267) to the front and telescope the telescopic section 2 out to the
Telescoping telescopic section 3 and 4 out

> Move the manual control lever (267) to the front and telescope the telescopic section 3 (with 4) out to the first
shut off (=23 %) .
If extension condition 23 % is not needed, but 46%, 69%, 92% or 100 %, then press the bypass button (268) in
the manual control lever (267) momentarily after shut off!
> Continue to deflect the manual control lever (267) to the front and telescope the telescopic section 3 (with 4)
out to the desired extension length.
255
183236
256
Control of crane movement ªTelescoping in ´

The speed of the telescoping movement is controlled by the deflection of the manual control lever (267) and via
the engine regulation (200).
Note: Telescopic section 2 should be positioned before telescopic section 3+4 .
When telescoping the various telescopic sections in, no shut off occurs.
Rapid gear is not applicable.

> Move the manual control lever (267) to the rear and telescope the telescopic section 2 in.
To telescoping telescopic section 3 + 4 in

> Move the manual control lever (267) to the rear and telescope both telescopic sections 3+4 in.

> Move the manual control lever (267) to the rear and telescope the telescopic section 1 in.
ªSlewing´ crane movement
For ªslewing´ control movement, refer to VERSION WITH TWO HOIST GEARS in this chapter.
257
4.06 REEVING 022160>02
184418
258
4.06 REEVING 022160>02
Reeving the hook block
Reeving
Prerequisite:
> The crane is properly supported and horizontally aligned.
> The engine is running.
> An assistant is present to guide the cable.
Installation procedure:
> Place the required hook block under the pulley head of the telescopic boom.
> On the hook block (19), remove the two spring retainers on both sides of the cable retaining bar (18) and pull
out both cable retaining bars.
> On the pulley head remove the spring retainers of the cable retaining bar (14 and 15) and pull out the four
cable retaining bars.
> Guide the hoist cable over the telescopic boom to the pulley head.
Note: While the assistant guides the hoist cable to the pulley head, the crane operator must
operate the winch. This procedure must be done in such a manner, that the cable does not
slack on the cable drum.
DANGER: This work should be completed while standing on a secure base.

If it is unavoidable that the cable must be hand guided on the telescopic boom to the
pulley head, use utmost caution when walking on the telescopic boom.
There is a great danger of causing a serious accident if the crane function is not
operated properly and the person guiding the cable slips on the telescoping boom.
> Lay the hoist cable over the top cable pulley (13) and reeve the hoist cable between the pulley head and the
hook block as shown on the reeving plan for the appropriate load capacity chart.
> Reinsert the cable retaining bars (14 and 15) and secure them with spring retainers.
Fig. 1
> On the cable lock (1), remove the pin (2) and pull out the pin (3).
> Depending on the reeving, bolt the cable lock either to the pulley head or to the hook block and secure with the
spring retainer.
Note: The pin (3) must always be placed from the inside to the outside and secured from the
outside, to prevent the hoist cable from rubbing against the pin (3) or the spring retainer (2).
Fig. 2
> On the cable lock (1), push in the lock pin (6), push the lever (5) ∫downward∫ and hold it in this position, this
causes the locking lever (4) to swing downward.
CAUTION: The locking mechanism (4, 5, and 6) on the cable lock must be movable.
> Hang the end of the cable with press fitting (8) into the cable lock and pull the cable ™downward∫ (in direction
of the arrow) until the cable fitting (8) touches the taper (7).
CAUTION: The cable fitting (8) must touch the taper (7) in the cable lock , the lever (5) must be
locked with the lock pin (6) .
259
4.06 REEVING 022160>02
184418
260
4.06 REEVING 022160>02
Install the hoist limit switch weight
Fig. 4
> Open the chain lock (9) on the hoist limit switch weight (A).
> Using a 13 mm wide (SW 13) open end wrench, loosen the hex head nut (10) and turn it ∫up∫ by hand.
> Release the hoist limit switch weight (A).
CAUTION: The hoist limit switch weight (A) consists of two interconnected parts (11 and 12) .
When releasing or attaching the weight, make sure that the two parts do not slide
apart and cause the weight (11) to fall out.
Danger of foot injuries!
> Push the weight (11) by hand onto the cable and hold it,
> with the other hand, guide the carrying part (12) behind the cable, underneath the weight (11).
Note: With multiple reeving, the hoist limit switch weight (A) must always be routed around the
∫fixed cable∫, meaning around the cable, whose end makes up the cable fixed point.
Fig. 5
> Push the weight (11) over the carrying part (12).
> Hang the hoist limit switch weight (A) again into the chain lock (9) ,
> Turn the lock nut (10) down and manually tighten with a SW 13 open end wrench.
DANGER: The chain lock (10) serves at the same time to secure the weight (11).
It may not be replaced with another part, such as a shackle, snap etc.
The chain lock (10) must always be attached in such a way that the lock nut (10 ) is
on ∫top∫, meaning on the chain (17) and the chain lock is closed by turning the lock
nut (10) ∫downward∫.
This procedure assures that the lock nut (10) does not loosen up by itself, causing
the chain lock to open.
Visual inspection: Is the chain lock (10) fully closed?

Is the hoist limit switch weight(A) attached to the ∫fixed or stationary cable∫?
> Enter the number of reeves into the ∫LICCON∫ safe load indicator or recheck it.
DANGER: The crane operator must make sure that the reeving process has been done
properly and that the safe load indicator has been set correctly.
Incorrect reeving or entering an incorrect number of reeves can lead to serious
accidents.
261
4.06 REEVING 022160>02
184418
262
4.06 REEVING 022160>02
Unreeving the hook block
> Lower the hook block and place it on the ground.
CAUTION: Make sure the hook block is positioned safely.

If this is not assured, it can result in serious injury as the hook block might tip over
when it is unreeved.
Release the cable
Fig. 2
> On the cable lock (1), push in the lock pin (6), push the lever (5) ∫downward∫ and hold it in this position, this
causes the locking lever (4) to swing sideways and releases the cable fitting (8).
Fig. 3
> Push the cable ∫upward∫ and release the fitting (8).
> Slowly rewind the hoist cable.
DANGER: The area around the hook block must be free and clear of any personnel .
During the rewinding procedure, the cable can lash out like a whip .
Have another person observe the rewinding procedure to make sure that the cable
does not rewind loosely .
> Mount the hoist cable with the cable lock to the front coupling and tighten it slightly or rewind the cable fully
onto the winch.
CAUTION : Rewind the hoist cable up to the point where there are at least 2 m of remaining
cable .
Do not pull the cable end under the winch!
263
4.06 REEVING 022160>02
184377
264
4.06 REEVING 022160>02
Attach and remove the load hook (26) *
Installation procedure:
> Place the load hook under the pulley head of the telescopic boom.
> On the pulley head, remove the spring retainers on both sides of the cable retaining bars (14 and 15) and
pull out the three cable retaining bars.
> Guide the hoist cable over the telescopic boom to the pulley head.
Note: While the assistant guides the hoist cable to the pulley head, the crane operator must
operate the winch. This procedure must be done in such a manner, that the cable does not
slack on the cable drum.
DANGER: This work should be completed while standing on a secure base.

If it is unavoidable that the cable must be hand guided on the telescopic boom to the
pulley head, use utmost caution when walking on the telescopic boom!
There is a great danger of causing a serious accident if the crane is operated
improperly and the person guiding the cable slips on the telescopic boom.
> Lay the hoist cable over the top cable pulley (13).
> Reinsert the cable retaining bars (14 and 15) and secure them with spring retainers.
Fig. 3
> Bolt the cable lock (1) to the load hook (26) and secure with spring retainers.
Fig. 1
> Hang the hoist cable into the cable lock,
On the cable lock (1) push in the pin (6), swing the lever (5) downward and hold it in this position, this
causes the locking lever (4) to swing to the side.
C AU T I O N : The locking mechanism (4, 5 and 6) on the cable lock must be movable.
> Hang the end of the cable with press fitting (8) into the cable lock and pull the cable ™downward∫ (in
direction of the arrow) until the cable fitting (8) touches the taper (7).
C A U T I O N: The cable fitting (8) must touch the taper (7) in the cable lock, the lever (5) must be
locked by the lock pin (6).
> Hang in the hoist limit switch weight (A), as described at the beginning of this chapter.
Visual inspection: Is the chain lock (10) fully closed?
> Enter the number of reeves into the LICCON system or recheck it.
D A N G E R: The crane operator must make sure that the reeving process has been carried out
properly and that the safe load indicator system has been set correctly.
Improper reeving or entering an incorrect number of reeves can lead to serious
accidents!
* Optional
265
4.06 REEVING 022160>02
184377
266
4.06 REEVING 022160>02
To remove the load hook (26) *

> Place the load hook on the ground.
> Remove the hoist limit switch weight (A), as described at the beginning of this chapter.
Fig. 2
> Unhook the hoist cable from the cable lock,
On the cable lock (1) push in the pin (6), swing the lever (5) to the side and hold it in this position, this
causes the locking lever (4) to swing to the side and releases the cable fitting (8).
> Push the hoist cable in direction of the load hook and release the fitting (8).
> Slowly spool back the hoist cable.
D ANGER: The area around the load hook must be free and clear of any personnel .
During the rewinding procedure, the cable can lash out like a whip .
Have another person observe the rewinding procedure to make sure that the cable
does not rewind loosely .
> Attach the cable with cable lock to the front tow coupling and tighten the cable slightly, this prevents the
telescopic boom from running out inadvertently.
If the hoist cable is not attached to the front tow coupling, then the hoist cable (without cable lock) must be
rewound fully onto the winch.
CAUTION: Rewind the hoist cable up to the point where there are at least 2 m of remaining
cable .
Do not pull the cable end under the winch!
* Optional
267
4.06 REEVING 022160>02
184605
268
4.06 REEVING 022160>02
Lower the load hook (26) into the load hook receptacle (28)*
> Fully telescope the telescopic boom with attached load hook (26) in, luff it up to the stop and raise the load
hook.
> Turn the crane superstructure in vehicle lengthwise direction ∫to the rear∫ and position the load hook (26)
over the load hook receptacle (28)*.
> Carefully and sensitively lower the load hook (26) into the load hook receptacle (28) until the hoist cable is no
longer tensioned.
CAUTION: When lowering the load hook, make sure that the cable on the winch does not
slacken up (check the winch visually).
Slack cable can cause damage to the cable
> Release the hoist cable from the cable lock (1) as described in this chapter, in paragraph ∫Remove the load
hook∫.
* Optional
269
4.06 REEVING 022160>02
182445
270
4.06 REEVING 022160>02
Reeving plan
14 fold reeving, Fig. 7

Fixed point on the side of the pulley head

Fixed point on the side of the hook block
7 > sheave hook block *

T
Added 2 > sheave tackle *
In order to be able to reeve the 7sheave hook block (19), the 2>sheave added tackle (20) must first be
inserted into the suspension (23).
Installation of added tackle (20)

> On the added tackle, remove the retaining spring (22) from the pin (21).
> Guide the added tackle into the suspension (23) under the pivot section of the telescopic boom, insert
the pin (21) through the bore holes into the suspension and the added tackle.
> Secure the pin (21) with the retaining spring (22).
Reeve the hoist cable

> Reeve the hoist cable according to Fig. 7 or Fig. 8.
*optional
271
4.06 REEVING 022160>02
182446
272
4.06 REEVING 022160>02
Reeving plan

11 fold reeving , Fig. 11

Fixed point on the side of the hook block
7 > sheave hook block *

T
5 > sheave hook block
Added 1 > sheave tackle *
In order to be able to reeve the 7sheave hook block 12 fold, the 1>sheave added tackle (20) must first be
In order to be able to reeve the 5sheave hook block 11 fold, the 1>sheave added tackle (20) must first be
Installation of added tackle (20)

> On the added tackle, remove the retaining spring (22) from the pin (21).
> Guide the added tackle into the suspension (23) under the pivot section of the telescopic boom, insert
the pin (21) through the bore holes into the suspension and the added tackle.
> Secure the pin (21) with the retaining spring (22).
Reeve the hoist cable

> Reeve the hoist cable according to Fig. 10 or Fig. 11 .
*optional
273
4.06 REEVING 022160>02
182447
274
4.06 REEVING 022160>02
Reeving plans
10 fold reeving,
8 fold reeving,
T
9 fold reeving ,
Fixed point on the side of the hook block.
∫Normal∫ reeving for::

275
4.06 REEVING 022160>02
182448
276
4.06 REEVING 022160>02
Reeving plans
7 fold reeving ,
5 fold reeving ,
T
3 fold reeving ,

6 fold reeving,
4 fold reeving ,
2 fold reeving ,
Fixed point on the side of the hook block.

1 fold reeving,
Fixed point on the load hook.
∫Normal∫ reeving for the load hook.
277
4.06 REEVING 022160>02
182449
278
4.06 REEVING 022160>02
Fig. 1
Reeving plan for single pulley hook block on mast stub (or folding jib)
Fixed point on the side of the mast stub (or folding jib)
max. 2 sheave reeving T

Fig. 2
Reeving plan for load hook on mast stub (or folding jib)
Fixed point on load hook (or on folding jib)
Single reeving
T
Operation with mast stub*

The mast stub is generally used in ∫T™ telescopic operation.
The LICCON safe load indicator must be set to smaller reeving of both hooks, and the appropriate CODE
number for the corresponding boom length must be entered.
CAUTION: In this case, the LICCON safe load indicator system will not show the exact radius
and load indication, because the mast stub has not been considered in the boom
geometry.
Operation with folding jib*

For two hook operation, the ∫LICCON∫ safe load indicator must be adjusted as described in guidelines given in
chapter 4.12, TWO HOOK OPERATION.
The auxiliary hoist (winch 2) may only be operated with a maximum of two reeves, the main hoist (winch 1)
may be operated with multiple reeves.
TWO HOOK OPERATION *
DANGER: The reeving on the telescopic boom must be the same or larger than the reeving on
the mast stub or folding jib.
If this is not assured, the hoist gear 1 or the hoist cable can be overloaded.
The LICCON safe load indicator system must be set to the smaller reeving number
of both hooks.
* Optional
279
4.07 COUNTERWEIGHT 022542>01
183237
280
Counterweight plates, without hoist gear 2
The counterweight plates are marked with their own weight.
DANGER: The mounted counterweight must correspond to the data given in the load capacity
chart.
If this is not followed, it could cause a serious accident!
The two hex head screws (10) of counterweight plate (1) may only be removed if the
counterweight plate (1)
> either is held by the counterweight plate (3) or (2 with 3) via the ballasting cylin>
der (7)
> or by an auxiliary crane.
Counterweight components
Individual
Pos.: Combination weights
[t]
1 Counterweight plate 2,1

5 Replacement ballast, instead of hoist gear 2 5,1
7 Ballasting cylinder >
8 Pin with lever, to mount the replacement ballast (5) >
9 Pin with splint, to mount the replacement ballast (5) >
10 Hex head screw M 30¥150, to mount plate (1) >
CAUTION : The replacement ballast (5) is part of the counterweight frame and must always be
installed on the counterweight frame!
The two mounting pins (8) must be folded back to secure the weight.
The two mounting pins (9) must always be secured with a splint.
This replacement ballast will only be removed if hoist gear 2 is installed.
Note: The counterweight plate (1) is screwed onto the counterweight frame with two hex head
screws (10) .
Tightening torque for hex head screws (9) =1000 Nm.
281
183238
282
Counterweight plates, with hoist gear 2 installed
DANGER: The mounted counterweight must correspond to the data given in the load capacity
chart.
If this is not followed, it could cause a serious accident!
The two hex head screws (10) of counterweight plate (1) may only be removed if the
counterweight plate (1)
> either is held by the counterweight plate (3) or (2 with 3) via the ballasting cylin>
der (7)
> or by an auxiliary crane.
Counterweight components
Individual
Pos.: Combination weights
[t]
1 Counterweight plate 2.1

5 Added counterweight 3.9
6 Hoist gear 2 1.2
7 Ballasting cylinder >
8 Pin with spring clip to mount the 2nd hoist gear
>
9 Pin with splint, to mount the 2nd hoist gear
>
10 Hex head screw M 30¥150, to mount plate (1) >
12 Hex head screw M 30¥300, to mount added counterweight
hoist gear 2 >
CAUTION : The 3.9 ton added counterweight (5) is part of the 2nd hoist gear and must always be
installed on the hoist gear with mounting screws (12)!
Tightening torque: Ma = 1000 Nm.
The two mounting pins (8) must always be secured with a spring clip.
The two mounting pins (9) must always be secured with a splint.
DANGER: If the 2nd hoist gear is being removed, the 5.1 ton replacement ballast for hoist gear
2 MUST be installed.
If this is not done, it could cause a serious accident!
Note: The counterweight plate (1) is screwed with two hex head screws (10) onto the counter>
weight frame .
Tightening torque for hex head screws (9) = 1000 Nm
283
183237
284
The following combinations are possible :
Counter>
Indiv.
weight Combination
weights
[t]
[t]
6,2 Replacement ballast (5) 5.1

or 2nd hoist gear (6) + added ballast 3.9 t (5)
Counterweight plate 3 1.1
13,0 Replacement ballast 5 5.1

or 2nd hoist gear (6) + added ballast 3.9 t (5)
DANGER : When working with load capacity chart :

∫Counterweight 6.2 t∫
then the counterweight plates (1+2) must be removed.
If this is not followed, it could cause a serious accident as the crane can topple over!
CAUTION : The counterweight plate (1) is installed to the counterweight frame with two hex he>
ad screws (10) .
Tightening torque : Ma = 1000 Nm.
When driving on public roads, the counterweight must be distributed as described

in chapter 3.04 .
285
183239
286
Installation / Removal
Prerequisites:
> The crane must properly supported according to the load capacity chart and horizontally aligned,
> The transport vehicle with the counterweight plates has been positioned close to the supported crane,
> the hook block is properly reeved, according to the reeving plan.
AC A U T I O N : The ballasting cylinders (7) must be fully retracted, otherwise there could be a col>
lision with the counterweight plates on the chassis.
DANGER: The slewing range must be free and clear of personnel and objects.
If the boom is positioned in a steep position for which no load capacities are entered
in the load capacity chart, there is great danger of tipping the crane to the rear, to
the counterweight side,when the crane is being turned.
This danger is especially acute if:

> the support base is reduced or
> if the crane is supported, but the sliding arms have been retracted.
287
183239
288
Installation procedure
> Start the crane engine as described in chapter 4.03.
> The mechanical crane superstructure lock has been released via the manual lever (261) , the indicator light
(306) turns off.
> Adjust the LICCON safe load indicator according to the load capacity chart.
DANGER: Before lifting the boom from the transport position, the crane must be supported as
noted on the load capacity chart and the LICCON safe load indicator must be adju>
sted according the load capacity chart .
When ballasting the crane, the boom lengths and radii given in the load capacity
chart MAY NOT be exceeded.
If this point is not observed, it could cause a serious accident as the crane may tip
over.
To stack the counterweight plates on the vehicle
CAUTION : Always move the manual control levers slowly and sensitively to take it easy on the
crane and to prevent accidents.
DANGER: Before initiating a crane movement, always sound the horn.
> Raise the required plates for the corresponding counterweight combination with the own crane and the supp>
lied tackle and place them on the vehicle frame.
The determining factor for the selection of the counterweight is the data given in the appropriate load capacity
chart.
Note: The base plate (3) must always be placed on the vehicle frame first, as it is the carrier plate
for the remaining plates.
CAUTION : The counterweight plate (1) is placed on the counterweight plate (3) or (2+3) , rai>
sed via the ballasting cylinders (7) onto the counterweight frame and is screwed di>
rectly onto it with the two hex head screws (10) .
> Turn the crane superstructure , (telescopic boom in travel direction to the rear) until the ballasting cylinders
(7) are above the counterweight plates on the vehicle.
CAUTION : The ballasting cylinders (7) must be fully retracted for this slewing movement, ot>
herwise there could be a collision with the counterweight plates on the vehicle!
DANGER: The slewing range must be free and clear of personnel and objects. Always sound
the horn before initiating a crane movement.
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Take up the counterweight

> Mechanically lock the crane superstructure with the crane chassis with the pin by moving the manual lever
(261), the indicator light !(306) must light up.
> Hold the button (316) ªdown´ until the green indicator light in the switch turns on, the ballasting cylinders
(7) are now extended into the recesses of the counterweight plate (3).
> Hold the button (317) ªdown´ until the red indicator light in the switch turns off, the ballasting cylinders (7)
are now locked with the counterweight plate (3) .
DANGER: If the button (317) is actuated and the red indicator light in the switch lights up con>
stantly, then both of the ballasting cylinders are not locked or released and no mo>
vement (raise / lower counterweight) may be actuated via the button (316)!
> Hold the button (316) ªup´ until the green indicator light in the switch lights up; the ballasting cylinders are
now retracted and the counterweight plate (3) or the plates on the counterweight plate (3) are now raised to
the stop on the counterweight plate (1).
> Adjust the LICCON safe load indicators system to the operating mode and the existing counterweight configu>
ration.
Note: The counterweight can also be placed directly on the counterweight frame with a 2nd crane.
This eliminates placement of the counterweight on the chassis and turning the crane super>
structure.
The remaining steps remain the same.
To remove the counterweight
CAUTION : The superstructure must be locked to the chassis via the manual lever (261) before
placing the counterweight on the vehicle.
If this is not assured, the counterweight will not be placed on the intended centering
and the counterweight might not be properly attached to the vehicle frame.
DANGER: Make sure the area is clear, that no foreign objects are under the counterweight
when the counterweight is placed on the vehicle frame .
If this is not the case, the counterweight cannot be locked down properly and
therefore cannot be secured properly and safely on the vehicle.
Before every trip, make sure to visually check the counterweight plate for damage.
Damaged counterweight plates must be replaced.
If there any distortions on the placement bracket, then it must be realigned and fi>
xed.
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292
To remove the counterweight

> Turn the crane superstructure ( telescopic boom in travel direction to the rear) until the counterweight is abo>
ve the vehicle frame.
DANGER: Before initiating a slewing movement and before lowering the counterweight, the
crane operator must make sure that there are no obstacles in the working range
and that the danger zone is free of personnel.
> Lock the crane superstructure to the crane chassis with the pin via the manual lever (261), the indicator light
(306) must light up.
CAUTION : The superstructure must be locked to the chassis so that the counterweight can be
placed on the intended centering and properly attached to the vehicle frame.
DANGER: Make sure the area is clear, that no foreign objects are under the counterweight
when the counterweight is placed on the vehicle frame .
If this is not the case, the counterweight cannot be secured properly and safely on
the vehicle.
To lower the counterweight

> Hold the button (316) ªdown´ until the green indicator light in the switch lights up; the counterweight plate
(3) is placed on the counterweight seating .
CAUTION : Lower the counterweight slowly and assure exact placement on the two studs (11) .
> Hold button (317) ªup´ until the red indicator light in the switch turns off; the ballasting cylinders (7) are
now released.
> Hold the button (316) ªup´ until the green indicator light in the switch lights up; the ballasting cylinders are
now retracted . !
To place the counterweight plate (1) )
DANGER : The two hex head screws (10) for plate (1) may be only be removed if plate (1) is held
by plate (3) via the ballasting cylinders (7) or by an auxiliary crane.
CAUTION : When driving on public roads, the counterweight must be distributed as described
in chapter 3.04 .
293
4.08 WORKING WITH A LOAD 022543>02
Safety technical guidelines for working with a load
Note : Refer also to the safety technical guidelines in chapter 2.04!
> Always maintain the maximum load as specified in the load capacity chart.
> Always maintain the working radius as specified in the load capacity chart.
DANGER: For steep boom positions, for which no load capacities are given on the load
capacity chart, there is the danger that the crane topples over to the rear, the
counterweight side, when the slewing platform is turned.
This danger is specially acute,

> if the support base is reduced or
> if the crane is supported, but with retracted sliding arms.
Operating the crane with a smaller working radius than specified on the load
capacity chart is not permitted.
This also applies if there is no load on the hook.
Doing so increases the risk of accidents!
> Always maintain the number of reevings corresponding to the maximum load capacity as specified in the
DANGER: If this rule is not observed, the cable could snap and cause a serious accident and
injury or death!
> Always initiate any crane movement and braking movement very slowly and carefully, to prevent the
load,which is suspended from the hook, from swinging.
> As soon as the lowest cable layer of a winch drum is reached, another person must make sure that there are
always at least three coils remaining on the winch drum.
DANGER: If this rule is not observed, it could cause a serious accident and injury or death.
> It is not permitted to use larger hook blocks than the size specified to hoist the maximum load as stated on
the load capacity chart. If this rule is not observed, the hook cannot be lowered to the ground because the
hoist cable is too short.
294
Inspection
Before beginning any crane operation, the crane operator must carry out a thorough inspection to ensure the
operating safety of the crane once more.
> Is the crane properly supported and horizontally aligned?

> Are all applicable values from the load capacity chart entered and adjusted to reflect the current equipment
configuration?
> Is the danger range of the crane free of any persons and objects?
DANGER: Before beginning any slewing movements, the operator must

> always give an audible warning signal by pressing the horn.
> The crane operator must make sure, especially when working on tight
construction sites, that there are no persons or objects within the slewing range,
in the rear area behind the counterweight and close to the vehicle chassis.
There is always a risk of accidents!
Visual inspection for damage.

The crane operator must report any problems he found on the crane to his supervisor, the designated person in
charge, including to his relieve person or assistant.
DANGER: The crane operator must immediately stop crane operation if any malfunctions are
found or should occur, which could endanger the operational safety of the crane
operation, particularly the following:
> if there is any damage to the load carrying parts of the crane structure, such as
boom, outriggers, etc.
> any time the load slips due to hoist brake failure,
> any time there is a functional problem in the crane control,
> any time any of the indicator and/or warning lights are not functioning properly,
> if there is any damage to the hoist cable,
> if any of the safety devices are not functioning properly,
> if there is a leakage anywhere on the craneπs hydraulic system.
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Setting the safety devices

> Start the crane engine, as described in chapter 4.03 and check the instruments.
DANGER: For safety reasons, do not remain or step into the driverπs cab (crane chassis) during
crane operation.
Enter operating mode and equipment configuration into the ∫LICCON∫ safe load indicator system
See control and indicator unit of the safe load indicator system in chapter 4.02.
The operating mode and the equipment configuration must be reentered before starting to work or after an
equipment change according to the load capacity chart into the LICCON safe load indicator system.If a function
in the operating mode and (or) in the equipment configuration is changed, then this change must be confirmed
with the ENTER key.
If an acoustical signal can be heard after the ENTER key has been pressed, then this change was not accepted.
In this case, it must be checked which of the entered functions is not correct.
DANGER: The proper function of the LICCON safe load indicator system and safe crane
operation is only assured, if the data given in the load capacity chart has been
entered correctly and matches the actual equipment configuration.
The crane operator is obligated to recheck the correct adjustment of the safe load
indicator system before starting to work with the crane (even if he only leaves the
cab for a short time) .
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298
Setting the safety devices, continuation
Limitation of slewing speed, Fig. 2

The slewing speed must be limited via the LICCON safe load indicator system*.
CAUT ION : The maximum permissible slewing speeds are given in percentages in the load chart
manual.
These values, which depend on boom length and operating mode, MAY NOT BE
EXCEEDED during crane operation with a load.
DANGER: A safe crane operation is only assured, if the adjustments are made according to the
If the given, maximum slewing speed is not preselected, then the crane can be
damages.
”
> with program key ! , select the ªCONTROL´ program.
On the screen (326) appears from left to right
the Vmax symbol for the slewing gear the symbol winch 1 the Vmax symbol for the luffing gear *
the symbol winch 2 *
> Push E1 or E2 to move the double arrow over the symbol to be changed.
> under the Vmax symbol for the slewing gear appear the preprogrammed speed values for slewing in
percentages [%].
> With function key F1 or F2 , move the cursor to the permissible speed value according to the load capacity
chart.
DANGER: The slewing speed, hoist speed and luffing speed or locking the winches may not be
changed as long as any movement is actuated.
> Press the ENTER Key to enter the speed. The changed value will now appear in the selected Vmax symbol.
> Press function key F8 (or program key P1) to change back to the CRANE OPERATING VIEW.
> Press function key F3 , to show the selected slewing speed in the OPERATING VIEW.
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300
Sliding arm monitor*

See also chapter 6.04 SLIDING ARM MONITOR.
the more detailed !LICCON operating manual.
The sliding arms are monitored via the LICCON safe load indicator system.
The LICCON sliding arm monitor checks the supporting width data, which the crane operator has entered on
the LICCON panel according to the load capacity chart.
CAUTION : The LICCON safe load indicator system does not monitor if the crane is supported
properly and if the sliding arms are pinned correctly in the intended positions.
Support force monitor * Fig. 1

See also chapter 6.04 SLIDING ARM MONITOR .
The support force monitoring is carried out via the LICCON safe load indicator system .
Prerequisite:
> the crane must be operated in supported condition,
> the installation keyed switch ( D ) may not be actuated.
CAUTION : To assure that the LICCON support force monitoring system works properly, do not
move the support cylinders to ∫lower block ∫ nor ∫upper block!∫ .
1. Indication of current support force

Press function key F3 to view the support force monitoring symbol, Fig. 1, which shows the support force
for every support in tons [t] next to the crane symbol.
The symbol appears automatically with the alarm signal ªSHORT HORN´, if a support has either exceeded
the maximum force or if it has fallen below it. However, the crane movements are NOT shut off.
The values, which triggered the warning are blinking.
DANGER: The crane movements are NOT shut off when the permissible support force is being
exceeded or fallen below. The LICCON support force monitor may NEVER be used
to utilize the crane to its tipping limit!
If this is not observed, it can cause a serious accident.
2. Programming the maximum and minimum support forces

The maximum and minimum support forces must be programmed as described in the LICCON! operating
manual in chapter 4.4. THE SUPPORT FORCE LIMIT VALUE MODIFICATION PROGRAM.
Push the B4 program key, and the ∫SUPPORT FORCE LIMIT VALUE MODIFICATION ∫ program will
appear. The right DISPLAY window, fig. 3 shows the current support force values. If one or more of these
values are below the adjusted minimum or above the adjusted maximum values, then they will blink. The
left window (EDIT window, Fig. 2) shows the programmed maximum / minimum values.
* Optional
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302
Wind velocity warning device *

The wind velocity warning device is integrated into the LICCON safe load indicator.
> Turn the CRANE OPERATING VIEW on via program key B2.
> Press function key F3 to show the wind sensor symbol, fig. 1.
The wind speed will appear on the screen, it is depicted in meters [m/s] or foot [ft/s], depending on the unit of
measurement used in the load capacity chart.
The maximum permissible wind velocity (same unit of measurement) shown below depends on the operating
mode, the equipment configuration and the boom length.
If the current value exceeds the maximum value, an acoustical signal ªSHORT HORN´ will sound and the
symbol will blink. However, the crane movement is NOT shut off.
DANGER: This safety device does NOT turn the crane off if the permissible wind velocity is
being exceeded.
The operator must cease crane operation and lower the boom.
If this is not done, a serious accident can occur.
C A U T I O N: When operating the crane with the folding fly jib*, the removable wind sensor must
always be installed and properly connected and fully functional, otherwise the
∫LICCON ™ safe load indicator will indicate a malfunction.
* Optional
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304
Working near overhead electrical wires

If there are any overhead electrical wires close to the job site, they must be disconnected by trained electricians.
If this is not possible, the danger zone must be covered or blocked off.
If these measures are not permitted or possible, the following safe distances must always be kept between the
crane / boom and any wires:
Minimum Minimum
Rated Voltage
distance in meters distance in feet
up to 1 kV 1 3
if rated voltage is 5 16
unknown
Note : If, despite all precautionary measures, a flashover occurs, proceed as follows:
> Keep calm,
> DO NOT leave the cab,
> Warn all those around the crane to remain standing where they are and not to touch the
crane,
> Move the crane from the danger zone.
DANGER: If this is not observed, serious injury or damage can occur!
High voltage warning device * HSW 40

The high voltage warning device monitors the safety distance between the boom and the overhead wires, as
long as they are high voltage (AC current) wires.
If the voltage in the wires is known :

Set the voltage value on the high voltage warning device.
As soon as a minimum distance is exceeded, a warning will sound.
If the voltage in the wires is unknown :

The high voltage warning device must be adjusted.
DANGER: This safety device does not turn the crane off.
A safe crane operation is only assured if all data and adjustments have been
entered and set correctly as noted .
* Optional
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306
Taking on a load
The crane must always be operated in such a manner that the load bearing parts are not damaged and the
stability is guaranteed.
Pulling a load at an angle is prohibited!

The crane is designed to lift loads vertically.
Pulling at an angle causes horizontal stress in addition to the vertical stress, which the crane has been designed
to handle. It makes no differences if the load is pulled in direction of the boom or crosswise to it, the crane is
simply not designed to handle loads which are pulled at an angle.
Since forces are transferred via the hoist cable to the boom jib, they have a stress effect which is above the
permitted stress level for the height of the boom head pulley.
DANGER: DO NOT pull a load at an angle!

Pulling a load at an angle can damage the crane and cause it to topple over.
Pulling a stuck or jammed load free is prohibited!

NEVER pull stuck or jammed loads free by using the crane, this is strictly prohibited!
DANGER: DO NOT pull stuck or jammed loads free with the crane !
This can cause the crane to topple over.
Hoisting the load

When hoisting a load, utmost care must be taken.
It can be very dangerous, there is always the danger that a load may fall and any persons, which are close to the
area of the load to be hoisted, can be crushed.
If the hoisting tackle is manually placed on the load by another person, the crane operator must assure :
> that the hands of this persons placing the tackle are not crushed between the tackle and the load when the
cable tightens,
> that arms and legs are not crushed by a swinging load while hoisting it .
DANGER: If there are any persons in the area where the load is being hoisted, they are in
danger of being crushed! Utmost care must be taken.
At 1 to 3 sheave reeving, it is NOT permitted to add the rapid gear (269, 278, 279), if
the crane is loaded with more than 50% of its maximum permissible load carrying
capacity at the corresponding reach.
It is strictly prohibited to lift a load by luffing the boom, after the LICCON safe load
indicator has shut off the system after an attempt was made to lift the load by the
hoist gear.
This would overload the crane and/or cause the crane to topple over.
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308
Crane operation
A swinging load must always be kept under control.
Only a safe, sensitive control of the crane functions can guarantee this.
All crane movements must always be initiated and slowed down slowly to prevent the load from swinging.
DANGER: A swinging load can damage the crane or cause it to topple over.
It could cause a serious accident!
Tag lines
To aid the crane operator to accurately guide the load, we recommend to use tag or guiding lines.
This can prevent unintentional movement of the load and resulting damage.
Moving persons
This crane is NOT designed to move any personnel.
It is prohibited to move or let anybody ride along on the load being lifted.
DANGER: Moving or letting any persons ride along on the load or load tackle is strictly
PROHIBITED.
It could cause a serious accident.
Danger of being crushed

When lowering the load, utmost care must be taken.
It can be very dangerous, there is always the danger that persons, which are close to the area of the load to be
lowered, can be crushed.
DANGER: When lowering the load, no personnel or objects may be below the load!
It could cause a serious accident!
309
4.09 DRIVING WITH ATTACHMENT IN PLACE 023409>00
185967
310
General guidelines
The crane can be moved on even ground, with the axle suspension system locked, and with the telescopic
boom raised and equipment installed.
DANGER: When moving the crane with the equipment in place, you must make sure to keep
within the values and observe the notes on the following charts.
If this is not done, you could cause a serious accident, the crane could topple over.
Before moving the crane, the following must be done:

When planning the operation to move the crane from one area on the job site to another, with the equipment in
place, you must assure that the support area as well as the travel route is flat and even, (horizontal), and can
support the weight of the crane including the equipment.
1. The travel route must be checked before driving on it and before placing the outriggers to sup>
port the crane, to assure that it is even and level, and that there is no downhill slope and no une>
ven areas or obstacles in the road.
D A N G E R: The surface of the roadway may not show more than a total slope of 3∞ in the per>
missible tolerance range of +/> 0.10 m over a distance of 10 m !
2. Before the support procedure, the vehicle must be leveled in horizontal direction via the automatic leve>
ling regulation (button 116) until the indicator light !(117) lights up.
Then the axle suspension must be blocked with switch (120) . These procedures are prerequisite for driving
the crane with the attachment in place.
Carry out the support procedure, as described in chapter 3.05 .
3. After the crane operation

> Telescope the telescopic boom in all the way
> Turn the crane superstructure to the position shown on the chart, to the front or to the rear
> Lock the crane superstructure to the crane chassis
Swing the manual lever (261) down, the indicator light (306) must light up.
> Set the telescopic boom or folding jib * and telescopic boom to the angle noted on the corresponding load ca>
pacity chart.
DANGER: Before turning the crane superstructure, make sure that the crane is properly
supported in horizontal direction and give a warning signal with the horn.
The sliding arms must be pinned.
The crane superstructure must be locked to the chassis after turning it into the ve>
hicle lengthwise direction.
4. Lower the crane onto the blocked axles

Lower the crane carefully onto the blocked axles by lowering the outrigger cylinders.
DANGER: Constantly check the horizontal position of the crane While lowering the crane.
C A U T I O N : All wheels must touch the ground evenly, otherwise the axle suspension can be
damaged!
The travel route must be level on horizontal, and must be hard enough to safely
support the axle load.
* Optional
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312
Charts for driving with the attachment in place

Chart 1: without folding jib Telescopic boom fully telescoped in T> 10.6 m (0 / 0 / 0 / 0)
Chart 2: with Folding jib0∞, 15∞ and 30∞ Telescopic boom fully telescoped in T> 10.6 m (0 / 0 / 0 / 0)
DANGER: The travel route must be checked before driving on it to assure that it is even and le>
vel.
The surface of the roadway may not show more than a total slope of 3∞ in the per>
missible tolerance range of +/> 0.10 m over a distance of 10 m !
Driving with raised boom is only permitted on level ground of sufficient load carry>
ing capacity, without a suspended load and only if the counterweights and distribu>
tion shown in charts 1!.!.!.!3 have been adhered to!
The crane may only be driving with blocked axle suspension system. If axles are
suspended, the crane can topple over.
Prerequisites for driving with the attachment in place :

> The crane superstructure must be positioned in lengthwise vehicle direction, to the rear or to the front, and it
must be locked to the chain chassis.
DANGER: Before turning the crane superstructure, make sure the crane is properly suppor>
ted.
> The hydro > pneumatic suspension of axles 1 . . . . 4 must be locked and the axle equalization (axles 1!+2!/!345)
must be turned on.
> The sliding arms must be extended at least to the stated minimum supporting width ![min.!B] or the next
higher supporting base and they must be pinned.
DANGER : The sliding arms must be pinned!
> The outrigger cylinders with support pads must be extended to about 10 > 15!cm above the ground, so that the
crane can catch itself , should the ground suddenly give.
> All tires must be inflated to the correct tire pressure.
> The crane may only be driving in 1st gear, with added off road gear (in step by step speed), with extreme care,
at the least possible increase of speed and with the most careful braking action.
> The ground must be even, horizontal and of sufficient load carrying capacity for the axle load (see chart) .
> There may be no persons or obstacles within the travel range.
> While driving, a guide must monitor the luffed up boom as well as the outrigger supports to assure that they
donπt collide with anything.
> The crane may only be driving without a load on the hook .
CAUTION : These prerequisites must be assured before driving the crane with the attachment
in place, otherwise there is a danger of causing a serious accident, as the crane may
topple over.
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314
Driving with telescopic boom fully retracted (telescoped in) (T>10.6 m) (0 / 0 / 0 / 0)
Chart 1
In the chart, a pulley weight of 430kg has been considered.
Slight axle load increase with folding jib installed on the side of the telescopic boom.
Counterweight
minimum maximum axle
on the crane Telescopic boom
Boom supporting load
superstructure angle a to the
direction width [t]
horizontal
min. B [ m ] 1/2 3/4
[t]
Boom to the 13.0 0∞ > 60∞ 2.3 8 21

front 7.2 0∞ > 80∞ 2.3 10 19
6.2 0∞ > 80∞ 2.3 10 18
5.1 0∞ > 80∞ 2.3 11 18
Boom to the 13.0 0∞ > 80∞ 2.3 17 15

rear 7.2 0∞ > 80∞ 2.5 15 15
6.2 0∞ > 80∞ 2.5 14 15
5.1 0∞ > 80∞ 2.5 14 15
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316
Driving the crane with the attachment in place

Driving with fully retracted telescopic boom (T>11.6 m) (0 / 0 / 0 / 0) TK $0∞, TK $15∞, TK $ 30∞
with folding jib *
Chart 2
In the chart, a pulley weight of 110kg or 225 kg on the boom head has been considered.
Counterweight
minimum maximum axle
on the crane Telescopic boom
Boom supporting load
Folding jib superstructure angle a to the
direction width [t]
horizontal
min. B [ m ] 1/2 3/4
[t]
K > 8.4 13.0 20∞ > 70∞ 2.3 10 22

7.2 20∞ > 80∞ 2.4 11 19
6.2 20∞ > 80∞ 2.4 11 19
5.1 20∞ > 80∞ 2.4 12 18
to the front
K > 15.8 13.0 20∞ > 70∞ 2.4 10 22
7.2 20∞ > 80∞ 2.5 12 19
6.2 20∞ > 80∞ 2.6 12 19
5.1 20∞ > 80∞ 2.6 13 18
K > 8.4 13.0 20∞ > 80∞ 2.3 17 16

7.2 20∞ > 80∞ 2.4 15 16
6.2 20∞ > 80∞ 2.4 14 16
5.1 20∞ > 80∞ 2.4 14 16
to the rear
K > 15.8 13.0 20∞ > 80∞ 2.5 17 17
7.2 20∞ > 80∞ 2.5 14 17
6.2 20∞ > 80∞ 2.6 14 17
5.1 20∞ > 80∞ 2.6 13 17
317
4.10 DRIVING FROM THE CRANE OPERATORπS CAB 023410>00
185969
318
∫Driving from the crane operatorπs cab™ *

If the crane is to be driven from the crane operatorπs cab and steered via the added hydrostatic rear axle
steering*, complete and observe all checks and measures described in chapters
3.02 ∫BEFORE VEHICLE START UP∫,
3.05 ™THE CRANE AT THE JOBSITE∫ and
4.03 ∫STARTING THE CRANE∫.
The control of engine regulation for the two engines and the foot brake in this crane differs from other
LIEBHERR machines .
CAUTION: Control for

> engine regulation of crane engine = pedal (200)
> engine regulation of travel engine = pedal (201)
> foot brake for chassis = pedal (202)
Change over to ∫Driving from the crane operatorπs cab∫

> Apply the parking brake in the driver∫s cab and in the crane operatorπs cab, turn the engine off by turning the
keyed switch (34) to the ™left™ and turn the ignition off.
In the driverπs cab

> Turn the switch (36) ∫to the left∫ to the ∫crane superstructure∫ symbol, the axle suspension is automatically
blocked.
In addition, for safety reasons, always turn the switch (120) to AXLE SUSPENSION LOCKED.
CAUTION: The switch (36) may only be turned when the engine is at a stand still and the
ignition has been turned off.
Note: If the switch (36) is actuated, the gear selector switch in the driverπs cab (98) as well as in the
crane operatorπs cab (208) must be in neutral ∫N∫ position .
If the switch (36) is actuated while the engine is running, the engine turns off
automatically.
The following functions are now changed to superstructure operation:

> Electrical system, steering, gear selection, engine regulation of travel motor (engine), parking and service
brake.
> Turn the ignition key (34) by one notch in clockwise direction and turn the ignition for the travel motor
(engine) on.
> Turn switch (120) to AXLE SUSPENSION LOCKED.
> Turn the ignition off again and pull the ignition key (34) .
DANGER: For safety reasons, do not remain or step into the driverπs cab (crane chassis) during
crane operation.
Danger of injury due to turning steering wheel.
* Optional
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320
In the crane cab, turn on the ignition for the travel motor (engine)
Whenever the travel motor is started, the DO NOT SHIFT indicator light in the digital indicator window!(209)
light up and turns off again after a few seconds. This means that the control of the indicator light is functioning
properly.
If the DNS indicator light does not light up when the ignition is turned on or remains on for a longer period of
time, then the system must be checked immediately.
If the DNS indicator light comes on during travel (except when starting) then the ELECTRONIC CONTROL UNIT
(ECU) control has found a diagnostics code . While it light up, short beeps can be heard from the gear control unit
of 8 seconds. They are acoustical notes that up or back shifting is limited and no changes in direction occur
any longer. The SELECT field on the control indicator is empty.
Note : See "Indication of stored codes for diagnostics indicator"

at the end of chapter !3.04 TRAVEL OPERATION ON PUBLIC ROADS.
If the DNS indicator light turns on and the ignition is turned off, then the gear remains in
"N" (neutral) until the DNS indicator light is being turned off.
Every time the engine is started, the warning light (301) lights up and turns off after a few seconds. This
means that the control of the warning light is functioning properly.
If the warning light (301) and the DNS indicator light in the digital indicator window (209) light up at the same
time during travel , then the gear may only be operated for a short time in the selected travel range, just long
enough to bring it to a service station.
CAUTION : The preselected gear may not be changed, i. e. continue travel in the selected gear,
only if the torque converter oil pressure is available (see chapter 3.04 , paragraph
7) .
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In the crane cab, turn the ignition for the travel motor (engine) on
> Switch the gear selector switch (208) to neutral position "N".
Note: The travel motor (engine) can only be started when both gear selector switches (in the
driver's cab and in the crane operatorπs cab) are in neutral position ∫N∫.
> Insert the ignition key into the ignition (283) and turn it by one notch in clockwise direction.
The following warning (indicator) lights will turn on when the ignition is turned on :
> Preselected travel range on the gear selector switch (209)
> Oil pressure (290)
> Indicator light > flame glow system (291),
> Parking brake (298)
> Alternator, battery voltage (299)
> Warning light (301) Insufficient oil pressure in oil circuit for torque converter/ automatic transmission, error
in electronic gear control in automatic transmission,
Increased oil temperature in oil circuit for torque converter / automatic transmission.
> Position of the crane superstructure to the front (287) or

> position of the crane superstructure to the rear (297),
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Start the engine at a lube oil temperature above the glow stop temperature (f+20∞ C)

If the travel motor does not start after max. 10 seconds, wait for 1 minute.
The starter should only be cranked 3 times for 10 seconds, with a 1 minute break in
between.
> Continue to turn the ignition key (283) in clockwise direction, slowly press the gas pedal of the travel
motor!(201) down and start the engine.
Note : Whenever the engine is started, it takes the starter takes about 1 second before it turns
after the ignition key is turned to position !"2"!.
This delay prevents damage to the electric motor shut off.
> Release the ignition key as soon as the engine starts and relieve the pressure on the gas pedal (201).
> If the engine does not start after approximately 5 seconds, slowly press the gas pedal of the travel motor!(201)
down and turn the starter again.
> Before restarting, return the ignition key all the way back to the stop.
Do not press the gas pedal (201) down if the engine is warm to reduce exhaust emission during the starting
procedure.
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Start the engine at a lube oil temperature below the glow stop temperature (e+20∞ C)

If the travel motor does not start after max. 10 seconds, wait for 1 minute.
The starter should only be cranked 3 times for 10 seconds, with a 1 minute break in
between.
1. Preglow
> Turn the ignition starter switch (283) to position ∫1∫ ,
The preglow time starts, indicated by the illuminated indicator light (291).
If the engine is started during this preglow period, the preglow function is automatically interrupted. In this
case, turn the ignition key back again to the stop and preglow again.
2. Start the travel motor

The starting readiness begins, if the indicator light !(291) blinks.
> Turn the ignition starter switch (283) to position ∫2∫ and start the engine without pressing down the gas
pedal!(201).
Note : Whenever the engine is started, it takes the starter takes about 0.6 second before it turns
after the ignition key is turned to position !"2"!.
If the engine is not being started during this starting readiness period, then the starting readiness drops off
automatically. In this case, repeat point 1. and 2.
> If the engine does not start after approx. 5 seconds, turn the ignition key back to the stop and preglow again,
> Slowly press down the gas pedal (201) and turn the starter again.
If the travel motor does not start after max. 10 seconds, wait for 1 minute. The starter should only be cranked
3 times for 10 seconds, with a 1 minute break in between.
Pay special attention to the batteries during the cold season.

The starting capacity is greatly reduced in cold temperatures, for example at >10∞C it is only 66% of its normal
capacity.
For that reason, the batteries should be stored in a heated room after the engine is turned off.
CAUTION : As long as the engine is running, do not loosen, remove or exchange the alternator
cable nor the terminals on the batteries nor the plug on the regulator.
The alternator must be connected to the batteries during operation.
DO NOT turn the running engine off by turning the battery master switch!(25) off !
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The travel engine runs, check the instruments

As soon as the engine starts, watch the warning light > oil pressure (290).
CAUTION: If the warning light (290) does not turn off, turn the engine off immediately by
pushing the engine stop button (320).
If this is not assured, the engine can be damaged due to insufficient oil pressure.
The engine must must turned off immediately , if :

> a drop in performance or speed without changing the regulator > throttle control
lever
Do not place a full load on the engine until it is at operating temperature!
The following warning (indicator) lights must turn off when the engine is running:
> Indicator light > travel engine flame glow system (291),
> Alternator, battery voltage travel engine (299),
> Oil pressure (290),
> Insufficient oil pressure in the circuit for the torque converter / automatic transmission (301)
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Travel readiness, the engine is running at low idle speed
Travel > shifting

To drive the crane from the crane operatorπs cab, 2 forward gears and 1 reverse gear are available.
The shift stages 1/2 or 2/1 can be shifted under load.
C A U T I O N : Changing from neutral to reverse, reverse to forward and vice versa is only permitted
when the vehicle is at a standstill, the parking brake is applied and the engine is
running at low idle speed!
The travel speed can be regulated via the pedal (201) and the gear selector (208) for the automatic transmission.
Gear selector (208)

The various positions of the gear selector, their meaning and use are as follows:
Push the arrow key ≠ (up) orØ(down) to get to the desired gear.
The SELECT indicator shows the highest usable great, the MONITOR always shows the currently placed gear.
R (Reverse travel)
If the Reverse gear is turned on, the SELECT range selection indication and the MONITOR show an "R" . Wait
for about 1 to 2 seconds before giving gas.
N (Neutral)
On the SELECT range selector and the MONITOR indication appears the "N", if the neutral position has been
reached. This is the required shift position when starting the engine.
C A U T I O N : For safety reasons, before starting the engine, apply the parking brake. Do not let the
vehicle run out in low idle speed ( (SELECT indicator "N") , this eliminates the engine
braking action, making the gear lubrication insufficient.
D Slow driving
If the D key is pushed, the following can be shown on the SELECT range selection indicator and the MONITOR :
SELECT MONITOR
2 => 2
In this travel stage, the transmission can automatically shift up or back, the gear stage cannot be retained
manually.
SELECT MONITOR
6 => 1
In this travel stage, only the 2st gear is actuated, the 2nd gear is locked.
This gear is recommended if the crane must be moved at extremely slow speed or where load and terrain make
it necessary.
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The engine runs at low idle speed

> On the gear selector (208), push the appropriate key for the desired travel direction (V or R (forward or
reverse) .
If the V or R key is pushed,

> a beeping sound can be heard
> in the window (209) under SELECT and MONITOR appears the indication V 6=>1 or R 6=>1
This shows that the automatic transmission is ready to work in the selected travel range.
A slight decrease in speed shows that the selected gear is shifted.
Release the parking brake

> Pull the parking brake lever (263) straight out and push it forward, indicator light (298) turns off.
Note: When the parking brake is released, the manual brake lever (263) points forward.
As long as the required brake release pressure of about 5.2 bar is not available in brake
circuit III, the parking brake will not release, even if the manual lever has been moved to
the front.
Move the parking brake lever (263) back again, increase the engine RPM by pushing the
pedal (200) to increase the pressure in brake circuit √.
CAUTION: Check the brakes immediately after the crane starts to move by pressing the brake
pedal (202) down.
Keep an eye on the following warning lights while driving:

> Oil pressure (290)
> Alternator, battery voltage travel engine (299),
> Coolant temperature (300)
> Warning light (301)
CAUTION: If the warning lights (290, 300 or 301) light up during travel, then the crane must be
stopped immediately, and the travel motor (engine) must be turned off via the
engine Stop button (320).
Low engine oil pressure or high coolant temperature can cause serious engine
damage.
Low oil pressure and (or) high oil temperature in the circuit for the torque converter
/ automatic transmission can cause serious transmission damage.
> Add Diesel fuel as soon as warning light (289) lights up .
CAUTION: Do not let the fuel tank get completely empty, because it will become necessary to
bleed the entire fuel system .
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Off road driving

For driving off road, on unpaved surfaces and during winter conditions, then the drive for the 1st (or 1st and
2nd)* axle can be added via switch (313) when the vehicle is at a standstill.
To add drive for 1st (or 1st and 2nd)* axle

> Bring the crane to a standstill.
> Move the gear selector switch (208) to neutral position ∫N∫
> Add the drive for the 1st (or 1st and 2nd*) axle via switch (313).
> On the gear selector (208) , push the key for the desired travel range (D or R) .
The second axle drive is not engaged until the indicator light in the switch (313) turns on.
CAUTION: Turn off the drive for the 1st (or 1st and 2nd)* axle as soon as the vehicle moves to
solid ground which provides sufficient traction and the gear is no longer required.
Note: For details on the axle suspension for off road driving, refer to
"AXLE SUSPENSION / LOCKING SYSTEM", chapter 3.03.
Hydraulic rear axle steering *

The rear axle steering makes it possible to move in the wheels of the 3rd and 4th axle in the same direction for
tight turning radii and to offset the crane (dog or crab walk).
CAUTION: The rear axle steering may NOT be used while driving on public roads.
To offset the crane (dog walk), all wheels must be turned into the same direction.
For tight turning radii, the wheels of the front axle must be turned in travel direction and the wheels for the two
rear axles must be against the travel direction.
The angle of the rear axles should be about the same as the angle for the front axle to prevent the tires from
∫chaffing∫ or rubbing against each other.
* Optional
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To put the hydraulic rear axle steering in operation

> Bring the vehicle to a standstill on level ground, turn the wheels on the front axle for ™straight travel™ and
apply the parking brake.
> Shift the gear selector switch (208) to neutral position ∫N∫.
> Turn the crane superstructure in ∫lengthwise direction of the vehicle∫, to the front or the rear and lock the
crane superstructure to the chassis.
> Move the manual control lever (261) ∫down∫, the indicator light (306) must light up.
Note: If the crane superstructure is positioned in ∫lengthwise direction∫ to the front, the indicator
light (287) must be on,
If the crane superstructure is positioned in ∫lengthwise direction∫ to the rear, the indicator
light (297) must be on.
> Via the switch (312), open the steering lock for the rear axles (3rd and 4th axle).
Note: The release is possible in neutral position, in 1st and 2nd gear forward as well as in 1st
reverse gear.
> Move the steering switch (270) slightly to the left and right.
If the wheels do not move, then the steering lock / release is in intermediate position.
In this case, turn the switch (312) off and on again.
Then move the steering switch (270) slightly to the left and right again.
> Via the steering switch (270) both rear axles can now be moved to the left or right, independent from the two
front axles.
To take the hydraulic rear axle steering out of operation
CAUTION: If the rear axle steering is no longer needed, then it must be locked again in straight
away direction on level ground before continuing to drive!
> Bring the vehicle to a standstill on level ground, turn the wheels of the rear axle for straight travel, apply the
parking brake.
> Shift the gear selector switch (208) to neutral position ∫N∫.
> Via switch (312), apply the steering lock for the rear axle.
> Move the steering button (270) for the rear axle steering slightly to the left and right to make sure that the
rear axle steering is locked, while watching the wheels of the rear axles, these wheels may no longer steer to
the right or left.
> Turn the travel motor (engine) via the engine Stop button (320).
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Other features for the travel operation

The crane operator's cab is equipped with a interior light (207) with switch.
The parking and low beam lights can be turned on via the 2>stage switch ( (310*) .
The emergency blinker system can be turned on via switch (311*) , the blinker in the switch shows that the
system is functioning.
The instrument panel can be illuminated via switch (325).
The windshield wiper for the front window can be turned on via switch (223).,
the windshield washer system * for the front window is turned on via button (222)*.
The windshield wiper for the for the overhead roof window is turned on via button (221),
the windshield washer system for the for the overhead roof window is turned on via button (220*).
The working floodlight is turned on via switch (239).
The travel direction indicator is turned on via switch (205*), its function is indicated by a blinking indicator
light (288*) .
The horn can be sounded via food button (204).
To end travel
> Bring the crane to a stop by applying the service brake (202) .
> Apply the parking brake with the manual lever ( 263) .
> Switch the gear selector switch (208*) to neutral position ∫N∫.
Turn the engine off*

> Relieve the engine by slowly decreasing the engine speed, then let the engine run for a short time at low idle
speed to give the turbocharger time to run down.
> Push the engine stop button (320) until the engine stops.
Turn the ignition for the travel motor (engine) off

> Turn the ignition off by turning the ignition key (283) counterclockwise to ∫0∫ position and then pull it off.
> Lock the crane operatorπs cab.
> Secure the crane with wedges to prevent it from rolling .

> Turn the main battery switch (in the battery box, on the right hand side behind the driverπs cab) off and pull
the cam .
* Optional
339
4.11 CRANE OPERATION ∫FREESTANDING∫ 023411>00
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340
Crane operation freestanding* on tires and driving with a load*

For the equipment configuration ∫CRANE OPERATION FREESTANDING ON TIRES∫, the crane must be po>
sitioned in vehicle lengthwise direction to the rear and must be mechanically locked to the chassis.
DANGER : The crane may only be operated "freestanding, on tires" and with suspended load if
the required load capacity charts have been programmed and set on the LICCON
safe load indicator system.
The instructions of the appropriate load capacity chart MUST be followed!
Non > adherence can cause serious accidents!
11. Crane operation ™freestanding on tires , working range to the ear∫
1.1 All tires must be inflated to the correct tire pressure, as noted in the load capacity chart for crane opera>
tion ∫free standing on tires" .
1.2 The boom may be moved, even without a load, only in ranges where load capacity values are available for
∫free standing, on tires∫, otherwise there is a danger that the crane will tip over.
1.3 The ground must be able to securely support the maximum operating weigh t of the crane and the weight
of the suspended load.
1.4 The ground must be level and without any slopes .
1.5 The axle suspension must be blocked,

> switch (120) must be turned on.
1.6 The crane superstructure must be in lengthwise vehicle direction ∫to the rear∫ and mechanically locked
to the chassis,
> To do so, move the locking lever (261) ∫downward∫, the indicator light (306) must light up.
1.7 The slewing brake must be applied,

> switch (272) must be turned on.
1.8 For safety reason, always try to work with the crane supported, even in cases, when you could work
∫freestanding on tires".
1.9 For safety reason, the crane must be supported and horizontally aligned before turning the crane super>
structure into the working position ∫to the rear∫ and before lifting the telescopic boom from the boom re>
tainer .
To do so, extend the sliding arms at least to the support basis 8.1m ¥ 2,3m (note the colored marks on
the sliding arms).
The telescopic boom must be fully retracted.
The LICCON safe load indicator must be set to the corresponding operating mode.
Proceed the same way to return the crane superstructure from working position "free standing on tires,
working range to the rear" into the travel condition.
1.10 If possible, the 4 sliding arms should remain extended and pinned and the outrigger cylinders with in>
stalled outrigger pads should be lowered close to the ground, so that the ground can support itself, if it
should give.
1.11 The LICCON safe load indicator system must be set to the operating mode "FREESTANDING*, ON TI>
RES" .
1.12 The telescopic boom may be telescoped out only to a maximum length of 17.4 m .
1.13 The suspended load must be carried as close as possible to the ground and it must be secured to prevent it
from swinging.
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2. Driving the crane with an attached load, ONLY TO THE REAR*

The crane can be moved with an attached load ∫to the rear∫ , if the notes in paragraph 1 are strictly ob>
served.
In addition, the following applies:

2. 1 The attached load must be carried as close as possible to the ground and must be secured to prevent it
from swinging.
2. 2 Drive only :
> in 1st gear.
> with utmost care and in step by step speed.
> the least possible increase in speed and careful braking action.
> Avoid jerky travel movements.
3 There is a danger of tipping over or a danger of overload :
3.1 if the crane superstructure is not positioned in lengthwise travel direction to the rear.
3.2 if the boom is extended to a length of more than 17.4m and the crane superstructure is turned from the
vehicle lengthwise direction.
3.3 if the axle suspension is not blocked,
3.4 if the ground is not able to securely carry the maximum operating weight and the weight of the suspen>
ded load,
3.5 if the ground is not level and without slopes.
3.6 if you drive too quickly with a load or if you start out or slow down jerkily or brake.
3.7 if the outrigger cylinders with installed outrigger pads are not lowered to just above the ground.
3.8 if the loads and / or radii given in the load capacity charts are exceeded or fallen below, depending on the
boom length.
3.9 if the sufficient distance to excavations, ditches and slopes is not adhered to .
3.10 if the load starts to swing due to improper crane control.
3.11 if the load is pulled diagonally. Pulling the load diagonally transverse to the boom lengthwise direction
is the most dangerous action.
343
4.12 TWO>HOOK OPERATIONS 021688>03
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344
Description
In two>hook operations, a distinction must be made between
1. Operation with mast stub, for which no load capacity charts are available, and
2. Operation with boom extension (auxiliary boom, folding jib, luffing jib).
3. Operation with load reversing device.
1. Operation with mast stub *

This operating mode makes quick lifts via the mast stub (hoist gear 2) possible; the reeved in hook block (hoist
gear 1) remains fully reeved on the telescopic boom.
The mast stub is generally operated in the (T) tele operation mode.
DANGER: The overload safety device ist only effective if the reeving on the telescopic boom is
the same or larger than the reeving on the mast stub. If this is not assured, the hoist
gear 1 or the hoist cable can be overloaded.
The LICCON safe load indicator system must be set to the smaller reeving of
both hooks.
> Set operating mode "T" on the LICCON safe load indicator system.
> Enter the cable reeving to reflect the actual reeving on the mast stub.
CAUTION: For crane operation with mast stub, be aware that the radius and load indicator of
the safe load indicator system is not exact, because the mast stub is not being
cosidered in the boom geometry.
The safe load indicator system must be set to the actual reeving on the mast stub
annd the corresponding CODE No. for the appropriate boom length must be
entered.
In addition, the counterweight, the support base, etc. must also be cosidered.
By setting the smaller reeving number of the two hooks, it is assured that the crane ist not overloaded.
Add the weight of the hook block (load hook) and the tackle to the weight of the load, which is to be lifted.
* Special equipment
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2. Operations with the folding fly jib and with the special auxiliary boom *
This capability is provided for turning the load while simultaneously operating both hoisting gears.
DANGER: The load must always be raised or lowered to 100% with the weakest component (fly
jib or special auxiliary boom*).
> Enter the reeving in the LICCON in accordance with the reeving present (folding fly jib or special auxiliary
boom *).
DANGER: The reeving on the main hook (telescopic boom) must be equal to or larger than the
reeving on the jib (folding fly jib or special auxiliary boom *).
If this is not observed, hoisting gear 1 or the hoisting cable could be overloaded.
> For operations with the folding fly jib and the special auxiliary boom *, the LICCON must be set to the
operating mode "Folding fly jib".
> Enter the cable reeving in the equipment mode diagram of the LICCON in accordance with the reeving
present on the jib.
In this case the maximum total load corresponds to the maximum permissible load on the folding fly jib given
in the corresponding load capacity table for jib operations.
The weight of the hook block and the slinging tackle must be added to the loads to be hoisted.
CAUTION: The radius display is given corresponding to the entered folding fly jib.
The individual loading capacity per hook during two> hook operations corresponds
to the permissible load given in the appropriate load capacity table for operations
with folding fly jib.
The sum loading capacity corresponds during two>hook operations to the

permissible load given in the appropriated load capacity table for operations with
folding fly jib.
DANGER: Hoisting a load with 2 hooks is only permissible in accordance with diagrams Va.1,
Va.2 and Va.3.
If this is not observed, there is a danger of accidents due to the overloading of the
individual crane components.
Protection via the overload safety device is then no longer provided.
If a load is hoisted in accordance with Va.1, the load must first be completely hoisted to 100% with the most
outer hook.
Note: As soon as the inner hook is drawn, the load display in the overload safety device is
incorrect!.
DANGER: If both hook are loaded, luffing the boom is prohibited!

Protection via the overload safety device is then no longer provided.
For this reason, the load must always be taken up at the maximum radius.
* Special equipment
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348
3. Load reversing device *
The load reversing device (Va.3) is a special device and is not included in delivery with the crane.
Starting up
> For two>hook operations with the load reversing device, the LICCON overload safety device must be set to
Tele>operations or L>mode and the present equipment mode.
> Both hooks must be quadruple>reeved.
> Cable reeving in the equipment mode diagram of the LICCON must be entered with "4".
Note: The overload safety device monitors the entire load.

The weights of the hook blocks and the slinging tackle must be added to the load to be
hoisted.
DANGER: Both hook blocks must be multiply reeved. If this is not done, a hoisting gear can be
overloaded.
* Special equipment
349
5.00 EQUIPMENT 021678>00
350
021678>00
Chapter 5
Equipment
351
352
Notes on assembly:
> The hoisting cable must be reeved in between the pulley head and hook block in accordance with the
reeving plans in Chap. 4.06, for the respective load capacity table.
> The ballast must be mounted in accordance with the specifications in the load capacity tables.
> Combining and mounting the ballast must be carried out in accordance with Chap. 4.07.
DANGER: For assembly works on the crane, an operationally safe assembly scaffold / working
platform must be used > improvisations are prohibited. Otherwise, there is a danger
of falling.
Checking the safety measures
> Is axle suspension / axle floating locked?
> Is the load bearing capacity of the foundation sufficient?
> Are all four sliding arms and support cylinders extended to the support base as indicated in the load
capacity table?
> Are the sliding arms secured with pins?
> Are the support pads secured?
> Is the crane horizontally aligned?
> Is the crane at a safe distance from slopes and trenches?
> Are the axles relieved; i.e., no contact between the tires and the ground?
> Has it been absolutely established that there are not electrical wires and lines within the operating range of
the crane?
> Has the operating site been selected so that operations can be carried out with the smallest possible working
radius?
> Are there any obstacles which would block necessary crane movements?
353
Bypassing the safety devices with the assembly key>operated switch
Parts of the safety device equipment can be bypassed with the assembly key>operated switch. For certain
assembly procedures, this is necessary and permissible.
DANGER: Using the assembly key>operated switch during crane operations is prohibited.
Only those persons may use the key>operated switch who are fully familiar with the
entire operation of the crane and who are aware of the effects of bypassing the
system.
After all assembly work has been carried out, the key must be removed immediately
and handed over to an authorized person.
If the load torque limiter is bypassed during crane operations, there is the danger of
accidents.
Checking the cables
Before assembly and at regular intervals, the cables must be subjected to expert inspection in order to recognize
possible damage and signs of wear.
DANGER: The cables must be taken off the crane immediately if any of the following defects
are found:
> broken strand
> broken wires
> groups of broken wires
> cable diameter 10% or more narrower than the nominal value
> cable deformation
New cables must be of the same design, strength rating and diameter as the old ones. After installing a new
cable, the cam limit switch in the hoisting gear must be reset.
CAUTION: If the cable pulleys are rewound, they must be wound out or replaced before
replacing an old cable with a new one. Otherwise, the new cable can be damaged.
354
Connecting or removing hydraulic lines with quick>release couplings
DANGER: When connecting or removing hydraulic lines by means of the quick>couplers, it

must always be ensured that the coupling procedure is carried out properly.
Requirement for a correct coupling connection is:

> Before any connections are made or loosened,there must be no pressure in the entire pressure system.
(Bring engine to a standstill > wait 5 minutes)
> Assemble the coupler parts (socket and plug) and tighten with hand nut.
> Turn the hand nut until a noticeable, fixed stop is reached.
> The couplers must only be attached and detached by hands > do not use tools as this could damage the
couplers.
DANGER: Improperly connected couplers could lead to a loss of pressure or sudden leaks and
thus lead to an accident.
Raising / Lowering
Before raising or lowering a boom combination, the following requirements must be fulfilled:
Requirements:
> The crane is properly supported and horizontally aligned.
> The ballast is attached to the slewing platform in accordance with the load capacity table.
> The telescopic boom is completely retracted.
> The jib is assembled in accordance with the load capacity tables and instruction manual.
> All limit switches are correctly mounted and properly functioning.
> All pinned connections are secured.
> The hoist cable is properly placed in the cable pulleys and is secured with cable retaining pins against
jumping out.
> There are no loose parts on the telescopic boom or jib.
In winter:
> The telescopic boom and the TA strut and its components (limit switch, cable drum, aircraft warning light,
wind speed gauge, etc.) are free of snow and ice.
DANGER: Incorrectly mounted or nonfunctioning limit switches as well as falling parts (pins,
spring keepers, ice, etc.) are dangerous and can cause serious injury.
355
5.02 FOLDING JIB > TK 022606>00
183336
356
5.02 FOLDING JIB > TK 022606>00
Short description
This crane can be equipped, as desired, with one of two different folding jibs.
1. Two part folding jib * Weighs about 1160 kg

Working length 15.8 m
consisting of:
Adapter 1,1 m
Pivot section
End section
1.1 Component overview for two part folding jib
1.1.1 Installation of two part folding jib as ªSHORT´ extension (working length 8.4m)
1.2 Installation of two part folding jib as ªLONG´ extension (working length 15.8m)
1.3 Angle installation of two part folding jib as ªSHORT´ extension (working length 8.4m)
1.4 Angle installation of two part folding jib as ªLONG´ extension (working length 15.8m)
1.5 Connecting the hoist limit switch (HES)
1.6 Erecting the folding jib
1.7 Crane operation with two part 8.4m . . . . 15.8m long folding jib
1.8 Removal of two part folding jib (working length 15.8m)
1.9 Removal of two part folding jib (working length 8.4m)
2. On part folding jib* Weighs about 770 kg

Working length 8.4 m
consisting of:
Adapter 1,1 m
Pivot section
2.1 Component overview for one part folding jib
2.2 Installation of one part 8.4m long folding jib
2.3 Angle installation of one part folding jib (working length 8.4m)
2.4 Crane operation with one part* 8.4m long folding jib
2.5 Removal of one part folding jib
*Optional
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Short description , continuation
The folding jibs can either be used as a straight extension or they can be installed at an angle of 15∞ or 30∞ to the
telescopic boom and can be operated on the 34.3 m . . . 40 m extended telescopic boom.
For the installation of the two folding jibs, an hydraulic > mechanical installation aid is installed.
For on road travel, the folding jib is folded on the telescopic boom and mechanically secured.
a) Angle adjustment (15∞ or 30∞ to the telescopic boom ) for the

two part folding jib ,(working length 8.4m) as short extension
one part folding jib (working length 8.4m)
The angle adjustment for the two folding jibs can only be done via the hoist gear with the aid of the special
hook block* (Fig. 1) or the load hook* (Fig. 2) and through sensitive movement of the corresponding manual
control lever.
CAUTION : Angle adjustment and crane operation via the folding jib with other hook blocks or
load hooks is not permitted.
b) Angle adjustment (15∞ or 30∞ to the telescopic boom ) for the

two part folding jib (working length 15.8m)
For the 15.8 m long working length, the cable pull of the hoist gear is not sufficient, the folding jib must be
raised with the aid of the special hook block* (Fig. 1) or the load hook* (Fig. 2) .
CAUTION : For the angle adjustment , the hook block (or load hook) must be removed, the hoist
cable must be attached to the lock on the bracket (fig. 3, pos. 41) and the angle ad>
justment must be done through sensitive movement of the corresponding manual
control lever, via the hoist cable .
*Optional
359
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360
5.02 FOLDING JIB > TK 022606>00
1.1 Component overview for the two part * folding jib
Pos.:
1 Pin with retainer clip > Swing pin and mount of end section on pivot section of folding jib at(A)
2 Pivot section of folding jib
3 End pulley > on pivot section of folding jib
4 End section of folding jib
5 End pulley > on end section of folding jib
6 Cable guide pulley > Cable guide over folding jib
7 Pin with retainer clip > Swing pin and mount of end section on pivot section (2) of folding jib at te>
lescopic boom head at (C)
8 Pin with spring retainer > Mounting of folding jib on telescopic boom head at (E)
9 . . . 14 > Installation aid for installation of upper pin (E)

9 Bore > (Installation receptacle of pin 11)
10 Bore > (Transport receptacle of pin 11)
11 Pin with spring retainer
12 Hydraulic cylinder
13 Valve
14 Manual pump
15 Pin >Swing pin with return spring and lock between folding jib and telescopic
boom pivot section at (D)
16 Lever > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
17 Sleeve > on end section of lever (16)
(to insert installation rod)
18 Bracket > To secure the lever (16) in transport condition
19 Link > To secure the lever (16) when swinging out folding jib
20 Pin with spring retainer > To secure the end section (4) of the folding jib on the pivot section of the
telescopic boom
21 Bore > To take up the pin (20), if the folding jib is installed in a working length
of !8.4m and the end section (4) remains secured on the pivot section of the
telescopic boom.
22 Bore > To take up the pin (20), if the folding jib is installed in a working length
of !15.8m and the end section (4) is folded out together with the pivot sec>
tion (2) of the folding jib .
23 Plastic rope > To release the lock (26) between end and pivot section of the folding jib
24 Pin with spring retainer >Lock for folding jib rest (25) in appropriate end position (in our out)
25 Folding jib rest > at the same time transport retainer (bracket X) of folding jib
26 Lock > To secure the end section (2) on pivot section!(4) of folding jib.
X Bracket > Transport retainer for folding jib
>> Installation rod > to release the lock (16) between folding jib and telescopic boom pivot sec>
tion
(X) Bracket > Transport retainer for folding jib
*Optional
361
5.02 FOLDING JIB > TK 022606>00
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362
5.02 FOLDING JIB > TK 022606>00
Installation procedure
DANGER: For the installation, a safe installation base (working platform) must be used, DO
NOT improvise!
There is a danger of falling down and causing a serious accident!.
Prerequisites for the installation of all folding jibs:

> The crane is properly supported and horizontally aligned,
> the counterweight is installed on the counterweight frame, according to the corresponding load capacity chart,
> the telescopic boom is fully telescoped in (retracted) ,
> the folding jib is mounted for transport on the telescopic boom pivot section ,
> the travel and crane engine is running.
> the telescopic boom is positioned to the rear or to the side, luffed down to 0∞ position,
angle indicator is at 0∞, see control and indicator unit of LICCON system.
DANGER: The telescopic boom must be in 0∞ position, otherwise there is a danger of causing a
serious accident because the folding jib might swing out by itself when the locks are
released!
If the folding jib is to be used for work for a longer period of time, then the hook block on the telescopic boom
should be unreeved and the hoist cable for winch 1 should be used when operating the folding jib .
This simplifies work with the folding jib, in addition, this will eliminate the load reduction for the reeved in
hook block on the telescopic boom .
If the hoist cable of winch 2* is used for work with the folding jib, then the hook block on the telescopic boom do>
es not have to be unreeved.
CAUTION : In this case, the load carrying capacities of the folding jib are reduced by the weight
of the reeved in hook block.
1.1.1 Installation of the two part * folding jib as ªSHORT´ extension (working length 8.4m)
> Unreeve the hoist cable on the telescopic boom head,

> Wind up the hoist cable from hoist gear 2 * all the way onto the cable drum.
DANGER: This work must be done from a stable base.

Extreme caution must be exercised when walking on the telescopic boom.
There is a danger of causing a serious accident due to erroneous control of crane
functions and slipping on the telescopic boom.
> Lock hoist gear 2 via the LICCON system.

> Extend the telescopic boom to about 8.4 m (depending on the length of the folding jib in use) and place the
hook block on the ground,
> on the pulley head of the telescopic boom, release the hoist limit switch weight and the hoist cable on the lock
(cable fixed point).
> Remove the cable retainer bars on the pulley head of the telescopic boom and pull the hoist cable from the pla>
ced down hook block,
> Reinsert the cable retainer bars, secure them with spring clips and telescope the telescopic boom in all the
way.
* Optional
363
5.02 FOLDING JIB > TK 022606>00
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364
5.02 FOLDING JIB > TK 022606>00
1.1.1 Installation Continuation
The not needed end section (4) of the folding jib remains secured by the retainer pin (20) on the telescopic boom
pivot section.
DANGER: The retainer pin (20) may not be removed.

If this is not observed, the unsecured end section will fall down when the folding jib
swings out, causing a danger to LIFE and DEATH!
Make sure there are no persons or objects within the swing range as well as the fol>
ding range of the telescopic boom and folding jib .
There is a potential danger of causing a serious accident.
> Adjust the LICCON system according to the load capacity chart by entering the CODE number and hoist ca>
ble reeving number for crane operation ∫Crane supported∫, with 8.4 m folding jib, (see separate LICCON
Operation Manual)
Take the two digit CODE number from the load capacity chart.
> Mount an auxiliary rope on the folding point on the pivot section (2) of the folding jib .
> Roll out the wound up plastic rope (23, which is used to release the lock (26) and let it hang down.
Swing out the folding jib rest (25)
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the pi>
vot sections(2) on the telescopic boom pivot section.
> Remove the spring retainer on the pin (24) , hold the ball joint of the pin (24) with one hand, pull it ªdown´
and swing the folding jib rest (25) out by hand,
> release the ball joint and continue to swing out the folding jib rest until the pin (24) notches in,
> secure the pin (24) again with the spring retainer.
Swing out the pivot section (2) to the side by 180∞

> Remove the spring clips on both swing pins (A), pull both swing pins (A) out and keep them in the installed
retainers, securing them with spring clips.
> Pull the plastic rope (23) in direction of the arrow Ø to release the lock (26) between the end section (4) and
the pivot section of the folding jib (2) .
CAUTION: During the release procedure at (26), you must hold the folding jib with an auxiliary
rope to prevent it from swinging out by itself.
> Swing the pivot section (2) with the auxiliary rope around its pivot point (D) onto the telescopic boom head un>
til it can be pinned at (C) on top and bottom.
* Optional
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366
5.02 FOLDING JIB > TK 022606>00
Pin the pivot section (2) on the telescopic boom head

> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secu>
re both pins with retainer clips (7) .
CAUTION : To secure the swing pins on the pivot points ( C) , you MUST USE the special retai>
ner clips (7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!(A and C) is not permitted!
Release the lock (15) on the pivot point (D) between the pivot section (2) and the telescopic boom pivot
section
DANGER: Before releasing the lock, make sure that at (C) both pins are pinned and secured
with the special retainers clips!(7) .
During the release procedure of the folding jib from the telescopic boom, you must
hold the folding jib with the auxiliary rope to prevent it from swinging out by itself.
> Insert the supplied installation rod into the retainer bracket (18) and swing it to the side,
> insert the installation rod into the sleeve (17), push the lever (16) upward and notch it to the left into the brac>
ket !(19) to secure, the link (15) between the folding jib and the telescopic boom pivot section is released.
Swing the pivot section (2) forward

> The end section (4) of the folding jib, which is not used, remains pinned (20) to the telescopic boom pivot
section.
> Swing the pivot section (2) with the auxiliary rope by 180∞ around the pivot point (C) to the front, until
it can be pinned at (E) on the bottom.
> Insert a pin at (E) on the bottom and secure with a spring retainer.
Pin the pivot section (2) at (E) on top

The upper pin (E) can only be pinned with the hydraulic > mechanical installation aid!(9 . . . 14) .
> After removing the spring retainer, change the pin (11) over to bore (9) and secure it again with the spring re>
tainer,
> on the manual pump (14) , close the valve (13) and actuate the pump until the fork of the adapter touches the
stop and the upper pin (E) can be inserted.
> Insert the upper pin (E) and secure it with spring retainers.
> Roll the plastic rope (23) up again and remove the auxiliary cable for storage.
CAUTION : When all pins ( 2¥ at C and 2¥ at E) are inserted and secured, the pin (11) in the bo>
re hole (9) must now be relieved on the installation aid by opening the valve (13).
*Optional
367
5.02 FOLDING JIB > TK 022606>00
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368
5.02 FOLDING JIB > TK 022606>00
Swing the cable guide pulley (6) "upward"

> After removing the spring retainer, take the retainer pin (32) for the cable guide pulley (6) from its transport
retainer, swing the cable guide pulley from its transport position into operating position ªupward´ , hold it and
> insert the retainer pin for the cable guide pulley (6) into the bore hole at (31) and secure with spring retainer.
Guide the hoist cable to the pulley head of the folding jib
> Remove the spring retainers and pull out the cable retainer pins (34 and 36) .
> Guide the hoist cable from winch 1 to the end pulley (3)
over the cable guide pulley (6),
through the cable guide (35),
over the end pulley (3)
and between the end pulley (3) and cable guide pulley (37) to the hook block * (to the load hook*).
> Reinsert the cable retainer pins (34 and 36) and secure with spring retainers.
> Reeve the hook block* (load hook *) according to the load carrying capacity chart for operation with 8.4 m fol>
ding jib and hang the end of the cable on the cable fixed point into the cable lock,
> Reinstall the hoist limit switch weight and chain, as described in chapter 4.06 and hang the hoist limit switch
weight onto the hoist cable.
Connect the hoist limit switch (see paragraph 1.5 in this chapter)
Erect the folding jib (see paragraph 1.6 in this chapter )
369
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5.02 FOLDING JIB > TK 022606>00
1.2 Installation of the two part * folding jib as ªLONG´ extension with a working length of 15.8 m
DANGER: DO NOT REMOVE the two swing pins (A)!.

If this is not observed, the unsecured end section (4) will fall down when the folding
jib swings out, causing a danger to LIFE and DEATH!
Make sure there are no persons or objects within the swing range as well as the fol>
ding range of the telescopic boom and folding jib .
There is a potential danger of causing a serious accident.
Operation Manual)
> Unreeve the hoist cable on the telescopic boom head

> Wind up the hoist cable from hoist gear 2 * all the way onto the cable drum.
DANGER: This work must be done from a stable base.

Extreme caution must be exercised when walking on the telescopic boom.
There is a danger of a serious accident due to erroneous control of crane functions
and slipping on the telescopic boom.

way.
> Install an auxiliary rope on the folding point on the pivot section (2) of the folding jib,
> install a second auxiliary rope at (5) on the end section of the folding jib ,
> roll out the rolled up plastic rope (23) and let it hang down.
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the fol>
ding jib on the telescopic boom pivot section.
*Optional
371
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5.02 FOLDING JIB > TK 022606>00
Swing the folding jib (pivot section with end section) to the side by 180∞
> Remove the spring retainer and then pull the retainer pin (20) of the transport retainer, change the pin over to
bore (22) and secure it again with the spring retainer.
CAUTION: When removing the retainer pin (20), make sure to hold the folding jib with the auxi>
liary rope to prevent it from swinging out by itself.
> Swing the folding jib (pivot section with end section) with the auxiliary rope,which is attached to the pivot sec>
tion of the folding jib around its pivot point (D) onto the telescopic boom head, so that it can be pinned at (C) on
the top and bottom.
Pin the folding jib (pivot section with end section) on the telescopic boom head
> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secure
both pins with retainer clips (7).
CAUTION : To secure the swing pins on the pivot points ( A and C) , you MUST USE the special
retainer clips (1 and 7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!(A and C) is not permitted!
Release the lock (15) on the pivot point (D) between the pivot section and the telescopic boom pivot
section.
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5.02 FOLDING JIB > TK 022606>00
Swing the pivot section with end section forward
> Swing the pivot section with end section with the auxiliary rope by 180∞ around the pivot point (C) to the
front, until it can be pinned at (E) on the bottom.
Pin the pivot section at (E) on top

tainer,
> Roll the plastic rope (23) up again and remove the auxiliary cable for storage.
375
5.02 FOLDING JIB > TK 022606>00
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5.02 FOLDING JIB > TK 022606>00
Swing the end section (4) forward
DANGER: During the release procedure of the end section (4) from the pivot section (2), you
must hold the end section with a second auxiliary rope to prevent it from swinging
out by itself.
> Pull the plastic rope (23) in direction of the arrow Ø to release the lock (26) between the end section (4) and
the pivot section of the folding jib (2) .
> Swing the end section with the second auxiliary rope by 180∞ around its pivot point (A) , until it can be pinned
at (B) on top and bottom.
> Insert a pin at (B) on top and bottom and secure both pins with spring retainers.
D A N G E R: All pins must be secured.

If this is not assured, a serious accident can be caused by falling crane sections.
> Remove both auxiliary ropes and roll up the plastic rope (23) .
377
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5.02 FOLDING JIB > TK 022606>00

retainer, swing the cable guide pulley from its transport position into operating position ∫upward∫, hold it and
Guide the hoist cable to the pulley head of the end section
> Remove the spring retainers and pull out three cable retainer pins (34, 36, and 39) .
> Insert the cable retainer pin (36) into its transport retainer and secure with a spring clip.
CAUTION : The cable retainer pin (36) may not be inserted again.
If this is not observed, the hanging hoist cable will scrape on the pin (36), and be da>
maged.
N o t e: If the folding jib is to be operated below an angle of 15∞ or 30∞ to the telescopic boom, do not
yet reeve the hoist cable.
At a working length of 15.8m, the cable pull of the hoist gear is not sufficient to lift the fol>
ding jib with the aid of the special hook block* or load hook* and to change it.
In this case, the hoist cable must be attached to the lock on the bracket (41) .
> Reeve the hook block* (load hook *) according to the load carrying capacity chart for operation with 15.8 m fol>
ding jib and hang the end of the cable on the cable fixed point into the cable lock.
Erect the folding jib (see paragraph 1.6 in this chapter).
Optional
379
5.02 FOLDING JIB > TK 022606>00
183346
380
5.02 FOLDING JIB > TK 022606>00
1.3 Angle installation of the two part * folding jib as ªSHORT´ extension (working length 8.4m)
CAUTION : The angle installation for working length of 8.4 m is NOT identical with the angle in>
stallation for working length of 15.8m.
To change the angle, the hook block (the load hook) must be attached and the angle
adjustment must be made through careful and sensitive movement of the corre>
sponding manual control lever, via the hoist cable.
The hoist limit switch weight and the chain must be removed to install the
ªSHORT´ folding jib at an angle.
1.3.1 Installation at an angle of 15∞
> Luff down the telescopic boom to 0∞ , while holding the hook block at about 1 m above the ground.
> Remove the hoist limit switch weight with chain and unhook the hoist cable from the cable lock (cable fixed
point).
> Bypass the LICCON overload system by holding the keyed switch in.
> Deflect the corresponding manual control lever very sensitively to bring the hook block * (or the load hook*)
carefully to the stop (38 ) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 ) of the folding jib, do not telescope
the telescopic boom out nor luff it down!
Only if the hook block has been lowered by at least one meter can be telescopic
boom be telescoped out or luffed down.
If this is not observed,the sections of the folding jib and the hoist cable will be over>
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) and raise the bracket (30) a little.
DANGER: The pin (33) may only be unpinned if the end section or the pivot section of the fol>
ding jib is held by the hoist cable.
If this is not observed,there is a danger of causing an accident, as the folding jib will
suddenly ªfold down´ !
> Insert the pin (33) into the corresponding bore for 15∞ and secure it with spring retainers.
*Optional
381
5.02 FOLDING JIB > TK 022606>00
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382
5.02 FOLDING JIB > TK 022606>00
1.3.1 Installation at an angle of 15∞ , continuation
> Carefully luff up the telescopic boom to about 10∞, while simultaneously luffing down the folding jib by lowe>
ring the hook block* (the load hook*), until the bracket (29) is on the pin for the bore for 15∞ (Fig. 5).
> Lower the hook block until it is about 1 m above the ground,
> Luff down the telescopic boom so that the hoist limit switch weight can be installed again.
D ANGER: When luffing down,

> the hook block may not run up on the pulley head,
> the telescopic boom may not be telescoped out!
onto the hoist cable.
Erect the folding jib (see paragraph 1.6 in this chapter)
*Optional
383
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384
5.02 FOLDING JIB > TK 022606>00
>Luff down the telescopic boom to 0∞ , while holding the hook block at about 1 m above the ground.
point).
carefully to the stop (38 ) on the end section of the folding jib and lift and hold it via the hoist gear.
DANGER: As long as the hook block touches the stop (38) of the folding jib, do not telescope
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) , insert it in the transport retainer and secure it with the
spring retainer.
*Optional
385
5.02 FOLDING JIB > TK 022606>00
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386
5.02 FOLDING JIB > TK 022606>00
> Carefully luff up the telescopic boom to about 20∞ , while simultaneously luffing down the folding jib by lo>
wering the hook block* (the load hook*) until the length slot of bracket (29) is on the pin for the bore for 30∞
(Fig. 5).
> Luff down the telescopic boom so that the hoist limit switch weight can be installed.

*Optional
387
5.02 FOLDING JIB > TK 022606>00
183342
388
5.02 FOLDING JIB > TK 022606>00
1.4 Angle installation of the two part* folding jib as a ªLONG´ extension (working length 15.8m)
Prerequisite:
> The folding jib is installed as a straight extension (0∞ position) , as described in paragraph 1.1 or 1.2 ,
> the crane is properly supported and horizontally aligned,
> the telescopic boom is positioned to the rear or to the side ,
> the hook block * (the load hook *) is reeved according to the load capacity chart,
CAUTION : The angle installation for working length of 15.8 m is NOT identical with the angle
installation for working length of 8.4 m.
To change the angle, the hook block (the load hook) must be removed, the hoist ca>
ble must be attached to the lock on the bracket (fig. 3, Pos. 41) and the angle adjust>
ment must be made through careful and sensitive movement of the corresponding
manual control lever, via the hoist cable.

> Luff down the telescopic boom to 0∞ and place the hook block on the ground.
> Unreeve the hook block and unhook the hoist limit switch weight on the hoist cable .
> Remove the spring clip and then remove the lock (Fig. 3) on the cable fixed point of the end section , pin it on
bracket !(41) and secure the pin again with the spring clip .
> Attach the hoist cable now to the lock on the bracket (41) .
> Deflect the corresponding manual control lever very sensitively to carefully lift and hold the folding jib with
the hoist cable .
DANGER: As long as the folding jib is held with the hoist cable, do not telescope the telescopic
boom out nor luff it down!
The telescopic boom be telescoped out or luffed down only when the folding jib has
been installed at a 15∞ angle.
loaded and damaged.
Fig. 1 and Fig. 2

*Optional
389
5.02 FOLDING JIB > TK 022606>00
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5.02 FOLDING JIB > TK 022606>00
1.4.1 Installation at an angle of 15∞, continuation
> Carefully luff up the telescopic boom to about 10∞, while simultaneously luffing down the folding jib by lo>
wering the hook block* (the load hook*), until the bracket (29) is on the pin for the bore for 15∞ (Fig. 5).
CAUTION: When spooling the hoist cable out, make sure that the cable does not slacken up on
the winch (check the winch visually).
Slack cable can cause cable damage!
Fig. 3
> Luff down the telescopic boom and spool the hoist cable out at the same time until the lock can be removed on
the bracket (41).
> Unhook the hoist cable on the lock on bracket (41) and place it on the ground.
> Remove the spring clip and remove the lock on the cable fixed point (bracket 41), pin it at the cable fixed point
of the end section and secure it again with the spring clip.
> Reeve the hook block * (or attach the load hook*) as described in chapter 4.06 and attach the hoist limit switch
weight on the hoist cable.
Erect the folding jib ( see paragraph 1.6 in this chapter)
* Optional
391
5.02 FOLDING JIB > TK 022606>00
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392
5.02 FOLDING JIB > TK 022606>00
> Luff down the telescopic boom to 0∞ and place the hook block on the ground.
> Unreeve the hook block and unhook the hoist limit switch weight on the hoist cable .
> Remove the spring clip and then remove the lock (Fig. 3) on the cable fixed point of the end section , pin it on
bracket !(41) and secure the pin again with the spring clip .
> Attach the hoist cable now to the lock on the bracket (41) .
> Deflect the corresponding manual control lever very sensitively to carefully lift and hold the folding jib with
the hoist cable .
DANGER: As long as the folding jib is held with the hoist cable, do not telescope the telescopic
boom out nor luff it down!
The telescopic boom be telescoped out or luffed down only when the folding jib has
been installed at a 15∞ angle.
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) and insert it in the transport retainer and secure it with
the spring retainer.
*Optional
393
5.02 FOLDING JIB > TK 022606>00
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5.02 FOLDING JIB > TK 022606>00
1.4.2 Installation at an angle of 30∞ , Continuation
> Carefully luff up the telescopic boom to about 20∞, while simultaneously luffing down the folding jib by
spooling out the hoist cable until the length slot of bracket (29) is on the pin for the bore for 30∞ (Fig. 5).
> Luff down the telescopic boom and spool the hoist cable out at the same time until the lock (fig.3) can be remo>
ved on the bracket (41).
> Unhook the hoist cable on the lock on bracket (41) and place it on the ground.
> Remove the spring clip and remove the lock on the cable fixed point (bracket 41), pin it at the cable fixed point
of the end section and secure it again with the spring clip.
> Reeve the hook block * (or attach the load hook*) as described in chapter 4.06 and attach the hoist limit switch
weight on the hoist cable.
Erect the folding jib ( see paragraph 1.6 in this chapter)
* Optional
395
5.02 FOLDING JIB > TK 022606>00
182801
396
5.02 FOLDING JIB > TK 022606>00
1.5 Connect the hoist limit switch (HES)
One hook operation

> On the connector box X (on the left hand side of the telescopic boom head), loosen the union nut and then re>
move the plug for the telescopic boom hoist limit switch cable from the socket X 451 .
> Change the dummy plug X 552 from socket X 500 to socket X 451 and tighten the union nut.
> Insert the plug of the hoist limit switch cable of the folding jib into socket X 500 and tighten the union nut.
> Attach the hoist limit switch weight.
Two hook operation
CAUTION : In two hook operation, the dummy plug X 552 must be removed and the plug of the
cable for the hoist limit switch for the folding jib must be connected to socket X 500 .
To remove the hoist limit switch

> Change the dummy plug X 552 again to socket X 500 and insert the hoist limit switch of the telescopic boom
into socket X 451 , tighten the union nut.
397
5.02 FOLDING JIB > TK 022606>00
183147
398
5.02 FOLDING JIB > TK 022606>00
1.6 To erect the folding jib
Prerequisites:
> the telescopic boom is fully telescoped in (retracted) ,
> the folding jib is mounted according to the load capacity chart and the operating manual,
> all limit switches are correctly installed and are fully functioning.
> All pin connections are secured.
> The hoist cable has been inserted correctly into the cable pulleys and is secured with cable retainer pins to pre>
vent it from jumping out.
> There are no loose parts on the telescopic boom and folding jib.
In Winter:
> The telescopic boom, the folding jib and their components, such as limit switch, cable drums, airplane war>
ning light*, wind velocity sensor* etc.) must be free of ice and slow.
DANGER: Improperly installed on non>functioning limit switches as well as falling parts, such
as pins, spring retainers, ice, etc. can cause accidents!
To erect
> Enter and confirm the operating mode >TK>, according to the installed folding jib length and the instal>
lation angle !(0∞,!15∞!or!30∞) as well corresponding data from the load capacity chart into the LICCON
system.
> Luff up the telescopic boom with installed folding jib to the steepest telescopic boom position (fig.!3) and
> telescope the telescopic boom out to the telescopic boom length given in the load capacity chart.
DANGER: Telescoping in and out with installed folding jib is only permitted if the telescopic
boom is at its steepest position.
If this is not observed, it can cause an accident !
The radii given in the load capacity chart may not be exceeded or fallen below ,
even if there is no load on the hook!
If this is not observed, then the crane can tip over!
399
5.02 FOLDING JIB > TK 022606>00
183350
400
5.02 FOLDING JIB > TK 022606>00
1.7 Crane operation with two part * 8.4m . . . . 15.8m long folding jib
The folding jib may be operated on the following boom lengths
Telescopic boom length [m] 34,3 37,6 40 30,9 37,6 40

Folding jib length [m] 8,4 8,4 8,4 15,8 15,8 15,8
Telescopic section 1 extended [ % ] ) 92 92 100 0 92 100
Telescopic section 2 extended [ % ] 92 92 100 92 92 100
CAUTION : The guidelines given in the load capacity chart for crane operation with
folding jib must be observed.
401
5.02 FOLDING JIB > TK 022606>00
183550
402
5.02 FOLDING JIB > TK 022606>00
1.8 Removal procedure of the two part * folding jib , (working length 15.8m)
DANGER: For the removal, a safe installation base (working platform) must be used, DO NOT
improvise!
Prerequisites :
> the folding jib is installed at an angle of 15∞ or 30 ∞ to the telescopic boom ,
> the telescopic boom is luffed up to 80∞ position,
> the folding jib rest is folded out and secured,
CAUTION : The removal procedure for working length of 15.8 m is NOT identical with the remo>
val procedure for working length of 8.4 m.
For removal, the hook block (the load hook) must be removed,the hoist cable must
be attached with the lock on bracket (fig. 3, pos. 41) and the angle adjustment must
be made through careful and sensitive movement of the corresponding manual con>
trol lever, via the hoist cable.
First the folding jib must be changed over again to a straight extension in 0∞ position to the telescopic boom he>
ad.
1.8.1 To change the folding jib from 15∞ to 0∞

> In the LICCON program TK, 15∞, telescope the telescopic boom with installed folding jib fully in.
> Luff down the telescopic boom until the hoist limit switch weight can be removed on the end section of the fol>
ding jib.
> Place the hook block on the ground, unreeve it and unhook the hoist limit switch weight on the hoist cable.
> Remove the lock (fig. 3) on the cable fixed point of the end section, after removing the spring clip, and pin it on
bracket (41) and secure the pin again with the spring clip.
> Bypass the LICCON overload safety device by holding in the keyed switch,
> through sensitive movement of the corresponding manual control lever, carefully raise the folding jib with
the hoist cable and pull it up, while luffing the telescopic boom down at the same time until the folding jib is at
0∞ position (stops on the bracket 29) (Fig. 2)
CAUTION : As soon as the folding jib is at 0∞, stop the ªup´ and ªluffing´ movement immediate>
ly.
loaded and damaged.
> Remove the spring retainer and take the pin (33) from the 15∞ bore hole, pin it into the (0∞) bore hole and secu>
re it with the spring retainer. (Fig. 1+2)
*Optional
403
5.02 FOLDING JIB > TK 022606>00
183551
404
5.02 FOLDING JIB > TK 022606>00
1.8.2 To change the two part* folding jib from 30∞ to 0∞
ding jib.
> Place the hook block on the ground,unreeve it and unhook the hoist limit switch weight on the hoist cable.
> Remove the lock (Fig. 3) on the cable fixed point of the end section, after removing the spring clip, and pin it
on bracket (41) and secure the pin again with the spring clip.
> Attach the hoist cable into the lock mounted on bracket (41) .
> Bypass the LICCON overload safety device by holding in the keyed switch,
> through sensitive movement of the corresponding manual control lever, carefully raise the folding jib with
the hoist cable and pull it up, while luffing the telescopic boom down at the same time until the folding jib is at
0∞ position (stops on the bracket 29) (Fig. 6)
ly.
loaded and damaged.
> Remove the spring retainer and take the pin (33) from the transport retainer, insert it in to the (0∞) bore hole
and secure it with the spring retainer. (Fig. 5+6)
*Optional
405
5.02 FOLDING JIB > TK 022606>00
183552
406
5.02 FOLDING JIB > TK 022606>00
1.8.3 Changing the two part * folding jib from 0∞ into transport position
> Luff down the telescopic boom to 0∞, check the LICCON operating and control unit for angle indicator for 0∞.
DANGER : The telescopic boom must be in 0∞ position, otherwise there is a danger of accidents
because the folding jib can swing in by itself when the pins are released!
> Spool out the hoist cable until the lock can be removed on bracket (41).
> Unhook the hoist cable from the cable lock (bracket 41) and place it on the ground.
> Remove the spring retainers and remove the cable lock on the cable fixed point (bracket 41) and place it in the
tool box.
> Pull out the cable retainer pins (39) on the end pulley and (34) on the cable guide pulley (6) after removing
the spring clips, and
> lift the hoist cable from the pulleys (5 and 6) and let it hang down next to the folding jib .
> Insert the cable retainer pins (34, 36, and 39) and secure with spring retainers.
Swing the cable guide pulley (6) into transport position ªdownward´
> On the retainer pin (32) , remove the spring, slightly lift the cable guide pulley (6) with one hand and pull out
the pin (32) ,
> swing the cable guide pulley (6) all the way ∫down∫ to the stop, insert the pin (32) into the bore hole!(31) and
secure with the spring retainer.
*Optional
407
5.02 FOLDING JIB > TK 022606>00
183553
408
5.02 FOLDING JIB > TK 022606>00
1.8.3 To change the two part * folding jib continuation
Swing the end section (4) to the rear
DANGER: The two swing pins (A) ) may not be removed.

If this is not observed, the unsecured end section (4) will fall down when the folding
jib swings in, causing a danger to LIFE and DEATH!
> Attach an auxiliary rope to the pivot section of the folding jib ,
> attach a second auxiliary rope to the end section of the folding jib .
> At (B) on the top and bottom unpin both pins after removing the spring retainers, and insert both pins into the
installed transport retainers and secure with spring retainers.
DANGER: While unpinning the two pins (B), hold the end section with an auxiliary rope to pre>
vent it from swinging by itself.
> Swing the end section (4) with the auxiliary rope by 180∞ around the pivot point (A) to the rear onto the pivot
section (2) until the lock (26) engages.
*Optional
409
5.02 FOLDING JIB > TK 022606>00
183554
410
5.02 FOLDING JIB > TK 022606>00
Swing in the folding jib (pivot section with end section ) to the side by 180∞
DANGER: The two swing pins (C) may not yet be removed.
If this is not observed, the unsecured folding jib will fall down when it is moved,
causing a danger to LIFE and DEATH!
Release the pin between the pivot section (2) and the end section of the telescopic boom at (E) .
Note: The upper pin (E) can only be unpinned with the hydraulic >mechanical installation aid (9 . .
. 14) .
> On the manual pump (14) , close the valve (13) and actuate the pump until the upper pin (E) can be removed
by hand.
> Remove the spring retainer and take out the upper pin (E) , insert it into the transport retainer and secure it
with spring retainer.
> On the installation aid, remove the spring retainer and pull the pin (11) from the bore (9), reinsert it in bore
(10) and secure again with the spring retainer,
> on the hand pump (14), open valve (13) .
DANGER: The lower pin (E) may only be unpinned, if the folding jib is being held with an au>
xiliary rope, to prevent it from swinging by itself.
> Hold the folding jib with the auxiliary rope and
> at (E) on the bottom, remove the pin after removing the spring retainer,insert the pin into the installed trans>
port retainer and secure with spring retainer.
> Insert the installation rod into the retaining bracket (18) , swing it to the side until the snub is on the retai>
ning bracket next to the lever (16) ,
> place the installation rod down .
> Swing the folding jib with the auxiliary rope by 180∞ around the pivot point (C) to the rear onto the pivot sec>
tion , until the lock (15) engages at the pivot point (D) .
> Insert the installation rod into the retaining bracket (18) , swing the retaining bracket to the center to the
snub of the retaining bracket is over the lever and secure it.
> Store the installation rod in the tool box.
411
5.02 FOLDING JIB > TK 022606>00
183554
412
5.02 FOLDING JIB > TK 022606>00
Release the folding jib from the telescopic boom head

Release the pin between the pivot section (2) and the end section of the telescopic boom at (C) .
DANGER: Before unpinning the two pins (C) it must be assured that the lock (15) is engaged at
(D) .
causing a serious ACCIDENT!
> At (C), unpin both pins after removing the retainer clips, insert them into the transport receptacles and secu>
re them with the retainer clips .
Secure the folding jib on the telescopic boom pivot section
> Pull the folding jib with the auxiliary rope to the pivot section and secure the end section of the folding jib on
the telescopic boom pivot section ( in transport retainer. )
> Remove the spring retainer and remove the pin (20) from its retainer (22) and insert it into the bore hole for
the transport retainer (21) , secure with spring retainer.
> Swing the folding jib rest (25) in (transport retainer )
Note: Due to the folded front section of the folding jib rest (25), the retainer bracket(X) , which is
welded onto the folding jib is ªtensioned´ , securing the folding jib for transport.
and swing the folding jib rest (25) in by hand,
> release the ball joint and continue to swing in the folding jib rest until the pin (24) notches in,
DANGER: The pin (24) must be notched in and secured with the spring retainer. If this is not
assured, then the folding jib is unsecured and can swing out by itself, causing an
ACCIDENT.
> Remove both auxiliary ropes and store them.

> Telescope the telescopic boom out to the hook block,
> remove the spring retainers and pull out the cable retainer bars on the telescopic boom head and on the hook
block and reeve the hook block,
> on the telescopic boom head and on the hook block, reinsert the cable retaining bars and secure with spring re>
tainers.
> Hang the cable end on the cable fixed point in the cable lock and the hoist limit switch weight on the hoist ca>
ble, as described in chapter 4.06 .
Secure the hook block for transport

> Telescope the telescopic boom in, while holding the hook block about 1 m to 1.5 m above the ground and
> attach the hook block, as described in chapter 2.04 , to the front bumper.
413
5.02 FOLDING JIB > TK 022606>00
183562
414
5.02 FOLDING JIB > TK 022606>00
1.9 Removal procedure of the two part folding jib (working length 8.4m)
CAUTION : For removal, the hoist limit switch weight and the chain must be removed and the
folding jib must be changed over to a straight extension in 0∞ position to the telesco>
pic boom head.
The removal procedure of the ªSHORT´ extension is the same as the removal procedure of the one part folding
jib with exception of paragraph 1.9.5 Secure folding jib on telescopic boom pivot section
1.9.1 Changing the folding jib from 15∞ to 0∞

(see paragraph 2.5.1)
1.9.2 Changing the folding jib from 30∞ to 0∞

1.9.3 Changing the folding jib from 0∞ into transport position

1.9.4 Swing folding jib to the rear
1.9.5 Secure folding jib on telescopic boom pivot section
Release the pins between folding jib (pivot section 2) and end section of telescopic boom at (C) (Fig. 8).
(D) .
> Pull the folding jib with the auxiliary rope to the pivot section.
> remove the spring retainer and remove the pin (20) from its retainer (22) and insert it into the bore hole for
the transport retainer (21) , secure with spring retainer.
*Optional
415
5.02 FOLDING JIB > TK 022606>00
183562
416
5.02 FOLDING JIB > TK 022606>00
1.9.5 Secure the folding jib on the telescopic boom pivot section continuation
> Swing the folding jib rest (25) in (transport retainer )
ACCIDENT.
> Remove both auxiliary ropes and store them.

tainers.

> Telescope the telescopic boom in, while holding the hook block about 1 m to 1.5 m above the ground and
417
5.02 FOLDING JIB > TK 022606>00
183555
418
5.02 FOLDING JIB > TK 022606>00
2.1 Component overview for the one part * folding jib
Pos.:
1 Reserved
2 Folding jib
3 End pulley
4 Reserved
5 Reserved
6 Cable guide pulley > Cable guide over folding jib
7 Pin with retainer clip > Swing pin and mount of folding jib at telescopic boom head at (C)
8 Pin with spring retainer > Mounting of folding jib on telescopic boom head at (E)
9 . . . 14 > Installation aid for installation of upper pin (E)

9 Bore > (Installation receptacle of pin 11)
10 Bore > (Transport receptacle of pin 11)
11 Pin with spring retainer
12 Hydraulic cylinder
13 Valve
14 Manual pump
15 Pin with spring retainer > Swing pin and lock between folding jib and telescopic boom pivot section at
(D)
16 Lever > to release the lock (15) between folding jib and telescopic boom pivot sec>
tion
17 Sleeve > on end section of lever (16)
(to insert installation rod)
18 Bracket > To secure the lever i(16) in transport condition
19 Link > To secure the lever (16) when swinging out folding jib
20 Reserved
21 Reserved
22 Reserved
23 Reserved
24 Pin with spring retainer >Lock for folding jib rest (25) in appropriate end position (in our out)
25 Folding jib rest > at the same time transport retainer (bracket X) of folding jib
26 Reserved
>> Installation rod > to release the lock (16) between folding jib and telescopic boom pivot sec>
tion
(X) Bracket > Transport retainer for folding jib .
*Optional
419
5.02 FOLDING JIB > TK 022606>00
183555
420
5.02 FOLDING JIB > TK 022606>00
2.2 Installation of the one part , 8.4 m long folding jib*
> Unreeve the hoist cable from the telescopic boom head.
> Wind the hoist cable from hoist gear 2 all the way onto the cable drum.
D A N G E R: The work must be carried out from a stable position. When walking on the telesco>
pic boom, use utmost care.
There is a great danger of causing a serious accident if any crane function is carried
out improperly or due to slipping on the telescopic boom .
Make sure there are no persons or objects within the folding range of the telescopic
boom and the folding jib, or it can cause a serious accident .

way.
Operation Manual)
> Attach an auxiliary rope to the end section (2) of th folding jib.
* Optional
421
5.02 FOLDING JIB > TK 022606>00
183555
422
5.02 FOLDING JIB > TK 022606>00
CAUTION : When ªfolded in´, the folding jib rest (25) is also the transport retainer!(X) of the pi>
vot sections(2) on the telescopic boom pivot section.
During the release procedure of the folding jib rest (25), you must hold the folding
jib with an auxiliary rope to prevent it from swinging out by itself.
Swing out the pivot section (2) to the side by 180∞

> Swing the pivot section (2) with the auxiliary rope around its pivot point (D) onto the telescopic boom head un>
til it can be pinned at (C) on top and bottom.
Pin the pivot section (2) on the telescopic boom head

> At (C) on top and bottom, connect the folding jib with the telescopic boom head by inserting a pin and secu>
re both pins with retainer clips (7) .
CAUTION : To secure the swing pins on the pivot points ( C) , you MUST USE the special retai>
ner clips (7),which have been supplied for this purpose.
Use of spring clips or spring retainers on the swing pins!( C) is not permitted!
* Optional
423
5.02 FOLDING JIB > TK 022606>00
183555
424
5.02 FOLDING JIB > TK 022606>00
Release the lock (15) on the pivot point (D) between the pivot section (2) and the telescopic boom pivot
section
Swing the pivot section (2) forward

> Swing the pivot section (2) with the auxiliary rope by 180∞ around the pivot point (C) to the front, until
it can be pinned at (E) on the bottom.
Pin the pivot section (2) at (E) on top

tainer,
> Remove the auxiliary rope for storage.
*Optional
425
5.02 FOLDING JIB > TK 022606>00
183556
426
5.02 FOLDING JIB > TK 022606>00

retainer, swing the cable guide pulley from its transport position into operating position ªupward´ , hold it and
Guide the hoist cable to the pulley head of the folding jib
> Remove the spring retainers and pull out the cable retainer pins (34 and 36) .
> Reeve the hook block* (load hook *) according to the load capacity chart for operation with 8.4 m folding jib
and hang the end of the cable on the cable fixed point into the cable lock,
Erect the folding jib (see paragraph 1.6 in this chapter )
*Optional
427
5.02 FOLDING JIB > TK 022606>00
183342
428
5.02 FOLDING JIB > TK 022606>00
2.3 Angle installation of the one part folding jib (working length 8.4m)
CAUTION : To change the angle, the hook block (the load hook) must be attached and the angle
adjustment must be made through careful and sensitive movement of the corre>
sponding manual control lever, via the hoist cable.
The hoist limit switch weight and the chain must be removed to install the one part
folding jib at an angle.
> Luff down the telescopic boom to 0∞ , while holding the hook block at about 1 m above the ground.
point).
carefully to the stop (38) on the end section of the folding jib and lift it via the hoist gear.
DANGER: As long as the hook block touches the stop (38 ) of the folding jib, do not telescope
loaded and damaged.
Fig. 1 and Fig. 2

*Optional
429
5.02 FOLDING JIB > TK 022606>00
183343
430
5.02 FOLDING JIB > TK 022606>00
> Carefully luff up the telescopic boom to about 10∞, while simultaneously luffing down the folding jib by lowe>
ring the hook block* (the load hook*), until the bracket (29) is on the pin for the bore for 15∞ (Fig. 5).
> Luff down the telescopic boom so that the hoist limit switch weight can be installed again.

* Optional
431
5.02 FOLDING JIB > TK 022606>00
183344
432
5.02 FOLDING JIB > TK 022606>00
>Luff down the telescopic boom to 0∞ , while holding the hook block at about 1 m above the ground.
point).
carefully to the stop (38 ) on the end section of the folding jib and lift and hold it via the hoist gear.
DANGER: As long as the hook block touches the stop (38) of the folding jib, do not telescope
loaded and damaged.
Fig. 1 and Fig. 2

> Remove the spring retainer and unpin the pin (33) , insert it in the transport retainer and secure it with the
spring retainer.
*Optional
433
5.02 FOLDING JIB > TK 022606>00
183345
434
5.02 FOLDING JIB > TK 022606>00
> Carefully luff up the telescopic boom to about 20∞ , while simultaneously luffing down the folding jib by lo>
wering the hook block* (the load hook*) until the length slot of bracket (29) is on the pin for the bore for 30∞
(Fig. 5).
> Luff down the telescopic boom so that the hoist limit switch weight can be installed.

*Optional
435
5.02 FOLDING JIB > TK 022606>00
183350
436
5.02 FOLDING JIB > TK 022606>00
2.4 Crane operation with one part * 8.4m . . . . 15.8m long folding jib
The folding jib may be operated on the following boom lengths
Telescopic boom length [m] 34,3 37,6 40

Folding jib length [m] 8,4 8,4 8,4
Telescopic section 1 extended [ % ] 92 92 100
CAUTION : The guidelines given in the load capacity chart for crane operation with
folding jib must be observed.
437
5.02 FOLDING JIB > TK 022606>00
183557
438
5.02 FOLDING JIB > TK 022606>00
2.5 Removal procedure of the one part folding jib
Prerequisites :
> the folding jib is installed at an angle of 15∞ or 30 ∞ to the telescopic boom ,
> the telescopic boom is luffed up to 80∞ position,
> the folding jib rest is folded out and secured,
CAUTION : For removal, the hoist limit switch weight and the chain must be removed.
First the folding jib must be changed over again to a straight extension in 0∞ position to the telescopic boom he>
ad.
DANGER: For the removal, a safe installation base (working platform) must be used, DO NOT
improvise!
2.5.1 To change the folding jib from 15∞ to 0∞
ding jib. Hold the hook block * (the load hook*) about 1m . . . 1.5m above the ground.
> On the hoist limit switch, remove the weight and the chain and store it in the tool box.
> Bypass the LICCON overload safety device by holding in the keyed switch.
> Through sensitive movement of the corresponding manual control lever, carefully move the hook block* (the
load hook*) onto the stop (38) on the end section of the folding jib and pull it up, while luffing the telescopic
boom down at the same time until the folding jib is at 0∞ position (stops on the bracket 29) (Fig. 2)
ly.
loaded and damaged.
> Remove the spring retainer and take the pin (33) from the 15∞ bore hole,
pin it into the 0∞ bore hole and secure it with the spring retainer. (Fig. 1+2)
*Optional
439
5.02 FOLDING JIB > TK 022606>00
183558
440
5.02 FOLDING JIB > TK 022606>00
2.5.2 To change the two part* folding jib from 30∞ to 0∞
> Luff down the telescopic boom until the hoist limit switch weight can be removed, hold the hook block* (the lo>
ad hook*) about 1m . . . 1.5m above the ground.
> On the hoist limit switch, remove the weight and the chain and store it in the tool box.
> Bypass the LICCON overload safety device by holding in the keyed switch.
> Through sensitive movement of the corresponding manual control lever, carefully move the hook block* (the
load hook*) onto the stop (38) on the end section of the folding jib and pull it up, while luffing the telescopic
boom down at the same time until the folding jib is at 0∞ position (stops on the bracket 29) (Fig. 6)
ly.
loaded and damaged.
> Remove the spring retainer and take the pin (33) from the transport retainer, insert it in to the (0∞) bore hole
and secure it with the spring retainer. (Fig. 5+6)
*Optional
441
5.02 FOLDING JIB > TK 022606>00
183559
442
5.02 FOLDING JIB > TK 022606>00
2.5.3 Changing the one part * folding jib from 0∞ into transport position
> Luff down the telescopic boom to 0∞, check the LICCON operating and control unit for angle indicator for 0∞.
DANGER : The telescopic boom must be in 0∞ position, otherwise there is a danger of accidents
because the folding jib can swing in by itself when the pins are released!
> Lower the hook block* (load hook*) and place it on the ground.
> Spool out the hoist cable until the lock can be removed on cable fixed point of the folding jib.
> Remove the spring retainers and remove the cable lock on the cable fixed point and place it in the tool box.
> Pull out the cable retainer pins (36) on the end pulley and (34) on the cable guide pulley (6) after removing
the spring clips, and
> lift the hoist cable from the pulleys (3 and 6) and let it hang down next to the folding jib .
> Insert the cable retainer pins (34 and 36) and secure with spring retainers.
Swing the cable guide pulley (6) into transport position ªdownward´
> On the retainer pin (32) , remove the reeving spring, slightly lift the cable guide pulley (6) with one hand and
pull out the pin (32) ,
> swing the cable guide pulley (6) all the way ªdown´ to the stop, insert the pin (32) into the bore hole!(31) and
secure with the spring retainer.
*Optional
443
5.02 FOLDING JIB > TK 022606>00
183560
444
5.02 FOLDING JIB > TK 022606>00
2.5.4 Swing the one part folding jib sideways by 180∞ to the rear
DANGER: The two swing pins (C) may not yet be removed.
causing a danger to LIFE and DEATH!
Release the pin between the pivot section (2) and the end section of the telescopic boom at (E) (fig. 7).
Note: The upper pin (E) can only be unpinned with the hydraulic >mechanical installation aid (9 . .
. 14) .
> Install and auxiliary rope on the end section of the folding jib.
> On the manual pump (14) , close the valve (13) and actuate the pump until the upper pin (E) can be removed
by hand.
> Remove the spring retainer and take out the upper pin (E) , insert it into the transport retainer and secure it
with spring retainer.
> On the installation aid, remove the spring retainer and pull the pin (11) from the bore (9), reinsert it in bore
(10) and secure again with the spring retainer,
> on the hand pump (14), open valve (13) .
DANGER: The lower pin (E) may only be unpinned, if the folding jib is being held with an au>
xiliary rope, to prevent it from swinging by itself.
> Hold the folding jib with the auxiliary rope and
> at (E) on the bottom, remove the pin after removing the spring retainer,insert the pin into the installed trans>
port retainer and secure with spring retainer.
> Insert the installation rod into the retaining bracket (18) , swing it to the side until the snub is on the retai>
ning bracket next to the lever (16) ,
> place the installation rod down .
> Swing the folding jib with the auxiliary rope by 180∞ around the pivot point (C) to the rear onto the pivot sec>
tion , until the lock (15) engages at the pivot point (D) .
> Insert the installation rod into the retaining bracket (18) , swing the retaining bracket to the center to the
snub of the retaining bracket is over the lever (16) and secure it.
> Store the installation rod in the tool box.
445
5.02 FOLDING JIB > TK 022606>00
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5.02 FOLDING JIB > TK 022606>00
Release the folding jib from the telescopic boom head

Release the pin between the pivot section (2) and the end section of the telescopic boom at (C) (fig. 8)
(D) .
> Pull the folding jib with the auxiliary rope to the pivot section
Secure the folding jib on the telescopic boom pivot section (transport retainer X)
> Swing the folding jib rest (25) in .
ACCIDENT.
> Remove the auxiliary rope and store it.

tainers.

> Telescope the telescopic boom in, while holding the hook block about 1 m . . . 1.5 m above the ground and
447
6.00 ADDITIONAL EQUIPMENT 021679>00
448
021679>00
Chapter 6
Additional Equipment
449
6.01 HEATER / ENGINE PREHEAT SYSTEM 2) 023412>00
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1. Heating system > driverπs cab

The driverπs cab can be heated with two 1) heating systems, which operate independently
from each other.
1.1 Engine dependent heater

The heat for the driverπs cab is supplied by the engine coolant, it can be regulated via the temperature
regulator (12) and used to heat the cab.
Via regulator (13) , you can chose between fresh air or air circulation.
The air distribution to the top or bottom can be preselected via the regulator (14) .
Via a 3$stage blower switch (15), the heated air flow can be regulated.
Close both doors and side windows.
1.2 Engine independent WEBASTO heater 1)

Please refer to the more detailed WEBASTO heater for operating instructions.
The engine independent heater is used to preheat the Diesel engine,as well as to heat the driverπs cab if
the engine is not running and as an auxiliary heating system in case ambient temperatures are extre>
mely low and the engine heating system is not sufficient.
DANGER: The heater may not be operated in closed areas, such as garages or works>
hops, not even with timer operation 2) or Tele start 2).
If this rule is not followed, there is a danger of poison or suffocation!
The heater must be turned off at gasoline stations.

If this rule is not followed, there is a danger of causing an EXPLOSION!
1.2.1 Additional heater 1) used as a heating system if the engine is not running.
> Turn the blower switch (15) to stage 1 , move the temperature regulator (12) to ∫WARM∫ and turn
the auxiliary heater on via switch (102) , indicator light (74) will light up.
By moving the sliding regulator (12) , the amount of water can be regulated and via the blower switch
(15) the air flow amount can be regulated.
1.2.2 Preheating the engine 3) with the WEBASTO auxiliary heater.

If temperatures fall below $15 ∞C ,then the engine can be preheated with the auxiliary heater.
> To preheat the engine, move the regulator (12) for the heater in the driverπs cab to ∫COLD∫ .
> Via switch (102) , turn on the auxiliary heater, indicator light (74) will light up.
Now the coolant fluid for the Diesel engine is preheated via this additional heating system.
It can take up to an hour, depending on the ambient temperatures.
*) 1 ) 2) Optional
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To bleed the system.
When draining the engine coolant fluid, the contents of the heating system must also be drained , because the
engine coolant system and heater system are part of the same single circuit.
When refilling the system, it must be bled carefully, the quickest way is to bleed the system with the engine.
> Add coolant via the expansion tank for the engine cooling system, according to the lubrication chart.
> Start the engine as described in chapter 3.04, paragraph 1 and 2.
> Move the temperature regulator (12) to ∫WARM∫ .

> Watch the expansion tank if air bubbles rise up.
If no more air bubbles are visible in the expansion tank, move the temperature regulator (12) to ∫COLD∫ ,
which bleeds the circuit for the engine preheat system.
> If even now no more air bubbles rise in the expansion tank, then this circuit is also bled properly.
CAUTION: The battery master switch (25) may only be turned off after the heater has stopped
running!
If arc welding must be done on the crane, remove the negative and positive battery
cable from the vehicle and the crane superstructure batteries to protect the heater
control unit. Attach the positive cable to the vehicle ground.
Note:
During the summer month, let the auxiliary heater (s) * run once a month, for at least 15 to 20 minutes.
Maintain the WEBASTO auxiliary heater according to the manufacturerπs Operation Manual.
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1.3 Driverπs cab > Air conditioning system *

The driverπs cab can be cooled with the air conditioning system.
Refer to the Operating Manual supplied by the air conditioner manufacturer for detailed information.
To put the system into service

> Turn on the battery master switch on (25) and also turn on the ignition ,
> set the sliding regulator (12) to ∫COLD∫.
> Close the regulator for fresh air / circulation (13) .
> Turn on the air conditioning system via switch (86) , the illuminated indicator light (60) shows that
the system is operational.
> Preselect the air flow to the top or bottom via regulator (14) ,
> Turn the blower on via rotary switch (15) ,
> Close both doors and windows.
> Adjust the temperature with regulator (37) .
Maintenance of air conditioning system *

Maintain the system as described in the Operating Manual supplied by the air conditioner manufactu>
rer .
* Optional
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2. Heater > crane superstructure

The crane operatorπs cab can be heated by three 1) heaters, which operate independently from each ot>
her.
2.1 Engine dependent heater

The crane operatorπs cab is heated with the engine coolant, the amount of heat for the cab heater is regu>
lated via a temperature regulator (252) .
The amount of air coming into the cab can be regulated via a 3$ stage blower switch (251) .
Via switch (253), the driver can choose between fresh air and air circulation.
Upward or downward air flow can be adjusted by opening or closing the air vents (255).
2.2 Engine independent WEBASTO heater 1)

Please refer to the more detailed manufacturer's operation manual.
The engine independent heater can be used to preheat the crane engine, as well as to heat the crane ope>
ratorπs cab if the crane engine is not running and in extremely low ambient temperatures, when the en>
gine heating system is not sufficient.
D A N G E R : The heater may not be operated in closed areas, such as garages or workshops,
not even with timer operation 2) or Tele start 3).
If this rule is not followed, there is a danger of poison or suffocation!
The heater must be turned off at gasoline stations.

2.2.1 Use the auxiliary heater as cab heater when the engine is turned off.
> Turn the blower switch (251) to stage 1 ,
> Turn the temperature regulator (252) to ∫WARM∫ and turn the added heater on via switch (227), the
indicator light (226) lights up.
Use the temperature regulator (252) to regulate the amount of coolant and the blower switch (251) to
regulate the amount of air.
2.2.2 Use the auxiliary heater to preheat the engine 4)

At temperatures below $15 ∞C, the crane engine can be preheated with the auxiliary heater.
> To preheat the engine2) , use the temperature regulator (252) and set the heater on ∫COLD∫ .
Use the switch (227) to turn the auxiliary heater on, the indicator light (226) lights up.
The auxiliary heater will now preheat the coolant fluid of the crane engine .
This can take up to an hour, depending on the ambient temperatures.
2.2.3 Digital clock 5) with thermostat

Refer to the detailed manufacturerπs operation manual for operating instructions.
Set the desired turn on time, temperature and running time on the digital clock (233).
> Upward or downward air flow can be adjusted by opening or closing the air vents (255).
> The temperature regulator (252) must be set to ∫WARM∫ .
> Close doors and windows.
1) 2) 3) 3) 4) 5) Optional
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To bleed the system.

When draining the engine coolant fluid, the contents of the heating system must also be drained , because the
engine coolant system and heater system are part of the same single circuit.
When refilling the system, it must be bled carefully, the quickest way is to bleed the system with the engine.
> Add coolant via the expansion tank for the engine cooling system, according to the lubrication chart.
> Start the engine as described in chapter 4.03.
> Move the temperature regulator (252) to ∫WARM∫ .

> Watch the expansion tank if air bubbles rise up.
If no more air bubbles are visible in the expansion tank, move the temperature regulator (252) to ∫COLD∫ ,
which bleeds the circuit for the engine preheat system.
If even now no more air bubbles rise in the expansion tank, then this circuit is also bled properly.
CAUTION: The battery master switch (328) may only be turned off after the heater has stopped
running!
If arc welding must be done on the crane, remove the negative and positive battery
cable from the vehicle and the crane superstructure batteries to protect the heater
control unit. Attach the positive cable to the vehicle ground.
Note:
During the summer month, let the auxiliary heater (s) * run once a month, for at least 15 to 20 minutes.
Maintain the WEBASTO auxiliary heater according to the manufacturerπs Operation Manual.
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2.3 TRUMATIC * auxiliary heater
The engine independent, gas operated heater is used to heat the crane operatorπs cab.
For details, refer to the manufacturerπs Operation Manual for the TRUMATIC auxiliary heater.
DANGER: The gas operated heater MAY NOT BE OPERATED at gasoline stations and in
closed areas, such as garages and workshops.
Operation
> On the crane superstructure, turn the battery master switch (328) on.
> in the crane cab, turn the ignition for the crane engine (282) on.
> Remove the chimney cover for the auxiliary heater.
> Open the valve on the gas bottle and the quick closure valve in the gas line (rear right, below the crane
operatorπs cab. )
> Preselect the air flow direction (upward or downward) by closing or opening the air vents (255) .
> Close both windows and cab door.
> Set the regulator (253) for fresh air / air circulation to air circulation (close).
> Set the desired room temperature on the thermostat (rotary knob ‘) and turn the temperature regula>
tor (252) to ªWARM´ (open it all the way).
> Turn the switch ” to ªHEAT´ and turn switch “ to the desired power.
At low ambient temperatures, run the heater at full power.
N o t e: If indicator light — lights up all the time, the cause might be insufficient gas, air
in the gas line, a dirty fan or a defect of the safety link.
Turn the switch ” off and then turn the heater on again to take care of the ∫PRO>
BLEM™.
> Regulate the temperature via the knob ‘ and the air flow via blower switch ” .
Maintenance of the TRUMATIC* auxiliary heater

Maintain the heater according to the manufacturerπs Operation Manual.
C A U T I O N : In Germany, the gas system must be rechecked every 2 years by a DVFG ex>
pert.
The operator is responsible to initiate and schedule this service and system
check up.
In other countries, always make sure to adhere to and observe any rules and re>
gulations applicable to the locality, state or country.
For your safety, make sure that the gas installation system and the unit is chec>
ked by an expert in regular intervals, but at least every 2 years .
* Optional
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2.4 Air conditioning system * for the crane operatorπs cab

The crane operatorπs cab can be cooled with an air conditioning system.
Refer to the Operating Manual supplied by the air conditioner manufacturer for a more detailed descrip>
tion.
Operation
> On the crane superstructure, turn on the battery master switch (328) .
> In the crane cab, turn on the ignition for the crane engine (282).
> Preselect the air flow to the top or bottom via the air vents (255).
> Close both windows and cab doors.
> Close the regulator (253) for fresh air / air circulation
> Turn on the air conditioning system via switch (224) , the illuminated indicator light (225) shows that
the system is operational.
> Turn the blower on via rotary switch (251) ,
> adjust the temperature with regulator (254) .
C A U T I O N : The battery master switch (328) may only be turned off after the heater has stop>
ped running!
If arc welding must be done on the crane, remove the negative and positive bat>
tery cable from the vehicle and the crane superstructure batteries to protect the
air conditionerπs control unit. Attach the positive cable to the vehicle ground.
Maintenance of the air conditioning system*

Maintain the system according to the manufacturerπs Operation Manual.
*Optional
463
6.02 EMERGENCY CRANE CONTROL 022496>01
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Prerequisite for emergency operation:

> The crane engine is running,and the hydraulic system in the crane superstructure is operational,
> the travel engine is running and the hydraulic system in the crane chassis is operational.
> Two persons are available to control the solenoids on the directional valves ( 1 . . . . 11 )
or
> one person and two emergency control union nuts * for the directional valves (1 and 2) are available.
GEFAHR: In emergency operation, the crane superstructure must always be taken care first.
1. Emergency operation > crane superstructure, Fig. 2 and 1

In case of a failure of the LICCON monitor or the LICCON safe load indicator system, the crane can still be
taken down via the emergency control keyed switch (17) with the two manual control levers in the crane
operatorπs cab.
DANGER: The keyed switch (17) bypasses the LICCON safe load indictor system and may
only be turned on in emergency situations!
Crane operation with the switch (17) turned on is strictly prohibited.
There is a great danger of LIFE AND DEATH!
2. Emergency control > crane chassis

Retract the outriggers
To control the various movements, 2 directional valves for the support system ( 4 . . . . 11 ) are located on all 4
sliding arm boxes.
In case of a failure of the electrical control for these directional valves, the hydraulic supports can also be re>
tracted manually by controlling the solenoids on the directional valves.
3. Emergency operation > rear axle steering

To control the hydrostatic rear axle steering, an additional directional valve (12) is located on the left rear
sliding arm box.
In case of a failure of the electrical control for this directional valve, the rear axle steering can also be con>
trolled manually by controlling the two solenoids on the directional valve (12).
The emergency control for the rear axle steering is used to straighten the rear wheels , in case a problem
had occurred when the rear wheels had been turned, which would prevent them from being returned to
straight forward position.
Note: The emergency control for the rear axle steering can be handled by one person.
*Optional
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1.1 Emergency operation on crane superstructure
The emergency control is possible in case of :

> a problem or failure of the LICCON monitor or
> a problem or failure of the LICCON safe load indicator system.
The monitor on the control and indicator unit of the LICCON is not functioning,
The working procedures are no longer displayed optically on the monitor.
DANGER: The crane may be operated in emergency operation only to take care of an emergen>
cy situation.
Since the monitor is not functioning in case of problems or failure of the LICCON
system and the telescoping procedure and angle indicators are no longer displayed
optically, every step must be done with extreme caution and care and must be chec>
ked visually.
In emergency operation, ALL IMPORTANT safety devices are bypassed .
The emergency crane control may only be performed by authorized personnel, who
are aware of the effects of these bypasses.
Components for emergency control on the crane superstructure

17
Keyed switch > Emergency control on / off
13 . . . . . . . . 16
Potentiometer for speed regulation of individual crane movements
13 > Hoist gear 1+2 down/ up,
Telescopic boom telescope in,
Telescopic boom luff up.
14 > Telescopic boom luff down.
15 > Slewing gear turn right
16 > Slewing gear turn left.
DANGER: The keyed switch (17) bypasses the LICCON safe load indictor system and may only
be turned on in emergency situations by personnel, who are aware of the effects of
this bypass!
Crane operation with the switch (17) turned on is strictly prohibited.

After completion of the emergency cooperation and after repairing the LICCON sa>
fe load indicator system, the keyed switch (17) must be turned OFF again, switch
position ∫VERTICAL∫.
When the keyed switch (17) is in ∫ON∫ position,

> the working speeds can no longer be regulated via the manual control lever,
> the LICCON system is no longer effective,
> the hoist limit switch is bypassed.
> the ªINSTALLATION´ symbol, (Fig. 5) blinks on the LICCON monitor, and an exclamation mark ( ! ) appe>
ars in the symbol. In this case, the operating view is not locked.
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1.2 To take down the crane
CAUTION : First, the load which is suspended on the hook must be set down.
In order to lower the load safety, the crane superstructure might have to be turned or the telescopic boom might
have to be luffed up .
DANGER: All crane movements must be carried out with utmost care and at the slowest possi>
ble speed.
Only load reducing movements may be carried out.
If this is not observed, there is a danger of causing a serious accident.
Emergency control procedure
On the crane cab , Fig. 2

> Open both locks on the cover of the control box by turning the control box key to the left, and remove the cover.
> Turn the keyed switch (17) to ∫ON∫ position.
DANGER: Crane operation with the switch (17) turned on is strictly prohibited.
In the crane cab Fig.1

> Carefully remove the mounting screws on the control box cover and keep them in a safe place,
Note: The mounting screws can fall down when they are removed, do not loose them!
> Remove the cover and set it aside.

> Turn the 4 emergency control potentiometers (13, 14, 15, 16) all the way to the left.
CAUTION : Before initiating a ªslewing´ crane movement, the four emergency control poten>
tiometers (13, 14, 15, 16) must be turned all the way to the left.
In emergency control, the right or left manual control lever must be all the way de>
flected.
The desired (reduced) speed is obtained by turning the potentiometers (13, 14, 15,
16) to the left or right.
for slower crane movement >turn Poti to the left,

for faster crane movement >turn Poti to the right
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1.3 Emergency control for machines with two hoist gears*
1.3.1
Luff the telescopic boom up (fig. 7)
> Turn the operating mode switch (280) to ª luffing the telescopic boom ´ position.
> Move the manual control lever (277) all the way to the left and hold it in this position.
> Turn the potentiometer (13) to the right until the desired luffing speed has been reached, and luff up the teles>
copic boom to the required position ,
> Release the manual control lever (277) .
> Turn the potentiometer (13) all the way to the left again.
1.3.2
Turn crane superstructure to the right
DANGER: Before initiating a ªslewing´ crane movement, the operator must make sure that
there are no persons or obstacles within the slewing range.
> Move the manual control lever (267) all the way to the right and hold it in this position.
> Turn the potentiometer (15) to the right until the desired slewing speed has been reached, and turn the crane
superstructure to the right ,
Turn crane superstructure to the left

superstructure to the left ,
1.3.3
Set down the load
Hoist gear 1 Manual control lever (277)
Hoist gear 2 Manual control lever (267)
> Move the left manual control lever (277 or 267) all the way to the front and hold it in this position.
> Turn the potentiometer (13) to the right until the desired hook speed has been reached, and set down the load.
> Move the left manual control lever (277 or 267) all the way to the rear and run up the hook block.
> Release the manual control lever (277 or 267 ).
*Optional
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Emergency control for machines with two hoist gears* (continuation)
1.3.4
Telescope the telescopic boom in
Telescope telescopic section 2 in

> Switch the operating mode switch (280) to position ªTelescopic section 2´ .
> Turn the potentiometer (13) to the right until the desired telescoping speed has been reached, and telescope te>
lescopic section 2 all the way in ,
Telescope telescopic sections 3 +4 in ( Fig. 4)

lescopic sections 3 + 4 all the way in ,
Telescope telescopic section 1 in ( Fig. 6)

*Optional
473
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1.4 Turn the crane superstructure forward into travel direction
1.4.1
Turn the crane superstructure
> See paragraph 1.3.2
1.5 Luff down the telescopic boom into the transport retainer (Fig. 7)
> Switch the operating mode switch (280) to position ª Luffing the telescopic boom´ .
> Turn the potentiometer (14) to the right until the desired slewing speed has been reached, and carefully luff
down the telescopic boom into the transport retainer ,
> Turn the keyed switch (17) off and pull the key.
CAUTION : After completing the emergency operation and repairing the LICCON system, re>
turn the keyed switch (17) again to the ∫OFF∫ position.
Switch position ∫VERTICAL∫.
If the keyed switch (17) is in ∫ON∫ position

> the LICCON system does NOT TURN OFF any functions,
> the hoist limit switch is bypassed,
> working speeds cannot be regulated via the manual control levers.
In the crane cab ( Fig.1 )

> On the control box, attach the cover and screw it back on.

> Attach the cover for the control box and lock it by turning the two control box keys to the right.
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1.6 Emergency control for machines with one hoist gear *
1.6.1
Luff the telescopic boom up (fig. 7)
> Turn the potentiometer (13) to the right until the desired luffing speed has been reached, and luff up the teles>
copic boom to the required position ,
1.6.2
Turn crane superstructure to the right
superstructure to the right ,
Turn crane superstructure to the left

superstructure to the left ,
1.6.3
Set down the load
> Move the left manual control lever (277 ) all the way to the front and hold it in this position.
> Turn the potentiometer (13) to the right until the desired hook speed has been reached, and set down the load.
> Move the left manual control lever (277) all the way to the rear and run up the hook block.
> Release the manual control lever (277).
*Optional
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Emergency control with one hoist gear* Continuation
1.6.4
Telescope the telescopic boom in
Telescope telescopic section 2 in

Telescope telescopic sections 3 +4 in ( Fig. 4)

lescopic sections 3 + 4 all the way in ,
Telescope telescopic section 1 in ( Fig. 6)

*Optional
479
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1.7 Turn the crane superstructure forward into travel direction
1.7.1
Turn the crane superstructure
> See paragraph 1.6.2
1.8 Luff down the telescopic boom into the transport retainer (Fig. 7)
> Turn the potentiometer (14) to the right until the desired slewing speed has been reached, and carefully luff
down the telescopic boom into the transport retainer ,
> Turn the keyed switch (17) off and pull the key.
CAUTION : After completing the emergency operation and repairing the LICCON system, re>
turn the keyed switch (17) again to the ∫OFF∫ position.
Switch position ∫VERTICAL∫.
If the keyed switch (17) is in ∫ON∫ position

> the LICCON system does NOT TURN OFF any functions,
> the hoist limit switch is bypassed,
> working speeds cannot be regulated via the manual control levers.

> On the control box, attach the cover and screw it back on.

> Attach the cover for the control box and lock it by turning the two control box keys to the right.
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1.9 Bypassing the electric crane control via the self>locking button (18)
If the crane engine is not running or in case of alternator failure, the electric crane control can be turned on by
actuating the bypass button (18).
In this case, the battery voltage may not drop below 20 Volt .
To bypass the electric crane control (fig. 2):

> Move the bypass button (18) to ∫ON∫ position (to the right).
> If the bypass function is not longer required, return the button (18) to the ∫OFF∫ position (to the left).
CAUTION : During crane operation, the bypass button (18) must be turned off.
483
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2.1 Emergency control on chassis, with two persons
Retract the outriggers ∫by hand∫
Via the batter master switch for the travel motor,

> On one of the two directional valves (1 or 2) , push in the solenoid ∫by hand∫ and hold it down, this establishes
the oil pressure supply from the crane hydraulic to the directional valves !( 4 . . . . 11 ) .
> On the corresponding solenoid of directional valves!( 4 . . . . 11 ) push in the piston in direction of the arrow ∫by
hand∫.
As soon as the pressure which is applied onto the piston stops, the movement will stop.
> After completing the emergency control, reinstall the cover and screw it down.
left side function right side function
Push in piston Push in piston
183630
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2.2 Emergency control on chassis, with one person

This requires a union nut (S)*
Retract the outriggers ∫by hand∫

> Via the batter master switch for the travel motor,
> On one of the two directional valves (1 or 2) , on the solenoids, unscrew both union nuts (a) with dust caps (b)
and actuator pins (c), (see illustration).
> Screw both union nuts (S) onto the solenoid on the directional valve (1 or 2).
This establishes the oil pressure supply from the crane hydraulic to the directional valves !( 4 . . . . 11 ) .
> On the corresponding solenoid of directional valves!( 4 . . . . 11 ) push in the piston in direction of the arrow ∫by
hand∫. As soon as the pressure which is applied onto the piston stops, the movement will stop.
> After completing the emergency control, remove both union nuts (S) and store them in the tool box.
> Reinstall union nuts (a) with dust caps (b) and actuator pins (c) in their original position.
> Reinstall the cover and screw it down.
left side function right side function
Push in piston Push in piston
183630
*Optional
487
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2.3 Lower the crane
The outrigger cylinders on the right hand side of the vehicle are extended and retracted individually via the di>
rectional valves installed on the right hand side.
The outrigger cylinders on the left hand side of the vehicle are extended and retracted individually via the di>
rectional valves installed on the left hand side.
> By actuating the directional valves 4, 6, 9 and 10, retract all outrigger cylinders evenly and carefully lower
the crane until all tires are in contact with the ground,
> then retract all outrigger cylinders all the way.
2.4 Retract and secure the sliding arms
The four sliding arms are individually pushed in and out via the directional valves on the opposite side of the
vehicle.
> By actuating the directional valves, 5, 7, 8 and 11, fully retract all sliding arms,
> then secure the sliding arms by inserting the pins into the sliding arm boxes to prevent them from moving out
by themselves.
DANGER: An assistant must observe the in and out movement of the sliding arms.
It must be assured that there are no persons or objects within the danger range.
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3.1 Emergency control of the rear axle steering
For the emergency control of the rear axle steering, only the right or left solenoid on the directional valve (12)
needs to be pushed, as shown on the illustration.
Letting the crane roll back slowly makes it easier to return the rear wheels into ∫straight forward∫ position.
CAUTION : Before driving the crane, lock the rear axle steering in ∫straight forward∫ position.
Note: Read the paragraph covering the rear axle steering in chapter 3.04 DRIVING THE CRANE
ON PUBLIC ROADS.
left side of vehicle right side of vehicle
Push in solenoid Push in solenoid
183630
491
6.03 RECOVERY 022005>00
492
6.03 RECOVERY 022005>00
Towing
In case the mobile crane must be towed, a coupling is installed on the right front below the bumper for the air
pressure supply . This coupling for external air pressure supply must be connected with the towing vehicle.
CAUTION: The reserve pressure during town must be at least 6 bar .

As a rule, the towing speed may not exceed 25 km per hour ( 15.5 mph).
To tow the crane, use a towing coupling with pin in the bumper!
The crane may only be towed when using a towing rod.
During the towing procedure, the parking brake must be released to prevent
damage to the operating system .
1. In case of damage on the Diesel engine and/ or automatic transmission

> The air pressure system must be constantly supplied with pressurized air (at least 6 bar) via an external
supply system .
> Switch the gear box into neutral position .
CAUTION: When the gear box is shifted into neutral position (coasting) , DO NOT start the
Diesel engine.
The automatic transmission may not be shifted from neutral position, which me>
ans, DO NOT select a travel gear.
2. In case of damage on the gear box

> Flange off the gear shaft from the gear box to the drive axles, and hold it up.
> Let the Diesel engine run in low idle, and turn the gear selector switch to neutral position ∫N∫.
3. In case of damage on the Diesel engine or powershift transmission

Note: Only valid for crane vehicles without gearbox.
CAUTION: The towing speed may never exceed 10 km per hour ( 6.2 mph) and the towing
distance may not be longer than 10 km ( 6.2 miles) !
3.1 In case of damage to the powershift transmission :

> Flange off the gear shaft from the gear box to the drive axles, and hold it up.
> Switch the gear selector switch to neutral position ∫N∫ and let the Diesel engine run at low idle.
3.2 In case of damage to the Diesel engine :

> Do not flange off the gear shaft from the transmission.
> The air pressure system must be constantly supplied with pressurized air (at least 6 bar) via an external
supply system.
4. In case of damage on the drive axles

> Remove the gear shaft to the defective axle.
> Remove the half shaft on the defective axle .
Note: Only especially trained, expert personnel may handle the towing procedures if there is any
damage on the drive axles !
493
6.04 SLIDING ARM MONITOR 022922>01
184372
494
General
The LICCON sliding arm monitor checks the support width data entered by the crane operator to select the load
capacity chart on the LICCON panel.
However, it does NOT monitor if the crane is properly supported and if the sliding arms have been pinned
properly in their intended positions.
The support bases

This crane can be operated in 3 different support widths :
* wide 7.2 m
* reduced 5.0 m
* retracted 2.3 m
CAUTION : In case of ∫retracted, reduced and wide™ support points, the sliding arms MUST be
secured with pins. These support bases have no tolerances and the sliding arms
must be pinned on these support bases.
The following exception is permitted for ∫retracted∫ and ∫reduced∫ support base:
If a sliding arm cannot be pinned on the intended position due to current circumstances, then it is permitted to
exceed the extension length toward the outside. In this case, the sliding arms cannot be pinned. To select the
load capacity chart, choose the next smaller load capacity chart for the LICCON system.
Example:
Sliding arm is between the pin holes of ∫retracted∫ and ∫reduced∫
$> select "retracted".
Sliding arm is between pin holes of ∫reduced∫ and ∫wide∫
$> select "reduced".
CAUT ION: If a pin hole is only some millimeters away, so that the pin cannot be pinned, then
you must choose the load capacity chart for the next lower sliding arm length.
495
184373
496
Working with the sliding arm monitor

Preparation of the crane
When the crane is utilized on the job site, the sliding arms are to be extended to the planned width for the
application, they are to be pinned and supported according to the operation manual. Then the load capacity
chart, which corresponds to the desired working range, the utilized ballast and the support width of the crane,
must be set on the LICCON panel. If this load capacity chart corresponds to the support base the sliding arm
monitor recognizes, then the crane operator is shows the load capacity chart on the monitor, pushes the "OK"
button and the operating view appears, the crane is operational.
Function and error indication of sliding arm monitor when setting the load capacity chart
(fig. 1)
If the selected support base and the sliding arm length of all sliding arms do not match, and the operator pushes
the "OK" button, an error message will appear ("ERROR 155") and the crane cannot be equipped according to
the preselected chart. In this case, the operator must either select a sliding arm length which matches the chart
or he must extend all four sliding arms to a length, which matches the preselected chart. It is not possible, for
example, to select a chart with a reduced base, if the supports are retracted; it is also not possible to select a
reduced or retracted support base chart if the crane is actually operated with a wide support base.
Function and error indication of sliding arm monitor during operation

If a valid load capacity chart has been set, and it was checked by the sliding arm monitor, then the crane can be
operated according to the appropriate guidelines in the operation manual and according to the load capacity
charts.
Monitoring the sliding arm lengths (fig. 2)

Just as when setting the load capacity chart, the position of the sliding arms is constantly being checked during
crane operation, and it is constantly being compared with the entered load capacity chart. If any deviations are
found, the system will also report "ERROR 155", the LICCON safe load indicator system reports overload and
the crane can only be operated by bypassing the LICCON safe load indicator system. In addition, the slewing
gear will be turned off when at standstill, and cannot be restarted if not in ∫installation∫ mode. The slewing
gear can also be shut off during rotation.
Monitoring the support forces (fig. 3)

In addition to the sliding arm length, the support forces are monitored. The system constantly checks if their
sum exceeds a minimum crane weight without attachment. If this is not the case, the error message
"ERROR!154" is shown, the LICCON safe load indicator system reports overload and the crane can only be
operated by bypassing the LICCON safe load indicator system. In addition, the slewing gear will be turned off
when at standstill, and cannot be restarted if not in ∫installation∫ mode. The slewing gear is not shut off during
rotation. The support force monitor has no influence on the load capacity chart adjustment in the configuration
program.
497
184374
498
Interpretation of extension condition by the sliding arm monitor

The sliding arm monitor measures the length of the various sliding arms and checks, if they are in the
preset,permissible intervals. If at least one sliding arm is not within such an interval, then the crane cannot be
equipped with a load capacity chart in the configuration program, as the crane must be supported and operated
with the proper sliding arm lengths.
If all sliding arms are extended to permissible, but different lengths, then that sliding arm, which shows the
smallest value, is taken as the basis for selecting the load capacity chart. The numbering sequence corresponds
to the sequence of support bases, as they are shown in the configuration program, when one pushes the F5
button several times.
As an example, the illustration on the opposite page shows in which extension condition which support is
permitted when selecting the load capacity chart. The last case shows a situation, where a sliding arm is
between two permissible extension conditions.
Error procedure
It must always be differentiated between an operational error by the crane operator and a problem due to a total
sensor failure or an erroneous sensor function.
If a sensor fails completely, then the monitor recognizes a length for this sliding arm, which corresponds to the
retracted condition. Automatically only a chart with retracted supports can be selected. However, as a result, it
is possible that no chart can be selected because in this operating mode, for example "TK" operation, the crane
cannot even be operated with retracted supports.
If a sensor does send a signal, which is within the permissible test range, but it is wrong, then the incorrect
sensor value can be deducted, and the retracted condition will be simulated. An incorrect length value can also
be given if the length sensor cable of a sliding arm is twisted up in the sliding arm box.
CAUTION: If a sensor fails completely or the retracted condition is simulated, it must be

assured that no sliding arm is between two pinable positions, because this could
cause a dangerous situation even for load capacities for retracted conditions.
For support points ∫RETRACED∫, ∫REDUCED∫ and ∫WIDE∫, the sliding arms
must always be pinned.
499
7.00 SERVICE AND MAINTENANCE 021680>00
500
021680>00
Chapter 7
Service and Maintenance
501
7.01 SERVICING AND MAINTENANCE 021681>02
502
Liebherr After Sales Service > what it means for you
Liebherr truck>mounted, mobile and crawler cranes are products incorporating mature engineering which is
able to cope day in, day out with the roughest operating conditions to which a crane may be subjected.
The high standards of engineering embodied in these cranes are reflected in their operation reliability, their
insusceptibility to faults and in their ease of servicing and maintenance.
Liebherr is constantly further developing their drive and control elements. The combination of tried and tested
components and modern production methods produces cranes which are reliable operating partners with a
range of convenient operating features.
We build many hundreds of cranes each year for the international market and provide the backup services for
them worldwise, too. For ∫After Sales Service∫ ranks high at Liebherr to ensure that your crane is always
available and operational.
Service at Liebherr begins from the moment the crane is handed over to you, the customer. We will provide your
crane operators with the specialist training tailored to their particular needs.
Also we will train your maintenace personnel in all questions relating to crane servicing and repairs because
we know that you are able not only to deal with all their minor repairs, but often have the specialists who can
quickly and reliably perform major crane repairs.
A further benefit of our After Sales Service are our special Service Advisors who are only a telephone call away
whenever a problem arises. This immediate contact saves you time and money and you should always take
advantage of it whenever your crane is ∫down∫.
Our Fild Technicians are also specialists with many year's experience who operate from strategically located
bases. They bring with them their specialist knowledge and a range of special tools for the job. They are at your
disposal as the last link in the range of Liebherr After Sales Services, although in most cases, your technical
problems can be solved by contacting our Service Advisors.
Note: The buyer may submit warranty claims and receive possible reimbursement only if Original
Liebherr spare parts are used in the Liebherr mobile crane.
Original Liebherr spare parts have been tested and are designed specifically for crane
operation and can be utilized without any safety concerns.
503
Cleaning and upkeep of crane
Wash crane with water
Note: If a steam jet is used for cleaning, a distance of at least 80 cm (2' 7∫) must be kept to the paint
work and foil label.
After cleaning, in particular with the steam jet, lubricate crane, e.g. drive shafts, slewing connections.
Steering wheel, centre console, control panel covering, floor covering and dirty upholstery in driver's cab and
crane cabin should only be cleaned with warm water mixed with a dish washing agent.
Do not use scouring agents!
504
The scope of maintenance works are described in the following chapters.
7.02 MAINTENANCE INTERVALS CRANE CHASSIS
7.03 MAINTENANCE INTERVALS CRANE SUPERSTRUCTURE
Maintenance work must carried out according the crane.
The following chapters describe maintenance work in more detail.
7.04 MAINTENANCE INSTRUCTIONS CRANE CHASSIS
7.05 MAINTENANCE INSTRUCTIONS CRANE SUPERSTRUCTURE
For individual assemblies note manufacturers instructions.
Maintenance work on the crane chassis is carried out according to the number of operating hours or
kilometres covered.
Maintenance work on the crane superstructure is carried out according to the number of operating hours
only.
505
7.02 MAINTENANCE INTERVALS FOR CRANE CHASSIS 021691>05
506
regular maintenance every minimum inspections

1st main>
main>
tenance
200 hrs. 400 hrs. 800 hrs. tenance
after
5000 km 10000 km 20000 km annually daily weekly
" Diesel engine
¥
> Check oil level
For all further maintenance

work, observe
manufacturer's instructions
> Check coolant level in

equalizing reservoir
¥
every
> Change coolant liquid
2 years
" Air filter
> Observe monitoring device ¥

> Clean the filter element
(Observe the guidelines If
issued by the engine necessary
manufacturer!)
> change the filter element

every
(and after having it cleaned
2 years
5¥.)
" Steering
> Check the steering hydraulic

¥
oil level
> Test steering rod and tie rod

tightness and split pin ¥
keepers
> Check hydraulic system for

¥
proper seals
> Test tie rod setting, test if

necessary
¥*
> Oil change ¥

> Replace oil filter 100 hrs. ¥
> Test hydraulic steering stop,
test if necessary
¥
> Check hydraulic pressure, set

if necessary
¥
* If used heavily off>road, at least 1¥per year.
507

1st main>
main>
tenance
after
" Automatic transmission
> Check oil level ¥

> Check oil pressure ¥
> Check operating temperature ¥
> check for proper seals ¥
> Check / tighten fastening
screws
¥
> Oil change 100 hrs. ¥ ¥

> Replace oil filter 100 hrs. ¥ ¥
" Power shift gearbox

> Oil change 100 hrs. ¥ ¥
> Replace oil filter 100 hrs. ¥ ¥
" Displacement gear

> check fastenings ¥
> oil change ¥ ¥
" Distribution gearbox
> Oil change 1000 km ¥ ¥

> Check for proper seals ¥
> Check/tighten fastening
screws
¥
> Check road/off>road gear

switchover function
¥
> Check all>wheel drive switch> ¥

on function
> Check tachometer connection ¥

> Clean ventilation nipple ¥ ¥
508
regular maintenance everyminimum inspections

1st main>
main>
tenance
after
" Drive shafts (cardan

shafts) and bearing
bracket
every
> Grease 25000 km
2 years *
> Check flange screws, tighten

100 km 2500 km
if necessary
" Driven axles
> Test for proper seals ¥

> Oil level check at axle
housing, differential housing ¥
and wheel hubs
> Grease steering knuckle 25000 km

every
bearings 2 years **
> Check fastening ¥

every
> Oil change 1000 km ¥ 2 years
> Clean ventilation on axle

¥ ¥
housing
" Axle drive DK>7
every
> Oil change 1000 km ¥
2 years
" Non>driven axles
> Grease steering knuckle every

25000 km
bearings 2 years **
> Check fastening ¥

> Change wheel hub grease
filling
¥ ¥
> Set wheel bearings ¥ ¥
* Maximum grease pressure: 15 bar. If used heavily off>road, at least 1¥per year.
** If used heavily off>road, at least 1¥per year.
509

1st main>
main>
tenance
after
" Tires
> Check lug nut tightness,

100 km ¥
tighten if nec.
> Check tire pressure ¥

" Brake system
> Check brake lining wear ¥

> Adjust brakes,
¥
if necessary, replace linings
> Grease ¥
> Oil fork head connections ¥
> Check service brake and
¥
hand brake functioning
510

1st main>
main>
tenance
after
" Compressed air system
> Test for proper seals ¥

> Check brake system
¥
operating pressure
> Check shutdown pressure ¥

> Check pressurized air
reservoir automatic water ¥
bleeder valve functioning
> Replace air dryer granulate

cartridges
¥
> Clean air dryer

pre>filter
¥
" Axle suspension
> Check hydraulic tank oil

¥
pressure
> Check hydraulic system seals ¥

> Blocking cylinder function ¥
test
> Replace oil filter 100 h ¥

> Check hydraulic pressure, set
¥
if necessary
> Check pressure reservoir

¥* ¥*
priming pressure (nitrogen)
> Oil change ¥ ¥

" Outrigger support plates
with equalizer
> Replace grease supply ¥

> Complete funktion test ¥
* refer to chapter 7.04, MAINTENANCE INSTRUCTIONS CRANE CHASSIS
511

1st main>
main>
tenance
after
" Hydraulic
supports
> Check hydraulic system seals ¥

> Check hydraulic tank oil
¥
pressure
> Check sliding arm

¥
movement / oil
> Grease fleyer chains ¥

> Oil sliding arm keeper pins ¥
> Oil operating level fork heads ¥
> Check level, adjust if nec. ¥
> Oil change (oil sample) ¥ ¥
> Replace hydraulic filter 100 hrs. ¥
> Replace bleeder filter on 100 hrs. ¥
hydraulic tank
> Check hydraulic system

¥
operating pressure
" Hydraulic accessories,

e.g. ventilator, ballasting
cylinders
> Check hydraulic operating ¥

pressure, set if necessary
" Driver's cab
> Check armature function ¥

> Check indicator light
¥
function
> Check motor brake

¥
activation
> Check retarder activation ¥
512
regular maintenance every minimum

main>
For crawler cranes only
tenance
10 hrs. 100 hrs. 800 hrs. annually
" Running gear
> Oil change ¥ ¥

> Check seals ¥
> Grease tumbler bearing ¥
" Track carrier
> Check seals on track rollers

¥
(with oil lubrication)
> Grease track rollers (with oil

¥
lubrication)
> Grease support rollers ¥

> Grease guide rails on sliding
¥
piece
" Track shoes
> Check shoe tension, tighten if ¥

necessary
> Inspect for fastening and

¥
damage
513
7.03 MAINTENANCE INTERVALS FOR CRANE SUPERSTRUCTURE 021933>05

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
hrs. hrs. hrs. hrs. annually
" Diesel engine
> check oil level ¥
for further inspections please

refer to manufacturers
maintenance instructions
> check cooling water level in
¥
the extension tank
every
> change cooling water
2 years
" Air filter
> check dust indicator ¥
> clean resp. change
according to manufacturers
maintenance instructions
" Slewing ring
> inspect and check bolts for 200 hrs. ¥ ¥
tightness
> check tilt play ¥ ¥
" Telescopic boom pivots
> lubricate ¥
" Rope winches
> inspect for leaks ¥
> check fastening bolts for
tightness
200 hrs. ¥ ¥
3 000 every
> oil change
hrs. 4 years
" Propeller shafts
> check flange bolts ¥
> lubricate ¥
514

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Overtopping guard struts
> lubricate pivots ¥
" Fall back cylinders
> inspect for leaks ¥*
> check preload pressure
¥ ¥
(nitrogen gas)
> check oil quantity ¥ ¥
" A bracket mounting
> lubricate ¥
" Counterweight
or
> check tightening torque of
1 000 km 10 000 ¥
fastening bolts
km
" Ballasting system
" Rope drum contact rollers
> grease guides ¥
" Rope pulleys
> inspect and lubricate ¥ ¥
" Ropes
> inspect, grease if necessary ¥ ¥
" Hook blocks
> lubricate ¥
* visual check before starting up the crane
515

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Crane cab
> check operation of
¥
instruments
> check operation of tell>tale
warning lights
¥
> check liquid level in the
reservoir of the engine speed ¥
control
" Extending crane cab
> check operation ¥
" Load moment limiter
" Slewing gear transmission
> check fastening bolts for
200 hrs. ¥ ¥
tightness
4 000 every
> change oil
hrs. 4 years
" Locking of the slewing
brake
> lubricate ¥
516

1st main>
main>
tenance
100 200 400 1200 tenance
after daily weekly
" Pump distributor gearbox
> oil change 400 hrs. ¥ ¥
" Hydraulic system
> check for leaks ¥
> replace control and feed
circuit pressure filter ¥
200 hrs.
element
> replace returnline filter
element (cranes with open 200 hrs. ¥
hydraulik circuit only)
> replace bleeder filter on

200 hrs. ¥
hydraulic tank
> check hydraulic oil
(oil sample test)
400 hrs. ¥ ¥
" Hydraulic cylinders

" Hydraulic pressure
reservoirs (nitrogen gas)
> check preload pressure ¥* ¥*
" Telescopic boom with
cable mechanism
> check cable mechanism,
200 hrs. ¥
adjust if necessary
> disassemble boom and 20 000 every
inspect it hrs. 10 years
" Pneumatic boom locking
> clear the air filter for
¥ ¥
compressed air
> check boom locking holes ¥ ¥
> lubricate boom locking bolts ¥ ¥
* refer to chapter 7.05, MAINTENANCE INSTRUCTIONS CRANE SUPERSTRUCTURE
517
7.04 MAINTENANCE GUIDELINES FOR THE CRANE VEHICLE 023413>00
185973
518
When performing maintenance and repairs in the engine area, observe the following:
CAUTION : Perform all maintenance tasks on the engine and service fuel, oil and air filters ac>
cording to the separately issued Operation Manual for !ªLIEBHERR Diesel engi>
nes´ .
Never step on the fuel lines.

When changing the filter, especially on the V>area of the engine,spread out a layer of absorbent material be>
fore loosing the filter to absorb any fuel which might drain out.
Dispose of the absorbent material properly.
DANGER: YOU MUST make sure that no Diesel fuel is spilled in the engine area and it re>
mains free of Diesel fuel, otherwise there is a risk of causing a
FIRE!
When you change the filters and bleed the system, you must assure utmost
cleanliness. Any fuel spills must be dried up.
N o t e: When changing filters or working on the fuel system, and if there are any filters in the V>
area of the engine, we recommend to support the crane from the rear so there is a slight drop
towards the front.
Any fuel spill can then flow toward the front away from the V>area.
Check the engine coolant (Fig. 1)
DANGER: Check the engine coolant only when the engine is cold!
The radiator cap must be cool enough to touch. Avoid contact with components
containing coolant, since it could cause SEVERE SKIN BURNS !
The coolant reservoir may only be refilled via the filler neck.
> Turn the radiator cap on the filling neck of the coolant reservoir to the left, to the first notch to release the
pressure.
> Remove the radiator cap.
> Add coolant, as specified on the lubrication chart until it runs over.
> Reinstall the cap and close it tightly.
CAUTION : If coolant must be added, add it in the same ratio, as specified on the LUBRICA>
TION CHART.
Ratio: 50 % corrosion protective fluid and antifreeze,

50 % fresh water.
519
185973
520
Check oil level and filters on the engine (Fig. 2)

The oil must be between the minimum and maximum ( MIN and MAX) mark on the dipstick.
CAUTION : Make sure to observe utmost cleanliness, to prevent any dirt infiltration into the en>
gine .
> To check the oil level in the engine, the crane must be in horizontal position.
> Turn the engine off and wait 2 to 3 minutes until the oil has drained into the oil pan.
> Pull the dipstick, wipe it off,reinsert it and pull it out again.
> After checking the oil level, make sure to push in the dipstick tightly.
> If necessary, add engine oil as specified on the lubrication chart.
CAUTION : If the oil level has dropped below the minimum ( MIN ) mark , you must add engine
oil as specified on the lubrication chart until the oil level is again between the mini>
mum and maximum (MIN and MAX) mark.
If no oil is added, the engine can be severely damaged.
To change the oil:

Refer to the separately issued !LIEBHERR!Diesel engine manual .
Check engine air filter

The air filters are electronically monitored.
If a vacuum is created in the air intake line due to contaminated filter elements, the corresponding warning
light (45) on the instrument panel in the driverπs cab will light up.
In that case, clean or replace the filter elements.
To change the filter:

521
185973
522
Check oil level and filters on the automatic transmission
The oil level can be checked two ways:

1. By hand, by pulling and reading the dipstick (Fig. 3)
2. Electronically, via the display in the gear selector.
Note: The oil level can only be checked manually if no counterweight plates are placed on
the chassis.
The oil level must always be checked, at least twice, with the crane standing in horizontal position and with the
engine running.
To be able to check the oil level in the transmission with the dipstick, the oil must be at operating temperature.
When measuring the oil with the dipstick, changes in gear oil temperatures between 60∞C and 104∞C (140 . . . .
220∞F) are automatically considered.
In temperatures <60∞C (140∞F) or >104∞C (140∞F) , the indication is invalid!
Check the oil level more often. If some individual test values do not fit, check if the gear vent is clean and not
plugged up.
Gear vent on the automatic transmission

The vent is at the highest point in the gear housing.
It prevents pressure build up within the transmission and must be clean and clear at all times.
The amount of dirt and dust collected in the vent determines how often it must be cleaned.
Maintenance
When cleaning the gear, care must be taken.
Do not direct the steam or water directly onto the gear vent to prevent moisture infiltration and resulting gear
damage.
Replacement
Use only a suitable wrench.
Pliers or pipe wrenches damage or destroy the neck of the bleeder vent and cause metal particles to fall into the
gear, resulting in gear damage.
Tighten the new gear vent to 12 . . . . 16Nm (9 . . . . 12 lb ft) .
523
185973
524
1.1To check the oil level by hand
DANGER: If the following safety measures are not observed, then it is possible that the vehicle
will suddenly start to move!
> Gear in neutral position"N"
> Parking brake applied
> Wheels supported with wedges / wheel chocks to prevent the crane from rolling
off!
> Before pulling the dipstick, clean the oil filler port carefully, to ensure that no dirt or foreign particles get into
the oil filler tube.
COLD CHECK
C AU T I O N : Do not start the engine before you are sure that there is sufficient gear oil in the
transmission.
Pull the dipstick and check if the static oil level is near the — "HOT FULL" mark.
> Park the vehicle on level ground, apply the parking brake, secure the wheels with wedges / wheel chocks to
prevent the crane from rolling off.
> Let the engine run for at least one minute in low idle (500 . . . . 800 RPM) in "N" , apply the service brake, se>
lect "D" and let the engine run for 30 seconds at 1000 . . . . 1500 RPM; then select "R" to bleed the system.
Then switch to "N" and let the engine run at low idle (500 . . . . 800 RPM)
> with the engine running, release the dipstick by turning it counterclockwise, remove it and wipe it with a cle>
an rag.
> Reinsert the dipstick and pull it out again.

> Read the oil level.
> Repeat the test procedure and compare the results.

If the oil level is within the ” "COLD RUN" mark, then the gear may be operated until the oil is warm enough
to take a "HOT RUN" measurement.
525
185973
526
1.1 Continuation
COLD CHECK
If the oil level is NOT within the ” "COLD RUN" mark, then oil must be added (or drained) until the oil level
is in the center of the "COLD RUN" mark.
> As soon as you can, after the engine has reached its normal operating temperature (71∞C . . . . 93∞C) , CHECK
THE OIL LEVEL AT OPERATING TEMPERATURE.
CAUTION : Do not let the gear run for an extended period of time before checking the oil level
at operating temperature.
Operation with incorrect oil level will cause gear damage.
An exact oil level check is only possible, if

> the engine runs at low idle (500 . . . . 800 RPM) ,
> the gear oil has the correct temperature
> the vehicle is standing on level ground.
CHECKING THE OIL LEVEL AT OPERATING TEMPERATURE

Make sure that the gear oil has reached its normal operating temperature
> Operate the gear in stage "D" until operating temperature has been reached.
> Oil pan temperature (71∞C . . . . 93∞C)
> Converter > output temperature (71∞C . . . . 93∞C)
> Park the vehicle on level ground, secure the wheels with wheel chocks to prevent it from rolling off.
> Shift to "N" , actuate the service brake and let the engine run at low idle (500 . . . . 800 RPM) .
> With the engine running, loosen the dipstick by turning it counterclockwise and wipe it off.
> Reinsert the dipstick and pull it out again. Read the oil level.
> Repeat the procedure and compare the results.

If the oil level is within the — "HOT RUN" mark, then the gear is ready for safe travel operation.
If the oil level is NOT within the — "HOT RUN" mark oil must be added (or drained) until the oil level is in the
center of the — "HOT RUN" mark.
> Reinsert the dipstick and pull it out again. Read the oil level.
> Repeat the procedure and compare the results, making sure that the results are consistent.
527
185959
528
2.1Tocheck the oil level electronically
Indicator > Stored codes for gear oil
Prerequisites:
> The gear is at operating temperature >+60∞C (140∞F) , <+104∞C (220∞F)
> The gear is in neutral N
> The vehicle has been at a standstill for about 2 minutes, to let the oil rest.
> The engine is running at low idle speed (500 . . . . 800 RPM)
> The vehicle is parked in horizontal and safe position.
> The parking brake has been applied, the vehicle is secured with wheel chocks to prevent it from rolling off.
> Push both arrow keys (Ø≠) once, at the same time,
> watch the digital indicator and read the codes, the oil level is shown on the display within the next two minu>
tes (the display blinks on 8, 7, . . . . 1 approx. 2 minutes).
After two minutes, the display shows the following:
Oil level sensor information
Code Cause
OL >OK Oil level is o.k..
CAUTION : Errors in above listed parameters will stop 1 minute sequence. One
of the following codes will appear on the display and show the
reason for the interruption. If all parameters are fulfilled, the
countdown starts over.
OL >0X Resting period too short
OL >50 Engine RPM too low
OL >59 Engine RPM too high
OL >65 Neutral is not selected
OL >70 Oil temperature too low
OL >79 Oil temperature too high
OL >89 Output shaft turns
OL >95 Sensor is defective

CAUTION: Call Service Dept. to fix this problem!
OL $ $ Conditions do not permit indication or functional problem
Turn oil level indicator off

Push any key twice (R, N or D) .
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3. Oil and filter change
The oil and the inner oil filter must be changed in intervals, as specified on the chart. Depending on operating
conditions, the oil might have to be changed even sooner.
If discoloration, strong smell or oil analysis reports show contamination or increased temperature, then the oil
must be changed.
Local conditions, frequency and severity of application can decrease oil change intervals.
APPLICATION GENERAL OIL AND FILTER CHANGE INTERVALS
On road First after 8000 km,then every 40.000km or 18 months*
Off road First after 500 operating hours, then every 500hrs. or 18 months*
* whatever comes first
CAUTION : For gear oil, do not use containers or filling devices which had been used earlier to
mix antifreeze mixture.
Antifreeze and coolant fluids contain ethylene glycole, which will damage the coup>
ling disks if it gets into the gear.
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Oil change
Note: Do not drain the oil if the filter is to be changed only.
To drain the oil

> With the gear at operating temperature, 71∞C . . . . 93∞C (160∞F . . . . 200∞F), the engine turned off and the crane
in horizontal position, remove the drain plug (magnetic plug with seal ring) and rain the old oil into a suitable
container.
> Check the oil and magnetic plug for contamination.
Filter change, Fig.4

> Remove (Pos.5 . . . . 1)
12 screws
2 filter cover
2 O>rings
2 Seal rings
2 Filter elements
> Dispose of old filter elements properly.
Note: Lubricate only the O>ring in the filter element with ATF .
> Insert a new O>ring into the new filter elements and lightly lubricate the O>ring on the inside with ATF .
> Please one seal ring eon each filter cover and set the filter elements on the covers.
CAUTION : The filter covers may NOT be pushed against the oil pan when inserting the 12
screws.
This will destroy or damage the filter cover, seals or the oil pan!
> Install both units (filter cover with seal and filter element) in filter housings,
> Align the screw holes on the filter cover with the holes in the oil pan.
> Slide each unit by hand into its housing to push on the seals >
> attach both units with 6 screws each, tightening torque 51 . . . . 61Nm (38 . . . . 45 lb ft)
> Clean the magnetic plug and sealing surface on the housing, reinsert the magnetic plug with new seal ring
and tighten. Tightening torque 25 . . . . 32Nm (18 . . . . 24 lb ft).
> Add oil as specified in the lubrication chart on the test tube (a) until the ” "COLD RUN" mark.
Check the oil level again.

> Check the oil level, first as described in
COLD CHECK, then as described in
CHECKING THE OIL LEVEL AT OPERATING TEMPERATURE.
533
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Offset gear (drop box, fig. 5)
Check the oil level

> With the crane in horizontal position, remove the plug (a) on the gear and visually check the oil level, it must
reach the lower edge of the inspection port (c).
Add oil if necessary, as specified on the lubrication chart.
CAUTION: If the oil level is low, oil must be added as specified on the lubrication chart until it
reaches the top of the filling nozzle ( c ) .
If no oil is added, the gear can be damaged severely.
> Clean the sealing surfaces on the housing and clean the plug,
> reinsert the plug ( a ) into the inspection port ( c ) and tighten it by hand.
Oil change :
> Change the oil when the gear is at operating temperature, with the crane in horizontal position. Remove both
magnetic plugs !(b) with seal rings and drain the old oil into a suitable container.
> Clean both magnetic plugs and the sealing surface on the housing, reinsert magnetic plugs with new seal rings
and tighten by hand.
> Remove the plug ( a ) on the oil level inspection port ( c ) ,
> clean the sealing surfaces on the housing,
> Add oil on the inspection port ( c ) as specified on the lubrication chart until it start to run over on the inspec>
tion port ( c ) .
> Clean the plug ( a ) , reinsert it with new seal ring and tighten by hand.
CAUTION : Make sure to observe utmost cleanliness, to prevent any dirt infiltration into the ge>
ar.
Transfer gear (fig. 6)
Check the oil level

> With the crane in horizontal position, remove the plug on the inspection port (c) and visually check the oil le>
vel. It must reach the lower edge of the inspection port (c).
Add oil if necessary, as specified on the lubrication chart.
CAUTION: If the oil level is low, oil must be added as specified on the lubrication chart until it
runs out at the top of the inspection port ( c ) .
If no oil is added, the gear can be damaged severely.
> Clean the sealing surfaces on the housing and clean the plug,
> reinsert the plug into the inspection port ( c ) and tighten it by hand.
Oil change :
> Change the oil when the gear is at operating temperature, with the crane in horizontal position. Remove both
magnetic plugs !(b and b1) with seal rings and drain the old oil into a suitable container.
> Clean both magnetic plugs and the sealing surface on the housing, reinsert magnetic plugs with new seal rings
and tighten by hand.
> Remove the plug ( a ) and clean the sealing surface.
> Remove the plug on the oil level inspection port ( c ) and clean the sealing surfaces ,
> Add oil on the filler port ( a ) as specified on the lubrication chart until it start to run over on the inspection
port ( c ) .
> Clean the plugs ( a and c ) , reinsert them with new seal rings and tighten by hand.
CAUTION : Make sure to observe utmost cleanliness, to prevent any dirt infiltration into the ge>
ar.
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Oil level on hydraulic tank (Fig. 10) for:

Steering, outrigger and axle suspension hydraulics
Note: Upper mark = maximum oil level, all cylinders are retracted
Lower mark = minimum oil level, all cylinders are extended
> With the crane in horizontal position, the oil level must be at the center of the corresponding sight gauge.
If no oil is visible in the sight gauge, oil MUST be added as specified on the lubrication chart, until the oil level
is again at the center of the corresponding sight gauge.
CAUTION: The outrigger cylinder as well as the sliding arms must be retracted when checking
the oil, and the vehicle must be brought down to the lowest axle suspension level. If
you would check the oil with the outrigger cylinders extended and with the vehicle
at a high axle suspension level, you would run the risk of adding too much oil and
overfilling the system.
When the cylinders are retracted, the oil is discharged through the bleeder valve.
Do not retract the cylinders too quickly, this can cause damage to the oil tank.
D A N G E R: If the oil level has dropped below the minimum mark, oil must be added according
to the lubrication chart.
If the oil level is too low, the hydraulic pump can be damaged, which increases the
risk of causing an accident, due to a decrease in steering ability.
In addition, the outrigger cylinders cannot be fully extended and the vehicle cannot
be leveled.
Add oil :
> Add oil, as specified on the lubrication chart until the center of the upper sight gauge, Fig. 10
CAUTION : Use a fine mesh strainer to add oil.
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Bleeder and return filter (Fig. 9)

> Turn the engine off ,
> turn the cover to open and check the filter for contamination (visually).
If it is very dirty, replace the filter.
> Close the cover again .
Return filter on hydraulic tank (Fig. 8)

The return filter is equipped with a maintenance indicator * .
If the red bar indicator is visible when the oil is at operating temperature (check weekly), then the filter insert
must be changed.
To change the filter

> Turn the engine off,
> loosen both filter covers, and collect oil in a suitable container.
> Remove both filter covers,
> take out both inserts and dispose of them properly,
> flush both filter housings,
> clean sealing surfaces on covers and clean filter housing,
> insert new filter inserts into the filter housing,
> lubricate the rubber seal rings in the covers with oil,
> reinstall both covers on the filter housings and tighten,
> start the engine and check for leaks,
> then recheck the oil level, add more oil if necessary.
Air drier, air pressure and brake system (Fig. 6)

The air dryer of the air pressure and brake system is maintenance free. However, the cartridge should be chan>
ged once a year.
* Optional
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Oil level in the planetary gears of wheel hubs (Fig. 11)
Check the oil level

> With the axle suspension blocked, align the crane in horizontal position via the support cylinders and raise it
until all wheels are off the ground.
> Turn every wheel until the drain plug ( b ) is at the lowest point, the mark ( c ) must be exactly horizontal.
> Remove the plug on the filler and control port ( a ) , the oil level must reach the lower edge of the inspection
port. Add oil if necessary, as specified on the lubrication chart.
> Apply a new seal ring to the plug for the filler and inspection port ( a ) , reinsert it and tighten by hand.
CAUTION: Make sure to observe utmost cleanliness to prevent any dirt or contamination of the
internal spaces of the axle or planetary gear.
Oil level is axles (axle casings)
Check the oil level

> Position the crane in horizontal position.
> The oil level in the axle casings of the driven axles must reach the lower edge of the corresponding inspection
port. Add oil, if necessary, as specified on the lubrication chart.
Hydraulic hoses
The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in safe wor>
king condition.
Changing hoses
The hoses and lines must be replaced periodically.
Due to our experiences with mobile cranes, we recommend the maximum usage:
> in severe operation
at high operating temperatures and frequent movements approximately 3 years
> in normal operation approximately 6years
> in assembly operation with rare high output frequency approximately 12 years
CAUTION: The hoses on the intake lines of the oil reservoirs must be checked visually once a
month for cracks and damage, and, if necessary, they must be replaced immediate>
ly.
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Axle suspension/Axle locking system

The pretension pressure in the diaphragm reservoirs of the axle suspension system must be 45 bar .
CAUTION : In case of strongly fluctuating ambient temperatures, for examples in countries

with extremely warm or cold temperatures, and in countries with great temperatu>
re differences between summer and winter, the pretension pressures MUST be
checked and corrected, if necessary.
If the pretension pressure is too low, the diaphragm reservoirs will be too
overworked and damaged.
If the pretension pressure is too high, the spring action in the axle suspension
system is no longer assured, and the vehicle can be damaged.
The pretension pressure in each of the reservoirs must be checked individually, as follows:
> Move the switch (120) to axles ∫ suspended ∫ .
> Push button 122, 123, 124, 125) ªon the front´ until the oil has drained from the reservoirs.
> Check the pretension pressure with a testing and inflation device and correct the pressure, if necessary.
DANGER: To fill the reservoirs, DO NOT use a i r or o x y g e n.

This can cause an E X P L O S I O N !
The pressure in the nitrogen cylinder MAY NOT exceed the maximum permissible
operating pressure of the reservoir or the pressure gauge. If the pressure is higher,
a pressure reducing device must be connected between the cylinder and the infla>
ting device.
After the pressure test :

> push button (116) "LEVEL" , until the indicator light (117) turns on.
The vehicle is automatically raised via the axle suspension cylinders to the required height for on road travel.
Tires
> Check the tires, including the spare tire, for damage.
The depth of the tire treads (including the spare tire) may not fall below the legal limit.
The tire pressure, including the spare tire, must be correspond to the recommended pressure given for the par>
ticular tires, which are installed on your vehicle.
Check the tire pressure when the tires are cold.
Tire pressure: refer to TECHNICAL DATA, chapter 1.03.

Tire change: refer to paragraph 5 Tire change, chapter 9.02.
DANGER: The risk of having an accident is greatly increased if you drive the vehicle and the>
re is any tire damage, if the tires are worn and the treads are too low, and if the air
pressure in the individual tires differs.
543
Wheel alignment
The wheel alignment must be checked in regular intervals.
If this is not done, it will cause increased tire wear.
If there was an especially high exposure, for example if the wheels hit the side of the curb, then it is especially
important to check the wheel alignment .
Note : The wheel alignment can only be checked by especially trained personnel.
To change the wheel

> Loosen the lug nuts on the defective wheel and support the crane properly.
Refer to SUPPORT, chapter 3.05 THE CRANE AT THE JOBSITE .
> Lift off the spare tire with the crane, set it next to the defective tire, make sure to secure it to prevent it from
rolling off or tipping over.
Note: Never lay tires down on the side, it is very difficult to raise them again.
> Replace the defective wheel after removing the lug nuts with the spare tire, reinstall the lug nuts and tighten
them in crosswise fashion.
CAUTION : Do not overtighten the wheel lugs!

The max. permissible tightening torque is 600 Nm.
Recheck the wheel lugs after driving the first 50 and 100 km, to assure they are
tight.
Safety and maintenance guidelines for the wheels (rims)

The below listed safety and maintenance guidelines are recommendations made by the manufacturer, in order
to prevent any safety risks due to damaged wheels or rims.
In addition, the manufacturer states that the manufacturerπs warranty is only valid if the guidelines noted be>
low have been strictly observed and followed.
The wheel is one of the most important safety components of the vehicle,. For this reasons, it is imperative that
the following guidelines are followed. When changing the tires, the wheels must be checked, the rim as well as
the complete dish, as follows:
> formation of excessive rust or corrosion
> bent rim flanges
> cracks in the rim
> cracks in the wheel dish
> damage on the side and lock rings
> damage to the lug nuts or bolts
> worn or damaged bolt holes
> rim components must match and fit
If any damaged rim components are found, they must be replaced immediately with new components. If chip>
ped paint or minor rust is found, the rust layer should be removed and the area should be repaired with com>
mercially available paint. You must make sure that the surface is smooth, especially on the tire seating surfa>
ce.
DANGER: NEVER perform or allow any welding on the wheel rim or wheel dish. It is strictly
prohibited to repair deformed or worn bolt holes or to replace or repair the wheel
center .
Any wheels with these defects must be scrapped immediately and replaced with
new wheels.
Any repair to these highly stressed parts of the wheel causes structural changes in
the material, which can lead to sudden fractures.
544
Electrical System > Lighting System

The maintenance of the electrical system is basically limited to changing defective fuses and bulbs and to batte>
ry maintenance.
CAUTION: Always replace defective fuses with fuses ob the same amperage. Never use a diffe>
rent size or stronger fuse, than the original fuse. This could cause an electrical fire!
NEVER repair or short circuit a fuse. This could severely damage the entire electri>
cal system.
The batteries must be kept clean and dry.

The vent holes in the cell plugs must always be kept clear.
Disconnect battery terminals, clean them and apply acid free and acid resistant grease.
Make sure no oil or grease gets on the battery sealing compound.
CAUTION: DO NOT place any tools on the batteries and keep sparks and open flames at a great
distance away from the battery.
Never disconnect the batteries with the engine running, as this could destroy the al>
ternator.
The electrolyte level in the batteries must be checked once a month, in the summer and in warm climates it
must be checked at least once a week.
The battery acid ( electrolyte) level must be at approximately 15 mm (5/8∫) above the top edge of the plates. Add
distilled water, if necessary.
C AU T I O N : Do not use a metal funnel to add distilled water.
If distilled water has been added, wait 1/2 hour and then check the specific gravity of the battery acid.
For this test, the temperature should be as close as possible to +20∞C ( 68∞ F) .
spec. gravity
Condition of battery charge
[kg/dm3]
1.28 well charge
1.20 half charged, recharge
1.12 dead, recharge immediately
The battery must be especially well charged before and during the cold season, since the electrical power con>
sumption increases as the battery performance decreases.
C AU T I O N : If the batteries must be recharged, use DC current only, the current may never be
higher than 1/10th of the battery capacity.
Example: To recharge a 143 Amp battery , the charging current may not be higher than 14.3 Amps .
CAUTION: When working on the electrical system of the crane, and any time any welding must
be done on any part of the crane, the battery MUST be disconnected from the elec>
trical circuit by turning the battery master switch off
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Diagnostics indicator > automatic transmission, indication of stored codes

Prerequisite:
> Gear selection in neutral N
> Parking brake is applied.
I M P O R T A N T :The diagnostics can also be run when the engine is turned off and the ignition tur>
ned on.
Read the code

1. > Go to the diagnostics system, and simultaneously push the arrow keys (Ø≠) twice.
2. > Read the first of five code positions on the display

Example:
Code 25 11is in the 1st position.
The display changes the readout every 2 seconds , as follows:

a) Code position d 1
b) Main code 25
c) Sub code 11
d) The display repeats indication a, b, c.
3. > Push the MODE key (113) quickly and read the code position d2 , as described in 2. .
4. > To read the code position d3, d4, d5, push the MODE key quickly each time.
5. > To read all code positions again, push after d5 the MODE key again and the display starts over with d1 .
End the diagnostics codes

To end the read mode and to return to the original display indicators, do the following:
1. Push the arrows keys (Ø≠) at the same time.

2. Push any of the selector keys R, N, D
(the gear is accepted if no active gear locking code is set).
3. Do nothing, after some time the diagnostics system returns automatically to the normal display indication.
N o t e: If a problem was shown, the error diagnostics described above must be carried out again, as
follows:
> Turn the engine off and turn the ignition off.
> Start the engine again, push the "R" key (reverse gear) , then push the !"N" key again.
CAUTION : If the error message is not deleted via this procedure, then you must call in an ex>
pert service technician.
547
Searching and fixing an error by using the code numbers
DIAGNOSTICS CODES
Error description for

Main Aux.
Service Technician,
Code Code Error remedy
possible error cause
13 12 ECU (computer) 1) Check

Incoming voltage too low a) Cable connections on batteries tight and clean?
b) Are batteries charged?
c) Charging device (alternator ) o.k.?
d) Fuses in VIM o.k.?
(Connector module between gear and vehicle
electrical system)
13 23 ECU (computer) Incoming e) Are connections in VIM tight and clean?

voltage too high f) Is vehicle electrical system to VIM o.k.?
g) Are all connection on ECU tight, clean and un>
damaged?
2) When all points are checked, contact Service
Dept.
21 12, 23 TPS load sensor 1) Check

(Gas pedal sensor) a) Are TPS cable plugs o.k.?
b) Is cable connection to plug o.k.?
c) Is injection pump in engine idle position?
d) Is the TPS actuated by the injection pump lever
over the correct path?
e) Check cable to TPS for interruption, short cir>
cuit between cables or short circuit on ground.
2) Replace TPS, if necessary.
Dept.
22 14, 15 Speed Sensors 1) Check

16 (RPM sensors) a) Are cable plugs tight, clean and undamaged?
b) Is sensor correctly installed and is screw tight?
c) Check cable to sensor for interruption, short cir>
cuit between cables or short circuit on ground.
Dept.
23 12, 13 Shift Selector 1) Check

14, 15 (Shift actuator) a) Are the ECU cable plugs properly engaged ?
23, 24 b) Are all plug connections tight, is the cable tie cut
off at the shift lever?
c) Check cable between ECU and shift actuator
for interruption between cables or short circuit
to ground.
2) Replace shift actuator if necessary.
Dept.
548

DIAGNOSTICS CODES

Main Aux.
Service Technician,
24 12 Oil sump temperature 1) Check

cold a) Temperature is < (+20 ∞ F)
($ 7 ∞C)
1) If yes, is indicator o.k.?
2) If no, check cable connections on gear for tight
seating, make sure plug connections are not da>
maged
3) Check cable connections on ECU for tight sea>
ting, make sure plug connections are not dama>
ged
Dept.
24 23 Oil sump temperature 1) let engine run in low idle

too hot 2) Vehicle must be in level position
3) Check oil measuring calibration
4) Check oil level
5) Correct oil level
6) Check engine for overheat, if engine can over>
heat the gear
7) Check cable plug on ECU and gear for dama>
ge and tight seating
Dept.
25 00, 11 Output shaft 1) Check

22, 33 Sensor a) Has the cable plug on the output shaft sensor
44, 55 connection?
66, 77 b) Is the sensor correctly installed and is the screw
tight?
c) Are the ECU connections o.k.?
d) Is the oil level o.k.?
e) Check cable to sensor for interruption, short cir>
cuit between cables or short circuit to ground.
Dept.
32 00, 33 C 3 Pressure switch open 1) Check with parking brake applied and engine
55, 77 running
a) correct dipstick
b) correct oil level.
2) Check
a) Are cable connections on gear tight, clean, unda>
maged?
b) Are cable connections on ECU tight, clean, un>
damaged?
c) Check cable between gear and ECU for inter>
ruption, short circuit between cables, short cir>
cuit to ground.
Dept.
549

DIAGNOSTIC CODES

Main Aux.
Service Technician,
33 12, 23 Oil sump sensor error 1) Check

a) Is gear plug tight, clean and undamaged?
b) Are plugs on ECU tight, clean and undamaged?
c) Check cable for interruption, short circuit bet>
ween cables, short circuit to ground.
Dept.
34 12, 13 EPROM 1) Reload (recalibrate) program

14, 15 2) Replace ECU
16 3) If no ECU is available, contact Service Dept.
35 00, 16 Power interruption 1) Check

EPROM reports interruption a) Are plugs on ECU tight, clean and undamaged?
b) Are cable connections on VIM o.k.?
c) Is vehicle electrical system to VIM o.k.?
d) Is battery Plus connected? (direct connection )
e) Is battery Minus connected? (direct connection)
f) Is ignition correctly connected?
Dept.
36 00 Hardware / Software 1) Replace ECU

not compatible 2) Reload (recalibrate) program
3) If both is not possible, contact Service Dept.
41 12, 13 Solenoid circuit interrupted 1) Check

14, 15 or short circuit a) Are all cable plugs on the gear tight, clean, un>
16, 21 damaged?
22, 23 b) Are cable plugs on ECU tight, clean, undama>
24, 25 ged?
26 c) Check cable for damage, chafings, torn areas.
d) Check cable for interruption,short circuit bet>
ween cables, short circuit to ground.
2) Change wiring harness.
Dept.
550

DIAGNOSTICS CODES

Main Aux.
Service Technician,
42 12, 13 Short circuit to battery 1) Check

14, 15 in solenoid circuit a) same are for 41
16, 21 b) Wrong (unauthorized) repairs
22, 23
24, 25 2) When all points have been checked, contact
26 Service Dept.
43 21, 25 ECU circuit 1) Replace ECU

26 2) Contact Service Dept.
51 01, 10 Gear transmission ratio test 1) Check

12, 21 of opening coupling a) Is cable connection to sensor (RPM, turbochar>
23, 43 (during shift ) ger speed, output speed) tight, clean, undama>
45, 65 ged?
b) Check sensor cable for interruption, short circuit
between cables or short circuit to ground
2) Check with engine running, vehicle with par>
king brake applied, gear in Neutral:
a) correctly calibrated dipstick
b) correct oil level
3) When all points have been checked, contact
Service Dept.
52 01, 08 C 3 Pressure switch is 1) Check as in point 1 and 2 at code 51

32, 34 interrupted 2) Check cable harness to gear for interruptions,
54, 56 (during shift) short circuit between cables, short circuit to
71, 78 ground.
Service Dept.
53 08, 18 RPM test of opening coupling 1) Check as for Code 51

29, 29 (shift from)
38, 39
48, 49
58, 59
68, 69
78, 99
54 01, 07 Gear transmission ratio test 1) Check as for Code 51

10, 12 of closing coupling (after
17, 21 shifting)
23, 32
34, 43
45, 54
56, 65
70, 71
80, 81
83, 85
86, 92
93, 95
96, 97
551
552

DIAGNOSTICS CODES

Main Aux.
Service Technician,
Code Code error remedy
55 17, 87 Increasing C 3 pressure (after 1) Check point 1 and 2 as for Code 51

97 shifting) 2) Check cable connection to C 3 pressure switch
for interruption, short circuit between cables,
short circuit to ground.
3) Check
a) Is cable plug on gear tight, clean, undamaged?
b) Is cable plug on ECU tight, clean, undamaged?
c) Are the cable plugs on the speed sensors tight,
clean, undamaged?
Service Dept.
56 01, 11 Gear check 1) Check as for Code 51

22, 33
44, 55
66, 75
57 11, 22 Gear check 1) Check as for Code 55

44, 66 (C 3)
88, 99
65 00 1) Currently not programmed
66 00 1) Check
a) Are serial cable connections to micro computer
tight, clean, undamaged?
b) Check serial interface cable for interruption,
short circuit between cables, short circuit to
ground
Service Dept.
69 12, 13 ECU Error 1) Delete code and try to start vehicle again
14, 15 2) If error code is repeated, change ECU
22, 23 Service Dept.
24, 25
26, 32
33, 34
35, 71
553
7.05 MAINTENANCE GUIDELINES FOR THE CRANE SUPERSTRUCTURE 023414>00
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554
When performing maintenance and repairs in the engine area, observe the following:
CAUTION : Perform all maintenance tasks on the engine and service fuel, oil and air filters
according to the separately issued Operation Manual for !ªLIEBHERR Diesel
engines´ .
Never step on the fuel lines.

When changing the filter, spread out a layer of absorbent material before loosing the filter to absorb any fuel
which might drain out.
Dispose of the absorbent material properly.
DANGER: YOU MUST make sure that no Diesel fuel is spilled in the engine area and it
remains free of Diesel fuel, otherwise there is a risk of causing a
FIRE!
When you change the filters and bleed the system, you must assure utmost
cleanliness. Any fuel spills must be dried up.
Check the engine coolant (Fig. 1)
DANGER: Check the engine coolant only when the engine is cold!
The radiator cap must be cool enough to touch. Avoid contact with components
containing coolant, since it could cause SEVERE SKIN BURNS !
The coolant reservoir may only be refilled via the filler neck.
> Turn the radiator cap on the filling neck of the coolant reservoir to the left, to the first notch to release the
pressure.
> Remove the radiator cap.
> Add coolant, as specified on the lubrication chart until it runs over.
> Reinstall the cap and close it tightly.
CAUTION : If coolant must be added, add it in the same ratio, as specified on the
LUBRICATION CHART.
Ratio: 50 % corrosion protective fluid and antifreeze,

50 % fresh water.
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Check oil level and filters on the engine (Fig. 2)

The oil must be between the upper and lower mark on the dipstick.
CAUTION : Make sure to observe utmost cleanliness, to prevent any dirt infiltration into the
engine .
> To check the oil level in the engine, the crane must be in horizontal position.
> Turn the engine off and wait 2 to 3 minutes until the oil has drained into the oil pan.
> Pull the dipstick, wipe it off,reinsert it and pull it out again.
> After checking the oil level, make sure to push in the dipstick tightly.
> If necessary, add engine oil as specified on the lubrication chart.
CAUTION : If the oil level has dropped below the minimum ( MIN ) mark , you must add engine
oil as specified on the lubrication chart until the oil level is again between the
minimum and maximum (MIN and MAX) mark.
If no oil is added, the engine can be severely damaged.
To change the oil:

Check the air filter on the crane engine (fig. 10)

The air filters are electronically monitored.
If a vacuum is created in the air intake line due to contaminated filter elements, the corresponding warning
light (304) will light up.
In that case, clean or replace the filter elements.
To change the filter:

* Optional
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558
Oil level on hydraulic tank for:

crane hydraulic, fan drive and air conditioner compressor*
> With the crane in horizontal position, the oil level must be at the center of the corresponding sight gauge
(fig.!6).
If no oil is visible in the sight gauge, oil MUST be added as specified on the lubrication chart, until the oil level
is again at the center of the corresponding sight gauge.
CAUTION: The luffing cylinder and the telescoping cylinders must be retracted when checking
the oil.
If you would check the oil with the cylinders extended, then you would run the risk
of adding too much oil and overfilling the system.
If they are retracted, the oil is discharged through the bleeder valve.
Do not retract the cylinders too quickly, this can cause damage to the oil tank.
D A N G E R: If the oil level has dropped below the minimum mark, oil must be added according
to the lubrication chart.
If the oil level is too low, the hydraulic pumps can be damaged, which increases the
risk of causing an accident, due to a decrease in steering ability.
In addition, the cylinders cannot be fully extended.
Note : If the cylinders (luffing and telescoping cylinders) are all the way extended, then the oil
level is visible in the lower sight gauge.
Add oil :
> Add oil, as specified on the lubrication chart until the center of the upper sight gauge, Fig. 6
CAUTION : Use a fine mesh strainer to add oil.
559
185976
560
Bleeder filter on hydraulic tank (Fig. 4)

> Turn the crane engine off,
> Open the cover and check the filter for contamination (visually).
If it is dirty, replace the filter.
> Reinstall the cover.
Return filter in the crane hydraulic system (Fig. 5)

One of the two return filters is equipped with a maintenance indicator * .
If the red bar indicator is visible when the oil is at operating temperature (check weekly), then the filter inserts
must be changed.
To change the filter

> Turn the crane engine off,
> loosen both filter covers, and collect oil in a suitable container.
> Remove both filter covers,
> take out both inserts and dispose of them properly,
> flush both filter housings,
> clean sealing surfaces on covers and clean filter housing,
> insert new filter inserts into the filter housing,
> lubricate the rubber seal rings in the covers with oil,
> reinstall both covers on the filter housings and tighten,
> start the engine and check for leaks,
> then recheck the oil level, add more oil if necessary.
* Optional
561
183636
562
Slewing gear
> Visually check for leaks.
With the slewing gear at a standstill

> check the oil level on the dipstick Fig. 8, the oil level must be between the two notches.
> Reinsert the dipstick after checking the oil level.
CAUTION : If any oil has been lost, then there is problem, which must be remedied immediately.
Hoist gear
> Visually check for leaks.
With the hoist gear at a standstill

> check the oil level on the dipstick Fig. 9, the oil level must be between the two notches.
> Reinsert the dipstick after checking the oil level.
CAUTION : If any oil has been lost, then there is problem, which must be remedied immediately.
Hydraulic hoses
The hydraulic hoses must be checked at least once a year by qualified personnel to assure they are in safe
working condition.
Changing hoses
The hoses and lines must be replaced periodically.
Due to our experiences with mobile cranes, we recommend the maximum usage:
> in severe operation
at high operating temperatures and frequent movements approximately 3 years
> in normal operation approximately 6years
> in assembly operation with rare high output frequency approximately 12 years
CAUTION: The hoses on the intake lines of the oil reservoirs must be checked visually once a
month for cracks and damage, and, if necessary, they must be replaced immediately
563
185151
564
Central lubrication system (fig. 13)

The crane superstructure is equipped with a central lubrication system. It is permissible to clean the crane with
water or steam.
All grease points of the slewing gear, the bearing of the pivot section, the bearings of the luffing cylinder and
hoist winches are automatically supplied with the proper amount of grease according to the operating hours.
The lubrication procedure takes two minutes, every 1.5 hours.
CAUTION: The lubrication interval must be set to 1.5 hours.

If the crane is not being operated for longer than 3 months, then it must be
lubricated every 3 month with an external grease pump on the grease fitting
block!(3), until grease emerges from all lube points.
Then repeat the corresponding crane movement several times and repeat the
lubrication procedure.
Component in the system
Pos. Description
1 Grease container
2 Grease nipple > to refill the central lubrication pump
3 Grease nipple > to refill the grease lines
4 Pump outlet
5 Pressure relief valve
6 Pump element
7 Button
8 Control
9 Indicator light (yellow)
10 Switch > interval set for .. hours (hrs.)
11 Switch > lubrication time set for .. minutes (min)
To set the lubrication and interval time

> Turn on the ignition of the crane engine, when the ignition is turned on, the yellow indicator light (9) lights up
for approx. 2 seconds, it shows that the control (8) is functional .
During the lubrication procedure, the yellow indicator light (8) blinks, on the pump housing, in 0.5 second
intervals.
The lubrication and interval time has been set at the factory. If necessary, these times can be changed via
switches (10, 11).
Function check
> With the ignition turned on, trigger 2 to 3 additional lube impulses to check if lubricant emerges from all lube
points.
> With the system block, but with a functioning electric pump, lubricated emerges on the pressure relief
valve!(5).
This assures the safety of the system and allows for system monitoring.
Access to the automatic lubrication system (intermediate lubrication).

> With the ignition turned on, press the red button (7) on the pump housing to initiate intermediate lubrication
intervals, for example after washing the crane. or to refill the grease lines with grease after a repair.
565
185151
566
To refill the grease container (1)

> With a commercially available grease pump, fill the grease nipple (2) on the central lubrication pump.
CAUTION: Make sure that the grease container (1) is always filled with grease, according to the
lubrication chart.
When filling the grease container, observe utmost cleanliness!
To bleed the system

If one of the grease containers (1) has become empty, then it might be necessary to bleed the system.
> Fill the grease container.
> Remove the main line from the pump outlet (4) .
> Trigger the lubrication impulse until the grease emerging from the pump outlet (4) contains no more air
bubbles.
> Reconnect the main line.
> Trigger additional lubrication procedure.
To refill the grease lines

> With an external grease pump fill on the grease nipple (3) or
> with the ignition turned on, press the red button (7) on the pump housing
CAUTION: After any repair work on grease lubricated components, refill the grease lines to
prevent the components from running dry.
When filling the grease lines, observe utmost cleanliness!
567
185151
568
Troubleshooting on the central lubrication system
Problem Cause Remedy
Pump does not work integrated, electronic control is Replace the lower part of the motor
defective, housing
electr. line is interrupted, replace electrical lines,
pump is defective replace pump
Pump works, but does not put Air cushion in supply piston Bleed pump,
out Fallen below min. level fill grease container,
Pump elements are defective replace pump elements
No grease collar on all lube Pump is not working see (Pump is not working∫
points Stop time is too long or lubrication Reduce stop time or extend lubrication
time is too short time
System is blocked see (Grease emerges from pressure
relief valve∫
No grease collar on several lube Lines to auxiliary distributor are Change lines
points broken or leak,
fitting leaks Retighten fitting or change it
No grease collar on one lube Corresponding line is broken or Change line

point leaks
fitting leaks Retighten fitting or change it
Pump speed reduced High system pressure Check system / bearing points
low ambient temperature no damage
(if necessary, grease once or twice in
between)
Grease emerges from pressure System pressure too high Check system
relief valve Progressive distributor blocked replace distributor
System blocked plugged / tight bearing point
Valve spring is defective replace pressure relief valve
569
183635
570
Check the maximum tilt play on the slewing connection:

The maximum tilt play is 1.0 mm.
If the play exceeds this measurement, change the slewing connection.
DANGER: If the maximum permissible tilt play is exceeded, there is the danger that the
slewing gear will break away and separate and cause the crane to topple over .
Test procedure:
1) Support the crane on tis widest support base and align it horizontally.
2) Turn the superstructure to the side or to the rear and extend the telescopic boom all the way.
3) Turn the superstructure and check if it moves freely and quietly, without any jerks .
If the superstructure jerks or moves sluggishly, then the slewing connection is damaged.
4) Attach the test gauge holder on the slewing platform and bring the telescopic boom into horizontal position.
5) Place the test gauge in such a way that the test pin is located on the outer ring ( see Fig 8 ) and set the test
gauge to ∫0∫.
6) Luff up the telescopic boom all the way and telescope it in.
7) Read the tilt play on the gauge.
8) Turn the superstructure a little, reset the gauge to zero and repeat steps 6 and 7.
9) Repeat this procedure on 2 to 3 other points.
10) Telescope the telescopic boom and place it down.

11) Remove the gauge and the holder, and store .
571
572
Diaphragm reservoir in the hydraulic system
The following diaphragm reservoirs are installed in the hydraulic system:

> Control pressure on base block 10 bar
> Ballasting ( 2 accumulators) each 40 bar
It is important that the pretension pressure noted in the hydraulic schematic and on the diaphragm reservoirs
is available.
The pretension pressure must be checked in each reservoir.
CAUTION : In case of strongly fluctuating ambient temperatures, for examples in countries

with extremely warm or cold temperatures, and in countries with great
temperature differences between summer and winter, the pretension pressures
MUST be checked and corrected, if necessary.
To check the pretension pressure

Prerequisite:
> The crane engine is turned off, this relieves the accumulators on the fluid side.
> Check the pretension pressure with a testing and inflation device and correct the pressure, if necessary.
DANGER: To fill the reservoirs, DO NOT use a i r or o x y g e n.

This can cause an
EXPLOSION !
The pressure in the nitrogen cylinder MAY NOT exceed the maximum permissible
operating pressure of the reservoir or the pressure gauge.
If the pressure is higher, a pressure reducing device must be connected between the
cylinder and the inflating device.
Note : In addition, you must observe any applicable national or local regulations
regarding pressurized container checks.
573
181761
574
Telescopic boom
The internal sliding surfaces of the telescopic sections (Kunststoff Gleitlagerplatten) are lubricated via grease
fittings (2) in the bearing pads.
These grease fittings (2) are accessible from the outside via inspection ports on both sides of the telescopic
sections, if the telescopic sections are extended to 92%.
For the internal sliding surfaces, you must use a special grease, as specified on the lubrication chart.
The external sliding surfaces can be spraved with special grease.
CAUTION: After appolying the special grease, wait for 4 to 8 hours to let the grease cure.
Telescope cables
The telescopic section — is extended and retraced via a single hydraulic cylinder .
The telescopic sections “ and ” are extended and retracted via a dual hydraulic cylinder.
Telescopic section ‘ is extended and retraced synchronously with the telescopic cylinder ”by a cable
mechanism.
Extension of telescopic sections ‘ occurs via two 5way flat cables (telescopic cable).
Retraction of telescopic sections ‘ occurs via two 2way flat cables (return cables).
Via several inspection ports each on both sides of telescopic sections, it is possible to monitor the telescopic and
return cables without having to disassemble the boom.
C AU T I O N : If a new cable is installed, then it must be the same make and strength and the same
diameter as the original cable.
The telescopic flat cables must always be replaced as a set.
Maintenance
In addition, the telescopic boom should be removed after 20,000 operating hours or once every 10 years, so all
bearings, telescopic and return cables, cable pulleys and telescopic cylinders can be inspected close up.
The telescopic cables are pretensioned by the return cables.
In case this pretension has slackened due to permanent stretching of the cables, then the return cables must be
retightened.
To retighten the return cables

Extend telescopic section ‘ by about 1 m and tighten the return cables on both sides evenly with the
adjustment nuts (1) , until the return cables are tightened.
Visually check the cables via the side openings in the telescopic sections.
The return cables should not slack more than 10 cm over the total length.
CAUTION: 1. When tightening the nuts (1) ,make sure not to twist the return cable.
2. After every retightening, the sliding synchronization of the telescopic sections
”!and!‘ must be checked.
To check the synchronization

Carefully telescope the telescopic sections in. The stop of telescopic section ” must touch telescopic section “
first .
If this is not the case, the stop of telescopic section ” must be reinforced by inserting and welding on a plate or
reduced by grinding it down.
575
181762
576
Slewing platform ballast (replacement counterweight )
CAUTION : On machines with one hoist gear and

if hoist gear 2 is removed,
the replacement counterweight, Pos. 5 must always be installed on the counter>
weight frame.
DANGER: The two mounting screws (item 8) must be folded backwards after insertion, they
must be checked before any travel .
In addition, check the mounting tightness every 10 000 km or every 400 operating
hours.
If this is not observed, then the mounting tightness of the replacement counter>
weight cannot be assured, and the counterweight can fall off.
577
7.06 LUBRICATION CHART AND FILLING CAPACITIES 023415>01
182794
578
CRANE CARRIER approx. litre

Vehicle engine D 9406 TI > E
Engine oil 26.0
Coolant water 55.0
Fuel tank
Diesel 400.0
Automatic transmission HD 4560
ATF Til change quantity 37.0
Transfer case VG 1600
Gear oil 8 x 6 drive 8.5
8 x 8 ** drive 7.1
1st axle
Gear oil axle drive 15.0
each wheel side 1.5
2nd axle
Grease >
2nd axle driven **
each wheel side 1.5
3rd axle
each wheel side 1.5
4th axle
Gear oil baxle drive 15.0
each wheel side 1.5
Hydraulic fluid reservoir *
Steering / Axle suspension / Support
ATF,hydraulic fluid Til change quantity 175.0
CAUTION: The given quantities are only orientation values.

All filling requirements must be carried out and fulfilled according to the markings
on the dip sticks, the glass view ports, etc.
Synthetic oil and mineral oil can not be mixed!
* When checking the oil level, all hydraulic jacks must be retracted!
The upper markings on the view ports must not be exceeded.
Explanation to the lubrication plan:

1 Engine oil
2 Grease
3 Gear oil
4 ATF
5 automatic grease supply via the central lubrication system
6 Diesel fuel
** Optional
579
182795
580
CRANE SUPERSTRUCTURE approx. litre

Crane engine D 924 T>E
Engine oil 22.0
Coolant water 27.0
Fuel tank
Diesel 300.0
Winch 1
Synthetic gear oil 3.2
Winch 2 **
Slewing gear
Hydraulic fluid reservoir *
ATF
in the hydraulic fluid reservoir 680.0
Central lubrication system
Special grease 2.0 kg
CAUTION: The given quantities are only orientation values.

All filling requirements must be carried out and fulfilled according to the markings
on the dip sticks, the glass view ports, etc.
Synthetic oil and mineral oil can not be mixed!
* When checking the oil level, all hydraulic jacks must be retracted!
The upper markings on the view ports must not be exceeded.
Explanation to the lubrication plan:

1 Engine oil
2 Grease
3 Gear oil
4 ATF
5 automatic grease supply via the central lubrication system
6 Diesel fuel
** Optional
581
7.07 SCHMIERSTOFFTABELLE 013098>04
582
TL> UND FETTBEFeLLUNG

OIL AND GREASE FILLING
REMPLISSAGE D'HUILE ET DE GRAISSE
Verwendungszweck Deutsche Tle und Fette, Werks>ErstbefÂllung
German oils and greases, original works filling
Intended use Huiles et graisses allemandes, remplissage original usine
Application $ 25 ∞C Æ + 50 ∞C $ 50 ∞C Æ + 10 ∞C
1 Dieselmotor SAE 15W>40 SAE 10W>40
diesel engine API CD/CE/CF>4 API CD/CE/CF>4
moteur Diesel CCMC D4/D5 CCMC>D4/D5
LWE>Identnr.: 861005408 LWE>Identnr.: 861002908
unter $ 15 ∞C mit unter $ 20 ∞C mit

Vorwßrmung Vorwßrmung
below $ 15 ∞C with preheating below $ 20 ∞C with preheating
en>dessous de $ 15 ∞C avec en>dessous de $ 20 ∞C avec
pr±chauffage pr±chauffage
2 Antriebsachse mit Differentialen, SAE 90 SAE 75W>80

Planetengetrieben und angebautem API GL 5 API GL 5
Verteilergetriebe LWE>Identnr.: 861901008 LWE>Identnr.: 861003508
driving axle with differential, planetary
gears and flanged transfer case
essieu moteur ° diff±rentiel, r±ducteurs
plan±taires et bo¿te transfert
ZF Achsantieb DK>7
axle drive ZF DK>7
entra¿nement des essieux ZF DK>7
Fahrzeug Verteilergetriebe
transfer box
bo¿te de transfert
KESSLER (VG 1800 / 2400)
STEYR PUCH (VG 1200 / 1600 / 2000)
STEYR PUCH Versatzgetriebe (drop box)

STEYR PUCH drop box
STEYR PUCH decaleur de bo¿te de
transfert
Pumpen>Verteilergetriebe
pump transfer cases
bo¿tes transfert de pompes
Bergewinde
recovery winch
treuil de remorquage
Fahrgetriebe fÂr Raupenkran

travel gear transmission for crawler crane
r±ducteur de translation pour grues sur
chenilles
583

german oils and greases, original works filling
3 ZF Lastschaltgetriebe SAE 15W>40 ATF 86 (66M)

(WG 120 / 150 / 180 / 181 / 200 / 201) API CD/CE/CF>4 DEXRON II D
ZF power shift gears CCMC D4/D5 ALLISON C4
ZF bo¿tes de vitesse et d'inversion LWE>Identnr.: 861005408 ZF TE>ML 14
LWE>Identnr.: 861900608
ALLISON Versatzgetriebe (drop box) unter $ 15 ∞C Warmfahren
ALLISON drop box nach gesonderter unter $ 35 ∞C mit
ALLISON decaleur de bo¿te de transfert Warmlaufvorschrift Vorwßrmung
below $ 35 ∞C warm up below $ 35 ∞C with preheating
CLARK Lastschaltgetriebe according to special warm up en>dessous de $ 35 ∞C avec
CLARK power shift gears specifications pr±chauffage
CLARK bo¿tes de vitesse et d'inversion en>dessous de $ 35 ∞C mise en
temp±rature d'apres les
consignes particuli∞res de
pr±chauffage
4 Automatikgetriebe ATF 86 (66M) ATF 86 (66M)

automatic transmissions DEXRON II D DEXRON II D
bo¿tes de vitesses automatiques ALLISON C4 ALLISON C4
ZF TE>ML 14 ZF TE>ML 14
ALLISON LWE>Identnr.: 861900608 LWE>Identnr.: 861900608
(CLBT 740 / 750 / 754 / 755)
(HT 755 / HD 4560) unter $ 35 ∞C mit
Vorwßrmung
ZF Wendegetriebe (WG 210 / 251) below $ 35 ∞C with preheating
ZF reversing transmission en>dessous de $ 35 ∞C avec
ZF bo¿tes d'inversion pr±chauffage
5 Seilwinde ISO VSG 220 ISO VSG 68

winch PGLP 220, DIN 51 502 PGLP 68, DIN 51 502
treuil LWE>Identnr.: 861901208 LWE>Identnr.: ohne
Drehwerksgetriebe nicht mischbar mit nicht mischbar mit

slewing gears Mineral‘len! Mineral‘len!
m±canismes d'orientation do not mix with mineral oils! do not mix with mineral oils!
non miscible avec des huiles non miscible avec des huiles
TA>Abspannwinde mit Klinkensperre min±rales! min±rales!
TA>pawl guy rope winch
TA>treuil de haubanage ° cliquet
584

6 Kranhydraulik ATF 86 (66M) Sondervorschrift:

fÂr Kranfahrgestell und Kranoberwagen DEXRON II D special prescription:
crane hydraulics ZF TE>ML 14 prescription sp±ciale:
for crane carrier and crane superstructure LWE>Identnr.: 861900608 ATF 44 M
hydrauliques LWE>Identnr.: 861902290
pour ch£ssis porteur et partie tournante
TA>Abspannwinde mit Lamellenbremse

TA>guy rope winch with multiple>disk
brake
TA>treuil de haubanage avec frein
multidisques
7 Scheibenbremsanlage DOT 4 Sondervorschrift:

disk brake system SAE J 1703e special prescription:
syst∞me de frein ° disque LWE>Identnr.: 861000108 prescription sp±ciale:
ATE Arktis 3.9901.5503.2
LWE>Identnr.: 861000190
8 Allgemeine Gleit> und Wßlzlagerungen Sondervorschrift: Sondervorschrift:

wßlzgelagerte Gelenke LIEBHERR Spezialfett 9610 LIEBHERR Spezialfett 1026
general plain and roller bearings LWE>Identnr.: 861301308 LWE>Identnr.: 861303708
joints on rolling bearings
paliers lisses et ° rouleaux courants special prescription: special prescription:
articulations ° palier LIEBHERR LIEBHERR
special grease 9610 special grease 1026
Zentralschmieranlage Kranoberwagen
centralized lubricating system crane prescription sp±ciale: prescription sp±ciale:
superstrcture LIEBHERR LIEBHERR
graissage central partie tournante graisse sp±ciale 9610 graisse sp±ciale 1026
Auslegerverriegelung
boom locking
verrouillage de la fl∞che
Drehkranz>Wßlzlagerungerungen
slewing ring rolling bearings
paliers couronnes d'orientation
Gelenkwellen
cardan shafts
arbres articul±s
585

9 Drehkranzschrauben (nur bei Montage) Sondervorschrift: Sondervorschrift:

slewing ring bolts (only at assembly) special prescription: special prescription:
boulons pour couronne d'orientation prescription sp±ciale: prescription sp±ciale:
(seulement lors montage) Gleitmo 100 S Gleitmo 100 S
10 Kunststoff>Gleitlagerungen der Sondervorschrift: Sondervorschrift:

Teleskopausleger LIEBHERR Spezialfett 9613 LIEBHERR Spezialfett 1026 LS
synthetic sliding bearings of the telescopic LWE>Identnr.: 861303608 LWE>Identnr.: 861302608
boom
paliers de guidage synth±tique de la fl∞che special prescription: special prescription:
t±lescopique LIEBHERR LIEBHERR
special grease 9613 special grease 1026 LS
Kunststoff>Gleitlagerungen der
Schiebeholme prescription sp±ciale: prescription sp±ciale:
synthetic sliding bearings of the LIEBHERR LIEBHERR
outriggers graisse sp±ciale 9613 graisse sp±ciale 1026 LS
paliers de guidage synth±tique des
stabilisateurs
AbstÂtzplatten mit Ausgleich

Outrigger plates with compensation
Patins de calage avec compensation
11 Innengleitlagerung der Teleskopausleger Sondervorschrift: Sondervorschrift:

(nur bei Montage) LIEBHERR Spezialfett 1336 LIEBHERR Spezialfett 1336
internal slide bearing application of mit L‘sungsmittel LM mit L‘sungsmittel LM
telescopic booms (only at assembly) (SprÂhfett) (SprÂhfett)
guidage ° glissement int±rieur des fl∞ches LWE>Identnr.: 861303308 LWE>Identnr.: 861303308
t±lescopiques (seulement lors du montage)
special prescription: special prescription:
LIEBHERR special LIEBHERR special
grease!1336 with LM carrier grease!9613 with LM carrier
(spray grease) (spray grease)
prescription sp±ciale: prescription sp±ciale:

LIEBHERR graisse LIEBHERR graisse
sp±ciale!1336 ° v±hicule LM sp±ciale!96103 ° v±hicule LM
(graisse ° pulv±riser) (graisse ° pulv±riser)
586

12 Offene Verzahnung der Drehkrßnze Haftschmierstoff Haftschmierstoff

open toothing of slewing rings OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
denture des couronnes d'orientation (wasserbestßndig) (wasserbestßndig)
Laufende Seile
running ropes adhesive lubricant adhesive lubricant
c£bles d±roulants OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
(water resistant) (water resistant)
lubrifiant adh±sif lubrifiant adh±sif

OGPF 2 S>30, DIN 51 502 OGPF 2 S>30, DIN 51 502
(r±sistant ° l'eau) (r±sistant ° l'eau)
13 Seil der Bergewinde Sondervorschrift: Sondervorschrift:

rope of the recovry winch special prescription: special prescription:
c£ble du treuil de remorquage prescription sp±ciale: prescription sp±ciale:
Motorex TW>Fluid Motorex TW>Fluid
14 KÂhlerfÂllung fÂr Dieselmotoren und KÂhlerschutzmittel KÂhlerschutzmittel

Heizanlagen LIEBHERR>Norm LIEBHERR>Norm
radiator filling for Diesel engines and 50 % KÂhlerschutzmittel 60 % KÂhlerschutzmittel
heatings 50 % Wasser 40 % Wasser
remplissage de radiateur pour moteurs LWE>Identnr.: 861600508 LWE>Identnr.: 861600508
Diesel et chauffages
radiator protective agent radiator protective agent
LIEBHERR standard LIEBHERR standard
50 % radiator protective agent 60 % radiator protective agent
50 % water 40 % water
agent de protection de agent de protection de

radiateur radiateur
norme LIEBHERR norme LIEBHERR
50 % agent de protection de 60 % agent de protection de
radiateur radiateur
50 % eau 40 % eau
587
8.00 CRANE INSPECTIONS 022101>00
588
022101>00
Chapter 8
Crane inspections
589
8.01 REPEAT CRANE INSPECTIONS 021686>04
General
This crane has been inspected before delivery at the factory, according to the valid ISO, FEM and DIN
standards or VBG 9 (ZH 1/27).
During crane operation, deviation may occur from the safety standard, which had existed at initial delivery.
Such deviations can be the result of wear, corrosion, intentional force, environmental changes or application
changes.
The operator must take care of the required tasks to maintain the same initial standard of safety at all times.
For that reason, the crane must be inspected by an experienced technician, depending on conditions of
application and operational conditions, at least once a year, counting from the day of initial service. See also:
ISO 9927>1, EU machine guidelines (EWG Maschinenrichtlinie) 89/655, VBG 9.
The crane must be inspected by an expert engineer at least once every 4 years, counting from the day of initial
service .
After the 12th year in operation, an expert engineer must check the crane annually.
CAUTION : If significant changes had been made on the crane, or after repairs of load carrying
part , the operator must have the crane inspected by an experienced technician
before putting the crane back in service.
In addition, national and regional regulations apply.
Experienced technicians are persons who, due to their vocational background and experience, have sufficient
knowledge in the field of lifting appliances (cranes) and are sufficiently familiar with the relevant regulations,
such as labor laws, OSHA regulations, accident preventions regulations, to determine deviations from the
proper and safe conditions (they are specially trained personnel).
Expert engineers are engineers experienced in the design, construction and maintenance of lifting devices, such
as cranes, with sufficient knowledge of the relevant regulations and standards, who have equipment necessary
to carry out the inspection and are in a position to judge the safe condition of the lifting appliance (crane) and to
decide which measures have to be taken in order to ensure further and continued safe operation.
A repeat crane inspection is generally a visual inspection, where the experienced technician / expert engineer
inspects the condition of the crane and components. .
This inspection should prevent accidents through timely recognition of defects.
Any defects found by an experienced technician / expert engineer must be documents, remedied and
reinspected.
Below, as an example, we have listed certain important items, which must be checked especially during repeat
crane inspections. We note that the experienced technicians / expert engineers are solely responsible for
carrying out the crane inspection. For that reason, we cannot list the complete range of inspections in this
chapter.
Attached is a checklist for the inspector for repeat inspections of LIEBHERR mobile and crawler cranes.
If the inspector has any questions, they should be directed via our Service Dept. to the appropriate departments
at LIEBHERR>WERK EHINGEN GMBH.
DANGER: Non>observance of the following inspection guidelines or non>adherance of the

inspection intervals can lead to a serious accident !
590
1. Inspection of load bearing / load carrying steel constructions
The load bearing steel constructions, such as boom , slewing platform, chassis, support systems (sliding
arms or folding supports) must be part of a careful inspection at least once a year. Even though the
welding seams normally are not in high stress areas, it is nevertheless important to pay special
attention to them during this repeat inspection.
We refer to DIN 15018, part 3, point 1, which lists permissible stress figures for highly resilient steel.
They also determine the life expectancy of the steel frame work. It cannot only be calculated from the
stress figures alone, but also depends on the collective load figures during time of operation.
LIEBHERR cranes are designed and sized for installation operation, whereby the following design
calculations have been used as a basis (DIN 15018, part 3):
Load collective : SO (light)
Stress figure: 25 000
For that reason, the load bearing or load carrying parts of the steel construction and the welding seams
must be subjected to an especially intensive check during the repeat inspection by an expert engineer.
If the crane was subjected to excessive stress, for example an unusual shock or impact during its time in
operation , the inspection of load baring components must be carried out immediately.
If any damage, such as cracks, can be found at any point of the steel construction, then the extend of
damage must be determined by expert personnel with the aid of material analysis methods, such as
magnetic powder test, ultra sound or X>ray tests. Then it must be determined by expert personnel if the
defective section can be repaired by repair welding or by other means.
The following drawings show examples of load bearing welding constructions. For example, welding
seams which need to be checked can occur in multiple areas on the steel components and in a variety of
shapes. The connections or zones around the points marked by arrows must be checked.
CAUTION : We note that all crane inspections, as far as content and extend, are the sole
responsibility of the inspector. The following drawings are given only as an
aid for the inspector. The drawings are only examples, and we do not claim
that they are complete!
591
Vehicle fame
185046
592
Sliding arms
185047
593
Folding arm
185060
594
Slewing platform frame
185048
595
Slewing platform frame
185049
596
Telescopic boom
185050
597
Lattice jib
185051
598
NA / WA> bracket
185052
599
Installation unit with lattice jib
185053
600
Pulley head
185054
601
Guy rods
185055
602
Lattice boom
185056
603
Folding jib
185057
604
Folding jib
185058
605
TA> guying
185059
606
2. Inspection of hoist and pull in winches
The hoist and pull in winches and slewing gears are closed planetary gear versions. These gears have
been designed for long service life, drive shafts and gear wheels are also long lasting.
Even though these gears have been designed for long service life, an external visual inspection is not
sufficient in this case, because the service life can be influenced by insufficient maintenance (lack of
oil), defective seals, improper operation or overuse. For that reason, the inspection must be made by
experienced technicians according to the following guidelines:
607
2.1 Inspections
2.1.1 Inspection intervals

Every 1000 operating hours, at least once a year (annually)
2.1.2 Inspection
Check oil level. On hoist and pull in winches, we recommend to drain the oil and compare the amount
with the stipulated oil quantity.
2.1.3 Check color of oil

If the oil is blackened and / or if the oil smells burnt, one can assume that the oil has been overheated. In
that case, the oil must be changed.
2.1.4 Check for foreign particles

This test should be done in a qualified lab. The used oil is dropped onto specified filter paper. The oil
sample is visually checked under a microscope for foreign particles. If any are found, then the oil must
be analyzed by a qualified lab to determine the make up of the particles.
2.1.5 Evaluation of foreign particles found in oil

Maximum permissible foreign particle parts are 0.15% of the total oil quantity, by weight.
Maximum permissible foreign particle size from fine shavings to 0.25 my.
If the above values have been exceeded, remove the gear and check out the cause of increased
contamination. Replace any damaged parts and fill the gear with new oil.
CAUTION: These repairs may only be made by expertly trained personnel.
2.1.6 Visual inspection

The gears must be checked for leaks, since any loss of oil > aside from environmental contamination >
can also lead to gear failure.
2.1.7 Check brakes in gears

Check the brakes at the same time you check the gears.
If the brakes should not hold the required test load of +33% cable pull increase on single line and fully
coiled drum, then they must be removed and the cause must be found. If the planetary gear is removed
due to increased oil contamination, check the brakes at the same time.
CAUTION: Only expertly trained personnel may inspect gears and brakes!
2.1.8 Document completed inspection

The result of annual inspections and repair / reconditioning work, including all completed tasks, must
be recorded by the expert or the trained service technician, if necessary, and signed off by the inspection
station or specialty shop.
This documentation must be enclosed in the crane inspection booklet and must be recorded in the repeat
inspection column.
608
2.2 Required measures to monitor the winches
2.2.1. Theoretical service life

When calculating and dimensioning the winches for your crane, the designer took certain operating
conditions and a calculated total service life time into account, which resulted in a theoretical service
life.
The winches in your crane are classified according to DIN report 1, ISO 4301/1 or FEM 9.511, as follows:
Drive group: M3 (1 Bm)
Load collective: Q1 (L1)
Factor of load collective km: 0.125
Theoretical service life D: 3200 hrs.
CAUTION: The "theoretical service life" may not be equated with the real (actual)
service life of a winch!
The real service life for a winch is influenced by many external matters, such as :
1. Overloads: because the crane was not utilized as intended
2. Insufficient maintenance: oil has not been changed at the proper intervals
3. Erroneous operation : extreme acceleration or deceleration of the load

Load fell into the cables
4. Maintenance errors: Use of wrong oil

Wrong quantity
Contamination during oil change
5. Installation errors during repair or maintenance
6. Leakages which were not taken care of
7. Improperly adjusted safety devices
8. Hidden accident damage
9. Extreme ambient conditions: Low or high temperatures

aggressive atmosphere
Dust and dirt
609
2.2.2 Used portion of theoretical service life

The crane operator is obligated to have the crane inspected at least once a year (ISO 9927>1 and VBG 8).
The used portion of the theoretical service life must also be determined. If necessary,the crane operator
must call in an expert.
When determining the used portion of the theoretical service life, the actual operating conditions (load
collective) and the operating hours of hoist gears per inspection interval must be determined. The user
is responsible to have it documented in the crane inspection booklet.
2.2.2.1 Determining the operating conditions (Load collective)

The load collective of the crane is divided into groups; see also DIN report 1, ISO!4301/1 or FEM 9.511.
From the determination of the actual operating conditions, choose one of the following load collectives
and enter them in the crane inspection book for the corresponding inspection interval.
Note: For mobile cranes in assembly operation, we normally use the load collective L1
(Q1), with the load collective factor km = 0.125.
610
Load Factor of
collective Definition Service life portion load Graphic view
Classification collective
Light Drive gear or parts 10 % of running time km=0,125 Load %

Q1 thereof, which run only with largest load
100
L1 at high utilization in (dead load + 1/1 load
exceptional cases , but capacity)
are subjected to 40 % of running time
constant, but only light with dead load + 1/3 50
40 %
duty load capacity)
50 % of running time 10 %
with only dead load 0
50 100
Running time %
Medium Drive gear or parts 1/6of running time with km = 0,25 Load %
Q2 thereof, which often largest load
100
L2 run at high utilization, (dead load + 1/1 load
but are subjected to capacity)
73 %
light duty 1/6 of running time
with dead load + 2/3 50 47 %
load capacity
20 %
1/6 of running time
with dead load + 1/3 0
load capacity 50 100
50 % of running time
only with dead load Running time %
Heavy Drive gear or parts 50 % of running time km = 0,5 Load %
Q3 thereof, which often with largest load
100
L3 run at high utilization, (dead load + 1/1 load
but are subjected to capacity)
constant medium duty 50 % of running time
only with dead load 50
40 %
0
50 100
Running time %
Very heavy Drive gear or parts 90 % of running time km = 1 Load %
Q4 thereof, which with largest load
100
L4 regularly run at high (dead load + 1/1 load
utilization, and are capacity) 80 %
subjected to constant 10 %of running time
heavy duty only with dead load 50
0
50 100
Running time %
611
2.2.2.2 Determining the effective operating hours Ti

The effective operating hours, as determined as follows, must be entered in the crane inspection
booklet for the corresponding inspection interval, differentiated by the following 4 points:
2.2.2.2.1 Hour meter is on every winch

If your crane is equipped with an hour meter on every winch, then the effective umber of operating
hours Ti per inspection interval can be read directly.
2.2.2.2.2 Hour meter for the total crane operation

The winch operation portion of the total operating hours of the superstructure must be guessed.
Note: For mobile cranes in assembly operation, normally, when hoist winches are used,
20% of the total superstructure operating hours can be contributed to winch
operation.
2.2.2.2.3 Hour meter for both travel and crane operation

The winch operation portion of the total operating hours of the superstructure must be guessed.
Note: For mobile cranes in assembly operation, normally, 60% of the total operating
hours can be contributed to superstructure operation. If 20% of the total
superstructure operating hours can be contributed to winch operation (see
paragraph 2.2.2.2.2), the result would be 12% of the total crane operating hours.
2.2.2.2.4 If there is no hour meter at all

In this case, the operator must guess and document the actual winch operating hours .
Note: The given percentage values apply normally for the main hoist winch. For
auxiliary hoist winches or adjustable boom winches, the actual share of total
operating hours can be significantly less and must therefore be guessed by the
operator.
612
2.2.2.3 To determine the used portion of the theoretical service life

For an inspection interval i (max. 1 year after ISO 9927>1 or VBG 8), the used portion Si of the
theoretical service life is determined according to the following formula:
kmi
Si = &&&&& ¥ Ti
km
km = Factor of load collective, which was the basis when calculating the winch. This factor can
be taken from the Operation Manual.
kmi = Factor of load collective in the inspection interval i according to paragraph 2.2.2.1
Ti = effective operating hours in the inspection interval i according to paragraph 2.2.2.2
This used portion is taken off after each inspection interval from the remaining theoretical service life
Di (see example).
If the remaining theoretical service life is insufficient for the next operating period, then the winch
must be reconditioned or overhauled.
When the theoretical service life D has been reached (see paragraph 2.2.1), then the winch may only be
operated again after it has been reconditioned or overhauled.
In any case, it must be reconditioned or overhauled at the latest after 10 years after putting the
crane into service.
The general reconditioning or overhaul must be initiated by the operator and must be done by the
manufacturer or by a person authorized by the manufacturer and the overhaul must be documented in
the inspection booklet.
After the general reconditioning or overhaul, the manufacturer or the person authorized by the
manufacturer will note a new theoretical service life D.
In any case, the maximum time frame to the next general overhaul is max. 10!years.
613
2.2.3. Example
According to the Operation Manual, a mobile crane with separate hour meter for travel drive and crane
operation is classified by the manufacturer as follows:
Drive gear group: M3

Load collective: light L1, km = 0.125
Theoretical service life: D = 3200 hrs.
The used part S of the theoretical service life can be calculated for the individual inspection intervals as
follows:
1st Inspection (1st year)
The crane has been utilized during the past year for assembly work:
Load collective L1, which means km1 = 0.125.
The superstructure hour meter read 800 hrs. Winch operation was about 20 % of that, which means
T1!= 160 hrs.
At the 1st inspection, the used part S of the theoretical service life is therefore as follows:
0.125
S1 = &&&&& ¥ 160 hrs = 160 hrs.
0.125
remaining theoretical service life:
D1 = 3200 hrs > 160 hrs. = 3040 hrs.
The above values are entered in the chart in the crane inspection booklet, see paragraph 2.2.4)
2nd Inspection (2nd year )
The crane has been utilized for unloading ships in the harbor:
Load collective: L3, which means km2 = 0.5
The superstructure hour meter read 2000 hrs, which means during this period:
2000 hrs. > 800 hrs. = 1200 hrs. (800 hrs. were used in the first year of operation)
Of that, the winch was used about 40 %, which means T2 = 480 hrs.
The used portion S2 of the theoretical service life can be calculated for the 2nd individual inspection
interval as follows:
0.5
S2 = &&&&& ¥ 480 hrs. = 1920 hrs.
0.125
D2 = 3040 hrs. > 1920 hrs. = 1120 hrs.
614
3rd Inspection (3rd year)
The crane has been used for assembly work and sometimes for unloading work in the harbor:
Load collective: L2,which means km3 = 0.25
The superstructure hour meter reads 3000 hrs, which means that during this period:
3000 hrs. > 2000 hrs. = 1000 hrs. (2000 hrs. were used up in the first two years of operation)
Of that, the winch was used about 30 %, which means T3 = 300 hrs.
The used portion S3 of the theoretical service life can be calculated for the 3rd individual inspection
interval as follows:
0.25
S3 = &&&&& ¥ 300 hrs. = 600 hrs.
0.125
D3 = 1120 hrs. > 600 hrs. = 520 hrs.
The above values are entered in the chart in the crane inspection booklet as shown in chart 1.
2.2.4. Addendum
Chart 1 shows an example.
Document the remaining theoretical service life on chart 2.
615
Chart to determine the remaining theoretical service life of winch No. 1 (Main hoist winch)
Crane type: LTM 1050
Fabrication No.: 0010 540 08
Put in service : 12345
Serial number of winch according to data tag: 0815 Si = Used part of theoretical service life since last inspection
Last general overhaul performed on: ................... Di = Remaining theoretical service life
Configuration data of winch (see Operating Manual): Di > 1 = Remaining theoretical service life after previous inspection
Drive gear group: M3 km = Factor of load collective, which was taken for calculation of winch.
Load collective: Q 1 (L1) This factor is to be taken from the Operating Manual
Factor of load collective km: 0.125 kmi = Factor of load collective in inspection interval i according to paragraph 2.2.2.1
Theoretical service life D: 3200 hrs. Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining
Name of Signa> Remarks
No. initial conditions since load operating hours of hours of hours of hours of winch theoretical theoretical service
inspector ture
service, last inspection connective hours super> super> winch since last service life D: life
data of (load collective) structure structure inspection Ti kmi
inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
0 10.06.90 > > > 0 0 3200
160
1 05.06.91 L1 0,125 > 800 800 > (20 % of 800) 160 3040 MÂller
480
2 20.05.92 L3 0,5 > 2000 1200 > (40 % of 1200) 1920 1120 Huber
300
3 18.05.93 L2 0,25 > 3000 1000 > (30 % of 1000) 600 520 Maier
CAUTION: Perform general overhaul at least once every 10 years.

General overhaul last performed on : .........................
Chart to determine the remaining theoretical service life of winch No. ....
Crane type: ...................
Fabrication No.: ...................
Put in service: ...................
Serial number of winch according to data tag: ................... Si = Used part of theoretical service life since last inspection
Last general overhaul performed on: ................... Di = Remaining theoretical service life
Configuration data of winch (see Operating Manual): ................... Di > 1 = Remaining theoretical service life after previous inspection
Drive gear group: M................ km = Factor of load collective, which was taken for calculation of winch.
Load collective: Q.......(L.....) This factor is to be taken from the Operating Manual
Factor of load collective km: ................... kmi = Factor of load collective in inspection interval i according to paragraph 2.2.2.1
Theoretical service life D: ................... Ti = Effective operating hours in inspection interval i according to paragraph 2.2.2.2
Inspection Date of Operating Factor of Total crane Operating Operating Operating Operating Used part of Remaining Name of Signa> Remarks
No. initial conditions since load operating hours of hours of hours of hours of winch theoretical theoretical service inspector ture
service, last inspection connective hours super> super> winch since last service life D: life
data of (load collective ) structure structure inspection Ti kmi
inspection since last Si =&&& ¥ Ti Di = Di > 1 > Si
inspection km
i kmi [h] [h] [h] [h] [h] [h] [h]
CAUTION: Perform general overhaul at least once every 10 years.

General overhaul last performed on : .........................
180068
618
3. Inspection of load hook

The load hooks must be regularly checked by an expert.
These inspections are made to prevent accidents through early detection of problems.
Any problems found during these inspections must be documented, remedied and then reinspected .
3.1 Inspections and monitoring procedures
3.1.1 Distortion
Check for any distortions, for example on the open end of the hook, regularly, but at least on an annual
basis.
The open end of the hook may not have stretched by more than 10% in relation to the initial
measurement ∫y∫ or exceed ∫y1∫ and ∫y 2∫.
DANGER: If the hook opening is now wider by more than 10 % of the initial
measurement, then the load hook may no longer be used.
In that case, contact the Service Department at Liebherr Ehingen .
Note: The initial measurements ∫y∫ or ∫y1∫ and ∫y2∫ are noted on the load hook. Measure
from point to point, as shown.
3.1.2 Corrosion
For this test, the nut must be removed from the hook shaft, so that the threads can be checked for
corrosion and wear.
DANGER: In case corrosion and wear is found on the threads, the load hook may no
longer be used.
In that case, contact the Service Department at Liebherr Ehingen .
refer to chapter
4. Check the cable push out mechanism in the telescopic boom.

4.1 Inspection of pretension of pull back cables, see chapter 7.05
4.2 Life expectancy of cables according to DIN 15020, or ISO 4309, see chapter 8.04
5. Check the inner and outer locking systems on the telescopic boom for function, pin set up,
wear and safety control, refer to chapter 8.11.
6. Check the safety control or the limit switch in the relapse support and the boom A>brackets,
refer to chapter 8.12.
7. Check the nitrogen reservoir for correct gas pressure, especially that of the relapse supports
and suspension accumulators (observe instructions).
refer to chapter 7.04, 7.05, 8.13, 8.14.
619
8. Check the cable pulleys

8.1 The cable pulleys must be checked once a year all around for damage and cracks.
If the cable pulleys have been hit during crane operation (for example on buildings, etc.) or if they were
subjected to any other stress factors, then they must be extensively checked for damage or cracks.
DANGER: If any damage or cracks are found, then the cable pulley must be replaced
immediately. If this is not observed, there is great danger of causing a
serious accident!
8.2 In addition, check the wear in the cable groove. If the cable groove base is run in by more than p of the
cable diameter, then the pulley must be replaced.
9. Check the safe load system for function.

9.1 With the longest boom, move to the minimum and maximum radius: Check the load indication, take the
hook block as a test weight.
The deviation may not be more than 10% of the load capacity in these two extreme positions.
9.2 The given radius must be measured again for the longest boom for the smallest radius and at a boom
angle of 45∞ .
The deviation may not be more than 10% of the measured radius.
10. Check the slewing ring connection

10.1 For tilt play measurement, see chapter 7.05
11. Check the mounting tightness of the load carrying components

Check the mounting screws of the pulley rotary connection, winches, slewing gears and tackle couplings
for tight seating.
11.1 The mounting screws of the rotary connections are pretensioned at the factory, and normally should not
loosen up during normal operation.
However, if the crane has been overloaded or if the load broke off, then it is possible that the screw
connection has been overloaded and the screw has been stretched.
For that reason, check these screws during the annual inspection or after an overload to make sure they
are seated tightly.
Any loose screws, as well the the two screws next to them on both the left and right hand side should be
completely removed and carefully checked for damage.
The screws must be especially inspected for cracks or distortion. If the screw has been stretched by more
than 0.2% (in relation to it original length) or if cracks or other damage can be seen, then the damaged
screws must be replaced. In case the screws were stretched or damaged, the screws next to the damaged
screw should also be replaced.
620
12. Check the oil and fuel tanks

Check the oil and fuel tanks at least once a year and in subsequent inspections every 4 years all around
for leaks.
Repairs may only be made by especially trained expert personnel.

Improper repairs, for example welding, brazing or soldering are not permitted without consulting the
Service Dept. at LIEBHERR Ehingen!
13. Check the reeving auxiliary winch, salvage and spare tire winch
Check the corresponding manufacturer for the life expectancy of the reeving auxiliary winch, salvage
and spare tire winch .
Addendum
To aid the inspector, attached find a check list for repeat inspections of LIEBHERR mobile and crawler cranes.
621
Inspection guidelines for repeat inspection of LIEBHERR mobile and crawler cranes according to
ß26(1) or (2) UV ™Cranes™ (VBG 9)
Company: . . . . . . . . . . . . . . . . . . . . . . . . Inspector: . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . . .
Crane manufacturer:LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . . .
Year: . . . . . . . . . . . Inventory number: . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature of inspector for No. 1 to 20: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Inspection group: Crane documentation

Item to be checked A B C D E Remarks
Crane inspection book
Operation> / installation manual
Crane control book
Load chart manual
Work planer
2. Inspection group:Decals / signs
Data tag
Load capacity data
Decal for operating instructions
Warning and safety decals
Other safety signs
3. Inspection group:Travel gear 1)
Frame 2)
Supports 2)
Axles
Wheels
Tires
Bearing
Gear
Universal drive shaft
Springs
Shock absorber
Steering
Brakes
Hydraulic axle suspension
A: existing / complete B: Condition / Maintenance C: Function

D: Repair / Replacement E: Reinspection required
done = ¥ not done = > not required = 0
622
Company: . . . . . . . . . . . . . . . . . . . . . . . Inspector: . . . . . . . . . . . . . . . . . . Date: . . . . . . . . . . . . . . . . . . . . .
Crane manufacturer:LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
4. Inspection group: Chassis 1)

Covers
Steps
Counterweight retainers 2)
Tackle devices
Ladders
Retainer for hook block 2)
Boom receptacle 2)
5. Inspection group: Chassis > Driverπs cab 1)
Doors
Window / windshields
Windshield wiper
Mirror
Seat
Heater
Ventilation
Noise protection
Recorder
First aid kit
Spare bulbs
Warning triangle
Warning vest

623
6. Inspection group: Chassis > Drive 1)

Engine
Exhaust system
Fuel tank
Filter
Muffler
Engine suspension
Oil levels
Fuel lines
7. Inspection group: Chassis > Hydraulic system 1)
Oil tank
Filter
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure relief valves
8. Inspection group: Chassis > Air pressure system 1)
Compressor
Filter
Air tank
Valves
Lines
Hoses
Cylinder

624
9. Inspection group: Chassis > Electrical system 1)

Motors
Generators / Alternators
Battery
Schalter
Lines
Fuses
Resistors
Lighting
Brake lights
Blinkers
Tail lights
Floodlights
Signal devices
Indicator lights
Battery switch
Limit switch:
Gear, steering, drive
Support force indicator 2)

625
10. Inspection group: Chassis > Control systems 1)

Engine regulation
Gears
Couplings / clutches
Gear shifts
Brakes
Steering
Indicators
Engine stop line
Control of outrigger supports 2)
Axle suspension
Crane leveling control
Rear axle steering
11. Inspection group: Superstructure
Frame
Covers
Steps
Mounting
Counterweight
Relapse retainer
Slewing ring: tilt play
Slewing ring: mounting screws
Slewing ring: gear
Slewing gear: Mounting screws
Slewing gear: Gear

626
12. Inspection group: Superstructure > Crane operatorπs cab

Doors
Windows / windshields
Windshield wiper
Mirror
Seat
Heater
Ventilation
Shock absorber
Control lever for working functions
Gear controls
Retention: Scrapes / chafings/ kinks
13. Inspection group: Superstructure > Retention and protective devices
Handles and ladders / steps to the cab and to drive gears
Covers
Coverings
Flaps
14. Inspection group: Superstructure > Drive system
Engine
Exhaust system
Fuel tank
Filter
Muffler
Engine suspension
Fuel lines

627
15. Inspection group: Superstructure > Hydraulic system

Oil tank
Filter
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure relief valves
Brake lowering valves
Brake control: Hoist gear
Brake control: Slewing gear
16. Inspection group: Superstructure > Electrical System
Motors
Generators / Alternators
Batteries
Switches
Lines
Fuses
Resistors
Lighting

628
Crane manufacturer: LIEBHERR Crane type: . . . . . . . . . . . . . . . . S/N: . . . . . . . . . . . . . . . . . . . . . .
17. Inspection group: Superstructure > Control systems

Engine regulation
Gear
Elastic couplings
Controls
Engine stop line
Indicators
18. Inspection group: Superstructure > Cable drive systems
Winch I 3)
Winch II 3)
Winch III 3)
Winch IV 3)
Cable pulleys
Cable end mounting
Cable for winch I
Cable for winch II
Cable for winch III
Cable for winch IV
Guy ropes
19. Inspection group: Superstructure > Hook
Pulleys
Cable guide bar on pulleys
Axle retainer
Load hook
Load hook mounting
Hook retainer

629
Crane manufacturer: LIEBHERR . . . . Crane type: . . . . . . . . . . . . . . . . . . . . . . . S/N:
20. Inspection group: Superstructure > Safety and Control devices

Hoist limit switch I
Hoist limit switch II
Lowering limit switch I
Lowering limit switch II
Boom limit switch I
Boom limit switch II
Luffing jib: boom limit switch I
Luffing jib: boom limit switch II
Load moment limiter
Angle indicator: Boom
Angle indicator: Luffing jib
Angle indicator: Slewing gear
Safety devices: Steuerung
Working range limitation
Pressure sensor
Speed sensor
Wind velocity sensor
Sliding arm monitor
Support force monitor
Incline monitor
Length indicator:
radius, boom length
Emergency off
Engine stop

630
20. Inspection group: Boom

Welding construction
Cable pulleys
Luffing cylinder
Telescoping cylinder
Push out cables
Return pull cables
Boom bearing / mounting
Boom pinning
Guy rods
Relapse cylinder

Remarks:
1) The inspection of the road safe condition of the carrier vehicle is also recommended if an error free expert
inspection result according to highway safety regulations is available. For vehicle cranes, which are not
cleared for use on public highways, the experienced technician or expert inspector should also check the
vehicle for road safe condition (see also UVV ∫Vehicles∫ (VBG 112)).
2) These inspections must be made by an expert engineer even if an error free expert inspection result
according to highway safety regulations is available.
3) Inspection of winches regarding used part of theoretical utilization time.
631
8.04 INSPECTION OF CRANE CABLES 022604>02
Discard time for wire cables due to broken wires.
Torsion free cables
Hoist cable I
Number of Number of visible broken wires at

Cable a time of discard over a length of
Crane type Cable turn carrying wires in
[mm]
outer strands 6 ¥ Cable a 30 ¥ Cable a
LTM 1070/1 17 Even lay 105 2 5
Hoist cable II

[mm]
LTM 1070/1 17 Even lay 105 2 5
Non torsion free cables
Telescoping cable

[mm]
LTM 1070/1 12 Cross lay 190 8 16
Back pull cable

[mm]
LTM 1070/1 8 Cross lay 208 9 18
632
Monitoring
The cables must be checked regularly, especially strict during the first initial period after placing them, in
addition to the time after they have been exposed to unusual strains, if there might be any damage which is not
clearly visible or after the first signs of cable damage show up.
The operating safety of cables can be determined according to the following criteria:
> Type and number of broken wires (see chart)
> Position and time frame of broken wires
> Reduction of cable diameter during operating time
> Corrosion, chafing, cable distortion
> Heat effects
> Total placement time
In addition, cable end connections and cable suspension must be regularly checked for proper condition. The
individual elements of the cable drive, cable drums and pulleys must easily rotate in their mounts and they may
not show an impression of the cable profile in their tracks.
Note: The groove radius on drums and pulleys must be 0.595 ¥ rated cable diameter.
Any changes in cable behavior must be especially well monitored.
DANGER: As soon as the cable strands hit together above the hook block, there is a danger of
serious cable damage. The cause is always added revolution tension in a torsion
free hoist cable, which can be due to a variety of influences and problems, but also
due to special stress or extension of the hoist cable in severe applications.
Note: Refer to the paragraph describing ™Extension torsion in torsion free hoist cables and its
elimination™
633
180069
634
Discard time
DANGER: The cables must be discarded immediately if one of the following problems is found:
> Break of a strand
> Occurrence of wire break pockets
> Reaching the wire break numbers according to the chart
> Corkscrew type deformations by more than 1/3 of the cable diameter (fig. 1)
> >Arch formation (fig. 2)
> Hair pin shaped penetration of wires or wire strands from the cable (fig. 3)
> Reduction of cable diameter as compared to the nominal diameter by more than 15% or
> by 10% with simultaneous occurrence of corrosion and / or abrasion (fig. 4)
> Slackening of cable structure (fig. 4)
> Constriction (fig. 5)
> Kinks and compressions (fig. 6+8)
> Pulls or remaining distortions (fig. 7)
If particular cable damages occur, you must find the cause for these damages and remedy them before placing a
new cable.
The damages and grinding traces on the construction parts of the crane can provide important clues.
CAUTION: If there are doubts if the crane cable is still operational safe, then put it down or
consult an expert for an opinion.
635
180070
636
Place the cable
DANGER: If a cable is changed, you must use a cable of the same type and solidity with the
same diameter as the original cable had when it was new.
If another wire cable is to be used, you must first get the approval of the crane
manufacturer .
Cables are very susceptible to external damage. Be especially careful when placing them for transport and / or
when they are unloaded.
Any cables held in reserve must be stored in a clean, cool and dry area. Be sure that they donπt lay on soil.
Cables can only work properly without any problems if they are without any twists or other external damage.
Winding procedure
Cables must be pulled in winding direction from the reel or the ring (fig. 1).
Do not pull off the cable sideways, because that will cause the cable to twist and will cause pulls which will
destroy the cable.
The best procedure is to spool up the cable from a raised reel to the drum ( fig. 2).
Winding the cable in the same bending direction prevents additional cable tension and assures that the cable
lays better on the drum.
CAUTION: Make sure that the cable is not pulled over the ground to prevent it from getting
dirty.
A swivel must be interconnected to protect torsion free hoist cables from forced twists.
If multiple layers are wound, the lower layers must be wound tightly with a pretension of about 1 to 2% of the
minimum braking force of the cable. This pretension can be reached by slowing down (braking) the reel.
For multi>sheave reeving, the hoist cable should be reeved at the same direction as it has in the drum. If a
limited cable length to reeve the hook block must be laid on the ground, then it must be assured that the cable is
not twisted.
After placing the cable, test it first with low partial loads and then retract it in several hoists, switching
between a loaded and an unloaded hook block. This ensures that the cable adapts to the bending direction and
the bending radius of pulley and drum.
637
638
Maintenance and care

Regular cable maintenance assures the operating safety of the crane and significantly increases the service life
of the cable.
Wire cables must be lubricated in regular intervals, depending on the operating conditions, especially in the
area where the cable bends on drums and pulleys.
It was determined that under the same test conditions well lubricated cables provide 4 times more bending
flexure than unlubricated cables.
The lubricants must be compatible with the original cable lubricant .
Note: The cables must be lubricated with standard, commercially available lubricants, as
recommended by the crane manufacturer. Refer to the lubrication chart.
Dirty wire cables should be cleaned regularly, preferably with brushes.
If the lower cable layers on the drum are hardly used or used not at all, then they should be unwound from time
to time and rewound with pre>tension. A cable is most economical when it is used in its entire length. For that
reason, for longer lasting crane work, it is recommended to match the cable length to the task.
If certain section of the cable are more used than others then the cable should be turned over after a certain
time. Service life of the cable can be increased significantly by attaching the previously free end to the drum,
and sections which were previously spared are now used more severely and areas which were previously used
more will now not be used as much.
If wear is predominantly in multi>layers on the Lebus drum, then the service life of the cable can be increased
by shorting the drum end by a length which corresponds to 1/3 of the drum circumference.
Extension torsion in torsion free hoist cables and its elimination

A torsion compensation is not only required after a new cable has been placed, but also if extension torsion has
been building up after a longer working period, resulting from stretching and settling of the cable structure.
Torsion compensation can be noticed when the hook block turns in multi reeve operation and when the load is
set down and / or the outer strands seem to loosen up and if, in extreme cases, the cable shows an arch
formation.
Measures to take care of an elongation cable twist are noted below.

If a crane is operated for a longer period of time with the same reeving, without unreeving or changing the hoist
cable reeving, then we recommend installation of a cable twist catcher on the fixed point of the hoist cable.
CAUTION: If this is not observed, the cable can be damaged!
639
183627
640
Measures to eliminate torsion compensation:
1 Set down the hook block

Lower the hook block as much as possible, so that the greatest cable length between pulley head and hook
block is exposed to compensation (twist, point 4).
2 Determine the turning direction

First determine in which direction the hook block is twisted.
The turning directions are shown on the illustration with a continuously lined arrow.
Since this is difficult, especially in large hoisting heights, check it by turning in direction of the dashed
arrow. The ∫braid∫ must dissolve.
3 Loosen the cable on the fixed point

When the direction of rotation has been determined, release the cable on the fixed point on the hook block.
Note: It is advantageous if, for torsion compensation, the hook block has been reeved in an
uneven number or that such a number will be reeved.
In that case,the fixed point of the cable is easily accessible on the hook block and it can
easily be released.
4 Carefully turn the end of the cable by 180∞ to 360∞, to compensate for the turn of the hook block
To compensate for the turn, turn the separately shown end of the cable, as marked by the solid line arrow.
Note: It is important that the correct reference point is taken and that the crane operator holds
the cable in front of him .
The right moving cable (Z), as shown in fig. 1 and the left moving (S) cable, as shown in fig. 4, is turned in
for compensation, while the right moving cable (Z), as shown in fig. 2, and the left moving cable (S), as
shown in fig. 3, must be turned out.
The rule is that for torsion compensation, the end of the cable must be turned against the direction of
rotation, which caused the release of the ∫braid∫ in the above test.
CAUTION: The cable section should be as long as possible for the turn. Through a hoisting
movement without a load, this turn should be distributed over the complete
length of the cable.
Under no circumstances turn the cable by force over a short section, because this
would destroy the cable structure permanently.
5 Reattach the cable on the fixed point

The end of the cable must be reattached and secured on the fixed point after the turn.
6 Carefully lift the hook block, raise it without a load and repeat the procedure, if necessary
Since a non>stretch cable construction is relatively safe from torsion, the cable can only be stretched a little
(actually, the torsion does not continue over the cable pulley), so that the hoisting movements with out a
load must be repeated several times.
After getting the compensating turn to the end of the cable, reattach the cable end again to the fixed point
and repeat the hoisting movements with out a load one or several times so that the torsion compensation
can be distributed over the complete length of the cable past the cable pulley.
Note: If necessary, in case the stretch was especially severe (multiple twisting of the lower
pulley block and / or slackening of outer strands over a longer stretch, or at several
points) then repeat this procedure several times, depending on hoist cable length.
641
8.07 INSPECTION OF PNEUMATIC BRAKE SYSTEM 022648>01
642
General
The pneumatic brake system in mobile cranes must be checked annually.
In Germany, this brake inspection must be made according to ß 29 STVZO.
For other countries, local and national regulations apply.
1. Visual inspection
To check the pneumatic brake system, the following requirements apply:
1.1 Pipe and hose lines are not damaged, not corroded and are properly routed.
1.2 Components are correctly installed and properly mounted.
1.3 Air tank is not damaged, no external corrosion can be seen.

The tank is marked properly.
CAUTION: No welding nor heat applications may ever be done on the tank walls .
1.4 Condensation is drained from the air tank.
1.5 Dust guards are not damaged.
1.6 Joints are secured, move easily and have not been knocked out.
1.7 Linkage has not been welded, is not bent, moves easily and is not damaged.
1.8 Brakes are adjusted properly (ventilation, brake cylinder stroke, pad thickness, linkage plate).
2. Function and action test
2.1. Function test
2.1.1 Pressure regulator , air compressor

Check cut in pressure, cut off pressure and output capacity.
2.1.2 Check seals and reservoir pressure in air pressure system.
2.1.3 Check multi circuit safety valve, overflow valves, warning device.
643
2.2 Brake action test

The brake function can be checked through the ports in the cover plates.
If the brake pedal is pressed down, both brake pads must touch the drum, when the brake pedal is relea>
sed, the brake pads must immediately return to starting position.
The brake action can be checked by measuring delay, brake path or by determining the braking action
on a brake test station.
2.2.1 Measure the delay with a declerometer

At a pressure of 6.5 bar, the measured median delay should be dm!>!4,5!m/s2 .
2.2.2 Measure the brake path

At a pressure of 6.5 bar, the brake path should be s!<!as the value given in the chart.
Test speed Brake path

v [km/h] s [m]
20 6.5
30 12.5
40 19.8
50 29.0
2.2.3 Determine braking action on a brake test station

To measure the brake power on the vehicle axles, calculate the braking action as follows:
F1¥i1+F2¥i2 ... Fn ¥ in
z = &&&&&&&&&&&&&&&&&&&&& ¥ 100 [%]
Gz
Gz = Permissible total weight of the vehicle [N]

z = Braking [%]
F1 = Brake power of first axle, which has been measured at p1 pressure [N]
F2 = Brake power of second axle, which has been measured at p2 pressure [N]
Fn = Brake power of last axle, which has been measured at pn pressure [N]
pN1 > 0,4
i1 = &&&&&&&
p1 > 0,4
pNn > 0,4

in = &&&&&&&
pn > 0,4
pN1 ... n = maximum brake pressure of corresponding axle [bar]

p1 ... n = Brake pressure, which is used [bar] at the brake test in the wheel cylinder of the correspon>
ding axle
644
3. Internal inspection of wheel brake

Independent of the function and action test, the following tests must be made:
3.1 Every 3 months, the brake pad condition should be checked through the ports in the cover plates.
Every 12 months, pull the brake drum to check the various, internal brake components .
CAUTION: The brake may not be actuated if the brake drum has been pulled.
3.2 Replace the pads when the pad thickness is 5.5 mm (new thickness = 18 mm), measured without ta>
king the thickness of the metal part of the brake pad into account; replace the pads if the pads are burnt,
slick or oily.
For replacement, only Jurid 546 and Bremskerl 6275 brake pads may be used.
Rivet and adhere these pads, as these asbestos free pads are not as rigid.
DANGER: Always replace the pads on both wheels of each axle.
3.3 The brake drums should also be turned.
Note: When turning the brake drums, do not exceed the permissible turning measurement
of 0.75 % of the nominal diameter!
Example: Nominal diameter: 500.00 mm

Permissible turning measurement: 3.75 mm
Permissible inside diameter: 503.75 mm
DANGER: If the inside diameter of the brake drum is larger than 503.75 mm, then the
brake drum must be replaced.
Otherwise there is a danger of causing a serious accident!
3.4 To correct the brake pad wear or to center the brake, it is equipped with an automatic adjustment devi>
ce, which is maintenance free.
DANGER: In case of damage to any parts, replace the automatic adjustment device
completely, using repair kit ∫adjustment device∫.
If this is not done, there is a danger of causing a serious accident!
3.5 The pressure and pull springs as well as seal rings, caps and dust covers must be replaced at least every
2 years.
DANGER: All maintenance and repairs on th brake system must be performed by aut>
horized and especially trained personnel.
Otherwise there is a danger of causing a serious accident!
3.6 After assembly, repeat visual, function and action test.
645
9.00 GENERAL NOTES 022102>00
646
022102>00
Chapter 9
General Notes
647
9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES 021687>00
Issued by: VDMA (association of german mechanical> and plant engineers) > January 1970
The telescopic boom crane which has been supplied to you is equipped in conformity with the Accident
Prevention Regulations Relating to Telescopic Boom Cranes with an overload safety device (overload motion
cut device) by means of which the hoist and the telescoping gear are switched off if the maximum permissible
load moment of the crane is exceeded. It must still be possible, after the overload safety equipment has been
activated, to perform the opposite movement in order to reduce the crane load, in other words, it must still be
possible to lower the load after the hoist has been switched off.
Installation of an overload safety device (overload motion cut device) is intended to prevent loads being lifted
with the crane which jeopardise the craneπs stability. The overload safety device (overload motion cut device) is
thus an emergency switch which switches off any movement which increases the load moment of the crane once
the crane has been overloaded and thus prevents a possible accident or damage or injury to persons or property.
It is essential to observe a number of points in order to ensure that the overload safety device is able to perform
its safety function:
1. Overload safety devices (overload motion cut devices) mut not be used in normal operations for switching off
the hoist or the telescoping gear. The crane operator is required to satisfy himself that lifting the load will
not exceed the specified maximum lifting capacity of the crane prior to performing the lifting operation.
Excessively heavy loads, which are in excess of the load lifting capacity of the crane, must not be lifted even
though an overload safety device is fitted. This safety device must not be used as a means of checking the
weight of the load to be lifted and the crane must not be loaded beyond its safe working load.
2. Duties involving freeing stuck loads may only be performed with the prior approval of the crane
manufacturer and only using such cranes as are properly equipped for such duties. If the crane is used for
such duties, the overload safety device (safe load limiter) must not be used as a means of measuring the
force.
3. The overload safety device fitted requires to be inspected and serviced at regular intervals and an
operational check should be performed each time before crane operations are commenced. A regular
inspection of the overload safety device is an integral part of the crane maintenance procedures in
conformity with the Accident Prevention Regulations for Telescopic Boom Cranes.
4. The overload safety device does not normally adjust automatically to the different operating states of the
crane. It is therefore the responsibility of the crane operator to also correctly set the overload safety device
to the altered lifting capacity or load moment range when the crane is to be used for different duties. The
instructions given in the manufacturerπs operating manual in this connection should be strictly observed.
Strict adherence to these instructions is essential to ensure proper operation of this safety device and to
ensure safe operation of the crane. An overload safety device which is incorrectly set, e.g. set to an
excessively large load moment with the outriggers retracted, is a far greater hazard than a crane not fitted
with such a device because this gives the crane operator a false sense of security, which in turn can be the
cause of a serious accident.
648
9.01 CODE OF PRACTICE FOR OVERLOAD SAFETY DEVICES OF BOOM CRANES 021687>00
5. The crane operator is required to set the overload safety device (overload motion cut device) which is fitted
to the crane to the altered lifting capacity or load moment range when the crane is to perform different
duties, for instance:
a) when extending or retracting the outriggers (switching over to large or small load moment)
b) when altering the boom length by
> manually extending or retracting (telescoping)
> fitting or dismantling intermediate sections
c) when turning or slewing the crane into the range of the greater or lesser moment of stability (changing
over to the large or small load moment)
d) when changing over to a different lifting capacity range by reeving the hoist or the telescopic gear with
several falls
6) Attention is expressly drawn to the fact that the overload safety device may not be activated or the gear
may not be switched off quickly enough if the crane is incorrectly operated. In such cases, it is not possible to
completely rule out an accident despite an overload safety device being fitted. This is particularly true for
> hooking the load or the lifting tackle from below
> excessive braking forces
> loads dropping into the rope
> pulling at an angle
> moving the crane to an area of ground with a greater slope
> ground which gives way
> wind load
7) If a device is provided which enables the overload safety device (safe load limiter) to be switched off or
overridden, this may only be used if special safety measures are taken and in the presence of a crane
supervisor, e.g. when conducting a test of the crane, and when performing the duties specifically authorised
by the crane manufacturer.
On no account may the overload safety device be switched off or overridden in order to lift a load which
exceeds the maximum permissible load lifting capacity of the crane.
Careful observance of the instructions contained in this Code of Practice and in the operating manual of the
crane manufacturer are essential requirements for safe and reliable operation of the overload safety device
(overload motion cut device). If there is any doubt, the manufacturerπs operating instructions should be
consulted. If the information contained therein is not sufficient, it is essential to contact the company
concerned. Unauthorized interference in the mechanism of the overload safety device will invalidate the
warranty provisions.
649
AND IMPORTANT SERVICE WORK TO BE PERFORMED 022103>02
1. Inspections
1.1 Check the engine area daily before starting the crane, and check all oil and fuel lines for leaks and make
sure they are dry. In addition, check the fuel and oil filter as well as the injection pump for leaks.
1.2 During the daily check up, also check all hydraulic components, the hydraulic motors for the fan drives
and corresponding hydraulic lines to assure that they are tight and that there are no leaks.
1.3 Check the exhaust system, especially the exhaust flange and the exhaust flap brakes to assure that they
are not leaking and are easily movable. The return springs to open the exhaust flaps must be
functioning properly, as stuck and therefore closed exhaust flaps during engine operation cause great
increases in temperatures and overheating.
1.4 Check if electrical lines are still routed and mounted properly, with sufficient distance to exhaust pipes,
and assure that they are not damaged and still properly insulated.
1.5 To reduce the noise emission, insulating mats are installed in the engine area (chassis > engine
covering) on some crane models. When the fiberglass mats with integrated noise reduction material are
are clean, they are not flammable and are flame retardant.
If engine compartments are is not cleaned regularly, oil and fuel may splash on the mats while
performing maintenance and repair work. Oil and fuel soaked noise reduction mats must be removed, as
they are now flammable. The same is true for insulating mats in the exhaust system area.
Clean the engine compartment only with nonflammable cleaning fluids. In addition, the fluid may not
be corrosive or chemically damaging to hoses and cables.
650
2. Care during repairs and maintenance work
2.1 When changing the fuel and oil filters, you must observe utmost cleanliness and carefully clean up any
spilled Diesel fuel or oil. Check the fuel and hydraulic system for leaks.
2.2 The V>area of the engine must be especially checked after repairs and service tasks, in addition to
regular intervals, to assure it is free of oil and fuel. Any fuel in the V>area can run throughout the
engine compartment during travel and cause a fire, if it hits hot engine parts.
2.3 We note again, that all electrical lines and wires must be properly routed and must be attached in their
harnesses, any chafings or defects of the insulation and wiring covers must be taken care off
immediately. Any improper installation lines must be replaced immediately.
2.4 Be aware that fuel and oil lines can become porous or brittle due to age. Any lines which look brittle or
porous must be replaced immediately. (See also Guidelines about the life expectancy of hoses and lines).
2.5 Please note, while carrying out repairs and service task, that you do not step on any pipe or hose lines in
the engine area. This applies especially to fuel injection lines. If you must step in that area during
installation, then the engine must be covered with a board or similar support plate.
3. Important service tasks
3.1 To prevent dry runs, the gear shafts must be lubricated regularly and properly with specified
LIEBHERR grease.
3.2 The gear shaft screws must be checked regularly to assure they are seated tightly.
3.3 Gear and engine oil levels must be checked regularly. Add oil to compensate for normal oil
consumption. However, if an unusual amount of oil must be added or has been lost, you must check for
and remedy the problem.
4. Maintenance guidelines for replacement components
4.1 When replacing drive components, such as Diesel engine, gear, axles, etc. you must observe the
following:
Before putting these components into service, make sure to add the specified oil to the max. mark; for
type of oil, check data tag and lubrication chart.
Perform the first maintenance check as noted in chapter MAINTENANCE INTERVALS; then carry out
all regular maintenance intervals as noted.
4.2 Make sure to follow initial operational instructions.
651
5. Notes for travel operation
CAUTION: DO NOT exceed the permissible engine speed in high gear, it could cause
engine damage!
6. Disposal
6.1 Engine, gear and hydraulic oils, grease, fuel:

To prevent pollution, these service fluids may not be spilled onto the ground, to prevent them from
getting into ground water, sewage, or drainage systems.
Observe all state and local regulations applicable to the disposal of these items.
6.2 Radiator fluids for Diesel engines and heater systems:

For disposal, undiluted antifreeze fluids / corrosion protective oils must be handled as special hazardous
material.
When disposing of used coolant fluids (mixture of antifreeze / corrosion protective oils and water,
observe all state and local regulations applicable to the disposal of these items.
7. Rotating wheels
7.1 Tires used on crane vehicles are exposed to different loads and stresses, depending on the location of the
wheels on the crane, such as:
> non > propelled steering and fixed axles.
> propelled steering and fixed axles and
> various wheel positions exposed to more or less load.
Depending on the type of the tire tread, tires often wear differently.
7.2 To assure that all tires wear equally, we recommend to rotate the tires as soon as a difference in tire
wear is visible. We recommend to rotate the tires after 5,000 to 10,000 km.
Rotate the tires in crosswise direction (see illustration). In addition, select the new tire positions in such
a way that tires with uneven tire wear are moved to positions where tires wore evenly.
These measures can influence driving comfort and tire wear in a positive way.
652
182295
653
182296
654
182297
655

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LIEBHERR

TELESCOPIC BOOM MOBILE CRANE

BAL >No. 09505>02>02

The operating instructions are part of the crane!

Always keep on hand!

Comply with road travel and crane operating

LIEBHERR>WERK EHINGEN GmbH, Postfach 1361, D>89582 Ehingen / Donau

Using these instructions

> makes it easier to become familiar with the crane

Observing these instructions

> increases reliability in operations

1.00 DESCRIPTION OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.00 OPERATION OF THE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.00 OPERATION OF THE SUPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.00 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

6.00 ADDITIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

7.00 SERVICE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

8.00 CRANE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588

9.00 GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646

Description of the Crane

Abbreviation of boom systems

TK = Telescopic boom with folding jib 0∞, 15∞ or 30∞

T > Boom combination T =10.6 m to 40.0 m

TK > Boom combination T =34.3 m to 40.0 m

2.1 Diesel engine with pump distributor gear

The crane carrier

Axles All 4 axles are steerable

Gear shafts All gear shafts with 70∞ cross gears.

Tires 8 wheels, all axles provided with single tires.

Electrical system: 24 V DC,

The crane superstructure

Luffing gear 1 differential cylinder with pilot controlled brake valve.

Electr. system 24 Volt DC, 2 batteries.

Drive 8¥8: Additional 2nd axle drive .

Steering: Hydrostatically from the crane operatorπs cab *

Tire pressure for travel on Tire pressure for crane

according to load capacity

according to load capacity

Emission values at the work place

Stationary sound LpAeq [db(A)]

Driver's cab, driver's side 74 73

Driver's cab, co>driver's side 73 73

Crane operator's cab 76 76

A hook block may only be carried on the front if:

> it is reeved not more than 4 times,

Carrying passengers in the crane cab is not permitted.

CAUTION: The crane is not yet running>in

For this reason, the following instructions must be followed:

CAUTION: Do not overtighten wheel nuts!

> Check coolant and oil levels in the engine.

Breaking in the brake pads

> Nature of work

> Site location (journey distance)

> Route to be driven

> Height and side clearances

> Electrical overhead wires (complete with voltage data)

> Space requirements at the operating sites

> Movement restrictions due to surrounding structures

> Weight and dimensions of load(s) to be lifted

> Required lifting height and radius

> Load>bearing capacity of soil or surface to be operated upon

> Hook blocks/load blocks

> Auxiliary telescopic boom