Tadano - Faun - Atf 80-4 - Full - Vip PDF

Operating, Service and
Maintenance Manual
ATF 80-4
Vehicle identification no: WFN4 RTY N9 62043…
Manufacturer After-Sales Service:

FAUN GmbH TADANO FAUN GmbH
Postfach 10 01 08 Postfach 10 02 64
D - 91205 Lauf a. d. Pegnitz D - 91205 Lauf a.d. Pegnitz
Tel: (09123) 185 - 0 Tel: (09123) 955 - 0
Fax: (09123) 7 53 20 Fax: (09123) 18 51 55
TX: 622990 TX: 62 29 90
Dear Customer,
We have gone to great lengths to provide the conditions for a long

service life of your FAUN crane.
High-grade coatings, multi-layer paint systems and high-performance
application procedures with a high process reliability characterize the
excellent visual appearance of our FAUN cranes. Service and upkeep
are indispensable to maintain this finish:
1. Paint takes some time to develop its maximum resistance. Thus,

please do not clean your crane with excessively hot water, nor
with excessive water pressure during the first 8 weeks. Avoid
steam-jet units.
2. When using the crane on construction sites, when loading it with

load take-up equipment and wooden planks, damage to the
paint is inevitable. Such damage will result in corrosion or rust
and must therefore be repaired in an expert fashion without de-
lay.
3. Damage may also be caused by stone impact during travel. This

also requires immediate action.
4. The paintwork is also vulnerable to weather conditions and thaw-

ing salt. Thus, regular cleaning of the crane and preservation of
connectors, welts and screw couplings is necessary.
Customer satisfaction is our aim!
KUNDE_EN.DOC
KUNDE_EN.DOC
TABLE OF CONTENTS
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TABLE OF CONTENTS
PREFACE
1 How to use this Operating Manual
2 Technical data, operation, maintenance, troubleshooting
3 Handling of this Operating Manual
4 Mounting locations of the vehicle identification number and of the nameplate
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TABLE OF CONTENTS
Part A) Technical Details
1 General technical details (chassis)

1.1 Dimensions and weights
1.2 Driving performance data (according to DIN 70020)
2 Technical details of components (chassis))

2.1 Engine
2.2 Gearbox
2.3 Transfer box
2.4 Axles
2.5 Axle suspension
2.6 Power transmission
2.7 Wheels and tires
2.8 Brakes
2.9 Steering
2.10 Electrical equipment
2.11 Instruments
2.12 Driver’s cab
2.13 Heating system
2.14 Frame
2.15 Outriggers
2.16 Fuel system
2.17 Tools, accessories, acceptance inspection
2.18 Painting
2.19 Optional equipment
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Part A) Technical Details
3 Technical details of components (superstructure)

3.1 Engine
3.2 Hydraulic system
3.3 Hoisting gear
3.4 Telescopic boom
3.5 Boom elevation
3.6 Swing drive
3.7 Superstructure frame
3.8 Safety equipment
3.10 Electronic Automatic Safe Load Indicator (ASLI)
3.11 Superstructure cabin
3.12 Heating system
3.13 Painting
3.14 Acceptance inspection
3.15 Counterweights
3.17 Noise level when the engine is operating under load and at max. engine speed
3.18 Vibration values in the crane cabin during crane work
4 Illustration of the vehicle
5 Notes referring to the load (lifting capacity) and supporting forces charts
5.1 Explanation regarding a load chart
5.2 Supporting forces charts
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TABLE OF CONTENTS
Part B.0) Safety Instructions
1 Requirements and conditions for vehicles used in public road traffic

1.1 Important instructions regarding the load ratings of tires depending on the maximum travelling
speeds and the stress to which the rims are subject
2 Instructions for the crane operator

2.1 Applications planning
2.2 Steps to be taken before crane operation
2.3 Supporting the crane by outriggers
2.4 Counterweight
2.5 Hoist winch and reeving of the winch rope
2.6 Taking account of the wind velocities
2.7 Hand signals recommended for communication between the crane operator and his assistant
2.8 Work in the vicinity of electrical overhead lines
2.9 How to behave in case of sparkover (if the crane has touched the power line)
2.10 Grounding the crane and the load
2.11 Work in the vicinity of supply lines
2.12 Crane work with a load
2.13 Notes regarding work with two cranes
2.14 Notes referring to crane operation
2.15 Crane application in accordance with the intended use
2.16 Crane application not in accordance with the intended use
2.17 Potential causes of accidents
2.18 Fire, smoke, inflammation and explosion hazard
2.19 Instructions and regulations concerning the compressed air tanks installed in air-operated braking
systems
3 Instruction Sheet for Overload Safety Devices for Boom Cranes (excerpts)
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Part B) Operating Instructions
B1) Chassis
1 General instructions concerning operation of the vehicle

1.1 Warning and instruction plates
1.2 Location of warning and instruction plates
1.3 Components, assemblies - installation location and position
1.4 Transport condition of the crane when used in public road traffic
2 Driver's cab
2.1 Explanation of the control elements and of the equipment
2.3 Front cover
2.4 Seat adjustment n
2.5 Adjustment of the steering wheel
2.6 Actuation of the roller sun visor
2.7 Seat belts
2.8 Cab lighting
4 How to put the machine into operation

4.1 Steps to be taken and checks to be made before start-up
4.2 Operation of the electrical equipment of the chassis
4.3 Functional check of the electrical equipment of the vehicle before starting driving operation
4.4 Air distribution; fan; heater unit; air circulation and air conditioner**)
4.5 Starting the engine
4.6 Monitoring the indicating, pilot, warning lamps and the instruments while the engine is running
4.7 Hydraulic system of suspension; inclination adjustment; level control
5 Gearshift and driving operation

5.1 Gearbox
5.2 Transfer box
5.4 Connecting and disconnecting the differential locks, inter-wheel locks, 2nd axle drive**)
5.6 Brakes
5.7 Cruise control
5.8 Temposet
5.9 Steering
**) Optional equipment

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B1) Chassis
6 Outrigger the vehicle

6.1 Locking the axle suspension / lowering the vehicle
6.2 Control of the electric outrigger actuation
6.3 Outrigger operation from the chassis
6.4 Instructions regarding outrigger operation
6.5 Extending the outrigger beams
6.6 Extending the outrigger cylinders
6.7 Outriggers - retracting the outrigger cylinders / outrigger beams
7 Emergency control features

7.1 Emergency control of the hydraulic system
8 Operation in winter
8.1 Engine
8.2 Gearbox
8.3 Warming up the hydraulic oil or changing the oil type
8.4 Batteries
8.5 Adjustable air vents
8.6 Windshield washing system
9 Steps for access to the superstructure
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B1) Chassis
10 Attachments, optional equipment and accessories

10.1 Electronc immobilizer (FinTronic Car Bloc TTS 24/12)
10.2 Fog lights
10.3 City / country horn (Supertone horn)
10.4 Acoustic reversing signal - warning device
10.5 Pilot lamp "centralized lubrication system"
10.6 Checking the air accumulator retaining force on upward gradients - vehicles equipped with trailer
coupling device
10.7 Eddy-current brake
10.8 ROCKINGER Trailer Coupling Device
10.9 RINGFEDER Trailer Coupling Device
10.10 Refrigerator box
10.11 Tool box
10.12 Starting the engine via an external power source
10.13 Battery charging plugbox (1)
10.14 Air conditioner
10.15 WEBASTO - Thermo 90 S / with engine pre-heating
10.16 WEBASTO diesel heater unit
10.17 Switch "Emergency OFF, undercarriage engine"
10.18 Spare wheel
11 Instrument panel - chassis

11.1 Pilot, indicator and warning lamps
11.2 Other components
11.3 Instruments
11.4 Switches, rocker switches (WS) and rocker tip switches (WT)
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TABLE OF CONTENTS
B2) Superstructure
1 General information
2 Crane cabin
2.1 Explanation - control elements
2.2 Adjustment of the seat in the superstructure
2.3 Roller sun visor - skylight
2.4 Opening the windscreen
2.5 Opening the rear window
2.6 Cab lighting
2.7 Emergency exit
2.8 Assignment of functions to the crane control levers
2.9 Superstructure locking mechanism

4.2 Operation of the electrical equipment
4.3 Functional check of the electrical equipment of the vehicle before starting work
4.4 Blower fan, heating, air regulation
4.6 Monitoring the pilot, indicating and warning lamps and the instruments while the engine is running
5 Gearshift, driving and outrigger operation from the superstructure

5.1 Changing-over to driving from the superstructure
5.2 Starting the engine in the chassis from the superstructure
5.3 Air brake system
5.4 Driving operation from the superstructure
5.5 Driving from the superstructure with complete counterweight
5.6 Outrigger operation from the superstructure
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B2) Superstructure
6 Crane movements in no-load condition

6.1 Notices regarding actuation of the crane control levers
6.2 Actuation of the hoisting gear (main hoisting gear)
6.3 Boom elevation
6.4 Telescoping (in the case of machines equipped with one rope winch)
6.5 Slewing the superstructure
6.6 Counterweights
6.7 Work involving metallic ropes
6.8 Inspection of the safety equipment
7 Crane operation with a load fixed to the boom

7.1 Crane operation with the machine stabilized by outriggers
7.2 Crane operation "free on wheels"
7.3 Driving with a load
7.4 Moving the crane in full rig arrangement on construction sites
8 Emergency control
9.1 Engine
9.2 Hydraulic oil
9.3 Batteries
9.4 Adjustable air vents Verstellbare Luftdüsen
9.5 Windshield washing system **)

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B2) Superstructure

11.1 Positioning the double ladder for mounting the jibs, and for access to the crane superstructure
11.2 Boom extension
11.3 2 m boom extension
11.4 Centralized lubrication system
11.5 Heating of working mirror
11.6 Aircraft warning lamp on the boom
11.7 Working floodlight on the hoist winch
11.8 Working floodlight on boom
11.9 Working floodlight - electrical adjustment
11.10 Emergency control of superstructure via hydraulic motor in the chassis
11.11 Supplementary heating
11.13 Switch "Emergency OFF, superstructure engine”
11.14 Checking the wind velocity via the anemometer
11.15 Front-end pulley
11.16 Mounting and dismounting the 2nd hoist winch
11.17 Warning in case of ASLI shut-off
11.18 Monitoring the service hours of the hoisting winch 1
12 Instrument panel
12.1 Monitoring superstructure and chassis, driving and outrigger operation from the superstructure, ASLI
control unit
12.2 Operation of the superstructure
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Part C) Service and Maintenance
C1)Chassis
1 General information
1.1 Before starting service and maintenance work
1.2 Welding and straightening work
1.3 Inspection of screw couplings
1.4 Checking the hydraulic system and its screw couplings for leakage
1.5 Cleaning
1.6 After having finished service and maintenance work
1.7 Configuration of electronic components
2 Maintenance intervals
2.1 Maintenance schedule
3 Engine
3.1 Oil level inspection
3.2 Oil change / oil filter replacement
3.3 Inspection of hose clamps of the charge air hoses
3.4 Fuil tank
3.5 Coolant
3.6 Cleaning of radiator
3.7 Air cleaner
3.8 Exhaust system
4 Gearbox
4.4 Clutch, and clutch control mechanism
5 Transfer box
5.2 Oil change
5.3 Cleaning the radiator
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C1)Chassis
6 Axles
6.1 Oil level inspection in the axle drive assemblies of the driven steering axles, and in the planetary
gears
6.2 Oil change in axle drive assemblies and planetary gears
6.3 Greasing the intermediate bearings of the propeller shafts of the non-driven 2nd axle (8x6 standard
version)
6.4 Greasing the axles
6.5 Check for leakage / visual inspection / inspection of the control function
6.6 Checking the axial play of the steering axle bearings and the planetary bearings; check the wheel
bearing backlash.
6.7 Checking screws and bolts on axles for tight fit; check axle fastening, drop arms, thrust rod fastening,
etc.
6.8 Preservation of axle and planetary gearings
6.9 Checking the propeller shaft flange screws for tight fit
7 Propeller shafts
7.1 Inspection of backlash
7.2 Noise test
7.3 Checking the flange couplings
8 Eddy-current brake **)

8.1 Service
9 Breather
10 Hydraulic system
10.1 Inspection of hydraulic oil level
10.2 Replacement of filter cartridges
10.3 Oil change
10.4 Changing the oil type
10.5 Hydraulic system of steering assembly
10.6 Hydraulic system of the suspension
10.7 Hydraulic system of outriggers
10.8 Test connectors and measured values
10.9 Location of the hydraulic measuring points on the vehicle

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C1)Chassis
11 Brake system
11.1 Drainage valves in the compressed air tanks
11.2 Air drier
11.3 Pressure governor with tire inflator socket (integrated in the air drier)
11.4 Brake cylinders
11.5 Inspection of wheel brakes
11.6 Wheel brakes - Maintenance
11.7 Check pressure limiting valve
11.8 Automatic anti-block system (ABV) - Maintenance
11.9 Engine brake
11.10 Test connectors
11.11 Test and setting values
11.12 Locations of the measuring and test connectors
12 Electrical equipment
12.1 Batteries
12.2 Three-phase generator
12.3 Starter
12.4 Lamps and lights
12.5 Fuse / relay arrangement
12.7 Relay arrangement in the distribution box
13 Wheels and tires

13.1 Measures to be taken to avoid accidents caused
13.2 Checking the wheel nuts on the disc wheel for tight fit
13.3 Tightening torque of wheel nuts (with thrust plate)
13.4 Tire pressure
13.5 Replacement of a disc wheel
13.6 Interchanging wheels in view of tire wear
14 Outriggers
14.1 Adjusting the guide pads
14.2 Check cable drag chain
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C1)Chassis
15 Driver’s cab
15.1 Warm water heating
15.2 Wiper-blade elements
15.3 Air conditioner **)
15.4 Supplementary heater unit**)
15.5 Engine pre-heating unit **)
16 Miscellaneous; other points of lubrication, servicing and maintenance

16.1 Other points of lubrication
16.2 Replacement of filter in the fuel pipe of the supplementary heater unit **)
16.3 Trailer coupling device **)
16.4 Sliding coupling
16.5 Steering
16.6 Suspension
24 Summary of oil types and filling capacities
25 Summary of lubricating grease types (recommended grease types)
26 Chart of approved consumables and lubricants
27 Inspection scheme (before start-up, daily)
28 Inspection and Cleaning Scheme
29 Oil/coolant level inspection and change scheme
30 Lubrication Scheme

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C2) Superstructure
1.1 Maintenance schedule - superstructure
2 Engine
2.4 Fuel tank
2.5 Coolant
2.7 Air cleaner
2.8 Exhaust system
3 Hydraulic system
3.3 Oil change
3.5 Replacement of filter insert of pressure filter
3.6 Checking and retightening the screw couplings of the hydraulic assemblies and pipes
3.7 Oil cooler / supplementary oil cooler**)
3.8 Maintenance instructions for hydraulic cylinders
3.9 Speeds of the working hydraulics of the superstructure
3.10 Pressure check in the hydraulic system of the superstructure
3.12 Measuring connectors

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C2) Superstructure
4 Slewing gear
4.1 Check for correct oil level and leakage
4.2 Oil change
4.3 Inspection of the hydraulic oil in the service brake circuit of the swing mechanism
4.4 Check tooth face backlash on swing motor gearbox drive shaft
4.5 Slewing gear - greasing ring gear and pinion
4.6 Greasing the ball bearing slewing ring
4.7 Greasing the slewing gear locking pin
4.8 Check mechanical superstructure lock and proximity switch for proper working order
4.9 Lubrication of the slewing gear multi-disc compartment
4.10 Checking the ring gear connecting bolts, the securing bolts of the hydraulic motor and the gearbox
flange bolts for tight fit
4.11 Checking the slewing gear for wear
5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)

5.2 Oil change
5.5 Check tooth face backlash on hoisting gear motor gearbox drive shaft
5.6 Greasing of hoisting gear drum bearing bush
5.7 Preservation of the hoisting gear drive
5.8 Inspection of hoisting gear brake
5.9 Checking the hoist limit switch for proper working order
5.10 Checking the rope limit switch of the hoisting gear
5.11 Length transmitter rope
6 Winch rope
6.1 Inspection of the rope
6.2 Cleaning and lubrication of the rope
6.3 Removal (replacement) of the rope
6.4 Inspection of rope drum
6.5 Placing a new winch rope
6.6 Care to the winch rope

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cont:
C2) Superstructure
7.1 Batteries
7.3 Starter
7.5 Load moment limiter (ASLI - Automatic Safe Load Indicator)
7.6 Inspection of the ASLI at regular intervals according to the legal regulations
7.7 Fuse arrangement
7.8 Relay arrangement
8 Crane cabin
8.1 Air conditioner**)
8.2 Wiper-blade elements / washing system
8.3 Replacement of dust filter and fuel filter
8.4 Heating system
9 Other points of lubrication, servicing and maintenance

9.1 Telescopic boom
9.2 Boom elevation cylinder
9.3 Bottom block
9.4 Counterweight
9.5 Boom extension**)
9.6 Centralized lubrication system**)
9.8 Rope drum
9.9 Rope supporting pulleys

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cont:
C2) Superstructure
16 Summary of lubricating grease types (recommended grease types)
19 Inspection and Cleaning Scheme
21 Lubrication Scheme
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Part D) Circuit and piping diagrams
D1)Chassis
1 Electric circuit diagrams (diagrams of chassis)

1.1 Chassis (99707782423)
1.2 ABV (99707782423)
1.3 Gearbox control (99707782423)
1.4 Chassis (99707782423)
1.5 Axle suspension (99707782423)
1.6 Steering (99707782423)
1.7 Outriggers (99707782423)
1.8 Eddy-current brake (99707782423) **)
1.9 Sliprin (99707792047)
1.10 Outrigger actuation, left-hand (99707778632)
1.11 Outrigger actuation, right-hand (99707778633)
1.12 Webasto heating, type Air Top 3500 (99707782215)
1.13 Emergency OFF Engine Stop (99707764338) **)
2 Pneumatic diagrams (diagrams of chassis)

2.1 Pneumatic diagram - compressed air system (99707784011)
2.2 Pneumatic diagram - auxiliary equipment (99707784011)
3 Hydraulic piping diagrams (diagrams of chassis)

3.1 Hydraulic system (99707783469)
3.2 Steering (99707783480)
3.3 Water separator (99707769783)
3.4 Engine (99707783479)
3.5 Fan drive (99707783478)
3.6 Oil tank (99707785893)
3.7 Transfer box (99707783485)
3.8 Outriggers (99707775506)

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cont:
Part D) Circuit and piping diagrams
D2) Superstructure
1 Electric circuit diagrams (diagrams of superstructure)

1.1 Chassis control (99707792063)
1.2 Chassis control – differential lock (99707792063)
1.3 Chassis control - lighting (99707792063)
1.4 Chassis control - gearbox control (99707792063)
1.5 Chassis control - steering (99707792063)
1.6 Chassis control - outriggers (99707792063)
1.8 Superstructure (99707792063)
1.9 Crane control (99707792063)
1.10 Telescope control (99707792063)
1.11 Counterweight (99707792063)
1.12 ASLI (99707792063)
1.14 Extensible fly jib (99707792063) **)
1.15 Heavy-lift fly jib / single top (99707792063) **)
1.16 Webasto heating, type Thermo 90S (99707792063)
1.17 Air conditioning system (99707792063) **)
1.19 Emergency OFF Engine Stop (99707764226) **)
3 Hydraulic diagrams (diagrams of superstructure)

3.2 Valve group (99707017205)
3.3 Pump assembly (99707785539)
3.5 Swing mechanism (99707017051)
3.6 Telescopic cylinder (99707766793)
3.7 Boom elevation cylinder (99707766792)
3.8 Hoist winch (99707775369)
3.9 Auxiliary hoisting gear (99707775372)
3.10 Emergency control (99707771869)

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TABLE OF CONTENTS
Part E) Crane testing instructions
Recurrent crane inspections
1 Inspection of supporting steel structures

1.1 Guidelines for areas to be checked
2 Inspection of the hook blocks

2.1 Inspection for widening of the hook mouth
2.2 Inspection for wear
2.3 Inspection for corrosion
3 Inspection of lifting ropes

3.1 Lifting ropes: Long lay - Cross-lay
3.2 Replacement state of repair of metallic ropes due to
3.3 Replacement of a metallic rope
3.4 Service and Maintenance
3.5 Elimination of elongation spin
4 Working life of the rope winch gear assemblies

4.1 Theoretical service life of the winch
4.2 Consumed portion of the theoretical service life
4.3 Determination of the consumed portion of the theoretical service life
5 Monitoring the slewing device

5.1 Inspection of the ring-gear securing pins
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Part F ) Troubleshooting
F1)Chassis
Troubleshooting in the chassis
1 Engine
2 Gearbox
3 Transfer box
4 Axle differential locks and drive assemblies
5 Hydraulic system in general

5.1 Steering system - mechanical section
5.2 Steering system - hydraulic / electrical section
5.3 Hydraulic system of suspension
5.4 Inclination adjustment and level control
6 Brake system
8 Eddy current brake**)
F2) Superstructure
Troubleshooting in the superstructure
1 Engine
2 Hydraulic system of the superstructure in general
3 Slewing gear
4 Telescoping mechanism
5 Boom elevation
6 Hoisting gear
7 Counterweight

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F3) Connection diagram
1 Connection diagram
Part G ) Annex
G1) Chassis
Operating instructions for ZF gearbox
Chart of lubricants for ZF gearbox
Central grease Lubrication system
G2) Superstructure
Operating Load Moment Limiter
Central grease Lubrication system
Documents regarding heating, ventilation and the air conditioning system**) -

superstructure cabin

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Memo:
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PREFACE
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How to use this Operating Manual V-1
1 How to use this Operating Manual
This Operating Manual provides vital information which is a prerequisite for working safely with the machine.
The chassis (undercarriage) and the superstructure are covered by separate sections.
This Operating Manual is intended primarily for the crane operator and for maintenance specialists. It must
be available to the operator and maintenance staff at all times. The Operating Manual must thus always be
kept within easy reach of the operator's workplace, i.e. in the driver's cab in the undercarriage, or in the
crane cab. The Operating Manual is an integral part of the vehicle.
Before putting your FAUN crane into operation, please study the Operating Manual thoroughly. Familiarize
yourself with Part B.0 "SAFETY INSTRUCTIONS" and with Part E) "CRANE TESTING INSTRUCTIONS", as
well as with the instruction plates mounted on the machine, and their meaning. You must also be informed
about the arrangement, functions and direction of operation of all the controls before you start up the ma-
chine for the first time.
Whenever you work with the crane, be sure to observe the instructions laid down in this Operating Manual!
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V-1 How to use this Operating Manual
Memo:
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Technical data, operation, maintenance, troubleshooting V-2
2 Technical data, operation, maintenance, troubleshooting
The performance and the availability of your FAUN crane will be influenced considerably by correct operation
and conscientious maintenance. Operating errors or incorrect maintenance will cause malfunctions which
can be avoided. Only expert handling and conscientious maintenance will ensure the permanent, satisfactory
and reliable operation of your machine. On principle, the crane may only be operated and serviced by well-
trained, qualified specialist staff.
Part A) "TECHNICAL DETAILS" contains all the important technical data. Part B) "OPERATING
INSTRUCTIONS" contains all the information which is required to operate the machine correctly.
The driver is expected to have good knowledge of cranes and their fields of application. Such knowledge is
imparted, e.g. by a driver's training course held at TADANO FAUN GmbH.
Part C) "SERVICE AND MAINTENANCE" contains all the inspection and maintenance jobs; they are
described in sufficient detail, so that the work can be performed in an expert fashion. The After-Sales Service
Department of TADANO FAUN GmbH will be pleased to give you further information.
Parts D) "CIRCUIT AND PIPING DIAGRAMS" and F) "TROUBLESHOOTING" are intended to help you
locate and eliminate faults and malfunctions more speedily.
Part G) "Annex" comprises documents supplied by subcontractors regarding vehicle components (e.g. gear-
box, operation of the automatic safe load indicator (ASLI) etc.) and specific optional equipment, separately
for the chassis and the superstructure.
This Operating Manual is no working instruction document enabling you to perform major repair work. The
TADANO FAUN GmbH After-Sales Service Department will be pleased to perform such work for you.
Use only genuine FAUN spare parts. We cannot accept any warranty claims for damage resulting from the
neglect of the Operating Manual and the information it contains, or due to the crane carrier being used
outside of its intended fields of application. This Operating Manual shall not be considered as an extension of
our General Conditions of Sale and Delivery.
Whenever you have any queries, the TADANO FAUN GmbH After-Sales Service Department will be pleased
to answer your questions. If you have any questios after studying this Manual, please contact that
Department.
Whenever you have any queries, please quote the type and the vehicle identification no. of your FAUN
carrier.
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V-2 Technical data, operation, maintenance, troubleshooting
Memo:
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Handling of this Operating Manual V-3
3 Handling of this Operating Manual
This Operating Manual covers the machine model supplied plus any optional equipment that may be avail-
able. To find the information you need, please consult the Table of Contents. Moreover, the headline of the
corresponding chapter appears in the header of each page.
The controls, gauges and switches installed in the driver's cab (at the operator's place) are mentioned on
many pages of this Operating Manual. They are illustrated at the corresponding end of part B1 and B2) "Op-
erating Instructions", for the chassis and/or the superstructure.
The Figures shown in the Operating Manual may differ from the machine model actually supplied. They are
still relevant, however.
Your attention is also drawn to the additional brochures included with the set of vehicle documents.
In the Operating Manual, the terms "NOTE", " ATTENTION " and " DANGER " are used to draw your at-
tention to particularly important information.
These terms have the following meaning:
"NOTE" This term is used whenever compliance with certain instructions is important
for economical application of the machine.
"ATTENTION „ This term is used whenever non-compliance with the Operating Manual may
result in damage to the machine.
"DANGER “ This term is used whenever non-compliance with the appropriate instruction
results in accidents with considerable material damage, the risk of injury or
danger of life of the persons involved.
The contents of this manual must not be copied, distributed, used for purposes of competition, or disclosed to any third party.
Copyright according to the Copyright Act expressly reserved.
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V-3 Handling of this Operating Manual
Memo:
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Mounting locations of the vehicle identification number and of the nameplate: V-4
4 Mounting locations of the vehicle identification number and of

the nameplate:
These plates are provided on the vehicle in the following locations:
The vehicle identification number (1) is stamped on the frame, on the right side of the vehicle, between the
1st and 2nd axles.
The nameplates bearing all the relevant vehicle data are located in the driver's cabin in the undercarriage (3)
to the right of the passenger's seat, next to the cab door, and on the rear outside of the superstructure cabin
(2).
1 = Vehicle identification number

2 = Nameplate, superstructure
3 = Nameplate, chassis
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V-4 Mounting locations of the vehicle identification number and of the nameplate:
Memo:
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Part A
Technical Details
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General technical details (chassis) A-1
1 General technical details (chassis)

1.1 Dimensions and weights
1.1.1 Dimensions of the chassis
Wheelbase mm 1990; 2305; 1700

Overall width mm 2750 with tires 14.00 R 25
mm 2750 with tires 16.00 R 25
Overall length mm 12690
Length of chassis mm 10700
Overall height mm 3680 with tires 14.00 R 25
in driving condition mm 3730 with tires 16.00 R 25 and
20.5 R 25
Overall height variable via mm by -120 / +150
suspension cylinders
Wheel toe on ground mm 2340 with tires 14.00 R 25
Tailswing radius mm 3600
Turning radii (approx.) 8 x 4 (on-road) 8 x 8 (off-road)

Inner edge of chassis 6800 mm 4400 mm
Over outer edge of chassis 12400 mm 9400 mm
Over boom 13000 mm 10500 mm
Over jib 13500 mm 11000 mm
Track radius 10600 mm 8100 mm
1.1.2 Axle loads (according to DIN 70020), and rig arrangements
NOTE Axle loads exceeding 12 t are not admissible for travelling on public roads in the coun-
tries of the European Community, according to EC regulations. Regarding axle loads, a
distinction must be made moreover between the axle loads permitted by the road traffic
regulations and the technically admissible axle loads. When the technically admissible
axle loads are exceeded, a speed reduction is required, depending on the actual extent
by which the specified axle loads are exceeded. The notes regarding tire load ratings
and the maximum travelling speeds according to Part B0, item 1.1.1, must be complied
with.
The legal regulations in force in the country where the crane is to be registered must
be observed. To conform with the registration requirements valid in the countries of
use, it may be necessary to deviate from the standard equipment, and provide the
vehicle with certain optional equipment, which may result in a changed distribution of
the counterweights and different axle loads.
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A-1 General technical details (chassis)
cont'd.: 1.1.2 Axle loads (according to DIN 70020), and rig arrangements
Version A:
Model with 5,6 t counterweight, 9.0 / 16m jib, 40 t bottom block attached to the bumper cross-member, and
6 t bottom block stowed, drive 8x8, tires 16.00 R26.
Version B :
Model with 7.0 t counterweight, 40 t bottom block attached to the bumper cross-member, 6 t bottom block
stowed, drive 8x8, tires 16.00 R25, tele section I extended by approx. 300 mm.
Version C :
Model with 4,8 t counterweight and auxiliary hoist winch (corresponds to load charts with a 5.6 t
counterweight), 9.0/16 m jib, 40 t bottom block attached to the bumper cross-member, 6 t bottom block
stowed, drive 8x8, tires 16.00 R25, tele section I extended by approx. 300 mm.
Version D with supplementary counterweight:
With 5.5 t supplementary counterweight (total counterweight 12.5 t), 9.0 / 16.0 m jib, 40 t bottom block and 6
t hook tackle, drive 8x8, tires 16.00 R25.
Version E with supplementary counterweight:
With 11.0 t supplementary counterweight (total counterweight 18.0 t), 9.0 / 16.0 m jib, 40 t bottom block and
6 t hook tackle, drive 8x8, tires 16.00 R26, tele section I extended by approx. 300 mm.
Version A B C D E
Axle loads 12 t 12 t 12 t 13.7 t 15 t
1st axle
Axle loads 12 t 12 t 12 t 13.7 t 15 t
2nd axle
Axle loads 12 t 12 t 12 t 13.7 t 15 t
3rd axle
Axle loads 12 t 12 t 12 t 13.7 t 15 t
4th axle
Gross vehicle 48 t 48 t 48 t 55 t 60 t
weight
The indicated axle loads only apply to the corresponding rig arrangements described above. Modifications of
the rig arrangement may result in different axle loads. Due to manufacturing tolerances, slight deviations are
possible.
To conform with the registration requirements and technical standards in the countries of use, it may be
necessary to deviate from the specifications and the standard scope of supplies.
The legal regulations in force in the country where the crane is to be registered must be observed.
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General technical details (chassis) A-1
1.2 Driving performance data (according to DIN 70020)
In manoeuvring mode, speeds as of 0 k.p.h. are possible. At the same time, the clutch position is controlled
electronically via the accelerator pedal position (slipping clutch). With the clutch engaged, a minimum speed
of 1.4 k.p.h. is possible in the 1st gear (off-road), at 800 rpm.
Tires 16.00R25 or 20.5R25, gross vehicle weight 48 t

Gear Vehicle speed at max. engine Gradability **
speed (off-road/on-road) (off-road / on-road) [%]
[k.p.h.]
1 3.5 / 6 62/ 35
2 4.5 / 8 44 / 35
3 6 / 10 33 / 26
4 7.5 / 13 25 / 20
5 9.5 / 16 19 / 15
6 12 / 21 14 / 12
7 16 / 28 11 / 8
8 21 / 36 8/6
9 27 / 46 6/5
10 34 / 59 4/3
11 43 / 75 3/2
12 56 / 85* 2/1
st
1 rev. 4/7 56 / 32
nd
2 rev. 5/ 8 41 / 32
* reduced by electronic engine management system

** depending on ground condition
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A-1 General technical details (chassis)
1.2 Driving performance data (according to DIN 70020) (cont'd.)
Tires 14.00R25, gross vehicle weight: 48 t

Gear Vehicle speed at max. engine Gradability **
speed (off-road/on-road) (off-road / on-road) [%]
[k.p.h.]
1 3/6 70 / 39
2 4/7 50 / 39
3 5/9 36 / 29
4 7 / 12 27 / 22
5 9 / 15 21 / 17
6 11 / 19 16 / 13
7 15 / 26 12 / 9
8 19 / 33 9/7
9 24 / 42 6,5 / 5
10 31 / 54 5/4
11 40 / 69 3,5 / 3
12 51 / 85* 2/2
st
1 rev. 3.5 / 6 62 / 36
nd
2 rev. 4.5 / 8 45 / 35
* reduced by electronic engine management system

** depending on ground condition
With tires 14.00 R25, the maximum distance covered per hour must not exceed 70 km.
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Technical details of components (chassis) A-2
2 Technical details of components (chassis)

2.1 Engine
Mercedes-Benz 6 cylinder diesel engine, type OM 501 LA, certified for EUROMOT 2 and EPA, water-cooled,
hydrostatically driven cooler fan, controlled by thermostat.
Power KW (HP) 315 (428)

at r.p.m. 1,800
Max. torque Nm 2,000
at r.p.m. 1,080
Lubrication Forced-feed circulating
lubrication
Operation Four-stroke direct injection
Piston displacement liters 11,946
(Engine power output according to 80/1269/EEC)
Exhaust system made of special steel.
For further details, please refer to operating manual of the engine manufacturer.
2.2 Gearbox
ZF AS-Tronic gearbox, type 12AS2302, with electro-pneumatically actuated dry clutch and fully automatic
gearbox control system.
The starting gear is selected manually or automatically. If necessary, semi-automatic mode (Tip-Tronic)
possible with manual gear selection. For extremely slow driving, manoeuvring is possible in the first two
forward and the two reverse gears. In manoeuvring mode, the vehicle can be moved particularly gently by
actuation of the accelerator pedal.
The gearbox features 12 forward speeds and 2 reverse gears.
Gear Reduction ratio i:

1st gear 12.33
2nd gear 9.59
3rd gear 7.44
4th gear 5.78
5th gear 4.57
6th gear 3.55
7th gear 2.70
8th gear 2.10
9th gear 1.63
10th gear 1.27
11th gear 1.00
12th gear 0.78
1st reverse gear 11.41
2nd reverse gear 8.88
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A-2 Technical details of components (chassis)
2.3 Transfer box
Two-step transfer box with on-road and off-road gear, neutral position for towing.
Emergency steering pump flange-mounted to the transfer box.
Gear positions Reduction ratio i =

On-road gear 0.89
Off-road gear 1.536
2.4 Axles
8 x 6 drive 8 x 8 drive**)
st
1 axle: Driven steering axle, i = 7.95, with Driven steering axle, i = 7.95, with
inter-wheel differential inter-wheel differential
2nd axle: Steering axle, non-driven Driven steering axle, i = 7.95
(connectable), with inter-wheel
differential
3rd axle: Driven steering axle, i = 7.95, Driven steering axle, i = 7.95,
mounted countershaft assembly, i = mounted countershaft assembly, i =
1.03, with inter-wheel and inter-axle 1.03, with inter-wheel and inter-axle
differential differential
4th axle: Driven steering axle, i = 7.95, with Driven steering axle, i = 7.95, with
inter-wheel differential inter-wheel differential
All stub axle bearings require only little maintenance.
2.4.1 Drive variants
8 x 6: On road: 1st, 3rd and 4th axles are driven; inter-axle differential between the 3rd and 4th axles
Off-road: Inter-axle differential between 3rd and 4th axles and lockable inter-wheel differentials.
8 x 8**): On road: 1st, 3rd and 4th axles driven, inter-axle differential between 3rd and 4th axles.
Off-road: 2nd axle connectable, inter-axle differential between 3rd and 4th axles and lockable inter-
wheel differentials.
2.5 Axle suspension
Hydro-pneumatic suspension with level control system; suspension cylinders electro-hydraulically lockable.
The axles are guided in longitudinal guide struts and transverse control arms. Inclination adjustment is
possible to all sides while the suspension is locked. The stroke of each suspension cylinder can be
influenced via push-buttons. Thus, it is possible to compensate unevennesses of the terrain within the stroke
of the cylinders. Control in the driver’s cab.
Stroke of cylinders: Inward deflection: 120 mm / outward deflection 150 mm
2.6 Power transmission
Via maintenance-free propeller shafts with cross-serrated flanges.

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2.7 Wheels and tires

2.7.1 Rims
Steel disc rims 9.50-25 / 1.7 (14.00R25 Optional equipment)

Steel disc rims 11.00-25 / 1.7 (16.00R25)
Steel disc rims 17.00-25 / 1.7 (20.5R25 Optional equipment)
2.7.2 Tires
Tires 16.00 R25 with on-road and off-road tread pattern.
2.7.3 Wheels and tires (optional equipment)
Tires 14.00 R 25.

Tires 20.5 R 25.
2.7.4 Tire inflating pressures
Tires Tire pressure

14.00 R 25 10.0 bar
16.00 R 25 9.0 bar
20.5 R 25 7.0 bar
The tire inflating pressures are indicated on the instruction plate in the driver's cab.
2.8 Brakes
Air-operated dual-circuit brake system with ABV system with air drier. Parking brake acting on 2nd, 3rd and 4th
axles as air accumulator brake. Continuous service brake, designed as constant throttle system with exhaust
flap brakes.
2.8.1 Service brake
1st service brake circuit, acting on axles 3 and 4.

2nd service brake circuit, acting on axles 1 and 2.
2.8.2 Auxiliary brake
Air accumulator brake, circuit acting on 2nd, 3rd and 4th axles via hand brake valve.
(Reduced braking effect!).
2.8.3 Parking brake
Air accumulator brake acting on 2nd, 3rd and 4th axles as parking brake.
2.8.4 Non-wearing brake
Continuous service brake, designed as constant throttle system with exhaust flap brake in the engine.
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2.9 Steering
ZF semi-block dual-circuit hydraulic ststeering, mechanical with hydraulic assistance. The steering is effective
with mechanical connection on the 1 and 2nd axles.
The steering of the two rear axles is mechanically locked during normal on-road travel.
At low travelling speed, both rear axles can be unlocked and steered together with the front axles via push-
buttons. (In the Federal Republic of Germany, it is not admissible to drive on public roads with the steering
acting on the rear axles as well).
Attention (In the Federal Republic of Germany, it is not admissible to drive on public roads with
the steering acting independently on the rear axles as well).
The legislation in force in the country where the crane is to be registered must be
observed.
All bearings require only little maintenance.
In case of failure of the main pump, a distance-governed emergency steering pump, which is flange-mounted
to the transfer box, is connected automatically; check is effected electrically in the driver's cab.
2.9.1 Steering and driving from the superstructure
Driving from the superstructure: Hydraulic power steering system, providing for the following steering
options via electric actuation.
a) Steering of the two front axles via manual sensor

b) Steering of the two rear axles via specific push-button for all-
wheel steering and diagonal steering
Attention In the Federal Republic of Germany, driving from the superstructure is prohibited on
public roads.
observed.
24 V DC system with 80 A three-phase generator; 2 batteries, 12 V, 170 Ah each.

4 main headlights for dimmed and high-beam light, lateral lights, 2 rear five-compartment lamps with rear fog
light and reversing light. Rotary beacon on undercarriage cabin.
The electrical equipment corresponds to the EC standard.
2.11 Instruments
Tachograph, revolution counter with hourmeter, fuel level indicator, air pressure gauge, alarm display for
engine functions. Error messages and diagnosis via gearbox display.
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2.12 Driver's cab in chassis
Front cab for two persons, of steel/plastic composite design, windshield made of laminated glass, side panes
made of tempered glass, side panes movable. Driver’s and passenger’s seat with integrated three-point seat
belt system, with height, inclination, length adjustment and headrest. Both seats are air-suspended with
automatic adjustment to occupant’s weight and quick lowering device. Windshield wiper with interval wiping
circuit, windshield washing system, 2 rearview mirrors (electrically adjustable), 1 wide-angle rearview mirror
and 1 start-up mirror on the right (all mirrors with electric heating). Radio with cassette unit, 24 V plugbox
with cigarette lighter.
1 single-key closing system for chassis and superstructure cabin, tank lock for chassis and superstructure,
and steering lock.
Cruise control function.
2.13 Heating system
Engine-fed warm water heating with defroster nozzles for the windscreen and side panes, and air vents for
the foot compartment. Variable air distribution.
2.14 Frame
The frame of the four-axle crane carrier is designed as a torsion-resistant and rigid box-type welded structure
of high-tensile fine grain steel, incl. the integrated outrigger casings.
2.15 Outriggers
Hydraulic 4-point twin telescopic outriggers with deblockable check valves on the outrigger cylinders.
Large-size floats which are mounted in sliding condition to the outrigger cylinders, to which they are
permanently mounted. The floats can be removed to improve the overhang angle.
Outrigger actuation is possible from either side of the chassis and in the superstructure cabin.
Extension width: longitudinal = 8.6 m; transverse = 7.20 m / 5.00 m.
Stroke of outrigger cylinders on front and rear: 650 mm each.
Size of outrigger floats 542 x 542 mm, weight of outrigger floats 22 kg.
2.16 Fuel system
Fuel tank: 400 l, lockable fuel cap (single-key system for driver’s cab and cabin doors, tank locks in
superstructure and chassis, as well as steering lock).
2.17 Tools, accessories, acceptance inspection
Sliding coupling on the front, support for 6 t hook tackle behind the driver’s cab, tool, first-aid kit, warning
light, warning triangle, 4 wheel chocks, fire extinguishers in chassis cab. As required by the country in
question: 4 wheel chocks, acceptance inspection by TÜV (German technical inspection authority).
2.18 Painting
Single-color painting.
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● Trailer coupling devices with a D value of 100 kN, pin diameter 40 mm, incl. light and brake connector (not
in conjunction with spare wheel holder)
● Trailer coupling devices with a D value of 190 kN, pin diameter 50 mm, incl. light and brake connector (not
in conjunction with spare wheel holder)
● Sliding coupling device at the rear of the vehicle.
● Autonomous supplementary heating with engine-preheating and defrosting of window panes (water heater
Webasto Thermo 90S); diesel-operated. A retrofit kit is additionally required if bio diesel fuel is used.
● Autonomous supplementary heater unit as cab heating (warm-air heater unit, type Webasto Airtop 3500),
diesel-operated (if bio diesel is used: Webasto AT 2000 S).
● Engine pre-heating unit (Calix).
● Air conditioner.
● Refrigerator box in carrier cabin.
● Bunk in driver's cab.
● Drive 8x8
● Eddy-current brake.
● Spark arrester made of special steel.
● Tool box on the rear of the vehicle (not in combination with spare wheel holder).
● Rear view camera.
● Backup alarm.
● Charging plugbox and plugbox for starting via an external power source.
● Emergency OFF switch.
● Fog lights.
● Working floodlight on the outriggers.
● Centralized lubrication system.
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Technical details of components (superstructure) A-3
3 Technical details of components (superstructure)

3.1 Engine
Mercedes-Benz 4 cylinder diesel engine, type OM 904 LA, certified for EUROMOT 2 and EPA 2, water-
cooled. The engine speed can be adjusted progressively via a pedal.
Power kW (HP) 130 (177)

at r.p.m. 2,200
Max. torque Nm 660
at r.p.m. 1,200
Lubrication Forced-feed circulating lubrication
Operation Four-stroke direct injection
Piston displacement liters 4.25
(Engine power according to DIN 6270B / DIN 6271).
Exhaust system made of special steel.
For further details, please refer to operating manual of the engine manufacturer.
3.1.1 Fuel system
Fuel tank: 220 l, integrated in rotary platform of superstructure, lockable fuel cap (single-key system for
driver’s cab and cabin doors, tank locks in superstructure and chassis, as well as steering lock).
3.2 Hydraulic system
Diesel-hydraulic system with three hydraulic circuits, one power-controlled axial-piston twin pump
(electrically adjustable and with cross-sensing feature), a twin geared pump for swing mechanism, tele lock
mechanism and supply with control oil.
3.2.1 Control of the hydraulic system
Two four-position cross-shift levers and electrically pre-controlled 4/3-way valves which enable simultaneous
and independent crane movements and stepless speed regulation.
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A-3 Technical details of components (superstructure)
3.3 Hoisting gear
Axial-piston constant-rate motor, hoisting gear drum with integrated planetary gears and spring-loaded
hydraulic multi-disc brake with integrated free wheeling (for lifting operation).
The hoisting gear is driven in an open hydraulic circuit; rope winch rotation indicator.
Winch rope with "Super Stop" rope socket.
Hoisting gear 1 Hoisting gear 2**)

Drum diameter mm 432 432
Rope diameter mm 18 18
Rope length, approx. m 230 230
Max. rope pull (1st layer), approx. kN 68 68
Max. rope pull (3rt layer), approx. kN 60 60
Max. rope speed (4th layer), approx.
m/min 70 70
approx. at fast speed
m/min 112 112
3.4 Telescopic boom
Six-section, box-type telescopic boom made of high-tensile fine grain steel, consisting of a basic boom and 5
telescopic elements with 1 telescopic cylinder to extend and retract the telescopes. The telescopes are
extended and retracted fully automatically, and locked fully automatically in the working position in question.
The telescopes can be extended and retracted hydraulically under partial load.
Overall length retracted m 10.8

extended m 48.5
max. pulley height m approx.
51.5
Time for extending the telescopes
from 10.8 m to 48.5 m sec approx. 380
High speed approx. 275
The loads under which telescoping is possible depend on the boom length, the hydraulic pressure, the
lubrication of the telescopes and the boom angle.
3.5 Boom elevation
1 differential cylinder with attached lowering brake check valve
Angle of boom adjustment from -2° to +80°

Time required for boom adjustment approx. 55 sec.
Fast speed (only for boom approx. 35 sec.
elevation movement "up")
3.6 Swing mechanism
Constant-rate motor, two-stage planetary gear with foot-actuated service brake and locking device. Slewing
speed steplessly variable from 0 to 2 r.p.m.

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3.7 Superstructure frame
Torsion-resistant welded structure with single-race ball-bearing slewing device with external gearing, rotating
through 360°.
3.8 Safety equipment
Safety valves for protection against hose and pipe ruptures. Hoist winch limit switch for safety rope windings
on the rope drum.
24 V DC system with 80 A three-phase generator, 2 batteries, 12 V, 110 Ah each, 1 rotary beacon on the
rotary platform, on the rear left side, near the hoisting gear, 2 working floodlights integrated in the
superstructure cab, 1 working floodlight on the basic boom, 2 lateral lights on the boom head.
3.10 Electronic Automatic Safe Load Indicator (ASLI)
Electronic automatic safe load indicator (ASLI) with shut-off in case of an overload, overload warning device,
safe load utilization indicator.
Working area limitation for telescope boom angle, height of pulley head and work radius. Digital displays for
work radius, boom angle, currently attached load and maximum admissible load, tare indication, boom
length, boom angle, height of pulley head, telescope configuration (in percent of tele extension length),
automatic deactivation in the limit range, operator-controlled speed selection of the movements (precise
control range).
Hoist limit switch.
3.11 Crane cabin
Spacious crane cabin in steel / plastic design with sliding door, safety glass with tinted panes, electrically
actuated hinged windscreen, glued-in skylight made of bullet-proof safety glass, and hinged backlight.
To ensure an optimum vision during crane work, the work place can be tilted progressively via the inclination
technique integrated in the cab. It features an adjustable, hydraulically damped driver’s seat with headrest,
mechanically adjustable lumbar support, windshield wiping and washing system for windscreen and skylight,
windshield wipers with interval circuit, sun visor, electric horn, radio with cassette unit, 24V and 12V plugbox.
Indicators for fuel supply, engine temperature, compressed air supply and hourmeter. Warning lights for
engine monitoring, compressed air and hydraulic system.
The machine can be driven over short distances from the superstructure in the first forward and reverse
gears; the outriggers can be actuated from the superstructure.
1 single-key closing system for chassis and superstructure cabin, tank lock for chassis and superstructure,
and steering lock.
Attention In the Federal Republic of Germany, driving from the superstructure is prohibited on
public roads.
observed.
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3.12 Heating system
Engine-fed warm water heating and autonomous supplementary heater unit (water heating Thermo 90S),
diesel-operated with engine pre-heating, defroster nozzles for the windscreen and air vents for the foot
compartment and the head area.
3.13 Painting
Single-coloured painting, telescopes: black.
3.14 Acceptance inspection
Acceptance according to UVV (regulations for the prevention of accidents).
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3.15 Counterweight
Total counterweight 7.0 t, divisible. Partial counterweight can be deposited via hydraulic cylinders. Actuation
from the crane cabin. The tailswing radius of the counterweight is approx. 3.6 m.
ASLI programming for 7.0 t and 5.6 t counterweights.
A supplementary divided 11 t counterweight is available; in this case the total counterweight amounts to 18 t.
3.15.1 Overview of all counterweights which can be mounted
Counterweight 1: 2 x 0.3t, screw-fastened to the

superstructure.
Counterweight 2: 0.8t, screw-fastened to the

superstructure. Removable for
auxiliary winch.
Counterweight 3: 3.5t.
Counterweight 4: 3.7t**).
Load distribution for the various axle loads and rig arrangements, refer to item 1.1.2.
Mounting the weight units, refer to Part B2), item 6.6.

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● Pivotable, divided 9.0 m / 16.0 m jib which can be positioned at offset angles of 5°/20°/40°, with ASLI
extension feature, hoist limit switch and ladder for mounting the fly jib. For transport, the jib is folded to the
side of the basic boom.
● Pivotable 1.6 m runner which can be positioned at offset angles of 0°/20°/40°/60°, with ASLI extension
feature and hoist limit switch. For transport, the jib is folded to the side of the basic boom.
● Pivotable 2 m jib which can be positioned at offset angles of 4°/30°, with ASLI extension feature and hoist
limit switch. For transport, the jib is folded to the side of the basic boom.
● Single top.
● Supplementary counterweight 11 t for a total counterweight of approx. 18 t, with ASLI extension feature.
● ASLI extension feature for additional load chart variant of 12,5 t.
● ASLI extension for additional load table version 4.9 t (partial counterweight, mounted to the superstructure
as standard equipment).
● Supported forces display in the superstructure cabin.
● Swing range limitation.
● Anemometer.
● Hourmeter for hoisting gear and auxiliary hoisting gear.
● 6 t hook tackle, dead weight 150 kg.
● 20 t bottom block, 1 pulley, with single hook, dead weight 200 kg.
● 40 t bottom block, 3 pulley, with single hook, dead weight 400 kg.
● 63 t bottom block, 5 pulleys, with twin hook, dead weight 600 kg.
● Support for bottom block with 1 or 3 pulleys on the front left of the chassis, behind the driver’s cab.
● Support for bottom block with 5 pulleys on the front left of the chassis, behind the driver’s cab.
● Auxiliary hoisting gear like main winch.
● Balancing weight 0.8 t for auxiliary hoisting gear (compensation of axle loads or counterweight, if these are
to be removed temporarily.)
● Air conditioning.
● Engine pre-heating unit (Calix).
● 2nd working floodlight on the basic boom.
● 2 working floodlights on the basic boom, adjustable via motor.
● 1 working floodlight suspended on the boom head.
● Aircraft warning lamp.
● Charging plugbox and plugbox for starting via an external power source.
● Emergency OFF switch.
● Supplementary oil cooler.
● Spark arrester made of special steel.
● Centralized lubrication system.
● Tool box with removable cover.
● Emergency mode incl. hydraulic transformer for PAM (cradle) as required by the employers' liability
insurance association.
● Conversion kit for the use of bio diesel.
● Equipment according to the country where the machine is to be registered.
● Special paint and lettering for superstructure and telescopic elements.
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3.17 Noise level when the engine is operating under load and at max. engine
speed
Noise level when Noise level when Noise at a distance

superstructure cabin is superstructure cabin is open of 7 m
closed
left-hand right-hand left-hand right-hand
77.0 dBA 77.0 dBA 80.0 dBA 79.0 dBA 79.0 dBA
Valid until 31 December 2001 pursuant to LNE (Environmental Protection Authority of France).
As of 01.01.2002: 2000/14 EC
3.18 Vibration values in the crane cabin during crane work
The measured vibration values do not exceed the limits of 0.5 m/s² according to the Machinery Directive
(98/37/EC) during any normal working operation.
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Memo:
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Illustration of the vehicle A-4
4 Illustration of the vehicle
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2001-06 1/2
A-4 Illustration of the vehicle
Memo:
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2/2 2001-06
Notes referring to the load (lifting capacity) and supporting forces charts A-5
5 Notes referring to the load (lifting capacity) and supporting

forces charts
5.1 Explanation regarding a load chart
The following diagram is an example of a load chart regarding boom actuation and entry or selection of the
appropriate code number in the ASLI, given the desired telescoping states in question, and the working ra-
dius as a function of the boom length.
The load charts are classified in various categories, depending on the crane's working position. For each job,
the operator must select the table which is as close as possible to the actual working position. All load charts
contain specific code numbers which depend on the length of the boom or the boom extension and the tele-
scoping state in question. The appropriate code no. must be entered into the ASLI before crane work is
commenced.
The further instructions given in the "Notes referring to the load chart" must also be observed.
1 = Working radius (distance between the center of the ringgear and the center of the hook block or the load)
2 = Extent of counterweight with outriggers, swing and/or working range and the specified outrigger extension
width.
3 = Data for the actual boom length and boom angle
4 = Telescoping states as percentage values, after entry of the code no.
5 = Code numbers to be entered
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A-5 Notes referring to the load (lifting capacity) and supporting forces charts
5.2 Supporting forces charts
Besides the load chart column, the supporting forces charts contain the maximum supporting forces which
might arise when the crane is supported by outriggers, when the loads specified in the load charts are
slewed through 360°.
The wheel loads occurring in the course of work with the crane "on wheels, to the rear" are also listed.
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Part B0
Safety Instructions
0085_EN_ALLGE_B0_00_00_00
Requirements and conditions for vehicles used in public road traffic. B0-1
SAFETY INSTRUCTIONS FOR DRIVING AND CRANE OPERATION
1 Requirements and conditions for vehicles used in public road

traffic.
The crane has been approved for use in public road-traffic, and has been registered by the competent,
authorized government agencies subject to the appropriate legal provisions.
According to an expertise issued by the German Technical Supervision Authority (TÜV), the following
conditions and requirements have to be satisfied to this effect:
• For the admissible axle loads, please refer to Part A) (Technical Data) of this Operating Manual.
• The boom must be positioned forward in the longitudinal direction of the vehicle, and be either completely
retracted, depending on the rig arrangement, or tele section I must be extended by approx. 300 mm (see
item B2-6.6.7), stowed and secured.
• The superstructure must be secured to prevent it from slewing, and the swing brake must be engaged.
• If a jib is provided, it must be folded laterally to the boom, and secured.
• The bottom block must be attached on the front bumper crossmember and secured, as described in the
Operating Manual. Any national regulations differing from those mentioned above must be taken into
consideration.
• Any additional bottom blocks transported with the machine must either be deposited in the bottom block
rests provided to this effect, or stowed on the chassis and secured appropriately. To this effect, refer also to
the admissible axle loads in part A) (Technical Data).
• A part of the counterweight - the weight of which depends on the machine model or the rig arrangement -
must be deposited in the counterweight rest on the chassis.
• Any counterweights and other items of equipment transported on auxiliary vehicles must be secured
adequately.
• The outriggers must be retracted completely and secured mechanically.
• The outrigger floats must be slipped into place and secured.
• The axle suspension must not be locked during on-road travel. The suspension system must be set to the
level required for "on-road travel" according to the Operating Manual.
• The differential locks must have been deactivated. The differential locks may only be engaged for off-road
use, if this should be indispensable; no curves should be taken when the locks are engaged.
• The 2nd axle drive**) (in case of 8x8 configuration) must have been deactivated.
• The mechanical steering lock between axles 3 and 4 must be engaged.

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B0-1 Requirements and conditions for vehicles used in public road traffic.
cont'd.: 1 Requirements and conditions for vehicles used in public road traffic.
• Attachments and superstructure components must be secured so that they cannot slip or fall down.
• Objects which are not sufficiently secured must not be deposited on the platforms of the chassis and the
superstructure.
• The traffic regulations must be observed taking account of the admissible axle loads (refer to part A) and
gross vehicle weights (according to the expert opinions of the technical inspection agencies, the data given
in the vehicle title or the vehicle registration papers).
• The tires must be checked for the specified pressure.
• The brakes must be checked for proper working order immediately after starting. The steering and lighting
systems must also be checked.
• The parking brake must be engaged while the vehicle is parked. The parking brake in the superstructure
must always be engaged; it may only be released while "driving from the superstructure". If parking on
downhill slopes is inevitable, the wheels must be blocked using additional wheel chocks.
• Before entering curves, a lower gear must be selected in good time. Make sure that the gearbox is never
shifted to neutral before or while negotiating a curve, as in this case the engine speed would drop suddenly
to idling level, impairing the hydraulic assistance of the steering system, which would require increased
effort at the steering wheel.
• The boom head must be marked on both sides with red-and-white diagonal section bars; when the
machine is operated in the darkness, one additional type-approved bordering light directed sideways must
be located on both sides. National registration requirements may differ from those mentioned and must be
taken into consideration.
• According to § 41/14 StVZO (German Federal Motor Vehicle Safety Standards), at least 4 wheel chocks,
and at least 2 warning triangles and 2 portable warning lights pursuant to § 53a, section 1 StVZO, must
also be carried in the vehicle. National registration requirements may differ from those mentioned and must
be taken into consideration.
• The vehicle owner or his authorized representative must instruct the driver regarding his particular
obligations concerning operation of the vehicle, as required by traffic safety, and about the
requirements specified in the exception permit. The driver has to confirm this instruction in writing.
The vehicle owner must keep this confirmation for 2 years.
Moreover, the provisions of the Federal Motor Vehicle Safety Standards (in Germany: StVZO) must be
complied with.
The instructions given in the following chapters are intended to help you prevent damage
and to increase the machine's availability by avoiding maintenance faults.
Particular attention should be paid to unusual sounds and occurrences during the first few operating hours.
Prerequisites of trouble-free operation are, apart from thorough application planning, an optimally
serviced crane and a well-trained crane operator.
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Requirements and conditions for vehicles used in public road traffic. B0-1
1.1 Important instructions regarding the load ratings of tires depending on

the maximum travelling speeds and the stress to which the rims are
subject
• The axle loads of the crane carrier have to be observed in view of the legal regulations valid in the country
where the machine is to be registered.
• Regarding axle loads, a distinction must be made between the technically admissible axle loads and the
axle loads specified by the legislation of the country where the machine is to be registered.
• Axle loads exceeding 12 t are not admissible for travelling on public roads in the countries of the European
Community, according to EC regulations.
If a machine with an axle load exceeding 12 t is used on public roads, the vehicle
operating company bears sole responsibility.
• Increased wear, especially on the brake linings, must be expected.

• Driving with increased axle loads may result in a considerable increase of the stopping distance.
• Due to their technical definition, the rims used have only a limited service life.
• As the rims are important safety components of the crane, they must be checked at regular intervals,
and these inspections must be recorded.
Given normal operation of the crane, the normal service life to be expected of the rim is approx. 80,000 to
100,000 km.
• High, jerky strains, or e.g. driving with excessive axle loads, which exceed the basic design data, may
reduce the specified service life.
• Thus, it must be ensured that regular inspections of the rims, the frequency of which depends on the
vehicle's operating conditions, or checks for fissures in the critical areas, e.g. the welding seam between
the disc and the rim, are carried out.
• It is not admissible to repair any cracks by welding.
The vehicle operating company may only use rims approved by the vehicle
manufacturer.
1.1.1 Correlation between the maximum technically admissible axle loads and the
maximum travelling speed
Tire size
14.00 - R 25 16.00 - R 25 20.5 R 25
Tire pressure
10.0 bar 9.0 bar 7.0 bar
Max. travelling
speed Axle loads Axle loads Axle loads
80 k.p.h. 12.0 t*) 12.0 t 12.0 t
70 k.p.h. 12.0 t 14.5 t 14.5 t
60 k.p.h. 13.5 t 15.0 t 15.0 t
50 k.p.h. 14.0 t 15.5 t 15.5 t
*)With tires 14.00 R 25, the maximum distance covered within one hour must not exceed 70 km.
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B0-1 Requirements and conditions for vehicles used in public road traffic.
Memo:
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Instructions for the crane operator B0-2
2 Instructions for the crane operator
As the operator of the mobile crane, you have a number of responsibilities, i.e.:
• You should ensure that the mobile crane is always in a safe operating and road condition.
Recurrent inspections according to VBG 9, § 26 (1) (2)
Cranes must be inspected as required by the application conditions and the operating circum-
stances, at least however once per year by a person disposing of special knowledge about cranes
(1), or by an expert (2) at least every four years.
These inspections must be carried out at the instigation of the crane operating company.
• You are entitled to refuse to work in contravention of the regulations.

• Inform your principal about all incidents. He must decide which steps are to be taken.
• You must ask unauthorized persons to leave your vehicle and its working range.
• If there is a risk to persons or equipment, you must take all the steps you consider appropriate to eliminate
the risk.
• You must not perform any operations contrary to the regulations, such as diagonal pulling of loads,
dragging of loads and working under troughs, reservoirs or equipment that is inclined but not secured.
Moreover, we would like to refer to the Regulations for the Prevention of Accidents (German: UVV) for
cranes (VBG 9a) and for winches, hoisting and towing equipment (VBG 8) of the Professional
Association, and the "acknowledged" rules of technology, the notices in DIN 15020 (pages 1 and 2) , to
the Road Traffic Regulations (in Germany: STVO) and the Federal Motor Vehicle Safety Standards (in
Germany: StVZO).
The provisions of the UVV mentioned in this Operating Manual are valid within the Federal Republic of
Germany.
In other countries, the national legal regulations must be complied with.
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B0-2 Instructions for the crane operator
2.1 Applications planning
The basis of trouble-free operation is thorough planning of the application.

In good time before the operator drives the machine to the site of operation, he must obtain or provide
himself with all the data and documents required for the work as a whole, especially as regards:
• preparation of a precise time schedule;

• the type of crane operation in question;
• the weight and the size of the load to be lifted;
• the required work radius and lifting height;
• the stability of the ground at the site of crane installation;
• the local conditions and restrictions at the site of crane installation, if any;
• finding out approach roads the vehicle can use given its length, width, height, and its total weight, and
taking account of the admissible carrying capacity of bridges, headroom of underpasses and road widths.
• electrical overhead lines and their voltage.
• If necessary, request a police escort and obtain official permits.
• The applicable travel or exception permits.
• The appropriate paragraphs of the Federal Motor Vehicle Safety Standards (in Germany: StVZO) and Road
Traffic Regulations (in Germany: StVO) of the country where the machine is to be registered, must be
observed.
• Admissible limits for admissible axle loads and gross vehicle weights.
The crane equipment required for execution of the planned application must be prepared in accordance with
the information on hand, especially:
• Load hooks or bottom blocks.

• Lattice-type fly jib.
• Counterweights,
• load securing ropes, chain suspension devices, crossbeams and other, similar attachments,
• supporting plates for the ground, if necessary,
• an auxiliary vehicle for transport, if necessary.
DANGER If the crane operator is not given all the data he requires, the work planned at the site
of application may prove to be impossible; this may even force him to improvise. This
in turn increases the risk of accidents.
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2.2 Steps to be taken before crane operation
• The ground conditions on the site of crane operation should be checked with regard to stability (load-bearing
capacity); if necessary, the ground should be reinforced with sheet metal plates.
• The driveways to be used by the vehicle on the site should be cleaned; any unevenness should be
eliminated.
• The lifting capacities indicated in the load charts are only valid for the vehicle standing on level ground
(crane standing free on wheels), or for the crane aligned horizontally and stabilized by outriggers.
• The crane must be supported by outriggers as specified; the axle suspension must be blocked before
outrigger operation, according to the Operating Manual.
• All outrigger beams must be extended completely and locked mechanically. If the outrigger beams are not
extended completely, this reduces the lifting capacity.
• The outrigger cylinders must be supported with robust materials (e.g. timbers), and centered on these
large-size supports. Deals or piles of bricks are not suitable.
• The outrigger cylinders must not be extended to their end positions. Wooden planks should be placed
underneath the outriggers, leaving a clearance of approx. 10 to 15 mm in the cylinders.
• The vehicle must be aligned horizontally (watch spirit levels).
• The tires must be lifted clear off the ground, if this is specified in the Operating Manual.
• The tires must be checked for the specified inflating pressure, if driving with a load fixed to the boom is
admissible according to the Operating Manual or the Notes referring to the load charts.
• Before starting to work with the crane, check the vehicle's hydraulic system and all controls and gauges for
proper working order.
• The shortest possible boom length and work radius must be used on all accounts. The work radius is the
distance between the center of the ringgear and the center of the bottom block or the load.
• The size and the weight of the load to be lifted must be known.
• The bottom block, the load securing ropes, the crossbeam etc. are parts of the load and must be deducted
from the lifting capacities in question.
• The safety equipment installed in the machine must be checked for precision and proper working order. If
the operating staff is not absolutely sure about its function or reliability (100 %), crane work must not be
started.
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2.2.1 Checking the ground quality
A prerequisite for safe crane operation is the utilisation of the machine on solid ground with a sufficient load
bearing capacity. The choice of the appropriate site of installation for the crane is also decisive for correct
execution of the planned work.
The site of installation must be chosen in such a way, that:

- the prevailing ground quality is sufficient to withstand the loads occurring during the work;
- the outriggers can be extended according to the value specified in the load chart.
- there are no obstacles in the slewing range of the counterweight or of the superstructure.
- the work can be effected with a minimum working radius.
DANGER To ensure safe crane operation, it is essential for the crane to be installed on
sufficiently solid ground. If ground stability is inadequate, there is an
enhanced risk of accidents.
When the crane is supported by outriggers during work, huge forces are directed onto the ground via the
outriggers. In specific cases, almost the whole weight of the crane plus the load may be directed onto the
ground via a single outrigger.
The maximum supporting forces which may occur while the loads specified in the load chart are slewed
within a working range of 360° have been specified in the supporting forces charts in the Operating Manual.
Accordingly, the corresponding wheel loads for work with the crane on wheels are specified in the wheel load
charts of the Operating Manual.
For information regarding specific ground pressures, please refer to the German DIN standard 1054
"Admissible loads acting on the construction site". The following table shows an excerpt of the
admissible ground pressures.
Under certain circumstances, it may be necessary to check the load-bearing capacity and the stability of the
ground where the crane is to be installed by means of appropriate testing methods (if necessary, have soil
surveys made using a piling ring). The outrigger floats may have to be provided with suitably sized
supporting material, depending on the soil's stability.
The prevailing maximum specific ground pressure can be computed on the basis of the crane's maximum
supporting force (see supporting forces chart) divided by the surface area of the outrigger float.
Supporting force
Ground = -----------------------------------------------
pressure Outrigger float surface area
The calculated ground pressure must by no means exceed the ground pressure which is admissible for the
ground in question.
The required minimum supporting surface can be computed on the basis of the crane's supporting forces
(see supporting forces chart), divided by the admissible load bearing capacity of the ground.
Required Supporting force

supporting = -----------------------------------------------
surface admissible load bearing capacity
of the ground
The existing supporting surface must by no means be less than the calculated minimum supporting surface.
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2.2.2 Admissible ground pressures (excerpt from German Industrial Standard DIN
1054)
Nature of soil daN/cm2

Loosely tipped soil, not artificially compacted: 0-1
Natural soil, obviously virgin soil:
Mud, turf, moorland 0

Fine to medium-fine sand 1.5
Coarse sand to gravel 2.0
Binding soil:
Very soft 0
Soft 0.4
Firm 1.0
Semi-firm 2.0
Hard 4.0
Rock with a low cracking rate, in good condition and position, free from
weathering:
in compacted strata 15
in block or pillar form 30
Artificially compacted soil

Asphalt 5 - 15
Concrete B I 50 - 250
Concrete B II 350 - 550
DANGER No thin boards, lime sand brick or similar material may be used as supports for the
outrigger floats.
Make sure that only sufficiently rugged material, e.g. sufficiently thick planks, are
used.
Moreover, it is very important to place the outrigger floats centrally on their supports,
for even distribution of pressure on the support.
Non-compliance signifies an
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2.2.3 Distance of the crane from ditches, slopes and excavations
Once the site of installation of the crane has been chosen, it must be ensured that the crane is not installed
too close to ditches, slopes or excavations.
There is a risk that the edge of the slope or the excavation might slip away under the load of the outriggers,
causing the crane to tip over.
Depending on the prevailing type of soil, a sufficient safety clearance must be provided between the
outriggers and the edge of the excavation; this safety clearance is measured from the base of the
excavation.
DANGER In case of loose or back-filled soil (gradient of slope approx. 30°),

the safety clearance = twice the depth of excavation ( A = 2 x T )
In case of natural soil which is not loose (slope gradient approx.45°),

the safety clearance = once the depth of excavation ( A = 1 x T )
If these minimum safety clearances cannot be guaranteed, the edge of the slope or
the excavation must be supported,
as otherwise there is an
∝
T
∝ ≤ 30 ° on soft soil A ≈2xT A
∝ ≤ 45 on firm soil
° A ≈ 1xT
T - Depth of excavation
96031
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2.3 Supporting the crane by outriggers
It is extremely important that the outriggers are extended according to the selected load chart and to
the extension width specified there, and that the load is divided up between all outriggers.
Make sure that the crane's actual supporting base does not fall short of the extension width specified in the
selected load chart.
Extension widths other than those specified in the load charts are not admissible, as the transmission of
transverse forces into the outriggers is only possible at appropriately constructed points defined by design.
DANGER Extension widths other than those specified in the load charts are not admissible.
The outrigger beams must be locked mechanically in their appropriate positions by
insertion of locking pins, so that they cannot slip.
If these instructions are not observed, there is an
The operator must extend the outrigger beams according to the selected load chart not only on the load side
of the crane, but also on the opposite side of the load. If the outrigger beams on the opposite side of the load
are not extended, there will be an increased risk of accidents for the following reasons:
DANGER Contrary to expectation, it might become necessary to swing the load over the other
side, where the outrigger beams are not extended.
This may cause the crane to tip over.
The load suspended on the hook deforms and consequently stresses the boom. If the
winch rope or a load securing rope breaks under such circumstances, or if the load
falls out of the load securing ropes, the crane would suddenly be discharged from its
load and the boom would bounce up.
This may cause the crane to tip over backwards.
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2.3 Supporting the crane by outriggers (cont'd.)
Besides the correct and safe supporting of all outrigger

floats and besides complying with the correct extension
width, the horizontal alignment of the crane's plane of
rotation is extremely important for safe crane operation.
In the case of a crane with a boom of 60 m, which is

placed at an inclination angle of 5°, the working radius
is increased by approx. 5 m ("a").
DANGER If the crane is not aligned horizon-

tally and if the boom is placed at
right angles to the slope, pressure
is exerted on the boom transverse
to the main loading direction when
the load is picked up, so that it may
even kink under certain
circumstances.
DANGER If the crane is not aligned horizontally and the boom is slewed towards the slope, this
increases the working radius which may cause the crane to tip over under certain
circumstances.
A crane which is not aligned horizontally implies an
2.4 Counterweight
The size of the counterweight required is determined by the working radius required for the crane work in
question, and by the weight of the load to be lifted. The counterweight has to be mounted onto the crane in
accordance with the counterweight data specified in the load chart which is required for the crane work in
question.
Attention None of the counterweight units belonging to the machine, which can be removed and
unscrewed, may be replaced by counterweight units of other machines.
DANGER If the crane is not equipped with the counterweight specified in the load chart, there is
a
risk of its overturning, i.e. a risk of accidents.
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2.5 Hoist winch and reeving of the winch rope
The lifting capacity of a crane depends on the traction

force of the hoist winch and on the selected number of
rope falls. When the work is effected with "direct" rope
arrangement (= rope fall), the crane can only lift the
weight which can be pulled by the hoist winch.
If the load to be lifted exceeds the traction force of the

hoist winch, the winch rope must be reeved between
the rope pulleys in the boom head and the pulleys in the
hook block as many times as necessary, according to
the principle of lifting tackle.
For rope reeving, please observe the "Notes referring to

the load charts" and the specifications of the Operating
Manual.
arrangement with arrangement with

a single rope fall four rope falls
DANGER If the maximum admissible traction force of the hoist winch is exceeded, there is an
increased risk of accidents as the winch rope may break, or as the planetary gears or
the hydraulic motor of the hoist winch may be damaged.
NOTE The annually consumed portion of the theoretical service life of the winch must be
determined according to the amendment and the supplement to the regulation for the
prevention of accidents "VBG 8, Winches, Hoisting and Towing Equipment". If the
theoretical service life of the winch has elapsed, a general overhaul of the winch is
necessary. After 10 years, a general overhaul of the winch must be effected on all
accounts (refer also to part E "Crane Testing Instructions").
2.6 Taking account of the wind velocities
The maximum wind velocities at which crane operation is admissible stated in the load charts must be
adhered to.
When the wind velocities exceed the specified values, crane work must be stopped and the boom must be
retracted or deposited.
DANGER If inadmissibly high wind velocities are to be expected in view of the prevailing
weather conditions, before he starts working with the crane, the crane operator
has to ascertain with the competent meteorological authority the wind velocities
which may occur.
Crane work must not be performed if inadmissibly high wind velocities are to
be expected.
If the admissible wind velocity limits are not observed, there is an
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2.6 Taking account of the wind velocities (cont'd.)
The following table contains a few reference values enabling the assessment of the prevailing wind velocities.
Wind intensity Wind velocity Action of the wind

Beaufort Description m/s k.p.h. in continental areas
scale
0 calm 0-0.2 1 Calm; smoke rises in straight line.
1 light draught 0.3-1.5 1-5 Direction of wind indicated only by draught of smoke,
not however by vane.
2 light breeze 1.6-3.3 6-11 Wind can be felt in your face; foliage rustles, vane
moves.
3 gentle breeze 3.4-5.4 12-19 Foliage and thin twigs move. Wind flattens a
pennant.
4 moderate breeze 5.5-7.9 20-28 Lifts dust and loose sheets of paper, moves twigs
and thin boughs.
5 fresh breeze 8.0-10.7 29-38 Small broadleaf trees begin to wave to and fro. White
crests appear on lakes.
6 strong breeze 10.8-13.8 39-49 Thick boughs move; telegraph lines whistle;
umbrellas can be used only with difficulty.
7 strong wind 13.9-17.1 50-61 Entire trees in motion; tangible resistance felt when
walking against the wind.
8 gale 17.2-20.7 62-74 Tears boughs from trees, walking outdoors is
extremely difficult.
9 gale-force wind 20.8-24.4 75-88 Minor damage to houses (chimney heads and roof
tiles are blown off).
10 severe gale 24.5-28.4 89-102 Uproots trees; severe damage to houses.
11 light hurricane 28.5-32.6 103-117 Extended storm damage in places (occurs very rarely
inland).
12 hurricane 32.7-36.9 118-133 Extremely severe devastation.
DANGER When a thunderstorm is brewing, crane work must be stopped immediately, and the
boom must be retracted!
2.6.1 Influence of and attention to the action of wind
In general, crane operation is only admissible at wind velocities which do not exceed the rating "v" indicated
in the "Notes referring to the load charts". In this context, the prevailing load wind area AWvorh must not
exceed the load wind area AWzul considered in the calculation. The load wind area AWzul which has been
considered in the calculation, is specified in diagram 2 "Load wind area". If the load wind area is greater than
that which has been considered in the calculation, crane work is only admissible at an accordingly reduced
wind velocity.
This reduced wind velocity is specified in diagram 1 "Dynamic pressure" (see the following example):
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2.6.1 Influence of and attention to the action of wind (cont'd.)
DANGER Before the crane operator starts any crane work, he has to obtain information about
the wind velocities which must be expected; if necessary, he may have to check the
wind velocities which may occur with the competent meteorological authority. Crane
work must not be performed if inadmissibly high wind velocities are to be expected.
The maximum admissible wind velocities specified in the "Notes referring to the load
charts" must not be exceeded on any account; even if the prevailing load wind area is
smaller than that which has been considered in the calculation.
Example for the determination of the reduced wind velocity
Admissible wind velocity for the crane, e.g. v = 12 m/s (from "Notes referring to the load charts".
Weight of the load to be lifted G = 20 t
Prevailing wind area of the load to be lifted: AWvorh = 40 m2
1. According to diagram 1 "Dynamic pressure", at a wind velocity of 12 m/s (= 43.2 k.p.h.), the resulting
dynamic pressure amounts to 88 N/m2.
2. According to diagram 2, an admissible load wind area of AWZUl = 23 m2 results for the load to be
lifted.
Formula for calculation
Fw = q x Awzul
2024N = 88 N/m2 x 23 m2
Thus, a load of 20 t with an admissible load wind area Awzul = 23 m2 is subject to a wind force of Fw = 2024
N.
Formula for calculation
Fw
q = -----
Awvorh
50.6 N/m2 = 2024 N/m2 /40 m2
In case of the prevailing load wind area Aw vorh = 40 m2 , at the calculated wind force Fw, the maximum
admissible dynamic pressure is q = 50.6 N/m2.
3. Thus, according to diagram 1 "Dynamic pressure", at a dynamic pressure of q = 50.6 N/m2, the
maximum admissible wind velocity of Vred = 9 m/s ( = 32.4 k.p.h. ).
Awvorh Prevailing wind area of the load to be lifted in m2

Awzul admissible load wind area in m2
Fw Prevailing wind force acting on the load to be lifted, in N
q Dynamic pressure in N/m2
vred Reduced wind velocity in m/sec
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Diagram 1 - Dynamic pressure; Staudruck = dynamic pressure; Windgeschwindigkeit = wind velocity
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Diagram 2 - Load wind area; Zul. Lastwindfläche = admissible load wind area; Last = Load
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2.7 Hand signals recommended for communication between the crane

operator and his assistant
During all intended crane movements (with or without load), the crane operator must always have the load or
the load lifting device in his field of vision. Loads fixed by hand may only be moved by the crane operator
after he has received a corresponding signal from the person fixing the load or from another responsible
person who has been determined in advance.
If the crane operator's field of vision is impaired by obstacles, he may only move the crane or the load with
the help of an assistant determined in advance, who gives him appropriate instructions.
The instructions can be given using radio equipment or hand signals. However, clear communication free
from misunderstandings must always be ensured between the assistant giving the instructions and the crane
operator.
DANGER Hand signals and special verbal expressions must be agreed between the crane
operator and his assistant, and observed precisely.
Any mistakes regarding the interpretation of the hand signals or verbal expressions
may result in accidents.
The persons giving the hand signals must always be placed so that he can see the
crane operator, and keep at a safe distance from the hook or the load.
The following hand signals are recommended for the working movements:
Explanation of the hand signals
1 Boom elevation "up" 10 Retracting the boom

2 Boom elevation "down" 11 Boom elevation "up" and lowering the load
3 Lifting the load slowly 12 Boom elevation "down" and lifting the load
4 Lowering the load slowly 13 Lifting the load
5 Boom elevation slowly "up" 14 Lowering the load
6 Boom elevation slowly "down" 15 Swinging load in the indicated direction
7 Boom elevation "up" and holding the load 16 Stopping all movements
8 Boom elevation "down" and holding the load 17 Stop! Working movement finished.
9 Extending the boom
Should any particular national regulations be valid in the country where the machine is to be registered,
these appropriate national regulations must be observed.
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2.8 Work in the vicinity of electrical overhead lines
When crane work is performed near electrical overhead lines, serious accidents may occur if the crane
moves the boom or the load too close to, or even touches, the overhead line.
In case of voltages below 1000 V, only direct contact with the overhead line will in general involve a risk;
however, at voltages over 1000 V, even an indirect approach of the overhead line may cause a current
sparkover and consequently accidents.
Before commencing work, the rated voltages of any overhead lines in the working area must be enquired at
the responsible power supply company.
If the possibility exists, the overhead line must either be switched off, or covers or barriers must be provided
for the danger zone.
However, both of these measures may only be performed by well-trained electricians or by employees of the
responsible power supply company.
If it is not possible to perform these measures, a sufficient safety clearance from the live lines must be kept
on all accounts. The appropriate safety clearances are indicated in the following table.
According to the German VDE directive 0105, the following safety clearances from live lines must be
observed even in the most unfavourable crane positions, and taking account of possible oscillations of the
overhead line which may be due to the action of wind.
Nominal voltage Minimum clearance to

be observed
up to 1000 V ( 1 kV ) 1m
over 1000 V up to 110,000 V ( over 1 kV up to 110 kV ) 3m
over 110,000 V up to 220,000 V ( over 110 kV up to 220 kV ) 4m
over 220.000 V up to 380.000 V ( over 220 kV up to 380 kV ) 5m
if nominal voltage is not known 5m
Work near overhead lines should only be performed with the help of an assistant. The safety clearances and
the hand signals used for communication must be determined together with the assistant. The assistant must
have free vision on the entire working area, and be in constant eye contact with the crane operator.
DANGER Crane work in the vicinity of live overhead lines requires extra care.
The minimum safety clearances specified above must be observed on all accounts, as
reduced clearances would entail a considerable risk of accidents.
There is a risk of lightning stroke!
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2.9 How to behave in case of sparkover (if the crane has touched the power
line)
If an overhead line has been touched or a current sparkover has occurred in spite of all precautions,
please observe the following instructions:
• Keep calm and do not leave the crane cabin.

• Warn persons outside about the danger; instruct them not to approach or touch the crane.
• Remove the crane from the danger zone by driving away or by slewing or adjusting the boom.
• Request persons outside of the danger zone to shut off the power supply.
• If it is indispensable to leave the crane cab, never touch the crane and the ground at the same time. Do not
climb down, but jump to the ground.
• Leave the crane area, making small steps.
2.9.1 Inspection measures required after an electric shock or a lightning stroke
DANGER After an electric shock or a lightning stroke, the electrical and electronic components
must be checked for proper working order. The ball-bearing slewing device must be
checked for damage and smooth motion.
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2.10 Grounding the crane and the load
During crane work, the crane and the load might be charged electrically under certain circumstances. This
may occur, e.g., during work near powerful radio transmitters or RF change-over stations.
The crane may be electrified especially if the crane's outrigger floats are supported with insulating material
(e.g. squared timbers).
The load may also be electrified (e.g. in case of hoisting tackles of non-conducting materials, or if plastic
rope sheaves are used on the crane).
Thus, it may be necessary to ground the crane and the load. To this effect, the part to be grounded (crane or
load) must be connected to the soil in an electrically conductive fashion.
Grounding the crane:
- Use a ground cable with a sufficient cross section (> 16 mm2).
- To save the ball-bearing slewing device, fasten one end of the

ground cable directly to the superstructure or the boom using a
screw clamp or a vise-grip wrench (do not fasten to screwed-down
or bolted components).
- Fasten the other end of the ground cable to a metal bar stuck into
the soil.
ATTENTION When slewing the crane, make sure the ground

cable can move without obstruction. The
ground cable must not be crushed or torn apart.
NOTE The ground cable and the ground spike are available as an assembly, including the
connectors and the fastening point on the vehicle (optional equipment).
Grounding the load:
- Use a ground cable with a sufficient cross section (> 16 mm2).

- Fasten one end of the ground cable to a metal bar stuck into the soil.
- Fasten the other end of the ground cable to a metal bar with insulated handle.
- Hold the metal bar against the load (only grasp at the insulated handle).
DANGER During grounding work, the operator must wear safety equipment, e.g. special shoes,
gloves.
NOTE When work is effected in the radius of action of RF transmitters, the transmitter company
must be contacted. The grounded crane may give rise to interferences.
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2.11 Work in the vicinity of supply lines
DANGER Particular caution is required in the area of exposed supply lines. Damage to
such lines and any resulting leakage may have imprevisible consequences.
Before crane work begins, it must be ensured which fluids are transported in the supply lines. To this effect,
the operating company involved must definitely be contacted.
If the lines contain substances which imply a hazard to the environment or to health, all the necessary safety
measures must be stipulated in cooperation with the operating company.
Such work should only be performed with the help of assistants. If necessary, the assistant must also be
familiar with all the safety precautions. Before work begins, hand signals must be defined for communication.
The assistant must have free vision on the entire working area, and be in constant eye contact with the crane
operator.
2.12 Crane work with a load
Before the crane operator starts to work with the crane, he has to verify that the operational reliability of his
crane is ensured.
All safety devices, e.g. brakes, hoist limit switches, winch limit switches, automatic safe load indicator (ASLI)
etc. must be in an operationally reliable condition.
The crane operator has to observe the following items:
• Before the crane operator starts crane work, he has to inform himself about the dimensions and the weight
of the load.
• The lifting capacities specified in the load chart have to be observed and must not be exceeded.
• The crane must be placed horizontally on solid ground with the extension width specified in the load chart,
and with an appropriate counterweight.
• The load moment limiter must be adjusted correctly according to the crane's rig arrangement.
• The load fixing, lifting and carrying devices must be suitable for the load to be lifted, and feature a sufficient
lifting capacity.
• The load securing, lifting and carrying devices are part of the load to be lifted and must be deducted from
the lifting capacities specified in the load chart.
Example for the determination of the actual payload of the crane:
Admissible lifting capacity according to the load chart (gross load) 11.100t
Dead weight of the load securing ropes 0.050t
Dead weight of the crossbeam 0.125t
Proper weight of the hook block 0.350t
Actual payload of the crane (net load) 10.575t
In this case, the weight of the load to be lifted must not exceed the calculated payload of the crane,
which amounts to 10,575 t.
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2.13 Notes regarding work with two cranes
Sometimes two cranes may be required to move bigger and considerably heavy loads.
DANGER Executing such work requires a high degree of operator experience and
attention, as otherwise there is a considerable
Risk of accidents!
When working with two cranes, take note of the following instructions:
• Work should be effected, as far as possible, with two identical cranes (e.g. telescopic cranes with the same
capacity rating).
• The load must be picked up and distributed so that the maximum lifting capacity of the crane is not
exceeded. In the case of cranes with different capacity ratings, the lifting capacity of the smaller (less
powerful) crane is decisive.
• It must be ensured that the load does not exceed 2/3 of the total lifting capacity of the two cranes.
• The winch ropes must always be suspended vertically; neither of the cranes must pull to the side.
• Before commencing work, the crane operators must determine a common approach. They must agree on
hand signals for communication.
• Work may only be performed with the help of an assistant. One assistant should be charged with guiding
the two cranes and giving signals for both of them. The assistant must also be informed about the work
approach and the hand signals. Moreover, he should be able to see the entire working range and be in
constant eye contact with the crane operators.
2.14 Instructions for crane operation
• The crane is ready to operate at ambient temperatures in the range from -25°C to +40°C.
• During crane operation, the gearshift lever must be set to neutral.
• The hydraulic axle suspension must be locked for crane operation according to the operating manual
before outrigger actuation and before driving the crane in full rig arrangement on construction sites.
• Loads may only be lifted after persons have left the danger zone.
• For moving the crane with a load and for work free on wheels, see Notes referring to the Load Charts, and
item B2-7.
• For moving the crane in full rig arrangement on construction sites, see Notes referring to the Load Charts,
and item B2-7.
• The maximum admissible wind velocity and load wind area according to the load chart must not be
exceeded.
• Check that the ground is completely level and sufficiently resistant.
• Construction sites must be sufficiently illuminated for work at night.
The crane's working floodlights alone might not be sufficient for this purpose. In this case, the construction
site must be illuminated sufficiently by additional light sources, independently of the crane lighting
equipment.
• To enhance the crane operator's safety, appropriate safety equipment must be used for crane work.
• As long as the engine is running and/or a load is suspended freely, the operator must not leave the crane
cabin.
• Before the operator leaves the superstructure cabin, he must place the load on the ground; the parking
brake must be in braking position, the engine must be stopped and the ignition key removed.
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2.15 Crane application in accordance with the intended use
Crane application in accordance with the intended use is operation as an assembly crane, and
consequently, lifting and transporting of loads.
The machine has been designed and built only for operation in areas where there is no risk of explosion.
2.16 Crane application not in accordance with the intended use
Crane application not in accordance to the intended use includes piling, vibrating and clamshell operation,
and the use as a loading and unloading crane.
2.17 Potential causes of accidents
The majority of the damage caused during operation of automotive cranes is due to operating errors,
whereas the minority is due to inadequate maintenance of the machine.
Consequently, to avoid accidents, it is important for the crane operator to be thoroughly trained in the
operation, application and maintenance of the crane.
The crane operator must be able to recognize any risks endangering the health and safety of himself and
other people, and to take the appropriate measures to avoid such risks.
2.17.1 Causes for driving faults
• Overspeed of engine and/or gearbox when driving on downward gradients.

• The gearbox has not been shifted down in time before the vehicle enters a curve. Make sure that the
gearbox is never shifted to neutral before or while negotiating a curve, as in this case the engine speed
would drop suddenly to idling level, thus impairing the hydraulic assistance of the steering system, which
would require increased effort at the steering wheel.
• The differential locks are not disengaged during on-road travel.
• The parking brake is not applied when the vehicle is parked; no additional wheel chocks are used when the
machine is parked on downward gradients.
• Loose items have been left on the machine; accessories are not secured and can fall off.
• Due to an insufficient passage clearance, the machine collides with bridges and roofs.
• The admissible axle loads or the gross vehicle weight have been exceeded.
DANGER The machine's braking performance decreases to the same extent as the axle loads or
the gross vehicle weight have been exceeded beyond the admissible limits against
the admissible ratings. Thus, the entire brake system no longer satisfies the legal
provisions.
If these items are not observed, there is an

increased risk of accidents.
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2.17.2 Causes for faults during crane operation
Such causes and faults may occur during crane operation for the following reasons:
• The crane is not mounted with the outrigger beams extended and secured as specified in the load chart;
• the outrigger floats are not supported with solid material, as required by the ground conditions;
• the outrigger floats are not placed centrally on their supports;
• the outrigger cylinders have been extended to their end position; in this case, wooden planks should be
placed underneath the outriggers, leaving a residual stroke of at least 10 to 15 mm in the cylinders.
• The crane is not aligned horizontally and the tires are not lifted off the ground as specified in the Operating
Manual;
• The crane is installed too close to the edge of slopes or excavations.
• The hydraulic axle suspension is not locked.
• Excessively fast driving with the crane in full rig arrangement - if driving is permitted; in this context comply
with the notes referring to the load charts - without extending the outrigger beams and keeping the
outrigger floats just above the ground, to the extent that this is possible in view of the available space.
• Driving the crane - if permitted; in this context comply with the notes referring to the load charts - on
excessively inclined ground or over excessively uneven ground.
• The rope becomes slack on the hoist winch.
• Improper securing of loads.
• Errors committed during operations, e.g. too fast braking of the load, fast slewing of the boom under load,
diagonal pulling of loads, or breaking them loose.
• Excessive loads imposed on the crane.
• Excessive wind loads acting on the load and/or the crane.
• The counterweight has not been selected according to the load chart.
• The automatic safe load indicator is not set to the actual rig arrangement of the crane.
• The automatic safe load indicator and other safety devices are faulty or not in operation.
• The admissible loads or the working radii specified in the load charts are exceeded.
• During crane work diagonal tensile stress is applied to the boom, especially in a lateral direction.
• Any obstacles impeding the crane's movements are ignored.
• The suspended load starts to swing due to negligent crane operation.
• Fixed loads are broken off using the hoisting gear. As the boom bounces up, this may cause the crane to
tip over backwards.
• The crane operator tries to lift too heavy loads from the ground using the boom elevation.
In this case, the automatic safe load indicator will emit an "overload" warning signal, however the
movement "boom elevation UP" is not stopped, as this is a movement which tends to reduce the load
moment.
• In the course of demolition work, too heavy loads are secured, which are suspended freely on the crane
once the connections have been released.
• The minimum clearance from live overhead lines is no longer maintained during crane work.
DANGER If these items are not observed, there is a considerable risk of accidents.
Before the operator starts crane work, he has to check whether the safety measures
have been effected as specified above.
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2.17.3 Servicing faults which may cause accidents
• Lack of oil, grease or anti-freeze agent in the various assemblies.

• Only the specified lubricants and oils may be used in accordance with the chart of approved lubricants.
• Anti-freeze agent must be used to protect the engine in winter.
• Water has entered the compressed air system, in spite of the air drier installed; actuate the drainage valves
at regular intervals and drain the water completely.
• Damage to the plastic tubes of the compressed air and centralized lubrication system during drilling or
welding; make sure that the plastic tubes are covered or removed during all drilling or welding work.
• Apparent or hidden damage to the tires which may result in a sudden loss of pressure.
• When replacing wheels or performing other assembly jobs, observe the specified tightening torques of the
nuts and bolts.
• Loosening of screw couplings; make sure that the correct tightening torques are adhered to on re-
tightening.
• Loosening of wheel nuts; make sure that the correct tightening torque is adhered to on re-tightening.
• Insufficient maintenance, which may result in an unexpected malfunction of assemblies, e.g. of the braking
and steering systems.
• Worn ropes which are ready for discarding and may break suddenly.
• Deficiencies in the hydraulic system, e.g. frayed hoses.
• Defective or unsatisfactorily operating safety devices, e.g. load moment limiters or hoist limit or winch limit
switches.
• The brakes have to be checked for proper working order.
• During this inspection, the brake linings must be checked for wear.
• Brake linings are subject to increased wear after installation; they must be checked more frequently during
this period.
• The steel structures, welded components and parts subject to increased stress must be examined visually.
DANGER The crane operator must have undergone thorough training with the crane, to be able to
detect and to avoid all dangers which may occur in the course of operation.
If work is not effected in an expert manner, there is an
increased risk of accidents.
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2.18 Fire, smoke, inflammation and explosion hazard
• The crane may on principle only be used in areas where there is no risk of explosion.
• Smoking is prohibited when handling fuels or consumables and during maintenance work on the batteries.
• Handling fire or open flames on the crane is prohibited.
• Due to the risk of burning, maintenance work must never be performed on hot machines, but only after they
have cooled down.
• In the vicinity of hot surfaces, insulating or sound-absorbing mats contaminated by fuel, oil or grease imply
a considerable risk of fire; thus, they must be replaced by new, clean insulating or sound absorbing mats.
2.19 Instructions and regulations concerning the compressed air tanks

installed in air-operated braking systems
• The compressed air tanks installed are in conformance with the EEC (EU) directive 87/404/EEC and are
approved exclusively for air-operated brake systems.
• During the vehicle's service life, recurrent pressure checks are only necessary if they are required by the
regulations in force in your country.
• The compressed air tanks must be checked visually in accordance to the maintenance instructions laid
down in your country's regulations.
• During the vehicle's service life, the drainage valves installed in the compressed air tanks of the brake
system have to be actuated at regular intervals, although an air drier is installed; accumulated water must
be drained away completely.
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Memo:
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Instruction Sheet for Overload Safety Devices for Boom Cranes (excerpts) B0-3
3 Instruction Sheet for Overload Safety Devices for Boom Cranes

(excerpts)
Issued by: VDMA-Fachgemeinschaft Hebezeuge

im Verein Deutscher Maschinenbau-Anstalten e.V.
The hydraulic crane supplied to you has been equipped with an overload safety device (automatic safe load
indicator), which serves to shut off the crane when the admissible load moment is being exceeded. In order
to enable discharging after the overload safety device has reacted, it must still be possible to perform a con-
trary movement. This means, for example, that it must still be possible to lower the load after the hoisting
gear has been switched OFF.
An overload safety device (automatic safe load indicator) is installed to prevent crane use for lifting of loads
which endanger its stability. Thus, the overload safety device is an emergency switch which, in case of crane
overloads, shuts off all movements which might increase the load moment, and thus prevents possible dam-
age or accidents.
In order to enable the overload safety device to fulfil its functions as a safety unit, please pay special atten-
tion to the following instructions:
1) Overload safety devices (automatic safe load indicators) must not be used for switching off the hoisting
gear or the boom retracting mechanism during normal operation. The crane operator has to make sure in
all cases before such work that the lifting capacity is not exceeded by the load to be lifted. Loads which
exceed the lifting capacity of the crane must not be lifted in spite of the fact that the overload safety de-
vice is installed. This device must not be used for weighing purposes, and the crane must not be charged
with loads exceeding the individually highest admissible load.
2) Tearing off fixed loads is only admissible if the crane manufacturer has agreed to it, and only with cranes
which are specially equipped for this purpose. During such operations, the overload safety device (auto-
matic safe load indicator) must not be used as load measuring equipment for normal operation.
3) The overload safety device installed in the crane must be serviced at regular intervals and checked for
safe operation before crane work. According to § 35 of the Provisions for the Prevention of Accidents
(German: UVV) "Boom cranes", crane maintenance work also comprises regular inspections of the over-
load safety device.
4) In general, the overload safety device is not automatically adjusted to the different modes of operation of
the crane. Therefore the crane operator is obliged to adjust the overload safety device to a different range
of lifting capacities or load moments, when the mode of operation of the crane is altered.
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B0-3 Instruction Sheet for Overload Safety Devices for Boom Cranes (excerpts)
3 Instruction Sheet for Overload Safety Devices for Boom Cranes (cont'd.)
Safe operation of the machine and crane work free of accidents depend to a large extent on careful compli-
ance with these instructions. An incorrectly set overload safety device, e.g. a device which is set to a high
load moment while the outriggers are retracted, is considerably more dangerous than a crane without an
overload safety device, as it conveys a feeling of safety to the driver, which is in fact not justified, and which
may cause severe accidents.
5) The overload safety device (automatic safe load indicator) installed must be adjusted by the crane driver
to the different ranges of lifting capacities or load moments, when the crane is adjusted to different modes
of operation, such as:
a) when the outriggers are extended or retracted (switching over to the high or low load moment)
b) when the boom length is changed by:

- extending or retracting (telescoping) manually, mechanically or hydraulically;
- mounting or dismounting intermediate elements;
c) when the crane is swung or slewed into the range of the higher or lower stability moment (switching over
to the high or low load moment)
d) when changing over to a different load moment by fitting multiple rope falls to the hoisting gear.
6) Please note positively that the overload safety device cannot become effective, i.e. the drive assembly
cannot be switched off quickly enough when the crane is operated incorrectly. In this case, accidents
cannot be precluded completely in spite of the overload safety device being installed. This applies particu-
larly to the following cases:
• the hook or the load lifting equipment is fixed underneath the load;
• excessive time-lag forces are effective;
• loads are dropped into the rope;
• the load is pulled diagonally;
• the crane is driven in an area with considerable ground inclinations, if the soil is yielding or if the wind ex-
erts an essential load.
7) If switch-off equipment for overriding the overload safety device (automatic safe load indicator) is in-
stalled, it may only be used if particular precautions have been taken, and in the presence of the crane
supervisors, e.g. during crane inspections and during the operations intended by the crane manufacturer.
Never switch off or override the overload safety device during normal operation to lift loads which
exceed the crane's specifically admissible lifting capacities for the individual work performed.
Careful compliance with the provisions comprised in this instruction sheet and in the operating manual of the
crane manufacturer is a prerequisite to safe operation of the overload safety device (overload disconnect
unit).
Should you have any doubts, please consult the Operating Manual. If it does not provide sufficient informa-
tion, it will be necessary to contact our specialist staff. Unauthorized tampering with the overload safety de-
vice's mechanical components will rule out all warranty claims.
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Part B
Operating Instructions
0105_EN_ALLGE_B_00_00_00
Part B1
Chassis
0110_EN_ALLGE_B_01_00_00
General instructions concerning operation of the vehicle B1-1
1 General instructions concerning operation of the vehicle
All controls and gauges required for operation of the vehicle are installed in the cabins of the chassis and/or
the superstructure.
Before putting the machine into operation, it is essential that the driver reads part "B" and the Safety
Provisions B.0 of this manual thoroughly.
• The driver must be absolutely familiar with the position and the purpose of all controls and operating
elements. This is a prerequisite for safe operation of the machine.
• Before the engine is started, the parking brake lever in the chassis and the rocker switch "parking brake" in
the superstructure must be set to "braking" position.
• Before the engine is started, especially if the vehicle has been immobilized for an extended period of time,
it is necessary to check the oil and fluid levels in the following components:
- Engine oil level.

- Oil level in hydraulic oil tank which supplies the steering, the suspension, the outriggers and the fan drive,
- Check the coolant level in the engine.
The cooling systems are filled correctly if the coolant reaches the rim of the filler socket on the compensating
tank.
DANGER Do not check the coolant level while the engine is warm; the cooling system is
pressurized.
There is a risk of scalding when the filler socket is opened while the engine is warm!
• To start the engine, make sure that the rotary switch "driving operation" is set to neutral.
• Before the vehicle is set into motion, the tires and the spare wheel**)must be checked for good condition.
DANGER Insufficient tread-pattern depth, incorrect tire pressures and damaged tires will result
in an increased risk of accidents.

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B1-1 General instructions concerning operation of the vehicle
Release air accumulator cylinders
Check wheel nuts.

After 50 / 100 / 200 / ... Refer to Operating Manual
kilometers travelled.
Nameplate Parking brake (handbrake)
DIFFERENTIAL LOCKS
must never be engaged while
driving in curves, but only briefly to
overcome an obstacle.
Accelerate carefully when driving
while the crane is mounted
ATTENTION
ATTENTION !
The rear axle steering must be
The brake system comprises Vehicle may only be lowered
locked during on-road travel
plastic piping. while the engine is running
Caution during drilling, welding and
grinding work. Protect piping
against battery acid.
Temperature-resistant in the range
from
-40°C to +100°C
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1.1 Warning and instruction plates (cont'd.)
CAUTION !
ATTENTION - DANGER OF
Nobody is allowed to stay in the
ACCIDENTS !
driver's cab during crane work!
When lowering the vehicle, make
sure that nobody stays under or on
the vehicle Apply the handbrake before you
leave the driver's cab!
STOP !
Access prohibited to unauthorized
persons.
Outriggers horizontal / vertical - Outriggers horizontal / vertical -

left-hand right-hand
99707754515
Key-actuated switch
Oil level indicator
Oil dipstick
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Tires according to vehicle model Plate
(only in the United Kingdom)
Instruction plates **) Instruction plates **)
Instruction plates**)
ATTENTION
Before changing-over to operation
from the superstructure, make sure
Only in case of optional feature
that:
"Emergency operation of the Instruction plate**)
superstructure controlled from the Maximum admissible load (weight)
1. the gearshift lever is set to
chassis".
neutral,
2. the vehicle is immobilized, and
that
3. the handbrakes are applied.
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The following diagram shows the position and the location of all the warning and instruction plates mounted to the chassis.
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NOTE The STGO travel speeds and axle

loads apply only for public roads in UK.
The STGO travel speeds are allowed only
up to tyre speed limits (see tag on
instrument panel and in manual).
Driving with axle loads higher than 12.000
kg will increase the braking/stopping
distance. The braking performance of the
crane shall be established by the driver at
the actual axel loads under normal
operating conditions. Special attention shall
be paid to local conditions (e.g. road
condition, weather condition, …)
Every attempt should be made to distribute
the load evenly on all axles were possible
(see instruction manual).
Axle loads higher than 12.000 kg will cause
significantly more wear and tear of
components (e.g. brake linings, tyres,
shafts, gearbox, engine, suspension,…).
The driver is responsible for taking into
account the above points when driving a
crane with axle loadings exceeding 12,500
kg per axle (as allowed under the STGO
Regulations).
**) According to the STGO regulations (only in the United Kingdom)

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1 Tool box**) 20 Hydraulic accumulator

2 Sliding coupling device at the rear 21 1st axle, driven
3 Trailer coupling device**) 22 Outrigger, front, left-hand
4 Fuel tank filler socket 23 Access to driver's cab
5 Outrigger, rear, left-hand 24 Steering gear
6 Compressed air tank 25 Air conditioning**)
7 4th axle, driven 26 Sliding coupling device, front
8 Rear axle lock 27 Radiator
9 Eddy-current brake**) 28 Coolant overflow tank
10 Hydraulic accumulator 29 Water separator
11 3rd axle, driven 30 Air cleaner
12 Access to superstructure 31 Engine
13 Test panel 32 Gearbox
14 Exhaust system 33 Suspension cylinder, 2nd axle
15 Hydraulic oil tank 34 Transfer box
16 Batteries 35 2nd axle, not driven
17 Air drier 36 Propeller shaft
18 2nd axle, driven **) 37 Compressed air tank
19 Brake cylinder, 2nd axle 38 Fuel tank
39 Handles

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1.4 Transport condition of the crane when used in public road traffic
When the crane is used in public road traffic, it is essential that the conditions and prescriptions specified in
the expertise of the Technical Inspection Association (German TÜV) are observed.
• For the admissible axle loads, please refer to Part A) (Technical Data) of this Operating Manual.
• The boom must be positioned forward in the longitudinal direction of the vehicle, and be either completely
retracted, depending on the rig arrangement, or tele section I must be extended by approx. 300 mm (see
item B2-6.6.7), stowed and secured.
• The superstructure must be secured to prevent it from slewing, and the swing brake must be engaged.
• If a basic section of the jib is provided, it must be folded laterally to the boom, and secured. The
intermediate section and the top jib must be transported separately
• The bottom block must be attached on the front bumper crossmember and secured, as described in the
Operating Manual. Any national regulations differing from those mentioned above must be taken into
consideration.
• Any additional bottom blocks transported with the machine must either be deposited in the bottom block
rests provided to this effect, or stowed on the chassis and secured appropriately. To this effect, refer also to
the admissible axle loads in part A) (Technical Data).
DANGER When the boom is completely lowered, it is not possible to slew the superstructure
through 3600. Collision of boom with counterweight, motor fairing or driver's cab.
• A part of the counterweight - the weight of which depends on the machine model or the rig arrangement -
must be deposited in the counterweight rest on the chassis.
• Any counterweights, intermediate section / top jib and other items of equipment transported on auxiliary
vehicles must be secured adequately.
• The outriggers must be retracted completely and secured mechanically.
• The outrigger floats must be slipped into place and secured.
• Attachments and superstructure components must be secured so that they cannot slip or fall down.
• Loose objects must not be deposited on the platforms of the chassis and the superstructure.
• The traffic regulations must be observed taking the admissible axle loads (refer to part A) and gross vehicle
weights into account (according to the expert opinions of the technical inspection agencies, the data given
in the vehicle title or the vehicle registration papers).
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1.4 Transport condition of the crane when used in public road traffic (cont'd.)
• The engine in the superstructure has been stopped.

• Ignition starter switch for the superstructure engine in position 0.
• Rocker switch for "ignition, chassis" in position - ignition OFF -.
• Key-actuated change-over switch in the chassis for "ignition, superstructure" in position 1 - ignition OFF.
• The windscreen and the sliding door of the crane cabin must be closed.
• The lids on the engine fairing or swing fairing of the superstructure must be locked to prevent unintentional
opening.
• The wheel chocks **) must be available on the vehicle and stowed in the storage box so that they cannot
be lost.
• Tools, accessories and loose components must be kept in a safe place or stowed in the tool box*) so that
they cannot be lost. The tool box cover must be locked.
• Safety accessories**)- warning triangles, first-aid kit, warning lights and fire extinguishers - must be stored
in an easily accessible place and checked for proper working order and completeness at regular intervals,
or taken to authorized agencies for inspection.
• The covers on the control boxes of the outrigger actuating systems must be closed.
DANGER All parts which can be lost, e.g. cotter pins, retaining clips, securing pins and locking
pins must be fixed to the machine so that they cannot be lost.
All sliding parts, such as outrigger beams, etc., must be locked to prevent
unintentional extension.
No loose objects must be placed on the platform.
If these instructions are not observed, there is a risk of accidents.
*) Optional equipment
**) Specific requirement of the country where the machine is to be operated
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1.4.1 Transport condition, graphic display
The safety accessories**) (warning triangles, first-aid kit, warning lights and fire extinguishers) can be stored
in the storage boxes in the driver's cabin.
The wheel chocks **) are installed to the right and left at the rear of the vehicle.
A tool box **) is located at the rear of the vehicle.
The rest for the auxiliary bottom block is located centrally above the 1st axle. The bottom block can then be
deposited in the rest of from above.
Any additional bottom blocks transported with the machine must either be stowed on the chassis and
secured appropriately, or deposited in the bottom block rests provided to this effect.
Partial counterweights **) must be transported in the counterweight rest provided to this effect on the carrier,
or on the superstructure (depending on the equipment provided and on the machine state at the time of
registration).
The crank used to mount the jib**) is located on the right side of the vehicle, on its platform above the 3rd
axle.
Attention All covers must be closed before the superstructure can be slewed !
**) Specific requirement of the country where the machine is to be operated

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Driver's cab B1-2
Memo:
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B1-2 Driver's cab
2 Driver's cab
2.1 Explanation of the control elements and of the equipment
1 Lateral bordering light

2 Flashing beacon**)
3 Air distributor, passenger
4 Passenger seat
5 Bunk**)
6 Storage box
7 Refrigerator box**)
8 Cigarette lighter
9 Electric mirror adjusting device
10 Switch for refrigerator box**)
11 Handbrake lever
12 Ashtray
13 Gearbox control device
14 Control element for Webasto supplementary heater unit**)
15 Fire extinguisher
16 First-aid kit
17 Driver's seat
18 Seat adjusting lever
19 Access plate
20 Accelerator pedal
21 Footbrake pedal
22 Steering wheel adjustment
23 Lateral light
24 Direction indicator
25 Air distributor - side pane
26 Steering column switch (direction indicators, windshield wiper etc.)
27 Instrument panel
28 Steering wheel
29 Steering column switch (engine brake etc.)
30 Radio
31 Control unit, heating, ventilation and air conditioning system**)
32 Air distributor, passenger compartment
33 Fuses
34 Diagnostic plug, engine
35 Relay box
36 Roller sun visor

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Driver's cab B1-2
Driver's cab
„X“
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B1-2 Fahrerhaus
Memo:
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Driver's cab B1-2
2.3 Front cover
Various assemblies have been arranged below the front cover where they are easily accessible for mainte-
nance and repair work.
2.3.1 Unlocking the front cover
The lever provided for unlocking the front cover is located on

the left, below the dashboard.
- Actuate the lever (1) to unlock the front cover.
2.3.2 Opening and securing the front cover
- Fold the unlocked front cover (1) upwards and secure it in

this position using the supporting bar (2).
DANGER When work is being performed with the

front cover open, this must definitely be
secured. Risk of accidents in case the
front cover should drop.
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B1-2 Driver's cab
2.3.3 Explanation of the devices located under the front lid
1 Voltage transformer 24/12 V

2 Tank for windshield washer fluid
3 Engine speed switching unit, eddy-current brake **)
4 Electronic system, gearbox control
5 Electronic system, engine
6 Windshield wiper motor
7 Speedometer - plug-and-socket connector
8 Brake valve
9 Change-over damper, outside air / circulating air
10 Air inlet, heating / ventilation

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Driver's cab B1-2
2.4 Seat adjustment
The driver's and the passenger's seat afford maximum comfort. Both seats are equipped with pneumatic
suspension and thus adjust automatically to the driver's weight. The downwards or upwards deflection
amounts to 20 mm each. To adjust the seats optimally as regards their position with reference to the control
elements, the seats' longitudinal position and the inclination of the seats' surfaces can be adjusted. More-
over, the backrest and the headrest are also adjustable. The seats' height can be adjusted easily to the
driver's stature by means of an air-assisted vertical adjusting device.
The driver's and the passenger's seats are equipped with identical control elements. The following illustra-
tions and descriptions refer to the adjustment of the driver's seat.
1 Linkage - longitudinal adjustment

2 Control lever - inclination adjustment
3 Control lever - height adjustment
4 Control lever - quick lowering feature
5 Control lever - backrest adjustment
6 Headrest adjustment
2.4.1 Longitudinal adjustment
To adjust the seat position and consequently its distance from the control elements in the longitudinal direc-
tion:
- Actuate the linkage - longitudinal adjustment - (1) upwards.
Longitudinal adjustment: approx. 140 mm.
2.4.2 Inclination adjustment
To adjust the seat surface inclination steplessly by approx. 10°:
- Lift the control lever - inclination adjustment - (2)
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B1-2 Driver's cab
2.4.3 Height adjustment
To adjust the seat steplessly in height by approx. 100 mm:
- Pull the control lever - height adjustment - (3) upwards and keep it in this position, until the seat is adjusted
to the desired vertical position.
2.4.4 Quick-lowering feature
With the quick seat lowering feature, the seat can be lowered entirely so that the driver can leave his cab
easily.
- Pull the control lever - quick lowering feature - (4) upwards.
The seat is lowered and remains in this position.
- After returning to the cab, the driver must push the control lever down.
The seat returns automatically to the position adjusted last.
2.4.5 Backrest adjustment
To adjust the backrest inclination in steps from approx. 0° to 36°:
Actuate the control lever - backrest adjustment - (5) upwards.
2.4.6 Headrest adjustment
The headrests (6) can be adjusted as regards their vertical position and
their inclination.
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Driver's cab B1-2
2.5 Adjustment of the steering wheel
The steering wheel can be adjusted to the driver's stature

easily and progressively by means of an air-assisted
inclination and height adjustment.
- Actuate rocker tip switch (1) down to release the steer-

ing wheel lock.
- Hold steering wheel in its position to adjust the angle of

inclination and the vertical position.
- Actuate rocker tip switch (1) upwards to re-engage the

steering wheel lock.
However, locking is also effected automatically after a

few seconds.
DANGER Do not adjust the seat and the steer-

ing wheel while driving.
2.6 Actuation of the roller sun visor
Roller sun visors are installed on the windscreen to protect the

driver and the passenger against dazzle. This sun protection
can be lowered approx. to the middle of the windscreen.
Actuation of the roller sun visor:
- Pick the tab (2) to pull the roller sun visor (1) down to the de-
sired position. The roller sun visor locks automatically in any
position desired.
To reset the roller sun visor:
- Pull the return cord (3) downwards. When the cord is released,
the roller sun visor locks automatically in any position desired,
or in end position.
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B1-2 Driver's cab
2.7 Seat belts
NOTE To protect the occupants, they should fas-

ten their seat belts even at low driving
speed to ensure their proper safety (observe
legal regulations regarding the use of safety
belts).
Function:
- Pull the seat belt (1) carefully out of its holder and forward
(jerky movements make the lock engage).
- Make the tongue (2) engage into the buckle (3).
- To release the belt, push the button (4) of the buckle.
The belt retractor returns the belt automatically into its original
position.
DANGER After an accident in which the seat was involved, it must be ensured that it has not
been damaged, e.g. possibly elongated.
An inspection and repair (replacement) by a specialist workshop are indispensable.
2.8 Cab lighting
Lamps are installed above the roller sun visor to illuminate the cabin.
0 = Lamp OFF.
1= Lamp is lit when the door is open (while the battery main
switch is ON).
2= Lamp is permanently lit (while the battery main switch is
ON).
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How to put the machine into operation B1-4
NOTE All the instruments, switches and indicator lamps are described in the following text
are illustrated in part B1-11 "Instrument panel".
The item numbers appearing in the text are printed in bold letters, and are
identical with those appearing in the illustrations.

- Actuate the rocker switch "battery main switch" 92 (item 4.2.1).
- The parking brake (handbrake) is engaged (item 4.5).
- The gearbox selector lever is in "neutral position" (item 4.5).
- Check the engine oil level when the machine is in horizontal position (Part "C1" Service and Maintenance
work on the chassis).
- Check the hydraulic oil level (Part "C1" Service and Maintenance work on the chassis).
- Check tires at regular intervals for the correct inflating pressure and for wear (Teil "C1" Service and
Maintenance work on the chassis).
NOTE The tire inflating pressures specified in part "A" apply to the original equipment of the
machine. When changing the brand, adhere to the prescriptions of the appropriate tire
manufacturer.
- Check the vehicle's electrical equipment for proper operation.
- The key-actuated change-over switch UW-OW 91 is in switch position "I" (item 4.1.1).
- The rear axles are locked in straight-ahead position (item B1-5.9.2).
- The drive of the second axle is disconnected**)(item B1-5.4.2).
- The differential locks in the axles have been disconnected (item B1-5.4).
- The axle suspension must be operating (item 4.7.2).
- The outriggers are retracted; the outrigger beams are locked by pins; the outrigger plates are inserted and
locked (item B1-6).
- The telescopes are retracted and set to transport position (condition required for on-road travel); the hook
block is attached to the securing eyelet.
- The parking brake (handbrake) in the superstructure is engaged.
- The swing brake in the superstructure has been engaged.
- The vehicle has to be checked (visually) for precisely horizontal alignment.
- Make sure that no detached parts are placed on the platform.

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B1-4 How to put the machine into operation
4.1.1 Key-actuated change-over switch - Switching options
Switch position Functions on the machine Key-actuated switch 91

Chassis Super-
structure
item B2-12, 31
1 Only operation from carrier (U.W.).
2 Connection to superstructure (O.W.) is established.
2 OFF Ignition, chassis, OFF.
2 ON Connection carrier - superstructure. Ignition of
carrier is switched ON. The superstructure can be
driven via the engine in the chassis.
4.2 Operation of the electrical equipment of the chassis

4.2.1 Battery main switch
Attention When the engine is running, the battery main switch definitely must not be turned
OFF. The current flow between the generator and the battery must not be interrupted
(destruction of the diodes of the generator).
Switching ON:
- Unlock the rocker switch 92 "battery main switch" by actuating the locking handle down, and
push the rocker switch down. The locking handle returns to its locking position automatically.
Thus, the connection between the chassis ground and the negative battery terminal ("-") has
been established.
Switching OFF:
- Actuate the locking handle down and the rocker switch upwards; now the electrical equipment is de-
energized.
NOTE Whenever work is interrupted for an extended period, e.g. at night, the battery main
switch must be turned OFF.
4.2.2 Ignition starter switch
The ignition starter switch is installed on the steering column and - ignition
key inserted - has the following switch positions (refer to Fig.).
Position 0: Ignition OFF, steering wheel lock active.

Position 1: Operation from superstructure, steering wheel lock open.
Position 2: Ignition ON.
Position 3: Engine start.
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4.2.2.1 Switch the ignition ON
- Turn the ignition key to position "2"; the following indicators and pilot lamps go on:
Generator 11, steering pump 15, emergency steering pump 32, parking brake 44, service brake 3 (in case of
insufficient brake-air pressure), engine malfunction 12; engine malfunction buzzer 80 - sounds briefly; ABV,
tractor 6 and ABV, trailer 5**). The fuel level indicator 52 indicates the current fuel level. "CH" appears in the
gearbox display 55.
4.2.3 Flashing beacon
- The rotary beacon is switched on and off via the rocker switch 76.
- Rocker switch pressed down = rotary beacon "ON";

- Rocker switch pressed upwards = rotary beacon "OFF".
An orange function lamp in the switch goes on to indicate that the switch is turned ON.
4.2.4 Rear fog light
The rear fog light is switched on via the rocker tip switch 77.
Actuate rocker tip switch downwards: The rear fog light is switched on.
Actuate rocker tip switch upwards: The rear fog light is switched off.
The indicator lamp 40 is lit while the rear fog light is switched on.
4.2.5 Hazard warning flasher system
To protect the machine in cases of emergency, actuate the rocker switch 58 "hazard warning
flashers".
- Rocker switch pressed down = hazard warning flasher system "ON";

- Rocker switch pressed upwards = hazard warning flasher system "OFF".
The red function lamp in the switch flashes while the hazard warning flasher system operates.

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4.2.6 Windshield wipers, windshield washing system
- To switch the windshield wipers ON/OFF, turn the switch ring (1)
forward / back.
Switch position 0 = Wiper OFF,

Switch position INT = Interval circuit,
Switch position I = Step I - Slow wiper operation,
Switch position II = Step II - Fast wiper operation.
- To actuate the windshield washing system, shift the switch ring (1)
towards the steering column.
4.2.7 Parking light, dimmed light
Actuate the rotary switch 47 to switch ON the parking light or the dimmed light.
Switch position 0 = no lights on

Switch position I = parking light
Switch position II = dimmed light
4.2.8 High-beam light, headlamp flashers
To change-over from dimmed light to high-beam light:
- Actuate rotary switch 47 into position II.

- Lever (1) in central position (dimmed light).
- Lever (1) pushed out of its central position to
- a / away from the driver = high-beam light (locked position).
- Lever (1) pushed out of its central position to
- b / towards the driver = headlamp flasher
When the lever (1) is released, it returns to its central position. The headlamp flashers go out.
When the high-beam light is switched ON, the pilot lamp „High-beam light“ 41 goes on.
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4.2.9 Direction indicators
Steering column switch (1) actuated:
- c = direction indicators to the right of the vehicle are actuated;

- d = direction indicators to the left of the vehicle are actuated.
The driving direction is indicated by the direction indicators, which are

flashing.
The green pilot lamp 14 "direction indicators, chassis" flashes to indicate that the chassis
flasher system is operating.
During operation with trailer, the green pilot lamp 33 "direction indicators, trailer"**) will go on
additionally.
4.2.10 Electric horn
- The electric horn is switched ON by pressing the horn push-button switch (2)
at the end of the steering colum switch (1).
4.2.11 Mirror heating system
The mirrors can be heated in order to prevent misting during the cold season.
- Actuate the rocker switch 68 "mirror heating"; the pilot lamp in the switch goes on to indicate
the heating process.

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4.2.12 Adjustment of rearview mirror
The mirror adjusting switch on the central bracket, to the right of the
driver's seat (refer to sect. B1-2, item 9), can be used to adjust the
right-hand or left-hand rearview mirror horizontally and vertically.
- If the switch is turned through 90° (see Figure), the mirror adjusting
function for the right-hand or left-hand rearview mirror is activated.
- Depending on the position of the arrow in the switch, the rearview

mirror can be adjusted up or down to the left or right by tilting the
switch in the desired position.
4.2.13 Cigarette lighter
A cigarette lighter (8) (item B1-2.1, driver's cab) is installed in the

bracket to the right of the driver's seat.
After removing the cigarette lighter insert, external consumers (e.g. an
inspection lamp, etc.) can be connected to the plugbox behind.
However, it may be necessary to use an adapter.
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4.3 Functional check of the electrical equipment of the vehicle before starting
driving operation
Before the driver sets the vehicle into motion, he has to check the hazard warning flasher system, the
windshield wipers, the electric horn and the complete lighting system for proper working order.
NOTE The inspection of the lighting system is only possible when the battery main switch
and the ignition are switched ON.
The following items of the lighting system have to be checked in particular:
- Parking light on the left and right, front and rear,

- Dimmed light / high-beam light on the left and right,
- Direction indicators on the left and right, front and rear,
- Stop lights on the left and right,
- Backup lights on the left and right,
- License plate illumination,
- Flashing beacon,
- Fog lights on the left and right**),
- Rear fog lights on the left and right.
- Border lights.
DANGER Any faulty functions and missing or defective lighting equipment increase the risk of
accidents.
Should there be any faults, they have to be eliminated by specialists before driving
begins.
Attention When fuses are replaced, the new fuses must absolutely have the same amperage as
the defective fuses.
Do not use fuses with a higher amperage.
It is definitely prohibited to "mend" defective fuses temporarily and to re-use them.
Non-compliance with these instructions may entail damage to the electrical

equipment.

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4.4 Air distribution; fan; heater unit; air circulation and air conditioner **)
4.4.1 Air distribution (1)
The rotary switch (1) enables stepless control of the air distribution.
- Air flow to the space.
- Air distribution to the space and to the windows.
- Air flow to the windows.
4.4.2 Fan (2)
- Fan OFF.
1 - First step, low power.
2 - Second step, medium power.
3 - Third step, high power.
4.4.3 Cold-warm air regulation (3)
- The temperature of the incoming air can be controlled progressively via the rotary switch (3), from cold
(rotary switch turned to the left) to warm (rotary switch turned to the right).

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4.4.4 Air circulation (4) (5)
- When the pushbutton switch (4) is actuated, the supply of outside air into the driver's cabin is stopped.
The air intake and the air circulation are now only effected in a closed circuit, within the driver's cab. When
the air circulation is switched ON, the pilot lamp (5) is lit.
4.4.5 Control switch "Air conditioner" **)(6) (7)
Control and operation of the air conditioner are explained in the chapter under item B1-10 "Optional
equipment".
NOTE Air conditioners can be retrofitted. For this reason, the control switch and the pilot lamp
have already been installed and are operative. When switch (6) is actuated, the pilot lamp
(7) goes on, even if no air conditioner is provided.

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Lock position
DANGER Before starting the engine, make sure that the
handbrake / parking brake levers in the chassis
(and the rocker switch in the superstructure) are in
"braking" (Lock position) position.
- The key-actuated change-over switch 91 is set to "position 1".
DANGER During driving operation, do not set the key switch to

position 2.
It is recommended that the key switch be removed during driving operation.
- The rotary switch - Gearbox is set to "N" (gearbox in neutral position).
- Insert ignition key into ignition starter switch, turn it to into "position 2" -
now the ignition is switched ON.
- Self-check of the control system ("CH" appears on the display).
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4.5. Starting the engine (cont'd.)
- Start the engine. Turn the ignition key to its stop (position "3" - start) and
hold it against the spring force. As soon as the engine ignites, release the
key. Do not actuate the starter longer than 20 seconds. To save the
batteries, make pauses of approx. 60 seconds between the various
starting attempts.
- Self-check is finished. "N" appears on the display; gearbox is in neutral

position.
NOTE Gearshifts are not possible when the engine is not running.
- After starting, only the warning lamps "parking brake" 3 and "emergency steering pump" 32 may be lit.
While the engine is running, the following instruments are in operation:
Revolution indicator with integrated hourmeter 51, engine temperature indicator 53 (according to load),
tachograph 50, fuel level indicator 52, air pressure gauge - BBA I 48 and air pressure gauge - BBA II 49.
Explanation of pilot lamps and instruments while engine is running: see item 3.4
(For further details, please refer to the operating manual of the engine manufacturer).
4.5.1 Stopping the engine
- Engage the parking brake (handbrake).

- Set rotary switch "driving operation" to neutral position "N".
- Stop the engine by turning the ignition key to the left, to position 0.
Do not stop the engine immediately after working under high load, but allow it to run at idling speed for a few
minutes, so that the temperature can adjust.
NOTE Do not stop the engine immediately after it has been working at high speed.
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4.5.2 Emergency operation of engine - emergency start - emergency stop
Push-button switches for "starting" (1) and "stalling" (2) the

engine are located directly on the engine casing.
- Remove engine cover.
DANGER Before performing an emergency start of

the engine, make sure that the gearbox is
set to neutral.
The parking brake (handbrake) is engaged.
Engine start actuation:

● The ignition in the chassis is ON and the engine is not
running.
● The gearbox is set to neutral position "N".
- Actuate push-button (1) – the engine is started and operates
at idle.
Õ Driving direction
Engine shut-off actuation:
● The ignition in the chassis is ON and the engine is running.
- Actuate the push-button (1) again – the engine comes to a standstill.
or
- Actuate the push-button (2) – the engine comes to a standstill.
Starting the engine and increasing the engine speed:
● The ignition in the chassis is ON and the engine is not running.

- Actuate push-button (1) and keep it pressed – the engine is started and runs at idle; 3 seconds after the
engine has started, the engine speed increases to max. level.
- Release the push-button (1) – the engine continues to run at its instantaneous speed.
- Actuate push-button (1) again, or actuate push-button (2) – the engine comes to a standstill.
Actuation of engine cranking function:

● The ignition in the chassis is ON and the engine is not running.
- Actuate push-buttons (1) and (2) at the same time – the engine cranks, but does not start.
- Release the two push-buttons (1) and (2) – starter activation is cancelled, the engine comes to a standstill.
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4.5.3 Manual fuel pump - fuel filter with water separator
The fuel filter with water separator and integrated manual pump is installed on the right-hand side of the
vehicle, behind the radiator housing.
Should air and/or dirt have entered into the fuel system, the filter cartridge must be replaced, and the fuel
system must be cleaned and bled.
Bleeding the fuel system, and supplying fuel via the manual pump, after
• the fuel tank has been emptied completely,
• leakage has occurred in the fuel system,
• the fuel filter has been replaced (filter replacement, refer to part C1, Service and Maintenance chassis).
Prerequisite:
- a sufficient amount of fuel has been replenished,
- any leakage has been eliminated,
- the filter cartridge has been replaced as described in part C1, Service and Maintenance chassis.
Bleeding, and supplying fuel:
- Open vent screw (1); actuate pump plunger (2) repeatedly, until
fuel flows out without bubbles.
(Collect overflowing fuel in an appropriate vessel and pour it back
into the fuel tank.)
- Tighten the vent screw (1) securely again.

- Start the engine. Should the engine fail to start immediately, have
an assistant actuate the pump plunger repeatedly, until the engine
is operating smoothly.
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4.6 Monitoring the indicating, pilot, warning lamps and the instruments while
the engine is running
4.6.1 Fuel level indicator
If the needle in the instrument 52 drops close to zero indication, fuel must be
replenished in time.
NOTE Make sure that the fuel tank is never completely emptied, as
otherwise air might get into the fuel system. Consequently the
system would have to be bled completely, and filters and
piping assemblies would have to be cleaned.
DANGER Explosion hazard: Do not smoke; do not use any open flames; to fill the fuel tank,
make sure that the engine is not running and that the machine is aligned in horizontal
position.
4.6.2 Engine
4.6.2.1 Engine oil level
The engine oil level is monitored via the warning lamp 35 “Engine oil level” while the engine is
not running.
If the red warning lamp 35 “Engine oil level” appears while the ignition is ON and the engine is
not running, the oil level must be checked and, if necessary, oil must be replenished.
Check oil level and, if necessary, replenish oil; if applicable, check for a loss of oil and eliminate
the reason. Make the engine run for approx. 2 or 3 minutes and stop it again; after approx. 5
minutes, check the oil level and, if necessary, repeat this procedure.
NOTE The oil level may only be checked while the engine is not running.
For further details, please refer to the Operating Manual of the engine manufacturer.
4.6.2.3 Function engine
In case of engine malfunction, the "Engine malfunction" warning lamp 12

goes on.
Eliminate the fault at the next opportunity; if necessary, take the machine to a
specialist workshop.
In case of serious defects, the buzzer 80 “Engine malfunction” sounds

simultaneously.
In this case, the vehicle must be stopped immediately; the reason for the
malfunction must be determined and eliminated without delay.
If necessary, the vehicle must be taken to a specialist workshop to have the trouble eliminated.
Attention The warning lamp "engine malfunction" 12 also goes on and the warning buzzer 80
"engine malfunction" sounds when the engine speed of 2350 rpm is exceeded. To
prevent the engine from being damaged, the machine must be decelerated
immediately by actuation of the service brake, and the engine speed must be reduced.
When the engine speed of 2800 rpm is exceeded, the engine brake is engaged
automatically by the engine's electronic system.
After the trouble has been eliminated, the error must be read out of the system by means of a diagnostic
device. This should be effected in a specialist workshop or by the TADANO FAUN after-sales service.
(For further details, please refer to the Operating Manual of the engine manufacturer.)
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4.6.2.4 Generator
As soon as the engine is running, the warning lamp 11 „generator“must go out. If it does not
go out, or if it goes on during traveling operation, there is a malfunction and the batteries are
not charged.
Make sure that the problem is eliminated in a specialist workshop as soon as possible.
The batteries must always be fully charged.
4.6.2.5 Coolant temperature
The coolant temperature is monitored via the instrument 53 “Engine temperature

indicator”.
The admissible service temperature is in the range from 70°C to max. 95°C.
If the coolant level drops, the coolant temperature consequently exceeds the
maximum admissible rating.
The needle moves into the critical range.
Eliminate the fault at the next opportunity; if necessary, take the machine to a
specialist workshop.
If the red warning lamp “engine malfunction” 12 goes on and the buzzer “engine malfunction” 80 sounds
additionally, stop the vehicle immediately, stop the engine, locate the reason for the malfunction and
eliminate it immediately.
For information on remedial measures in case of excessive temperatures, please refer to the operating
manual of the engine manufacturer.
4.6.2.6 Coolant level
A sensor installed in the coolant expansion tank monitors the coolant level. If the level is too
low, the warning lamp 36 “Coolant level” in the instrument panel will go on.
In this case, top up coolant via the filler port in the expansion tank. (Refer to part "C1" Service
and Maintenance, Chassis).
The reason for the loss of coolant must be determined and eliminated.
DANGER Do not check the coolant level when the engine is hot; the engine cooling system is
pressurized.
When the filler socket is opened while the engine is hot, there is a risk of scalding!
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4.6.2.7 Change-over lever of cooling system
The rotary speed of the fan which serves to cool the engine coolant is controlled via the thermostatic valve
(2) independently of the engine speed.
At the same time, the change-over cock is placed in its original position (1) (change-over cock parallel with
reference to the piping).
In case of failure or of a deficiency of the thermostatic valve, the fan only runs at dragging speed and the
cooling effect on the engine diminishes substantially.
In this case, to achieve the required cooling effect, the system can be set to operation depending on the
engine speed.
The maximum coolant temperature must not be exceeded even if the change-over cock is moved down (item
B-4.6.2.5).
When working from the superstructure, the central warning light of the superstructure cabin must not go on.
Note A defective thermostatic valve must be replaced or repaired as quickly as possible. As

soon as the thermostatic valve is operating normally again, the change-over cock
must be returned to its original position.
Ö
1 = Basic position
4.6.2.8 Engine speed
The engine speed is indicated by the instrument 51 “revolution counter”.

The maximum admissible speed is 2000 r.p.m.
In overrun condition, e.g. while driving on downhill grades or in continuous braking

mode, the control electronic system is inoperative, i.e. this engine speed can be
exceeded. In this case, the max. admissible engine speed is 2350 r.p.m.
4.6.2.9 Operating hours
A hourmeter is provided for monitoring the operating hours. It is integrated in the

revolution counter 51. The hourmeter is activated as soon as the engine is started.
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4.6.2.10 Contamination of air cleaner
The intake air resistance or the vacuum on the clean air end of the dry air cleaner is
monitored by the yellow indicator lamp 13 "air cleaner".
If the indicator lamp goes on while the engine is running, this means that the air cleaner
cartridge must be replaced. (Refer to part "C1" Service and Maintenance, Chassis).
4.6.3 Hydraulic system

4.6.3.1 Contamination of the hydraulic oil filter
The degree of contamination of the hydraulic filters is monitored. In case of an excessive

contamination of the hydraulic oil filters, the red warning lamp "hydraulic oil filters" 34 goes
on.
Should this occur, the hydraulic oil filters have to checked and, if necessary, replaced
immediately.
4.6.3.3 Monitoring the steering hydraulics (dual-circuit steering system)
The steering pump and the emergency steering pump are checked for proper operation via
the red warning lamp 15 "steering pump" and 32 "emergency steering pump". Both warning
lamps go on when the ignition is switched on. After the engine has started, the warning lamp
15 "steering pump" goes out. If the vehicle is set into motion, the warning lamp 32
"emergency steering pump" of the reserve pump goes out.
DANGER If a lamp goes on during traveling operation, this indicates a deficiency in the
corresponding steering pump circuit. In this case, stop the vehicle immediately, and
determine the reason for the deficiency (e.g. loss of oil).
After the deficiency has been eliminated, check the steering system for proper
working order before the vehicle is returned to service.
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4.6.4 Gearbox
4.6.4.1 Gearbox malfunction
A warning lamp "gearbox malfunction" 57 goes on in case of a malfunction in

the gearbox. At the same time, the buzzer "gearbox malfunction" 81 sounds. In
this case, the vehicle must be stopped immediately and the reason for the
malfunction must be determined.
If necessary, the vehicle must be taken to a specialist workshop to have the
trouble eliminated.
4.6.4.2 Display - gearbox
The „Display gearbox“ 55 shows all the system information required (e.g. gear stage,
fault etc.).
Attention It is essential to watch the malfunction indicators in the display. Failure to comply
with this instruction may result in damage to the gearbox and/or the clutch!
Attention In the 1st gear / manoeuvring mode, the self-protective functions of the clutch are not
active.
Non-compliance with the warnings “gearbox malfunction buzzer 22” and “gearbox
display - warning CL” may result in damage to the clutch.
For further details, please refer to the Operating Manual of the gearbox manufacturer.
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4.6.5 Brake system

4.6.5.1 Air pressure gauge
The brake-air pressures of the service brake circuits I and II are indicated via the
two air pressure indicators 48 and 49.
Air pressure indicator 48 = service brake circuit I
Air pressure indicator 49 = service brake circuit II
When the compressed air system is filled, or during driving operation, the needles of
the air pressure indicators must indicate 8.5 to 10 bar.
4.6.5.2 Pilot and warning lamps

!
Warning lamp 3 - "Service brake"
The red central warning lamp "service brake" 3 has been installed to monitor the brake-air
pressure of the brake system (brake-air pressures of service brake system, circuits I and II, and
circuit III - air accumulator system).
The red warning lamp goes out as from a brake-air pressure of approx. 5.5 bar.
NOTE If the red warning lamp 3 "service brake" goes on, the air pressure indicators 48 and
49 must be checked to see whether the needle exceeds the 5.5 bar indication.
If it does so in both air pressure gauges, this indicates a malfunction in the air
accumulator circuit (FBA) or in the auxiliary equipment circuit.
DANGER Whenever the red warning lamp "service brake" 3 goes on, stop the vehicle immediately,
determine the reason for the malfunction and eliminate it immediately.
Warning lamp 44 "parking brake"
The red warning lamp "parking brake" 44 goes on when the vehicle is positively braked via the
handbrake lever (air accumulator section is released), and goes out when the handbrake is
released (air accumulator section is ventilated).
If the warning lamp goes on, this indicates a malfunction in the air accumulator circuit.
P
NOTE Set the vehicle only into motion once the air pressure indicators 48 and 49 indicate a
brake-air pressure of at least 7.5 bar and after the warning lamp 3 "service brake"
and/or the red warning lamp 44 "parking brake" have gone out.
Attention The warning lamp 44 monitors directly the correct working order of the air
accumulator parking brake which acts on the second, third and forth axles. When the
parking brake is applied, this warning lamp must go on.
4.6.5.2.1 Acoustic warning device in brake system**)
The compressed air supply of circuits I and II of the service brake system is monitored by a warning lamp
(refer to item 4.6.5.2).
Moreover, an acoustic warning device is installed in the system. If the pressure level in the supply system of
the brake circuits drops below approx. 5,5 bar, a warning sound is emitted (this warning buzzer is installed in
the area of the dashboard).
DANGER When the warning buzzer sounds, the vehicle must be stopped immediately and the
reason for the pressure decrease must be determined.
**) According to the regulations in the United Kingdom

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4.6.5.3 ABV system (automatic anti-block system)
The ABV system prevents the individual wheels from blocking in case of excessively powerful actuation of
the service brake system, when the appropriate electronic system detects skidding or otherwise varying road
conditions.
Thus, the vehicle's driving and steering stability remains ensured to a large degree, due to non-blocking
wheels, as far as this is possible considering the prevailing physical possibilities, even during full braking
operation.
When the engine is started, the safety circuit checks actively the sensor-based monitoring of the wheels and
axles, as well as all the other essential components of the ABV system.
The vehicle is equipped with the following warning and inspection lamps which ensure detection of the
functions and the continuous monitoring of the ABV system:
Warning lamp "ABV - tractor" 6
The warning lamp 6 "ABV - tractor vehicle" monitors the chassis. After the ignition has been
switched on, the ABS warning lamp must go on, and go out again after 2 to 3 seconds.
When the warning lamp 6 "ABV - tractor" goes on during travelling operation, this indicates a
failure of the ABV components. However, in this case the functional safety of the conventional
air-actuated brake system remains fully ensured.
Warning lamp "ABV - Trailer" 5**)
The warning lamp „ABV - Trailer“ 5 monitors the trailer. After the ignition has been switched
on, the ABV warning lamp must go on, and go out again after 2 to 3 seconds.
If a trailer without ABV system is coupled, the warning lamp 5 “ABV trailer” must not be lit.
When the warning lamp „ABV - Trailer“ 5 goes on during operation with trailer, this indicates a
failure of the ABV / trailer components. However, in this case the functional safety of the
conventional air-actuated brake system remains fully ensured.

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4.6.5.2.2 ABV system “off-road mode”
The ABV system can be switched over to an increased brake slip via the rocker tip switch 90
“ABV OFF-road mode” in the instrument panel.
If this mode is selected, the braking distance in rough terrain and on dirt tracks (e.g. on soft or
extremely uneven ground and on downhill gradients) can be reduced.
The off-road mode in the tractor vehicle and in the trailer can be actuated while the vehicle is
at a standstill (key in steering lock in "driving" position), or during driving operation.
Once the engine has been stopped and re-started, the off-road mode ABV function is reset
automatically.
When driving in rough terrain, the function can be switched off again via the rocker tip switch
90 “ABV off-road mode”.
Driving in rough terrain: Off-road mode switched ON via rocker tip switch 90, the warning lamp 6 or - if a
trailer is coupled, the warning lamps 6 and 5 - is (are) flashing on the instrument panel.
Driving on solid roads: Off-road mode switched OFF via rocker tip switch 90; the warning lamp 6 - or the
warning lamps 6 and 5 - has (have) gone out.
Attention On public roads, the ABV system must not be in “off-road mode”, as otherwise the
wheels may be blocked.
4.6.6 Monitoring the tachograph

(EC tachograph)
The tachograph 50 is combined with a speedometer and

records the speed and the distance covered automatically and
in relation to the actual time-of-day. The periods of work and
rest of the drivers are recorded in time groups. Each time
group is assigned a certain symbol (1 and 2). This function is
controlled via the adjusting knobs (1a and 2a). A LED (3) is
installed to allow a function check. When the admissible
maximum speed is reached, the LED (4) goes on.
For further details, please refer to the enclosed manual on the

tachograph.
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4.7 Hydraulic system of suspension; inclination adjustment; level control
Important instructions for operation of the hydraulic suspension system
DANGER z Leveling is only admissible on horizontal and level ground.

The rear steering must be locked. The pilot lamp 1 "rear axles unlocked" must not
be lit.
z Leveling is only admissible while the vehicle is at a standstill, and never during
traveling operation.
z Make sure that the axle suspension is locked before lowering the suspension.
z When leveling the vehicle for on-road driving operation, the axle suspension must
not be locked.
z Make sure that the axle suspension is locked before adjusting the vehicle's
inclination.
4.7.1 Inclination adjustment
If the inclination of the ground is to be compensated, e.g. during off-road operation with the crane standing
free on wheels, or if the outriggers on one side of the vehicle are to be extended beyond an obstacle, it is
possible to correct the vehicle's inclination or to lift/lower the machine only in one position, to enable
extension of the outriggers, by varying the oil filling in the individual suspension cylinders.
DANGER Do not tilt the vehicle out of its horizontal alignment more than is absolutely
necessary. The necessary stability must always be ensured - risk of overturning!
DANGER The inclination adjusting device must be put into operation while the engine is
running. The parking brake must be engaged, the rear axle steering must be locked.
After an inclination compensation, the vehicle must return to the horizontal position.
However, while the vehicle is driven in off-road terrain and on uneven roads, the
individual suspension cylinders must not be extended or retracted to their final end
position.
In the case of maximum inclination adjustment, e.g. left side lowered, right side lifted,
the chassis must not be moved while the steering is actuated.
DANGER For safety reasons, the inclined vehicle must not be moved while the steering is
actuated!
NOTE Leveling is only admissible up to an engine speed of max. 1200 rpm (in case of
approx. 12 t axle load. At a lower axle load, the engine speed must be reduced
accordingly).
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4.7.1.1 Actuation of the axle suspension lock / inclination adjustment feature
The axle suspension must be locked:
● In case of an inclination adjustment (refer to item B1-4.7).

● Before lowering the vehicle (refer to item B1-4.7).
z When driving on the construction site with the complete counterweight mounted (item B2-7.4);
z Before outrigger operation (item B1-6);
z For driving with load, boom directed to the rear, or for work free on wheels with load, boom directed to the
rear, if admissible. Comply with the Notes referring to the load charts and item B2-7.
When the suspension is locked, the axle compensation between the two front and rear axles is maintained.
Before the inclination tip switches are actuated, the axle suspension must be locked:
Engaging the axle suspension lock:
- Unlock the rocker switch 84 "axle suspension lock" by actuating the lock
handle down, and push the rocker switch down.
The yellow pilot lamp 31 "axle lock" goes on.
The suspension cylinders are actuated via the four rocker tip switches in the instrument panel.
Tip switch 64 Front axles, right side of vehicle
Tip switch 65 Front axles, left side of vehicle
Tip switch 65 Tip switch 64
Tip switch 86 Rear axles, right side of vehicle
Tip switch 85 Rear axles, left side of vehicle
Tip switch 85 Tip switch 86
- Tip switches actuated upwards from their central position = cylinders are extended (lifting)
- Tip switches actuated down from their central position = cylinders are retracted (lowering)
Keep tip switches pressed until the desired inclination is reached.
DANGER Nobody is allowed to stay below and on the vehicle when the vehicle's inclined
position is corrected or when individual cylinders are extended or retracted.
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4.7.1.2 Control of level position into on-road state
Attention Once crane work is finished, the chassis suspension must be returned into its "on-
road" state. To this effect, the vehicle must be lowered completely on a horizontal
road (see item 4.7.3.2), and returned in its preset position by means of tip switches
(see item 4.7.3.1).
NOTE Before leveling is effected, the rear axle steering must be locked.
4.7.2 Leveling
To return the vehicle to its predetermined level position in "on-road" state after an inclination adjustment, it
must be parked on a horizontal road, the vehicle must have been lowered previously to its lowest level and
the rear axle steering must be locked.
NOTE When the level control is actuated, the axle suspension must not be blocked. (The
rocker switch 84 must be locked). The pilot lamp 31 must not be lit.
4.7.3 Lowering the suspension
In on-road driving condition, the vehicle's suspension is set to automatic level compensation.
4.7.3.1 Lowering the suspension for leveling
DANGER Make sure that nobody stays under or on the vehicle while it is being lowered.
- Switch the ignition ON.
- Unlock the rocker switch 84 "axle suspension lock" by actuating the lock
handle down, and push the rocker switch down.
The yellow indicator lamp 31 "axle lock" goes on.
The lock handle automatically returns to its locking position.
- By actuating the rocker tip switch 65 for 1st and 2nd axles on the left, and the
rocker tip switch 64 for 1st and 2nd axles on the right, lower the vehicle on the
front end to its lowest level.
- By actuating the rocker tip switch 85 for 3rd and 4th axles on the left, and the
rocker tip switch 86 for 3rd and 4th axles on the right, lower the vehicle on the
rear end to its lowest level.
After the vehicle has been lowered to its lowest level, disengage the axle suspension lock (refer to
item 4.7.1.1).
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cont'd.: 4.7.3.1 Lowering the suspension for leveling
NOTE When the level control is actuated to "on-road" driving condition, the axle suspension
must not be locked. (Rocker switch “axle lock” 84 must be locked). The yellow
indicator lamp 31 “axle lock” must not be lit.
Prerequisites for leveling:
The vehicle is lowered for level control, as described under item 4.7.3.1; the axle suspension
lock is disengaged, as described under item 4.7.1.1.
- While the engine is running (engine speed between idle and 1500 rpm), actuate the rocker
tip switch “leveling” 66 and keep it pressed.
- After the chassis has reached the predetermined level, the leveling procedure is
automatically terminated.
The red warning lamp 16 "normal level" goes out.
During the control process to reach normal level, the warning light 16 “Normal level” goes on.
After the vehicle has reached normal level, the warning light goes out. Now the control
process can be finished as described under item 4.7.2.
- Release the rocker tip switch 66 "leveling".
Now the vehicle is positioned again so that all its sides are aligned parallel to the road; the suspension is
ready to operate for on-road travel, and set to automatic level compensation.
- Finally, check whether the vehicle is aligned perfectly in horizontal position (check visually).
4.7.3.1.1 Leveling “all down“
- Switch the ignition ON.

- Start the engine.
- Lock the axle suspension via the rocker switch 84. The indicator lamp 31 is
lit.
- Lower the vehicle completely by actuating the rocker tip switch "level control - all down" 63.
DANGER While the vehicle is lowered, make sure that nobody stays under or on the vehicle.
- Perform the level control as described under item B1-4.7.2.
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4.7.3.2 Lowering the suspension in case of repair work
In case of necessary repairs, e.g. if there is a leakage in the hydraulic system of the suspension, a deficiency
of a cylinder or hydraulic accumulator, the hydraulic system must be depressurized before repair work is
effected.
- Lower the suspension as it is described under item 4.7.3.1.
The oil contained in the suspension cylinders is drained into the hydraulic tank.
DANGER The oil-bearing end of the hydraulic accumulators is still pressurized.
- Switch the ignition OFF.

- Connect a hose to the measuring coupling "M" of the
appropriate pair of cylinders of the hydraulic accumulators
(Fig.), and drain the residual oil from each accumulator into
an appropriate vessel.
- After the residual oil has been drained from the
accumulators, work on the suspension hydraulics can be
performed, or a pressure test in the hydraulic accumulators
can be effected (nitrogen end).
(For further details, refer to part "C1", Service and

Maintenance, Chassis)
For re-adjustment of the level position of the vehicle for on-road travel, refer to item 4.7.3.1 "Leveling".
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Gearshift and driving operation B1-5
5 Gearshift and driving operation
DANGER During driving operation, do not set the key switch 91 to position 2.
It is recommended that the key switch be removed during driving operation.
5.1 Gearshift
The vehicle is equipped with a gearbox featuring the automatic ZF control system, series AS Tronic. The
gearbox is adapted to the engine via a standard dry clutch.
The gearbox installed, type 12 AS 2302, has 12 forward and 2 reverse speeds.
Before starting the engine, make sure that the handbrake - parking brake lever in the chassis and
rocker switch for parking brake in superstructure - is in braking position.
DANGER There is no braking effect when the engine is not running and while the gearbox is set
to neutral position.
Even without actuation of the accelerator pedal, the vehicle might roll away.
Do not place the gearshift lever in NEUTRAL during travelling operation. In this case,
the engine's braking effect would not be available, which might result in extremely
dangerous situations.
It is not admissible to leave the vehicle while the engine is running and a gear is
engaged.
Before leaving the vehicle with the engine running, the gearbox must be set to neutral,
and the parking brake must be engaged.
Even if gear "D" is engaged, the vehicle may roll backwards. The clutch is only
engaged when the vehicle is set into motion.
While the vehicle is at a standstill with the engine running and a gear engaged, it is
sufficient to actuate the accelerator pedal to set the vehicle into operation.
Perform brake tests immediately after starting to drive.
As the vehicle must be stopped with the gearbox set to neutral, so that there is no
rigid connection from the engine to the axles, the vehicle must be blocked during
stopping and parking, so as to prevent it from rolling away, especially on uphill or
downhill gradients.
To this effect, apart from engaging the parking brake, secure the vehicle, if necessary,
by wheel chocks placed under the tires.
Do not allow the vehicle to roll contrary to the driving direction of the gear engaged.
ATTENTION Engage the reverse speed only when the vehicle does not move.
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B1-5 Gearshift and driving operation
5.1 Gearshift and driving operation (cont'd.)
ATTENTION The vehicle may accelerate when driving on downhill gradients. There will be no
automatic upshifting of the gearbox. To protect the engine against damage in the
overspeeding range, the driver must take appropriate measures (for ex. braking) to
avoid overspeeding.
In case of excessive engine speeds, "emergency" upshifting will take place to protect
the engine.
At 2,650 rpm, "emergency" upshifting will be effected even if the service and
continuous service brakes are engaged.
At 3,500 rpm, "emergency" upshifting will take place when the continuous service
brake is engaged, but also in mere overrun condition.
The engine might be damaged if the vehicle accelerates during downhill driving, thus
accelerating the engine to the overspeeding range.
- When leaving the vehicle, engage the parking brake and, if necessary, block the wheels additionally by
placing wheel chocks under the wheels.
- In case of irregularities of the gearbox (error message in the display), stop the vehicle, look for the fault and
- if it cannot be eliminated by the equipment available in or on the vehicle, request specialist staff.
- Before stopping the engine, set the gearbox to neutral.
- The 3rd gear has been programmed as starting gear. However, it may be useful to preselect a lower gear
for starting.
- Maneuvering is only admissible in the 1st and 2nd forward and reverse gears.
- In case of extended stops (at traffic lights etc.), set the gearbox to neutral.
For further details on gearshift and driving operation, refer to the enclosed operating manual of the gearbox
manufacturer.
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5.2 Transfer box
The vehicle is equipped with a two-step transfer box with three shift positions for on-road and off-road gear
and a neutral position.
The control position ”on-road / off-road” is effected electro-pneumatically via a rocker tip switch 62 “on-road /
off-road gear” in the “instrument panel” and is monitored by two indicator lamps 30 “off-road gear” and 17
“on-road gear”: The "neutral" position is selected pneumatically via a change-over valve. The neutral position
is only used for towing the vehicle.
The off-road gear is used if the vehicle is operating under considerable load, on long uphill gradients, in
difficult terrain, during manoeuvring and under winter-time road conditions.
Attention The gear steps "on-road / off-road / neutral" may only be changed over when the
vehicle is at a standstill and when the gearbox is set to neutral.
5.2.1 Changing over from on-road to off-road gear
- The on-road state in the transfer box is engaged; the green indicator lamp 17 "on- On-road gear
road gear" is lit.
- Decelerate and stop the vehicle; the engine must run at idle.
- Engage the parking brake.
- Set gearbox to neutral position "N".
- Actuate the rocker tip switch 62 "off-road / on-road gear" downwards.
Off-road gear
The green indicator lamp 17 "on-road gear" goes out and the green indicator lamp 30
"off-road gear" goes on if the off-road gear is correctly engaged.
- Set gearbox to the desired position (gears 1 to 3).

- The display indicates the starting gear engaged.
- Accelerate gently and release the parking brake.
5.2.2 Changing over from off-road to on-road gear Rocker tip switch
62
- The “off-road” driving state in the transfer box is engaged; the green indicator lamp 30
"off-road gear" is lit.
- Decelerate and stop the vehicle; the engine must run at idle.
- Engage the parking brake.
- Set gearbox to neutral position "N".
- Actuate the rocker tip switch 62 "off-road / on-road gear" downwards.
The green indicator lamp 30 "off-road gear" goes out and the green indicator lamp 17
"on-road gear" goes on if the on-road gear is correctly engaged.
- Set the gearbox to the desired position.

- The display indicates the starting gear engaged.
- Accelerate gently and release the parking brake.
Shifting the transfer box to neutral position is described in section "towing" (item 5.10).
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5.4 Connecting and disconnecting the differential locks, inter-wheel locks, 2nd
axle drive**)
NOTE When the machine is used in rough terrain, it might be useful, under certain
circumstances, to switch the ABV off-road mode ON.
DANGER When the vehicle is driving on public roads, the ABV off-road mode must be switched
off.
In ABV off-road mode, the wheels may be blocked.
It is essential that the instructions appearing under item B1-4.6.5.3 ABV system “off-
road mode” are complied with.
With the standard vehicle model, the 1st, 3rd and 4th axles are driven (8x6 drive). Optional, the 2nd axle
features a connectable axle drive (8x8 drive).
All drive axles are equipped with inter-wheel differential locks. Moreover, an inter-axle lock can be connected
optionally between axles 1 and 3.
NOTE For connecting the differential locks and the 2nd axle drive**), the vehicle must on
principle operate under minimum load (moderate driving thrust) or, as far as possible,
the vehicle should be immobilized with the gearbox set to neutral "N"; if practicable,
differential locks and the 2nd axle drive**) should be connected immediately before
the vehicle enters the difficult terrain or when one or several wheels start to spin.
When setting the vehicle into motion, accelerate gently. After having left the difficult
terrain, switch the differential locks and the 2nd axle drive**) off immediately.
ATTENTION Never drive on a firm road while the differential locks and the 2nd axle drive**) are
connected. When the inter-wheel differential locks are engaged, only-straight-ahead
driving is admissible. Connect the differential locks only if this is absolutely
indispensable. The differential locks in the axles are only engaged correctly if the
appropriate yellow indicator lamps go on.
8x6 drive:
The locks should be engaged in the following sequence:
1. Connect the inter-axle differential lock between the 1st and the 3rd axles.
2. Connect the inter-wheel differential locks in the 1st, 3rd and 4th axles The inter-wheel differential locks are
connected together.
8x8 drive**):
The locks should be engaged in the following sequence:
1. Connect the inter-axle differential lock between the 1st and the 3rd axles.
2. Connect the 2nd axle drive.
3. Connect the inter-wheel differential locks in the 1st, 2nd, 3rd and 4th axles. The inter-wheel differential locks
are connected together.

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5.4.1 8 x 6 drive
5.4.1.1 Connecting and disconnecting the inter-axle differential lock
Connection
- Turn the rotary switch 59 from pos. "0“ to pos. „1“ The inter-axle differential lock
between the 1st and the 3rd axles is connected.
- The yellow pilot lamp 18 "front inter-axle differential lock" goes on to indicate that the
lock is engaged.
Disconnection
- To disconnect the inter-axle lock, actuate the rotary switch 59 to position "0".
- The inter-axle differential lock is disengaged correctly when the yellow pilot lamp 18
"front inter-axle differential lock" goes out.
5.4.1.2 Connecting and disconnecting the inter-wheel differential locks
If the connection of the inter-axle differential lock is not sufficient to prevent the wheels from spinning, the
inter-wheel differential locks in the axle drive assemblies can be connected additionally. The inter-wheel
differential locks are connected and disconnected together.
Connection
- Actuate the rocker tip switch 60; the inter-wheel differential locks are engaged.
- The yellow pilot lamp 28 goes on to indicate that the inter-wheel differential locks are
engaged.
NOTE The differential locks are only engaged as long as the rocker tip
switch is actuated.
Disconnection
- To disconnect the inter-wheel differential locks, release the rocker tip switch 60.
- The inter-wheel differential locks are disengaged correctly when the yellow pilot lamp
28 goes out.
NOTE Should it not be possible to disconnect the differential locks at

the first attempt, repeated brief interruptions of the driving thrust
(by releasing the accelerator pedal) discharge the locking
assemblies and facilitate disconnection.
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5.4.2 8 x 8 drive**)
5.4.2.1 Connecting and disconnecting the inter-axle differential lock
Connection
- Turn the rotary switch 59 from pos. "0“ to pos. „1“ The inter-axle differential lock
between the 1st and the 3rd axles is connected.
- The yellow pilot lamp 18 "front inter-axle differential lock" goes on to indicate that the
lock is engaged.
Disconnection
- To disconnect the inter-axle lock, actuate the rotary switch 59 to position "0".
- The inter-axle differential lock is disengaged correctly when the yellow pilot lamp 18
"front inter-axle differential lock" goes out.
5.4.2.2 Connecting and disconnecting the 2nd axle drive

Connection
- Turn rotary switch 59 from pos. "1” to pos. “2”. The inter-axle differential lock
between the 1st and the 3rd axles and the 2nd axle drive are connected.
- The yellow pilot lamp 27 "2nd axle drive" goes on to indicate that the 2nd axle drive
is engaged.
DANGER The steering behavior may be affected while the vehicle is

taking a bend.
Disconnection
- To disconnect the 2nd axle drive, actuate the rotary switch 59 to position "1".
- The 2nd axle drive is disengaged correctly when the yellow pilot lamp 27 goes out.

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5.4.2.3 Connecting and disconnecting the inter-wheel differential locks
If the connection of the inter-axle differential lock is not sufficient to prevent the wheels from spinning, the
inter-wheel differential locks in the axle drive assemblies can be connected additionally. The inter-wheel
differential locks are connected and disconnected together.
Connection
- Actuate the rocker tip switch 60; the inter-wheel differential locks are engaged.
- The yellow pilot lamp 28 goes on to indicate that the inter-wheel differential locks are
engaged.
NOTE The differential locks are only engaged as long as the rocker tip
switch is actuated.
Disconnection
- To disconnect the inter-wheel differential locks, release the rocker tip switch 60.
- The inter-wheel differential locks are disengaged correctly when the yellow pilot lamp
28 goes out.
NOTE Should it not be possible to disconnect the differential locks at the

first attempt, repeated brief interruptions of the driving thrust (by
releasing the accelerator pedal) discharge the locking assemblies
and facilitate disconnection.
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5.6 Brake system
DANGER After starting to drive, perform immediately a brake test using the service brake and the
auxiliary brake (handbrake), if possible on a dry road. During traveling operation, the
air pressure gauges 48 and 49 and the warning lamps of the brake system 3 and 44
must be watched permanently.
5.6.1 Service brake (footbrake)
The foot-actuated brake pedal (1), which acts on all wheels,

must be used for slowing down and for stopping the vehicle.
To this effect, the brake pedal must be actuated gently.
DANGER The warning lamp 3 "service brake" must

not go on during traveling operation.
Should they nevertheless go on, stop the
vehicle immediately and determine the
fault.
NOTE When the service brake (foot brake) is actuated, the engine brake is connected
automatically.
The brake has been designed as a dual-circuit brake; however the effect of the auxiliary brake (handbrake)
cannot be assumed by each circuit, but only a certain residual braking effect can be reached (reduced
braking effect).
5.6.2 Auxiliary brake (handbrake)
The auxiliary braking effect is achieved by the air accumulator cylinders via the handbrake.
In case of failure of the service brake (foot brake), or of a part of the service brake, the vehicle
can only be braked via the handbrake valve. The warning lamp 44 “parking brake” goes on. P
The handbrake can be actuated gradually. To this effect, pull the handbrake lever backwards
and make it lock in.
5.6.3 Parking brake (handbrake)
If the vehicle is to be stopped or parked, actuate the

handbrake valve lever backwards until the vehicle is fully
braked, and make it lock in. The warning lamp 44 “parking
brake” goes on when the ignition is switched on.
DANGER If the vehicle is to be parked on upward

or downward gradients for an extended
period of time, it must be protected
against rolling away by means of wheel
chocks.
To release the handbrake, pull the handle of the lever out of Pos. 1: lock position
its locking mechanism and push it forward to its stop (pos. 3). Pos. 2: positively braked
The warning lamp 44 “parking brake” goes out when the Pos. 3: released
brake-air pressure is sufficient.
NOTE An acoustic warning signal sounds if the parking brake is not released when setting
the vehicle into motion.
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5.6.4 Engine brake and constant throttle valve (continuous service brake)
The non-wearing engine brake should be used especially on

extended downward gradients in order to save the service
brake. The effect of the continuous service brake cannot be
graduated.
- Move the control lever from position 0 to position 1. The

continuous service brake is activated. The indicator lamp
"continuous service brake" 4 goes on. Switch positions 2 to
5 only in case of optional equipment “eddy-current brake”.
- Move the control lever from position 1 to position 0. The

continuous service brake is deactivated. The indicator lamp
4 "Continuous service brake" must go out.
NOTE While the ABV control is activated, the continuous service brake is
automatically deactivated. However, the indicator lamp 4 "Continuous
service brake" does not go out.
NOTE The lower the gear step selected in the gearbox, the greater the
resulting braking effect.
DANGER The continuous service brake is only operative while a gear is engaged.
Attention The continuous operation brake is inoperative as long as the accelerator pedal is
actuated.
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5.7 Cruise control
The cruise control functions enable the driver to maintain a certain speed previously selected, even under
changing load conditions, without having to actuate the accelerator pedal.
The cruise control can be adjusted as of 15 k.p.h. up to the vehicle's maximum speed.
DANGER Do not use the cruise control under winter-time or skidding road conditions nor if the
traffic conditions are not absolutely clear. Risk of accidents !
NOTE Only use the cruise control if the traffic conditions allow driving at a constant speed.
When the cruise control is activated, the driver can release the accelerator pedal.
The set speed can be exceeded, e.g. in order to overtake another vehicle, by actuating
the accelerator pedal accordingly.
Switch the cruise control off if you want to exceed the set speed for an extended
period of time.
Due to the engine power output, the current speed may be lower than the set speed
when driving on uphill gradients.
To maintain the set speed when driving on downhill gradients, the fuel flow is reduced
to the flow needed at idle speed via the engine control system (FMR). If the braking
effect of the engine is no longer sufficient, the set speed might be exceeded.
The set speed must not exceed the admissible maximum speed for the corresponding
gear (observe the revolution counter).
5.7.1 Traveling
The cruise control is activated via the control lever installed

on the steering column.
- Accelerate the vehicle to a traveling speed of more than

15 k.p.h..
- Set the control lever to position (1) and keep it in this
position.
- Accelerate until the vehicle reaches the desired speed.
- Release the lever; the current speed will be maintained and
stored in the memory.
- Set the control lever to position (1) and touch it slightly; the
current speed will be maintained and stored in the memory,
or the stored speed will be increased in steps of 0.5 k.p.h.
each.
- Set the control lever to position (2) and keep it in this position; the current speed will be reduced steadily.
- Release the control lever; the current speed will be maintained and stored in the memory.
- Set the control lever to position (2) and touch it slightly; the current speed will be maintained and stored in
the memory, or the stored speed will be reduced in steps of 0.5 k.p.h. each.
- Set the control lever to position (3) and touch it slightly; the cruise control system will be switched off. The
speed must again be controlled by actuating the accelerator pedal. The set speed will be deleted.
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(cont'd.) 5.7.1 Traveling
NOTE The cruise control system is automatically switched off and a set speed is deleted
when:
• the service brake or the continuous service brake are actuated,

• the vehicle speed drops below 10 k.p.h.,
• the Temposet is activated,
• the ignition key is turned to the left to its stop.
The cruise control function is briefly interrupted, but subsequently re-activated

(standby function, the set speed remains stored) while:
• control or gearshift operations are performed,

• the vehicle is accelerated via the accelerator pedal with the cruise control system
activated. After releasing the accelerator pedal, the vehicle will return to the set
traveling speed.
5.8 Temposet
The Temposet functions enable the driver to set a maximum speed between 15 k.p.h. and the set maximum
speed.
The vehicle speed is regulated via the accelerator pedal, as in case of traveling operation without the
Temposet function.
5.8.1 Operation of the Temposet
- Touch the Temposet key (4) slightly. The vehicle speed is

limited to the current traveling speed.
Changing the maximum traveling speed:

- Press the Temposet key "4" and keep it pressed; accelerate
or decelerate the vehicle to the desired new speed.
- Release the Temposet key "4"; the current traveling speed
is stored as the new maximum speed.
Terminating the Temposet function:

- Set the actuating lever to position "3" and touch it slightly;
the set maximum speed is deleted.
NOTE In order to exceed the set maximum speed for a short period of time, e.g. to overtake
another vehicle, depress the accelerator pedal to its stop (full throttle). Release the
accelerator pedal and actuate it once again after the vehicle has been accelerated.
Subsequently, the set maximum speed is reactivated.
The set maximum speed is automatically deleted when the ignition key is turned to its
left to its stop, or when the cruise control system is activated.
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5.9 Steering variants
The possibility to unlock the rear axles and to steer them along with other axles enables a number of
steering variants which are shown schematically below.
Variant:
A= Two-axle steering - front axle steering. The steering

acts only on the front axles.
Attention Only this variant is admissible for on-road

travel.
B= Four-axle steering - front and rear axles are steered.

This variant (steering position) enables driving and
manoeuvering with minimum turning radii.
C= Four-alxe steering - front and rear axles are steered.

This variant (steering position) - the so-called diagonal
steering - allows the vehicle to be driven in slanted
position.
A B C
Fahrtrichtung = Driving direction
5.9.1 Steering the rear axles from the chassis
Attention The rear axle steering can only be actuated in the speed ranges of the gear steps
"Forward 1 - 3, Neutral and Reverse 1 - 2". The rear axles cannot be unlocked in a
different gearbox position.
Consequently, with the rear axles unlocked, driving is only possible in the gear steps
"Forward 1 - 3, Neutral and Reverse 1 - 2". In this steering mode, no other gear steps
can be selected.
The rear axle steering permits very small turning radii in very confined areas, on a level road; it
also permits the crane to be moved laterally (diagonal steering).
- Unlock the rear axles by means of the rocker switch 75.
- The pilot lamp 1 flashes.
- Now the rear axles can be steered, as desired, via the rocker tip switch 74.
Rocker tip switch actuated to the left = steering towards the left side.
Rocker tip switch actuated to the right = steering towards the right side.
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5.9.2 Locking the rear axle steering
- Check whether the steering locking cylinder of the rear axle is still unlocked. The indicator lamp 1 must still
flash.
- Push the rocker tip switch 74 to set the wheels to straight-ahead steering position.
- Actuate the rocker switch 75 to "lock" the rear axles.
- When the steering locking cylinder has locked the system, the warning lamp 1 goes out as well.
- If the warning lamp does not go out, i.e. the indicator lamp 1 continues flashing, the wheels' straight-ahead
steering position must be corrected.
- Lock the rear axles by actuating the rocker tip switch 74 (moving the steering wheel from the right to the
left). The indicator lamp 1 must have gone out.
- Before starting to drive on the road, check the vehicle for level condition and, if necessary, realign it.
Attention Make sure that the rear axle steering is locked in straight-ahead position, for safety
reasons, while the vehicle is driving on public roads, and when it is standing in
inclined position, e.g. on downward gradients. (The indicator lamp 1 must have gone
out).
IT IS NOT ADMISSIBLE TO ACTUATE THE REAR AXLE STEERING CONFIGURATION ON PUBLIC

ROADS.
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Memo:
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Stabilizing the vehicle by outriggers B1-6
6 Stabilizing the vehicle by outriggers

6.1 Locking the axle suspension / lowering the vehicle
- Actuate the rocker switch 92 "battery main switch".

● The parking brake (handbrake) is engaged.
● The gearshift lever is in "neutral" position.
- Start the engine in the chassis and make it run at medium speed level.
- Block the axle suspension via the rocker switch "Axle suspension lock" 84. The indicator lamp "axle
suspension lock" 31 goes on.
DANGER If the indicator lamp 31 "axle suspension lock" is not lit, this may indicate a fault in
the locking system.
NOTE Before commencing outrigger operation, the vehicle should be completely lowered
(refer also to item B1-4.7).
- Actuate the rocker tip switches 64, 65 (front axles) and 85, 86 (rear axles) downwards to lower the vehicle
to its lowermost level.
DANGER During the lowering procedure, no other persons are allowed to stay on or under the
vehicle.
- Turn key-actuated change-over switch "chassis/superstructure" 91 from position 1 to position 2.
Now the vehicle can be supported by outriggers, as described below.
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B1-6 Stabilizing the vehicle by outriggers
6.2 Control of the electric outrigger actuation
For crane operation, the crane carrier must be supported by the four outriggers. They are located on the right
and left sides of the vehicle, on the front and rear ends. All outriggers are operated hydraulically, via an
electric trigger circuit. For outrigger operation, a control box (refer to the illustration) has been installed on the
left and right sides of the vehicle. Only the outriggers located on the side of the outrigger casing can be
actuated from each control box.
The various operating elements are explained under items 6.2.1 and 6.2.2.
6.2.1 Control elements, right-hand control box
1 Instrument illumination, outrigger casing

2 Light switch
3 Rocker switch, preselection "outrigger beams / outrigger
cylinders".
Rocker switch actuated upwards = outrigger beams have
been preselected
Rocker switch actuated downwards = outrigger cylinders
have been preselected
4 Rocker tip switch, extending/retracting the outrigger
cylinder, front, left-hand.
Rocker tip switch actuated upwards = extending
Rocker tip switch actuated down = retracting
beam/cylinder, front, right-hand.
Rocker tip switch actuated upwards = retracting
Rocker tip switch actuated down = extending
beam/cylinder, rear, right-hand
cylinder, rear, left-hand
Driving direction
8 Spirit level
9 Rocker tip switch, engine speed regulation
Rocker tip switch actuated upwards = engine speed is
reduced
Rocker tip switch actuated down = engine speed is
increased
10 Rocker switch, working floodlight, outriggers right-hand**)
Rocker tip switch actuated upwards = working floodlight
OFF
Rocker tip switch actuated down = working floodlight ON
11 free

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6.2.2 Control elements, left-hand control box
1 Instrument illumination, outrigger casing

2 Light switch
3 Rocker switch, preselection "outrigger beams / outrigger
cylinders".
Rocker switch actuated upwards = outrigger beams have
been preselected
Rocker switch actuated downwards = outrigger cylinders
have been preselected
cylinder, front, right-hand
beam/cylinder, front, left-hand
beam/cylinder, rear, left-hand
cylinder, rear, right-hand
Rocker tip switch actuated upwards = extending Driving direction
8 Spirit level
9 Engine speed regulation
Rocker tip switch actuated upwards = engine speed is
reduced
Rocker tip switch actuated down = engine speed is
increased
10 Rocker switch, working floodlight, outrigger left-hand**)
Rocker tip switch actuated upwards = working floodlight
OFF
Rocker tip switch actuated down = working floodlight ON
11 free
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6.2.3 Engine speed regulation (manual throttle, working speed)
For outrigger operation, the engine speed can be raised by hand. The maximum working speed is 1800
r.p.m.
DANGER Driving operation with activated manual throttle control is prohibited.

The working speed must always be reset to idling level and the rocker switch 83
"working speed" must be switched off.
In the carrier instrument panel:
Switching on the working speed:
- Actuate the rocker switch 83 "working speed" downwards.
Thus, the engine speed regulation is connected.
In the outrigger casings on the left or right:
Increasing the engine speed:
The engine speed can be adjusted progressively.

- Actuate the rocker tip switch (9 in the outrigger casing) "engine speed regulation".
- Rocker tip switch pressed upwards = engine speed is reduced.

- Rocker tip switch pressed down = engine speed is increased.
Reset the engine to idle speed for traveling operation:
- Keep the rocker tip switch (9 in outrigger casing) "engine speed regulation" pressed upwards until the
engine has reached idle speed level.
- Actuate the rocker switch 83 "working speed" upwards; the engine speed regulation is inoperative.
NOTE The rocker tip switch (9 in outrigger casing) serves moreover to increase the idling speed
up to a level of 900 rpm, if the rocker switch (83 in the instrument panel) is not actuated.
This function is only active while the vehicle is at a standstill.
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6.3 Outrigger operation from the chassis

6.3.1 Changing the position of and securing the outrigger floats for outrigger
operation by means of pins
Position of the outrigger floats during on-road travel
In on-road driving condition, the outrigger floats are slipped in the

stay tubes (12) with the guide assemblies, and locked.
The outrigger floats must be secured with pins through the front
bore-hole (13) of the guide frame, and locked.
Attention In on-road driving condition, the lock pin (15)

must be secured through the bore-hole (13)
behind the cylinder rod.
Position of outrigger floats for crane operation
Before the outrigger jacks can be extended, the outrigger floats must
be removed from their supports.
- Take the folding plug (14) out of the lock pin (15) and remove the
pin.
- Pull the outrigger float forward until the guide frame touches the
cylinder rod and until the rear bore-hole (16) of the guide frame can
be fastened with lock bolts (15) and secured.
Attention Before outrigger operation begins, the lock pin (15) must be inserted through the
bore-hole (16) in front of the cylinder rod.
NOTE The surface of the outrigger floats may discolour (turn grey) due to atmospheric
exposure, e.g. to sun. However, this does not affect the outrigger floats' functional
reliability.
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6.4 Instructions regarding outrigger operation
NOTE The outriggers may be operated (extended or retracted) on principle only if the
operator has full vision of the supporting area during the whole supporting procedure.
The outrigger beams located can only be extended or retracted from the respective
operator's side of the chassis.
Attention Before outrigger operation, the axle suspension must be locked and the vehicle must be
lowered.
While the vehicle is supported by outriggers, the tires must not be in contact with the
ground, as otherwise the axles could be damaged during crane work when under load.
The tires must not be placed on supporting material.
When changing the crane's rig arrangement for on-road travel, the axle suspension
lock may only be deactivated if the wheels have full ground contact, due to the
outrigger cylinders' being retracted.
DANGER While outriggers are extended or retracted, nobody is allowed to stay close to the
outrigger beams and the outrigger cylinders.
! Risk of accidents ! The axle suspension lock must never be deactivated while the
vehicle is supported by outriggers. This will damage the axle suspension components.
To prevent damage to the outrigger assembly and accidents during travelling and
crane operation, it is particularly important to unlock (by removing the pins) the
outrigger beams before extending and retracting them, and to lock (by means of pins)
the outrigger beams during crane work.
Once crane work is finished and the crane retrofitted for on-road travel, it must be
ensured that the outrigger cylinders and beams are completely retracted and locked
with pins.
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6.5 Extending the outrigger beams
DANGER Make sure that the extended outrigger beams are secured with pins, as there is a risk
of accidents otherwise.
The program of the automatic safe load indicator (ASLI) must always be set to the
correct supporting base (refer to load charts). Should this instruction not be
observed, there is a risk that the crane might tip over during crane work.
6.5.1 Outrigger operation in on-road driving condition
z In on-road driving condition, locking pins (17) and (18) are inserted in the locating bore-holes of the four
outrigger casings and outrigger beams, and locked underneath the grooves (17a) and (18a).
z The locking pins (19) are inserted into the locating clips (20) and locked underneath the securing plates
(2a).
z The outrigger floats are fixed and locked in "on-road" travel position (item 6.3.1).
Only outrigger front, left-hand Outrigger front, right-hand; rear left-hand

and right-hand
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6.5.2 Extending the outriggers to middle extension width
- Change position of outrigger floats to "crane operation" (item 6.3.1).
NOTE The locking pins (19) remain inserted in the locating clips (20) and locked underneath
the securing plates (19a).
- Remove the locking pins (17) from the outrigger casings and insert them in the bore-holes of the pin
holders (21).
- Unlock locking pins (18) by turning them out of the securing plate (18a). Pull locking pins (18) slightly out of
the outrigger casings and lock them by turning in the notch (22).
Only outrigger front, left-hand Outrigger front, right-hand; rear left-hand

and right-hand
- Actuate the preselector "3" from its central position upwards

(pilot lamp in switch is lit).
- Actuate the selector tip switches "5" or "6" down one by one
and keep them pressed until the outrigger beams have been
extended on one side to the extension width specified for the
crane work in question.
NOTE Middle extension width is reached as soon

as the outrigger beams are extended so far
that the colour marks >
for the first
extension width are flush with the outer
edge of the outrigger casing.
Control box, right side of vehicle

Driving direction
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6.5.2.1 Securing the outrigger beams extended to middle extension width with pins and
locking them
- Reset preselector "3" to its central position.
- Remove the locking pins (17) from the pin holders (21) and insert them into the bore-holes of the outrigger
casings. Secure the outrigger beams with pins and engage the locking pins underneath the supporting
plates (17a).
- Unlock locking pins (18) by turning them out of the notch (22). Insert the locking pin (18) in the bore-hole of
the outrigger casing and lock it by turning below the securing plate (18a).
Only outrigger front, left-hand Outrigger front, right-hand; rear left-hand and right-hand
Repeat the pin locking procedure on the other side of the vehicle analogically.
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6.5.3 Extending the outriggers to full extension width
NOTE If the outriggers are to be extended from fully retracted condition to their full
extension width, the locking pins (17, 18 and 19) must have been removed previously.
If the outriggers are to be extended from middle extension width to full extension
width, the locking pin (17 and 18) remains inserted in the outrigger casing, and
secured.
z The outrigger is fastened with pins at middle extension width, and secured.
- Unlock locking pins (19) from the securing plates (19a), pull them out of the locating clips (20) and insert
them into the pin holders (23).
- Actuate the preselector "3" from its central position upwards

- Actuate the selector tip switches "5" or "6" down one by one
and keep them pressed until the outrigger beams have been
extended on one side to the extension width specified for the
crane work in question.
NOTE The full extension width is reached as soon

as the outrigger beams are extended so far
that the colour marks > for the full and the
middle extension width are flush with the
outer edges of the outrigger casings.

Driving direction
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6.5.3.1 Locking the outrigger beams extended to full extension width
- Reset preselector "3" to its central position.
- Remove the locking pins (19) from the pin holders (23) and insert them from the top into the bore-holes of
the outrigger casings.
Repeat the pin locking procedure on the other side of the vehicle analogically.
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6.6 Extending the outrigger cylinders
DANGER Use large-size, stable steel or concrete plates or wooden planks according to the
ground conditions, and place them centrally below the outrigger floats (uniform
supporting pressure). Do not extend the outrigger cylinders to their end position, but
prop them in an appropriate manner, so that a residual stroke of at least 10 to 15 mm
remains in the outrigger cylinders.
Correct
Incorrect
6.6.1 Actuation of outrigger cylinders
- The outrigger floats are placed in position "crane operation"

(item 6.3.1), the outrigger beams are extended to middle or
full extension width (item 6.5).
- Actuate the preselector "3" down from its central position
- Actuate the selector tip switches "5" or "6" down and keep
them pressed until the outrigger floats are resting firmly on
the ground.
- Raise the machine until all the tires are clear of the
ground. Do not prop the wheels with supporting
material.
- Actuate the selector tip switches "4" or "7" to extend the
outrigger cylinders on the other side of the vehicle.
Control box, right side of vehicle Driving direction
DANGER For safety reasons, the outrigger cylinders should only be extended or retracted on
the side in question where the operator is positioned. Actuation of all outrigger
cylinders from one machine side should be restricted to cases where the machine is
to be aligned horizontally.
- Align the chassis in horizontal position (watch the spirit level (1)). The air bubble must be in the center of
the reticule (max. deviation from the horizontal line: + 0.3 %).
- When the crane is aligned in horizontal position, set the preselector "3" in central position, as otherwise
outrigger operation will not be possible from the other side of the vehicle.
- Shut off the engine in the chassis.
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6.7 Outriggers - retracting the outrigger cylinders / outrigger beams
- The key-actuated change-over switch "chassis-superstructure" 91 is set to position 1.
- The axle suspension must still be locked; the pilot lamp 31 "axle suspension lock" is lit.
- Start the engine in the chassis and make it run at medium speed.
(Engine speed regulation / working speed, refer to item 5.3).
6.7.1 Retracting the outrigger cylinders
- Actuate the preselector switch "3" downwards from its central

position.
- Retract the outrigger cylinders uniformly to their stop by

actuating the selector tip switches "4"-"5"-"6"-"7".
- Set preselector "A" to its central position.

Driving direction
6.7.2 Retracting the outrigger beams
Attention Remove all lock pins from the outrigger beams / outrigger casings and insert them
into the bore-holes of the pin holders.
- Actuate the preselector switch "3" upwards from its central position.
- Actuate the selector tip switches "5" or "6" and completely retract the outrigger beams on the operator's
side.
- Set preselector "3" to its central position.
- To retract the outrigger beams on the other side of the vehicle, proceed analogically by actuating the
selector switch "3" and the selector tip switches "5" or "6".
- After the outrigger beams have been retracted completely, remove the locking pins (17) from the pin
holders (21), insert them into the bore-holes of the outrigger casings / outrigger beams and lock them
underneath the securing plate (17a).
- Unlock locking pins (18) by turning them out of the notch (22). Insert the locking pin (18) in the bore-hole of
the outrigger casing and lock it by turning below the securing plate (18a).
- Remove the locking pins (19) from the pin holder (23), insert them into the locating clips (20) and lock them
underneath the securing plate (19a).
- Change position of outrigger floats to "on-road driving" (item 6.3.1), and lock them.
- Set the vehicle level to "on-road" driving condition (item B1-4.7.2).
Attention In "on-road" driving condition, the outrigger cylinders and outrigger beams must be
completely retracted; the outrigger beams must be secured with pins and locked.
The outrigger floats are changed to the "on-road driving" position, and secured with
pins.
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Memo:
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Emergency control features B1-7
7 Emergency control features

7.1 Emergency control of the hydraulic system
In case of failure or malfunctions of various control and operating elements, or in case of malfunctions of the
electric equipment, the functions failed might be effected, e.g. via emergency controls. The solenoid valves
are located as shown in the Figure.
NOTE To ensure the oil supply of the hydraulic system, the emergency control (E) of the
solenoid valve (2) located on the valve block must be kept pressed down by an assis-
tant at the same time.
Attention Make sure that emergency control devices with rubber caps are never actuated with
sharp-edged or pointed objects! Should the rubber caps be damaged, this may result
in failure of the valves.
DANGER Emergency control devices must never be used instead of the operating elements for
normal operation. Any damage to the control and operating elements must be elimi-
nated immediately.
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B1-7 Emergency control features
7.1.1 Functionalities of the emergency push-buttons on the solenoid valves:
Solenoid valves (1) Emergency control of outriggers.
A = retract outrigger cylinders. B = retract outrigger beams.

C = extend outrigger cylinders. D = extend outrigger beams.
Solenoid valve (2) - Oil supply.
E= Oil supply.
F= Change-over cock, fan drive.
Solenoid valve (3) Emergency control of rear axle steering.
H= Rear axle steering

steering turned to the left.
G= Rear axle steering

steering turned to the right.
7.1.2 Actuation of the emergency tip switches
- Start the engine.

- Set the engine to idling speed.
- Set gearbox to neutral position "N"
- Engage the parking brake (handbrake).
- Block the vehicle, if necessary, using wheel chocks.
7.1.2.1 Retracting and extending the outrigger cylinders
Solenoid valve 1:
Tip switch A = retract outrigger cylinders.
Tip switch C = extend outrigger cylinders.
Solenoid valve 2:
additionally: Tip switch E = oil supply.
7.1.2.2 Retracting and extending the outrigger beams
Solenoid valve 1:
Tip switch B = retract outrigger beams.
Tip switch D = extend outrigger beams.
Solenoid valve 2:
DANGER On actuation of the tip switches, the outrigger cylinders and the outrigger beams on
the opposite side of the machine will be retracted or extended. Therefore, for safety
reasons, an assistant must be posted to watch the working area which is not within
the operator’s vision.
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Emergency control features B1-7
7.1.2.3 Rear axle steering
Solenoid valve 3:
Tip switch H = steering actuated to the left.
Tip switch G = steering actuated to the right.
Solenoid valve 2:
DANGER During actuation of the solenoid valve (3), the rear axles are steered; risk of crushing!
7.1.2.4 Suspension
Solenoid valve 2:
Tip switch E = oil supply.

Actuate rocker tip switches 64, 65, 85 or 86 in the carrier cabin.
7.1.2.5 Fan drive
Change-over cock F parallel to piping = normal operation.

Change-over cock F transverse with reference to piping = Emergency function; fan fully con-
nected.
Refer also to item B1-4.6.2.7 "Function of the change-over cock in the cooling system".
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B1-7 Emergency control features
Memo:
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Operation in winter B1-8
Depending on the climatic conditions of the area where the crane is to be used, the weather conditions may
be more or less extreme during the winter months. Thus, the instructions mentioned below must definitely be
observed to ensure trouble-free and safe operation in winter.
DANGER Particular care is required when climbing up or using steps, ladders and platforms in
damp weather and snow.
• Access steps and platforms must be cleaned to remove dirt, oil, grease and smeary substances.
! Risk of slipping !
• Loose snow, frozen layers of snow and ice may form a dangerous coating on the boom surfaces, counter-
weights and platforms on the chassis.
! Risk of accidents!
• Snow and ice must be removed from the vehicle before the machine is set into motion.
• Snow or lumps of ice which are blown down or which fall down during crane work may endanger the road
users.
! Risk of accidents !
DANGER In case of extremely low freezing temperatures, do not touch metal surfaces with your
naked hands - danger of freezing to metal surfaces!
NOTE The recommendations regarding oil sorts provided in part "C1" must be observed for
the following assemblies.
Under extreme weather conditions, it may be advisable to use snow chains.

The instructions of the snow chain manufacturer regarding assembly, speeds and other data must be ob-
served.
8.1 Engine
8.1.1 Engine oil
In order to ensure a sufficient lubrication in case the vehicle is to be started at low ambient temperatures, the
viscosity of the engine oil must be selected according to the ambient temperatures prevailing at the time
when the engine is started.
Adhere to the specifications of the engine manufacturer supplied in the separate brochure.
8.1.2 Coolant in water-cooled engines
Attention The engine must be filled with anti-corrosion - anti-freeze agent all the year round.
The engine must be checked for a sufficient portion of coolant or anti-freeze agent in time, before the tem-
perature drops below zero.
Adhere to the specifications of the engine manufacturer supplied in the separate brochure.
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B1-8 Operation in winter
8.1.3 Diesel fuels
In order to avoid operating malfunctions, the winter diesel fuel available on the market during the cold sea-
son must be used. If only summer-type diesel fuel is available, or if winter-type diesel fuel is used at very low
ambient temperatures, a certain amount of petroleum, the quantity of which depends on the ambient tem-
peratures, must be added to the fuel in order to avoid segregation of paraffin.
The approximate values for the amount of additive are indicated in the operating manual of the engine manu-
facturer.
There is a simple method to check the diesel fuel for its suitability at the prevailing low temperatures:
- Fill diesel fuel into a flask and expose it to the ambient temperatures. If flakes develop in the fuel (paraffin),
the latter is only suited for operation at higher temperatures.
8.1.4 Starting the engine at low ambient temperatures
For the steps to be taken and for further details, please refer to the brochure of the engine manufacturer.
8.2 Gearbox
8.2.1 Start-up, vehicle operation and parking the vehicle at low temperatures
For information on operation in winter, refer to the enclosed operating manual of the gearbox manufacturer.
(For recommended oil types, refer to ZF Chart of Lubricants in part "G1".)
8.3 Warming up the hydraulic oil or changing the oil type in winter
At low ambient temperatures, the hydraulic oils recommended in part "C1" must be used.
If the oils to be used at the appropriate ambient temperatures approach the limits (values of max. 10°C be-
low the minimum temperature limit are admissible), the hydraulic oil can be warmed up without requiring a
change of the oil type.
The admissible service temperature is approx. 70°C to 80°C.
Attention Avoid relatively high engine speeds while the hydraulic oil is still cold. Allow the oil to
warm up at least until it reaches the lower service temperature level.
If the hydraulic system is filled e.g. with hydraulic oil HLP 68 or HLP 46, the oil type must be replaced by the
specified pressure fluids at low ambient temperatures.
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8.4 Batteries
Well-charged batteries are a prerequisite for starting the engine at low ambient temperatures.
At ambient temperatures lower than -30°C, when the machine is standing in the open air for an extended
period of time without being operated (for ex. at night), the batteries must be heated or removed from the
vehicle and stored in a warm room.
In winter, the current consumption should be kept as low as possible.
Check the acid density and the acid level as described in part "C1".
Discharged batteries freeze already at temperatures as from -10°C.
Adhere to the instructions of the battery manufacturer.
The supply of warm / fresh air can be controlled by means of the adjustable air vents item. 2.1, Pos. 3; 25
and 32.
During the winter months, a certain amount of antifreeze agent for windshield washing systems, the quantity
of which depends on the temperature, must be added to the water of the windshield washing system.
The washer water is made frost-proof by adding washer additives (cleaning agent and antifreeze agent for
windshield washing systems). Observe the manufacturer's instructions for use.
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Memo:
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Steps for access to the superstructure B1-9
9 Steps for access to the superstructure
Steps for access are located on the right (1) and left (2) of the crane carrier.
An additional access step (3) is provided on the right rear end of the vehicle.
An access step (4) on the left rear end of the vehicle facilitates refuelling.
These access ladders are fixed.
These steps enable safe and comfortable access to the vehicle's platform and to the superstructure cabin.
DANGER Steps and platforms must always be kept clean!

Dirt and other smeary substances must be removed immediately and thoroughly!
Risk of slipping and of accidents !
When climbing and stepping on access steps and platforms, particular care is also
required in damp and rainy weather, in rain, fog and snow.
This also involves an increased risk of slipping and accidents !
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B1-9 Steps for access to the superstructure
Memo:
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Attachments, optional equipment and accessories in the chassis B1-10
10 Attachments, optional equipment and accessories in the

chassis
The optional equipment of the vehicle is listed and explained in this chapter. The following list is an overview
of the optional equipment which has been described and explained in other sections for logistic reasons.
Optional equipment mentioned in other sections:
● Pilot lamp, direction indicators, trailer. Refer to part B1-4, item: 4.2.9.
● Air conditioning. Refer to part B1-4, item: 4.4.5.
● Connecting the axle drive. Refer to part B1-5, item: 5.4.
● Switch working floodlight, outriggers. Refer to part B1-6, item: 6.2.
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B1-10 Attachments, optional equipment and accessories in the chassis
10.1 Electronc immobilizer (FinTronic Car Bloc TTS 24/12)
The immobilizer is operated via a keyring pendant fastened to the ignition key, i.e. the so-called transponder.
The transponder as such is passive, i.e. it is maintenance-free and does not require any battery.
Activation of the immobilizer
- Stop the engine by turning the ignition key from position 2 into position 0.
- Remove the ignition key.
The immobilizer is activated automatically after approx. 20 seconds. The red LED 73 starts
flashing in the instrument panel.
Deactivation of the immobilizer
- Insert the ignition key into the ignition switch and turn it in position „ignition ON“ (position 2).
- Hold the ignition key in this position until the red LED 73 goes out.
- Turn the ignition key to its stop in position 3 and start the engine.
NOTE The immobilizer is only deactivated when the LED 73 has gone out.
10.2 Fog lights
To switch on the fog lights, actuate the rocker switch 78. A pilot lamp in the switch goes on to
indicate that the fog light is turned ON.
10.3 City / country horn (Supertone horn)
To change over from the electric horn to the supertone horn, actuate the rocker switch 72.
10.4 Acoustic reversing signal - warning device
An acoustic warning signal sounds when the reverse speeds are engaged in the gearbox. It is
to warn persons who are in the manoeuvering area of the vehicle.
This warning device can be switched ON and OFF via the rocker switch 71.
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10.5 Pilot lamp "centralized lubrication system"
If a centralized lubrication system is installed, various lubricators on the chassis are supplied
with grease via centralized lubrication.
For operating instructions and data regarding the lubricating points, please refer to the
documents of the unit's manufacturer (see Annex).
Pilot lamp 24 - centralized lubrication system.
10.6 Checking the air accumulator retaining force on upward gradients -

vehicles equipped with trailer coupling device
In the case of vehicles with trailer coupling device, it must be possible to check the tractor's air accumulator
retaining force for the whole tractor-trailer combination.
X= Lock position
This check position has been integrated in the valve of the
handbrake.
Checking the air accumulator retaining force:
- The valve of the handbrake is engaged (refer also to item
B1-4.5).
- Push the handle (2) down and pull the lever (1) back to its
stop.
- Check whether the air accumulator retaining force is
capable of holding the whole vehicle combination (the
whole tractor-trailer combination does not move).
- Return the lever (1) to its locking position (braking position).
The check should be effected whenever the vehicle

combination is to be parked on upward or downward
gradients.
The tractor's air accumulator system must be capable of
holding the whole vehicle combination up to a gradient of
12% while the handbrake is engaged.
While the vehicle is parked, it must be protected from rolling by additional wheel chocks placed under the
tires.
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10.7 Eddy-current brake
Attention The accelerator pedal is inoperative as long as the hand-actuated switch of the eddy-
current brake is actuated.
The use of the eddy-current brake avoids the systematic use of the service brake. This, in
turn, remains cool, efficient and ready for use for cases in which it is indispensable.
- Set the hand-actuated switch to the positions 2 - 5; the eddy-current brake is activated, the
yellow indicator lamp 4 "Continuous service brake" is lit.
The braking effect of the eddy current brake can be graduated.
The hand-actuated switch has 6 positions:

Position Braking effect
0 0
1 Engine brake/
constant throttle
valve (continuous
service brake)
2 ¼ (eddy-current
brake)
3 ½ (eddy-current
brake)
4 ¾ (eddy-current
brake)
5 Total (eddy-current
brake)
NOTE The eddy-current brake is ready to operate as soon as the vehicle starts moving (as
from approx. 3 - 5 k.p.h.). The various steps of the control device enable the driver to
obtain the desired braking effect.
It is however necessary to make the switch lock in briefly for each step (i.e. no switch
position must be skipped), in order to prevent the limits of adherence from being
exceeded on slippery surfaces.
10.7.1 Terminating braking operation with the eddy-current brake
After the braking procedure has been finished, the hand-actuated switch must be in position 0; the yellow
pilot lamp 4 "Continuous service brake" must go out.
10.7.1.1 Stopping and parking the vehicle
Attention As soon as the vehicle has stopped completely, return the hand-actuated switch to
position "0" and engage the parking brake. This is to prevent unnecessary power
consumption and overheating of the eddy-current brake. The pilot lamp 4 "Continuous
service brake" must go out.
- When the machine is parked for an extended period of time, shut the engine off and set the battery main
switch to OFF.
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(cont'd.) 10.7 Eddy-current brake
Attention The eddy-current brake is without function when the vehicle is not running, and thus
cannot be used as parking brake. Make sure that the parking brake is engaged and
that the gearbox is set to neutral "N".
NOTE The braking effect of the eddy-current brake and the engine exhaust flap brake should
be coordinated with the operation of the service brake, i.e. they should be actuated
alternately, to obtain an optimum braking effect and to save the service brake, i.e. to
have the full service brake effect available for unforeseen cases.
10.7.2 Examples for application of the eddy-current brake
In "city" mode
- At very low speeds, the eddy-current brake is highly effective for the most
common braking operations in city travel (at junctions, around bends, at
turning points etc.) and when stopping the vehicle, without actuating the
service brake.
On roads / trunk roads

- The eddy-current brake enables the necessary deceleration procedures
even from a relatively high speed, to save the wheel brakes.
Hilly terrain
- It is recommended to couple the effect of the eddy-current brake with that of
the engine brake by utilizing the correct reduction ratios. Thus, the
appropriate speed for the existing slopes and routes can be reached as fast
as possible.
On long downhill slopes

- As soon as the vehicle has been braked down to the desired speed, only the
second eddy-current brake step should be engaged to obtain the optimum
continuous braking effect. It may be useful to utilize the effect of the service
brake, continuous service brake and continuous service brake/eddy-current
brake alternately to adapt the speed of the vehicle.
On slippery roads, in snow, ice and dirt

- When the tires' adherence is diminished considerably, the eddy-current
brake is particularly effective. It not only allows progressive braking, but can
also be used to set the machine smoothly into motion on slippery roads.
Attention The fact that the machine is equipped with an eddy-current brake does not exclude
extreme caution. Thus, if the road conditions are not absolutely safe, the driver
should operate first step 2, and then, while watching the roadholding and the general
behaviour of the vehicle, the next step up.
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10.8 ROCKINGER Trailer Coupling Device

10.8.1 Coupling
DANGER For coupling or uncoupling, the regulations of the employers' liability insurance
association must be adhered to.
The trailer must be equipped with a towing eyelet ∅ 40 DIN 74054 with bushing.
Coupling
- Push manual lever upwards to its second stop location.

- Check whether the coupling jaw is positioned firmly (refer also to part C,
item 13.5).
- Back the tractor up.
On coupling, the front axle of the trailer with pivoting bolster must not be
braked.
NOTE When coupling a central-axle trailer, proceed as coupled

follows:
• Back the tractor up carefully.
• The towing eyelet must touch the coupling jaw in its center.
Attention Non-observance of this instruction may result in

damage to the coupling jaw, the towing eyelet and the
supporting device.
Check:
After each coupling operation, make sure that the coupling is checked for
After coupling, the check pin must not protrude from its guide bushing.
When the check pin is protruding from its guide bushing, this means that
the coupling process has not been completed correctly; there is a
RISK OF ACCIDENTS!
10.8.2 Closing the coupling by hand
- Pull hand lever down.
10.8.3 Uncoupling
- Actuate the hand lever to its stop (1st stop location).

- Move the tractor forward.
NOTE When the towing eyelet slides out of the coupling jaw, the latter is automatically
locked by the releasing lever.
During operation without trailer, the coupling must be kept closed to protect the lower
bushing from dirt.
During operation without trailer, the pneumatic coupling heads (reserve and brake
connectors) must be kept closed to protect them against dirt.
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10.9 RINGFEDER Trailer Coupling Device
DANGER For coupling or uncoupling, the regulations of the employers' liability insurance
association must be adhered to.
10.9.1 Opening and closing the trailer coupling device
- Turn the knob locking device (1) to the left by 90°, pull
it out and make it engage in the locking device.
- To open the coupling with the hand lever (2), the

coupling jaw must be placed centrally, or be turned
into one of its lateral end positions by hand.
NOTE The coupling can only be opened

and locked in one of the above-
mentioned positions.
When the trailer's towing eyelet is moved in, the

automatic coupling mechanism is released as the
coupling bolt (3) is lifted.
When the coupling bolt is in its lower position, the second, independent knob locking device secures the
coupling bolt automatically.
Attention After coupling, it must be checked whether the knob locking device (1) is engaged
correctly.
A special plastic plate (4) in the coupling jaw saves the towing eyelet and dampens sound.
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10.10 Refrigerator box
A refrigerator box is installed to the right of the driver's seat. The control switch is located on
the right, in the bracket near the driver's seat. (Refer to item B1-2.1, item 10.)
For instructions regarding operation, service and maintenance, please refer to the
manufacturer's operating manual.
10.11 Tool box
A tool box is installed on the rear of the vehicle. It provides space for items of equipment and tools.
Attention The cover of the tool box must be kept closed during driving and crane operation.
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If the vehicle's batteries are discharged or if their capacity is

insufficient, the engine can be started with power supplied from an
external source.
Such an external power source are the batteries of another vehicle

with 24 V system, or the batteries of the superstructure or the
chassis of the vehicle in question.
However, this requires that the vehicle supplying power is equipped

with a plugbox for starting via an external power source.
On your own vehicle, the plugbox for starting via an external power
source (1) is installed on the left side of the chassis, below the
battery box (refer to Fig.).
The batteries of the vehicle supplying power should have the same
or a higher capacity (Ampere) than the vehicle to be supplied with
power.
To avoid damage to the alternator, make sure that the following sequence of operations is observed.
Vehicle to be supplied with power Vehicle supplying power

1. The ignition is switched OFF. The ignition is switched OFF.
2. The battery main switch is turned OFF. The battery main switch is turned OFF.
3. Connect jumper cable to plugbox. Connect jumper cable to plugbox.
4. Switch the battery main switch ON.
5. Switch the ignition ON.
6. Start the engine and make it turn at half-load.
(Do not switch the battery main switch ON.)
9. Start the engine.
10. Stop the engine, switch the ignition OFF;
Switch the battery main switch OFF.
11. Disconnect the jumper cables Disconnect the jumper cables
Attention Make sure that the engine is never running without connection to the battery (either to
the vehicle's own battery, or to the battery of another vehicle). (Destruction of the
rectifier diodes in the three-phase alternator).
NOTE Current can also be supplied via the plugbox for starting the vehicle by means of an
external power source, i.e. another vehicle can be started.
0160_EN_FA043_B1_10_00_00
2003-01 9/14
The battery charge condition is checked by measurement of

the acid density.
If the acid density is below 1.21 kg/l - referred to a

temperature of 20°C and the specified acid level - the battery
must be charged.
The battery may only be charged with direct current.
To charge the batteries, connect the charging plugbox directly

to the charger via a cable; it is not necessary to remove the
batteries.
For further details, please refer to the brochures of the battery

manufacturer.
Attention The charging plugbox must not be used for starting the vehicle with externally
supplied power while the charger is connected. The plugbox only serves to charge the
battery.
0160_EN_FA043_B1_10_00_00
10/14 2003-01

10.14.1 Instructions to ensure optimum function of the air conditioner
Vehicle owners are frequently unaware of the fundamental fact that air conditioners only function properly if
they are operated in an enclosed space. The air circulation must be a directed flow. The interior of the cabin
must be kept clean.
If the filter installed upstream of the evaporator is clogged, it reduces the air flow.
10.14.2 Starting-up the air conditioner
The air conditioner can only be operated while the engine of the vehicle is running. Before the engine is
stopped, the air conditioner must be switched off.
- Start the engine.

- Adjust the rotary switch (3) "Cold-warm air regulation" as required.
- Actuate the pushbutton switch (4) to connect the air circulation. When the air circulation is switched ON, the
pilot lamp (5) is lit.
- Actuate the pushbutton switch (6) to switch ON the air conditioner. When the air conditioner is switched
ON, the pilot lamp (7) is lit.
- Regulate the air flow via the rotary switch (1) and the air vents (keep air flow away from the windscreen, as
far as possible).
- Regulate air quantity via the three-stage blower fan (three-stage fan switch (2)) as required.
- Actuate the pushbutton switch (6) again to switch OFF the air conditioner. The pilot lamp (7) goes out.
In this context, refer also to item B1-4.4.5.
0160_EN_FA043_B1_10_00_00
2003-01 11/14
10.14.3 Utilization of the air conditioner
In hot weather at normal air humidity:

The heating is switched off; switch off the blower fan (fresh / warm air); switch ON air conditioner.
In very hot weather at high air humidity:

The heating is switched OFF; switch ON the blower fan (fresh / warm air); switch ON air conditioner.
In autumn and early winter, at high air humidity, in rain/snow and mist on the window panes:
Adjust heating as required; switch ON the blower fan (fresh / warm air); switch ON the air conditioner.
During cold weather in winter:

Switch OFF the air conditioner; adjust heating as required; switch OFF the blower fan (fresh / warm air), if
necessary.
In very cold weather and at very low air humidity:

Switch OFF the air conditioner; adjust heating as required; switch ON the blower fan (fresh / warm air).
10.15 WEBASTO - Thermo 90 S / with engine pre-heating
A heater unit, type Thermo 90 S, is installed in the chassis as

supplementary heater unit.
The heating is programmed and operated via the timer.
Operation and maintenance of the heating are described in detail in the
operating instructions of the heater unit's manufacturer which is supplied
with the machine.
10.15.1 Use of the supplementary heater unit Webasto - Thermo 90S
The supplementary heater unit Thermo 90S can be used for preheating of the engine alone, or as a heater
unit for engine preheating combined with heating of the cab in the chassis.
Only engine preheating: Engine preheating and preheating of cab in the

chassis:
z The heating is programmed and operated via the z Switch on battery main switch (92).
timer. z Set blower fan (refer to item B1-4.4.2) to step 1.
Operation and maintenance of the heating are z Set blower fan (refer to item B1-4.4.3) to position
described in detail in the operating instructions of “warm”.
the heater unit's manufacturer which is supplied
z Programming the timer.
with the machine.
NOTE The heater unit must be switched off during traveling operation.
0160_EN_FA043_B1_10_00_00
12/14 2003-01
10.15.2 Do-it-yourself troubleshooting in case of malfunction
Shut-down on faults in case of overheating of the heater unit with error

code F10 "overheating":
- Allow the heater to cool down.

- Check the coolant in the expansion tank and, if necessary, top up as
described in part C1), item C1-3.5.1.
- Press button of the temperature limiting device on the heater unit (refer to
Fig.). The heater unit is installed below the driver's cabin, on the right
side.
- Deaerate the heater unit.
- Put the heater unit into operation.
10.16 WEBASTO diesel heater unit
When a supplementary diesel-operated heating is installed,

the driver's cab can be heated independently of the engine-
fed warm water heating. The operating element is provided for
control and inspection of this unit.
Service, operation and maintenance of the WEBASTO diesel-
operated heater unit are described in detail in the operating
instructions of the heater unit's manufacturer supplied with the
machine.
AIR-TOP 3500
10.16.1 Adjustable air vents
The supply of warm/fresh air of the driver's cab can be

controlled by means of the adjustable air vents (1).
Operation of the engine-fed warm-water heating system, refer to item B1-4.4.
10.17 Switch "Emergency OFF, undercarriage engine"
One switch is installed on each mudguard of the 1st front axle, to the left and
right sides of the vehicle.
To stop the running engine in the chassis in cases of emergency, press the
push-button.
If it is intended to restart the engine, press the push-button once more; now
it will return to its initial position.
Engine Stop
0160_EN_FA043_B1_10_00_00
2003-01 13/14
10.18 Spare wheel
Prerequisite:
• The crane is supported by outriggers as specified.

• The superstructure is slewed to the rear, the boom is raised, the telescopes are completely retracted. The
mechanical swing lock is engaged.
- Fasten the spare wheel (3) with an appropriate
securing device.
- Release the securing bolts (1) and remove the
holder (2).
DANGER The spare wheel will turn up

after releasing the bolts.
RISK OF ACCIDENTS.
- Remove the spare wheel from the spare wheel

holder, lifting it in the direction of the arrow, and
place it on the ground.
DANGER Secure the spare wheel against

falling over.
- To fasten, the faulty wheel in the spare wheel holder, reverse the above sequence of operations.
0160_EN_FA043_B1_10_00_00
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Instrument panel B1-11
Memo:
0165_EN_FA043_B1_11_00_00
2002-12 1/4
B1-11 Instrument panel
11 Instrument panel
(for drawings, refer to the following page)
11.1 Pilot, indicator and warning 11.2 Other components
lamps Item
Item 55 Gearbox display
1 (ge) Rear axle steering unlocked 80 Buzzer, engine malfunction
2 free 81 Buzzer, gearbox malfunction
3 (rt) Servicebrake 11.3 Instruments
4 (ge) Continuous service brake**)
48 Air pressure indicator, BBA I
5 (rt) ABV, trailer **)
49 Air pressure indicator, BBA II
6 (rt) ABV, tractor
50 Tachograph
7 - 10 free
51 Tachometer with hourmeter
11 (rt) Generator
52 Fuel level indicator
12 (rt) Engine malfunction
53 Engine temperature indicator
13 (ge) Air cleaner
54 Frei
14 (gn) Direction indicators, chassis
15 (rt) Steering pump 11.4 Switches, rocker switches (WS) and
16 (rt) Normal level rocker tip switches (WT)
17 (gn) On-road gear
47 Rotary switch, lights
18 (ge) Inter-axle differential lock, front axles
58 WS*) - Hazard warning flashers
19 -23 free
59 Rotary switch, axle drive assembly
24 (gn) Centralized lubrication system **)
60 WT - Inter-wheel differential locks
25 free
61 free
26 free
62 WT - On-road / off-road gear
27 (ge) 2nd axle drive **)
63 WT - Level control, all down
28 (ge) Inter-wheel differential lock
64 WT - Inclination adjustment, VR
29 free
65 WT - Inclination adjustment VL
30 (gn) Off-road gear
66 WT - Leveling
31 (ge) Axle suspension lock
67 free
32 (rt) Emergency steering pump
68 WS - Mirror heating
33 (gn) Direction indicators, trailer**)
69 free
34 (rt) Hydraulic oil filter
70 free
35 (rt) Engine oil level
71 WS - Reversing signal **)
36 (rt) Coolant level
72 WS - Supertone horn **)
37 free
74 WT - Rear axle steering, left-hand / right-hand
38 free
75 WS*) - Rear axles unlocked
39 free
76 WS*) - Flashing beacon
40 (ge) Rear fog light
77 WT - Rear fog light
41 (bl) High-beam light
78 WS - Foglight **)
42 free
79 free
43 free
82 free
44 (rt) Parking brake
83 WS - Working speed
45 free
84 WS - Axle suspension lock
46 free
85 WT - Inclination adjustment HL
56 free
86 WT - Inclination adjustment HR
57 (rt) Gearbox malfunction
87 - 89 free
73 Immobilizer **)*) 90 WT - ABV-of-road mode
91 Key-actuated change-over switch, chassis -
superstructure
92 WS*) – Battery main switch
Pilot lamps = (gn) grün, green, vert UW = Chassis (carrier), OW = Superstructure
Indicator lamps = (ge) gelb, yellow, jaune HR = Rear right-hand; HL = Rear left-hand
(or) orange (bl) blau, blue, bleu VR = Front, right-hand; VL = Front, left-hand
Warning lamps = (rt) rot, red, rouge BBA = Service brake system
ABV = Anti-lock system WS = Rocker switch; WT = Rocker tip switch;
WS*) = Rocker switch with function lighting

0165_EN_FA043_B1_11_00_00
2/4 2002-12
Instrument panel
0165_EN_FA043_B1_11_00_00
2002-12 3/4
Memo:
0165_EN_FA043_B1_11_00_00
4/4 2002-12
Part B2
superstructure
0170_EN_ALLGE_B_02_00_00
General instructions concerning operation B2-1
1 General instructions concerning operation
All control elements and monitoring instruments which are required for operation of the chassis and the
superstructure are installed in the cabin of the superstructure.
Before the operator puts the superstructure into operation, he should absolutely read the following operating
instructions for the superstructure, and the Safety Provisions (part B.0).
• The driver must be absolutely familiar with the position and the purpose of all the controls and operating
elements. This is a prerequisite for safe operation of the machine.
• Before the engine in the superstructure is started, the parking brake lever in the chassis and the
rocker switch "parking brake" in the superstructure must be set to "braking" position.
• Before the engine is started, especially if the vehicle has been immobilized for an extended period of time,
it is necessary to check the oil and fluid levels in the following components:
- Engine oil level.

- Oil level in hydraulic oil tank,
- Check the coolant level in the engine.
The cooling system is filled correctly if the coolant level is between the "Max. and Min." marks on the
expansion tank.
DANGER Do not check the coolant level while the engine is hot; the cooling system is
pressurized.
There is a risk of scalding when the filler socket is opened while the engine is hot!
• To start the engine in the chassis from the superstructure, the gearbox must be set to "N" in the chassis,
and the rotary switch 40 "gear selector, gearbox" in the superstructure must be set to zero.
DANGER During operation from the superstructure, nobody is allowed to stay in the driver's
cabin in the chassis.
0175_EN_FA043_B2_01_00_00
2003-01 1/8
B2-1 General instructions concerning operation
Nameplate - Superstructure
Steering only operative while
Refer to Operating Manual. engine is running
OUTRIGGERS
Preselector switch
Outrigger beam and outrigger Zero (0) position Outrigger beam and outrigger
cylinder front, left-hand cylinder front, right-hand
extending / retracting extending / retracting
Outrigger beam and outrigger Outrigger beam and outrigger

cylinder rear, left-hand cylinder rear, right-hand
Extending and retracting outrigger
cylinders
Nobody is allowed to stay in the

Standard equipment with optional swing range
equipment Hubwerk ab/auf - Hoisting
Left-hand control lever down/up;
Multifunction Wippen ab/auf - Lowering/raising
boom
Standard equipment
Right-hand control lever
Boom elevation and hoisting gear
(main winch)
0175_EN_FA043_B2_01_00_00
2/8 2003-01
(cont'd.) 1.1 Warning and instruction plates in the superstructure
The brake system comprises

plastic piping.
Danger of crushing Caution during drilling, welding and
grinding work.
Protect piping against battery acid;
temperature-resistant in the range
from -40°C to +100°C.
Hoist limit switch override feature Access prohibited to unauthorized

persons. Danger due to suspended load
Rear axle steering Front axle steering

Hydraulic oil
Max. fluid level in expansion tank Min. fluid level in expansion tank
Apply the handbrake before you

leave the crane cabin!
0175_EN_FA043_B2_01_00_00
2003-01 3/8
(cont'd.) 1.1 Warning and instruction plates in the superstructure
Instruction plate
(Only in the Netherlands)
Swing brake engaged / released Change-over: 2nd winch /
counterweight
Engine speed regulation, chassis
Gear selector, gearbox
Filling pressure depending on the tires

Operating prescription
(Only in Germany)
Only in case of optional feature Instruction plate sound power

"Emergency operation of the
superstructure controlled from the
chassis".
0175_EN_FA043_B2_01_00_00
4/8 2003-01

The following diagram shows the position and location of all the warning and instruction plates mounted to the superstructure.
**) Specific requirement of the country where the machine is to be used, or according to vehicle model
0175_EN_FA043_B2_01_00_00
2002-12 5/8
Memo:
0175_EN_FA043_B2_01_00_00
6/8 2001-06
1 Ring gear - slewing device 16 Hydraulic oil filter

2 Batteries 17 Hydraulic oil tank
3 Air cleaner 18 Hydraulik oil drain port
4 Water separator/fuel strainer 19 Oil level indicator, hydraulic oil
5 Expansion tank, cooling system 20 Supplementary heater unit
6 Radiator 21 Filler socket, fuel
7 Engine 22 Gearbox of swing mechanism
8 Exhaust system 23 Crane cabin
9 High pressure filter 24 Length transmitter equipment
10 Hydraulic pumps 25 Crane boom
11 Drain plug, fuel tank 26 Winch rope
12 Hoist cylinder, counterweights 27 Hoist limit switch
13 Hoist winch 28 Releasing weight, hoist limit switch
14 Lubricator, ring gear 29 Bottom block
15 Oil cooler 30 Boom extension (jib)**)

0175_EN_FA043_B2_01_00_00
2003-01 7/8
Memo:
0175_EN_FA043_B2_01_00_00
8/8 2003-01
Crane cabin B2-2
Memo:
0180_EN_FA043_B2_02_00_00
2003-01 1/10
B2-2 Crane cabin
2 Crane cabin
2.1 Explanation - control elements
1 Cab lighting
2 Roller sun visor
3 Instrument panel
4 Windshield wiper, skylight
5 Heated air / fresh air vent
6 Loudspeaker - radio
7 Spirit level
8 Control lever, steering of chassis - rear axles
9 Rocker switch - unlock rear axles
10 Storage tray
11 Locking mechanism, rear window
12 Accerlerator lever, engine of chassis
13 Key-actuated switch, ASLI override feature
14 Plugbox 24 V
15 Fuses
16 Relays
17 Diagnostic connector, engine
18 Seat
19 Servicing lid
20 Ashtray
21 Superstructure locking pin
22 Control element, heating/ventilation (air conditioner)**)
23 Direction indicators, chassis
24 Heated air / fresh air vent
25 Expansion tank - swing brake
26 Control lever, steering chassis - front axles
27 Crane control lever
28 Foot-brake pedal, chassis
29 Swing brake pedal
30 Kick-strip, access
31 Working floodlight
32 Radio
33 Handhold
34 Accelerator pedal, superstructure engine
35 Tank for windshield washing fluid
36 Mushroom-head emergency OFF pushbutton
37 Instrument panel
38 Windshield wipers
39 Sun visor
40 Crane control lever
41 Plugbox 12 V
42 Hourmeter, hoisting winch 1**)
43 Hourmeter, hoisting winch 2**)
0180_EN_FA043_B2_02_00_00
2/10 2003-01
Crane cabin B2-2
Crane cabin
„X“
0180_EN_FA043_B2_02_00_00
2003-01 3/10
B2-2 Crane cabin
Memo:
0180_EN_FA043_B2_02_00_00
4/10 2003-01
Crane cabin B2-2
2.2 Adjustment of the seat
The seat is equipped with a weight-dependent suspension system. Its height and longitudinal position are
adjustable as are the surface's distance and inclination with reference to the control levers and switches and
the backrest inclination, and it is equipped with a lumbar support. The seat must be adjusted so that the
control levers and the pedals are within easy reach for the driver. The headrest can be removed, but it
cannot be adjusted. The armrests on the left and right are adjustable vertically and with regard to their
inclination. Thus, the appropriate seat position can be adjusted for any operator. To facilitate entering, the
left bracket can be tilted upwards.
NOTE When the bracket is tilted up, all crane movements are switched off.
DANGER Make sure that the bracket is tilted up when getting into and out of the crane cabin.
Otherwise, there is a risk that crane movements might be triggered by touching of the
control levers unintentionally. This results in an increased
! Risk of accidents!
2.2.1 Vertical adjustment of armrests
- Loosen the star grip (1) to set the armrests to the desired
height.
2.2.2 Adjustment of armrest inclination
- Turn adjusting wheel (2) to set the armrest inclination.
2.2.3 Longitudinal adjustment of seat in the

direction of the control device
- When the lever (3) is actuated, only the longitudinal position

of the seat is changed.
The control device remains in its original position. Thus, the
distance from the control device can be adjusted at random.
2.2.4 Longitudinal seat adjustment
- Actuate the linkage (4).

Longitudinal adjustment of the seat, incl. the control device.
2.2.5 Adjustment of seat's position with regard to the levers and switches.
- Actuate lever (5) to set the seat's position.
2.2.6 Seat inclination adjustment
- Actuate lever (6) to set the inclination of the seat's surface.
0180_EN_FA043_B2_02_00_00
2003-01 5/10
B2-2 Crane cabin
2.2.7 Adjustment of seat suspension
- Turn lever (7) to adjust the operator's weight. This permits an optimum suspension effect. The weight to be
adjusted is displayed visually in no-load condition.
2.2.8 Vertical seat adjustment
Seat upwards: Lift seat until it locks in with a click (1st stage). Lift seat once more until it locks in (2nd stage).
Seat down: - Lift seat up to its stop (beyond the 2nd stage); then lower it to its lowest position.
2.2.9 Adjustment of backrest inclination
- Actuate handle (8) to set the backrest inclination.
2.2.10 Adjustment of the lumbar support
- Turn adjustment wheel (9) - the lumbar support is adjusted steplessly.
2.2.11 Headrest
The headrest (10) cannot be adjusted.

- To remove the headrest, pull it up.
2.2.12 Electrical seat adjustment
- Actuate rocker tip switch 69 “seat adjustment”. The inclination of the seat, incl. the console,
can be adjusted.
2.3 Roller sun visor - skylight
A roller sun visor (1) has been installed as a protection against

exposure to the sun through the skylight.
The roller sun visor can be set to various locking positions.
1
0180_EN_FA043_B2_02_00_00
6/10 2003-01
Crane cabin B2-2
2.4 Opening the windscreen
Lock/unlock windshield
Lever in position (1) - windshield locked.

Lever in position (2) - windshield unlocked.
- Actuate rocker switch 68. The windscreen can be opened or closed steplessly.
Attention Unlock the windshield before opening it.
2.5 Opening the rear window
- Actuate the rear window locking mechanism (sect. 2, item 11) and open the rear window.
2.6 Cab lighting
Switch positions:
0= OFF
1= Lamp is permanently lit (while the battery main switch is
ON)
2= No function
2.7 Emergency exit
If it is not possible to leave the crane cabin through the cabin door in case
of an emergency, open the windshield and leave the crane cabin in this
way.
Opening the crane cabin:
1. Actuate rocker tip switch 68, open windshield,
or:
2. Remove spring clip (1), remove the adjusting cylinder (2) from the pin,
open windshield by hand.
Attention Unlock the windshield before opening it.
0180_EN_FA043_B2_02_00_00
2003-01 7/10
B2-2 Crane cabin
2.8 Assignment of functions to the crane control levers
Pos. 1 = Left-hand crane control lever

Pos. 2: Right-hand crane control lever
Pos. 3: WS swing brake engaged / released
Pos. 4: WS change-over; assignment of functions to
the left crane control lever
Rocker switch (3) swing brake
Actuate rocker switch to the left = swing brake engaged.

Actuate rocker switch to the right = swing brake released.
Rocker switch (4) change-over - assignment of functions to the left-hand crane control
lever:
Rocker switch in central position = telescoping / slewing.

Actuate rocker switch to the right = counterweight.
Actuate rocker switch to the left = 2nd winch**)/ slewing.
Right-hand crane control lever (2): Right-hand crane control lever

forward - bottom block of 1st winch down;
backwards - bottom block of 1st winch up;
to the left - boom is raised,
to the right - boom is lowered.
Left-hand crane control lever (1): Left-hand crane control lever

forward - telescopes are extended;
Rocker switch (4) in central position.
to the rear - telescopes are retracted.
to the left - superstructure swings to the left
to the right - superstructure swings to the right

forward - counterweight down,
Rocker switch (4) positioned to the right.
backwards - counterweight up,
to the left - counterweight locked,
to the right - counterweight unlocked.

forward - hook block of 2nd winch**) down;
Rocker switch (4) positioned to the left.
backwards - hook block of 2nd winch**) up;
to the left - superstructure swings to the left

0180_EN_FA043_B2_02_00_00
8/10 2003-01
Crane cabin B2-2
2.9 Superstructure locking system
DANGER Work with the crane standing free on wheels, driving with a load suspended "over-
rear", picking up and depositing counterweights from the counterweight support is
only admissible if the superstructure is locked via the lock pin.
Slewing the superstructure is only admissible when the machine is supported by
outriggers.
ATTENTION The swing mechanism may only be locked while the superstructure is immobilized.
2.9.1 Locking the superstructure via hand lever (item 2.1., pos. 21)
- Swing the superstructure in its position "over-rear".

- Raise the locking pin by approx. 10 mm, turn it 45° to the left and lower it.
- If necessary, slew the superstructure slightly until the pin and the bore-hole coincide.
• The green pilot lamp 17 "swing locked" goes on.
2.9.2 Unlocking
For unlocking, proceed analogously by reversing the above sequence of operations.
If necessary, swing the superstructure slightly until the pin can be pulled out of the bore-hole.
• The green pilot lamp 17 "swing locked" goes out.
2.9.3 Monitoring of the swing lock
2.9.3.1 Pilot lamp "swing mechanism locked"
When the boom is directed to the rear and the locking pin (hand lever) is inserted, the green
pilot lamp 17 "swing mechanism locked" goes on.
0180_EN_FA043_B2_02_00_00
2003-01 9/10
B2-2 Crane cabin
Memo:
0180_EN_FA043_B2_02_00_00
10/10 2003-01
NOTE All the instruments, switches and indicator lamps are described in the following text
are illustrated in part B2-12 "Instrument panel".
The item numbers appearing in the text are printed in bold letters, and are identical with the
item numbers appearing in the illustration "Instrument panel".
DANGER The parking brake (handbrake lever) in the chassis and rocker switch 38 in the
superstructure must be engaged.
DANGER During operation from the superstructure, nobody is allowed to stay in the driver's
z Before putting the crane superstructure into operation, perform all the necessary inspections in
the chassis, as described under item B1-4.1.
In the chassis:
- Switch on battery main switch.

- turn ignition switch to position 1,
- set key-actuated switch to position 2 (the connection to the superstructure is established).
(Control positions of key-actuated switch, refer to item B1-4.1.1)
NOTE When the key-actuated switch in the chassis is set to position 2, the
axle suspension is locked automatically. The yellow pilot lamp 15 "axle
lock engaged" must be lit in the superstructure.
If the pilot lamp is not lit, the suspension is not locked, or there is a
fault in the axle suspension locking system.
In this case, the axle oscillation is also inoperative while the crane is
driving "free on wheels with the boom over-rear", even if the
superstructure locking assembly is actuated.
DANGER If the symbol goes out during crane work, work must be stopped immediately, the
reason for the malfunction must be determined and eliminated.
In the superstructure:
z The boom is completely retracted and deposited on the mast rest (on-road driving condition).
z Switch the battery main switch 70 in the superstructure on (item 4.2.1).
z The parking brake in the superstructure has been engaged via the rocker switch 38.
z The rotary switch 40 "gear selector, gearbox" is set to positon "zero" (0).
z The swing mechanism is braked positively via the rocker switch "swing brake" (refer to item B2-2.8).
z Insert the ignition key into the ignition starter switch 54.
z Check the engine oil level in the superstructure (refer to part "C2", item 2.1).
z Check the hydraulic oil level in the superstructure (refer to part "C2", item 3.1).
z Check the superstructure electrical system for proper working order (refer to item 4.3).
0185_EN_FA043_B2_04_00_00
2003-01 1/12
4.2 Operation of the electrical equipment

4.2.1 Battery main switch
Attention When the engine is running, the battery main switch definitely must not be turned
OFF. The current flow between the generator and the battery must not be interrupted
(destruction of the diodes of the generator).
Switching ON:
- Unlock the rocker switch 70 "battery main switch" by actuating the locking handle down, and
actuate the rocker tip switch downwards.
The locking handle returns to its locking position automatically.
Thus, the connection between the superstructure ground and the negative battery terminal
("-") has been established.
Switching OFF:
- Actuate the locking handle down and the rocker switch upwards; now the electrical equipment is de-
energized.
NOTE Whenever crane work is interrupted for an extended period, e.g. at night, the battery
main switch must be turned OFF.
4.2.2 Ignition starter switch
While the ignition key is inserted, the ignition starter switch 54 has the following positions:
Position P: no function,
Position 0: Ignition OFF,
Position 1: Ignition ON,
Position 2: Engine start.
4.2.2.1 Switching the ignition ON
- Turn the ignition key into "position 1"; the following indicator, pilot and warning lamps go on:
Red warning lamp 6 "generator", red warning lamp 11 "service brake/parking brake, chassis" and red
warning lamp 2 "service brake, superstructure".
The instrument 5 "fuel level indicator" indicates the fuel level.
0185_EN_FA043_B2_04_00_00
2/12 2003-01
4.2.3 Working floodlight on the basic boom
- To switch ON, actuate the rocker switch 63 down.

- To switch OFF, actuate the rocker switch 63 upwards.
4.2.4 Working floodlight on crane cabin, and instrument illumination
- Actuate the rocker switch 64.

Top position OFF
Central position Instrument illumination
Bottom position Instrument illumination/working floodlight on the crane cabin
4.2.5 Wiper system
Rocker switch 66 "Windshield wiper, windscreen of cabin"
- Top position OFF

- Central position Interval action
- Bottom position Wiper operation
Rocker switch 65 "Windshield wiper, skylight"
- Top switch position OFF

- Central switch position Interval action
- Bottom switch position Wiper operation
4.2.6 Windshield washing system
- Actuate the rocker tip switch 67 "windshield washing system". The windshield washing
system for the windscreen and the skylight is actuated. Both wipers move once.
0185_EN_FA043_B2_04_00_00
2003-01 3/12
4.2.7 Plugbox
External consumers (24 V DC), such as an inspection lamp, etc., can be connected via
the plugbox (sect. B2-2.1, item 14).
External consumers (12 V DC), such as an inspection lamp, etc., can be connected via
the plugbox (sect. B2-2.1, item 41).
4.2.8 Electric horn
The electric horn serves as a warning signal before starting or while

performing crane work; it is actuated via a tip switch (1).
4.2.9 Mushroom-head emergency OFF pushbutton
The mushroom-head emergency OFF pushbutton 1 is installed in the

superstructure cabin.
To stop the running engine in the superstructure in cases of emergency, press
the push-button.
To re-start the engine in the superstructure, turn the releasing ring in the push-
button to the right, in the direction of the arrow; then the push-button will return to
its original position.
4.3 Functional check of the electrical equipment of the vehicle before starting
work
Before starting work, the driver has to check the wipers, the electric horn and the entire lighting system
(working floodlights) for proper working order.
NOTE The inspection of the lighting system is only possible when the battery main switch
and the ignition are switched ON.
DANGER z Any faulty operating elements and missing or defective lighting equipment increase
the risk of accidents.
z Should there be any faults, they have to be eliminated by specialists before working
is commenced.
ATTENTION z When fuses are replaced, it is essential that the new fuses have the same amperage
as the defective fuses.
z Do not use fuses with a higher amperage on any account.
z It is absolutely prohibited to repair or jumper and re-use defective fuses.
z Non-compliance with these instructions may entail damage to the electrical
equipment.
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4.4 Blower fan, heating, air regulation
Fan (1)
- Fan OFF.
1 - First step, low power.
2 - Second step, medium power.
3 - Third step, high power.
Heating system (2)
The rotary control device (2) serves to progressively regulate the temperature of the inflowing air.
- Rotary control device in left-hand position cold,
- Rotary control device in right-hand position warm.
Air regulation (3)
The rotary control device (3) serves to progressively regulate the relationship between external and
recirculating air.
- Rotary control device in left-hand position only external air,
- Rotary control device in right-hand position only recirculating air.
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4.4.1 Supplementary heater unit Webasto Thermo 90 S with engine pre-heating
A heater unit, type Thermo 90 S, is installed in the superstructure as

The heating is programmed and operated via the timer.
Operation and maintenance of the heating are described in more details in
the operating instructions of the heater unit's manufacturer which are
supplied with the machine.
4.4.1.1 Application of the supplementary heater unit Webasto - Thermo 90S
The supplementary heater unit Thermo 90S can be used for preheating of the engine alone, or as a heater
unit for engine preheating combined with heating of the superstructure cabin.
Only engine preheating: Engine preheating and preheating of superstructure

cabin:
zProgramming the timer (refer to manufacturer's zSwitch on battery main switch (70).
operating manual). zSet blower fan (refer to item 4.4) to step 1.
zProgramming the timer (refer to manufacturer's
operating manual).
4.4.1.2 Do-it-yourself troubleshooting in case of malfunction
Shut-down on faults in case of overheating of the heater unit with error

code F10 "overheating":
- Allow the heater to cool down.

- Check the coolant in the expansion tank and, if necessary, top up as
described in part C2, item 2.5.1.
- Actuate button of the temperature limiting device on the heater unit
(refer to Fig.). (The heater unit is installed behind the rear wall of the
superstructure cabin.)
- Deaerate the heater unit.
- Put the heater unit into operation again.
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(For details, please refer to the Operating Manual of the engine manufacturer.)
NOTE Before starting the engine in the superstructure, make sure that the handbrake /
parking brake lever in the chassis, and the rocker switch 38 "parking brake" the
superstructure are in "braking" position.
z The measures described under item 4.1 have been taken and the corresponding inspections have been
made.
- Insert the ignition key into the ignition starter switch 54 and turn it to "position I" - now
the ignition is switched ON.
- Turn the ignition key to "position II" (starting the engine) to its stop and hold it against
the spring force.
- As soon as the engine ignites, release the key; the key returns to position I.
z Do not actuate the starter for more than 20 seconds. To save the batteries, pause for approx. 60 seconds
between the various starting attempts.
z After the engine has been started, the following warning lamps/ warning devices must go out:
generator 6 and engine oil level 8.
z While the engine is running, the following instruments are in operation:

Hourmeter 22, engine temperature indicator 4 (depending on load) and fuel level indicator 5.
Explanation of the pilot lamps and instruments while the engine is running: refer to item 4.6.
4.5.1 Stopping the engine
NOTE Do not stop the engine immediately when it has been working at high speed.
- Return engine speed to idling level.

- Actuate the rocker switch 53 "engine stop" until the superstructure engine
stops running.
- Switch off the ignition by turning the ignition key to the left, to position "0".
- Remove the ignition key.
z Do not stop the engine immediately after working under high load, but allow it to run at idling speed for a
few minutes, so that the temperature can adjust.
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4.5.2 Emergency control of engine: emergency start / emergency shut-off
Directly on the engine case, push-buttons are provided for starting (1) and stopping (2) the engine.
- Remove engine cover.
Engine start actuation:

● The ignition in the superstructure is ON and the engine
is not running.
- Actuate push-button (1) – the engine is started and

operates at idle.
Engine shut-off actuation:

● The ignition in the superstructure is ON and the engine
is running.
- Actuate the push-button (1) again – the engine comes
to a standstill.
or
- Actuate the push-button (2) – the engine comes to a
standstill.
Starting the engine and increasing the engine speed:
● The ignition in the superstructure is ON and the engine is not running.
- Actuate push-button (1) and keep it pressed – the engine is started and runs at idle; 3 seconds after the
engine has started, the engine speed increases to max. level.
- Release the push-button (1) – the engine continues to run at its instantaneous speed.
- Actuate push-button (1) again, or actuate push-button (2) – the engine comes to a standstill.
Actuation of engine cranking function:

● The ignition in the superstructure is ON and the engine is not running.
- Actuate push-buttons (1) and (2) at the same time – the engine cranks, but does not start.
- Release the two push-buttons (1) and (2) – starter activation is cancelled, the engine comes to a standstill.
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4.5.3 Manual fuel pump - fuel filter with water separator
The fuel filter with water separator and integrated manual pump is installed on the right-hand side of the
vehicle, below the radiator cover, in front of the radiator.
Should air and/or dirt have entered into the fuel system, the filter cartridge must be replaced, and the fuel
system must be cleaned and bled.
Bleeding the fuel system, and supplying fuel via the manual pump, after
• the fuel tank has been emptied completely,
• leakage has occurred in the fuel system,
• the fuel filter has been replaced (filter replacement, refer to part C2, Service and Maintenance).
Prerequisite:
- a sufficient amount of fuel has been replenished,

- any leakage has been eliminated,
- the filter cartridge has been replaced as described in part C2, Service and Maintenance.
Bleeding, and supplying fuel:
Open vent screw (1); actuate pump plunger (2) repeatedly, until fuel
flows out without bubbles.
(Collect overflowing fuel in an appropriate vessel and pour it back
into the fuel tank.)
- Tighten the vent screw (1) securely again.
- Start the engine. Should the engine fail to start immediately, have an
assistant actuate the pump plunger repeatedly, until the engine is
operating smoothly.
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4.6 Monitoring the pilot, indicating and warning lamps and the instruments
while the engine is running
4.6.1 Fuel level indicator
If the needle in the instrument 5 "Fuel level indicator" drops close to zero indication, fuel
must be replenished in time.
Make sure that the fuel tank is never completely emptied!
NOTE Make sure that the fuel tank is never completely emptied, as otherwise air might get
into the fuel system. Consequently, the system would have to be bled completely.
Moreover, filters and piping assemblies would have to be cleansed.
If the engine does not start after several vain attempts, the fuel system must be
checked for contamination or leakage.
DANGER Explosion hazard: Do not smoke, do not use any open flames; to fill the fuel tank,
make sure that the engine is not running and that the machine is aligned in horizontal
position.
For further instructions, please refer to the Operating Manual of the engine manufacturer.
4.6.2 Engine
4.6.2.1 Engine oil level
The engine oil level is monitored via the warning lamp 8 “Engine oil level” while the engine is
not running.
If the red warning lamp appears while the ignition is ON and the engine is not running, the oil
level must be checked and, if necessary, oil must be replenished.
Check oil level and, if necessary, replenish oil; if applicable, check for a loss of oil and
eliminate the reason. Make the engine run for approx. 2 or 3 minutes and stop it again; after
approx. 5 minutes, check the oil level and, if necessary, repeat this procedure.
NOTE The oil level may only be checked while the engine is not running.
For further details, please refer to the Operating Manual of the engine manufacturer.
4.6.2.2 Engine function
In case of an engine malfunction, the red warning lamp 7 "Engine malfunction" will go on.
Eliminate the fault at the next opportunity; if necessary, take the machine to a specialist
workshop.
In case of serious faults, the buzzer „engine malfunction“ (installed on the underside of the
instrument panel) sounds simultaneously.
In this case, the vehicle must be stopped immediately, the reason for the malfunction must be
determined and eliminated without delay.
If necessary, the vehicle must be taken to a specialist workshop to have the trouble
eliminated.
After the trouble has been eliminated, the error must be read out of the system by means of a diagnostic
device. This should be effected in a specialist workshop or by the TADANO FAUN after-sales service.
(For further details, please refer to the Operating Manual of the engine manufacturer.)
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4.6.2.3 Generator
As soon as the engine is running, the red pilot lamp 6 "Generator" must go out. If it does not
go out or if it goes on during operation, this indicates a malfunction, and the batteries are not
being charged.
The machine must be taken to a specialist workshop immediately for the fault to be eliminated.
It must be ensured that the batteries are always fully charged.
4.6.2.4 Coolant temperature
The coolant temperature is monitored via the “engine temperature indicator” 4.

If the coolant level drops, the coolant temperature consequently exceeds the maximum
admissible rating of 95°C.
The needle moves into the critical range.
Eliminate the fault at the next opportunity; if necessary, take the machine to a specialist
workshop.
If the red warning lamp “engine malfunction” 7 goes on and the buzzer “engine malfunction” (installed on the
underside of the instrument panel) sounds additionally, stop the vehicle immediately, stop the engine, locate
the reason for the malfunction and eliminate it immediately.
For information on remedial measures in case of excessive temperatures, please refer to the operating
manual of the engine manufacturer.
4.6.2.5 Contamination of air cleaner
The intake air resistance or the vacuum on the clean air end of the dry air cleaner is monitored
by the yellow pilot lamp 9 "air cleaner".
If the pilot lamp goes on while the engine is running, this means that the air cleaner cartridge
must be replaced or cleaned.
4.6.2.6 Service hours
Monitoring of the engine service hours is effected via the instrument 22 "hourmeter".
The hourmeter is activated as soon as the engine is started.
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4.6.3 Hydraulic system

4.6.3.1 Hydraulic oil filter contamination
The degree of contamination of the hydraulic oil filters is monitored by the red warning lamp 16
"Hydraulic oil filter". It goes on to indicate an inadmissible degree of contamination of the
hydraulic oil filters.
Should this occur, the hydraulic oil filters have to checked or replaced immediately.
4.6.3.2 Hydraulic oil temperature
The temperature of the hydraulic oil is monitored by the red warning lamp 23 "Hydraulic oil
temperature". It goes on as soon as the oil temperature exceeds 80°C. If it does, crane work
must be interrupted.
After the warning lamp has gone out, crane work can be continued.
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Gearshift and driving operation; actuation of the outriggers from the superstructure B2-5
5 Gearshift and driving operation; actuation of the outriggers

from the superstructure
DANGER Driving from the superstructure is not admissible on public roads.
5.1 Changing-over to driving from the superstructure
- The measures described under items B1-4.1 and B2-4.1 have been taken and the corresponding checks
have been made.
- Turn key-actuated change-over switch in chassis from position 1 to position 2.
- The parking brake in the chassis is engaged, and the rocker switch 38 in the superstructure
"parking brake" is actuated.
- The battery main switch in the chassis must be turned on.
- The ignition key in the chassis must be in position 1.
ATTENTION The engine in the chassis cannot be stopped from the

superstructure, while the ignition in the chassis is switched on
(ignition key in ignition starter switch must be set to "1").
Positions of key-actuated change-over switch in chassis and of rocker switch in superstructure
Position of key- Position of rocker switch 31 Functions

actuated change-over "ignition, chassis, ON" in
switch in chassis (Item superstructure
B1-11, Pos. 91)
Ignition in chassis OFF =
2 OFF only operation from superstructure possible
Ignition in chassis ON =
2 ON The carrier engine can be started from the
superstructure, driving and outrigger actuation from
the superstructure possible with carrier engine.
5.1.1 Establishing the connection "chassis / superstructure" in the

superstructure
- Switch on rocker switch 31 "Ignition chassis ON" (function lighting in the rocker switch is lit).
The ignition in the chassis is switched ON; the engine in the chassis can be started from the
superstructure; the outriggers can be actuated and the crane can be driven from the
superstructure.
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B2-5 Gearshift and driving operation; actuation of the outriggers from the superstructure
5.1.2 Axle lock indicator lamp
The axle lock is switched on as the key-actuated change-over switch in the carrier is turned
from position 1 to position 2 (Item B1-11, Pos. 91).
During superstructure operation, the yellow indicator lamp 15 "axle lock engaged" is constantly
lit.
DANGER If the indicator lamp goes out during crane work, work must be stopped
immediately, the reason for the malfunction must be determined and
eliminated.
5.2 Starting the engine in the chassis from the superstructure
- Actuate the rocker tip switch 32 "start of engine in chassis" until the engine ignites. Do not
actuate the starter for more than 20 sec.
After the engine has started, the red warning lamp 3 "central warning, chassis" goes out.
5.2.1 Stopping the engine in the chassis from the superstructure
- Return engine speed to idling level.

- Switch off rocker switch 31 „Ignition, chassis, ON“, the engine comes to a standstill.
5.2.2 Speed regulation of the engine in the chassis from Engine speed
the superstructure
- Actuate accelerator lever (1). The speed of the engine in the chassis can
be adjusted steplessly.
Actuate the hand lever forward = engine speed increases.

Actuate the hand lever backwards = engine speed decreases.
Driving direction
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5.2.3 Lighting system, chassis
- Actuate the rocker switch 34 "chassis lighting". The lighting system of the chassis is switched
on.
5.2.4 Central warning, chassis
The red warning lamp 3 "central warning, chassis" is used to monitor the engine in the
chassis.
The functions of the generator, engine malfunction and the coolant level are checked.
Attention Watch the warning lamp 3 "central warning, chassis"; it must not go on while the
engine in the chassis is running. Should this occur nevertheless, the engine in the
chassis must be stopped immediately by switching off the rocker switch 31 “ignition
chassis ON”. The reason of the malfunction must be determined and eliminated.
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5.3 Air brake system

5.3.1 Air pressure gauge
The brake-air pressure of the superstructure compressed air system is displayed via the
instrument 21 air pressure gauge".
When the system is filled, the needle must indicate 7.0 to 8.1 bar.
5.3.2 Warning lamp "service brake, superstructure"
The brake-air pressure of the compressed air system in the superstructure is monitored by the
red warning lamp 2 "service brake, superstructure". It goes out as soon as a brake-air
pressure of approx. 5.5 bar is reached.
As soon as this pressure is reached, the vehicle is ready for driving from the superstructure.
If the warning lamp goes on, the air pressure gauge 21 must be checked to see whether the
needle indicates more than 5.5 bar.
DANGER Whenever the pilot lamp "service brake superstructure" 2 goes on, stop the vehicle
immediately and determine the reason.
5.3.3 Warning lamp "service brake/parking brake, chassis"
The red warning lamp 11 "service brake/parking brake, chassis" goes on when the vehicle is
braked positively via the handbrake lever in the chassis and the rocker switch 38 "parking
brake" in the superstructure, or when the brake-air pressure of service and parking brake in
the chassis is no longer sufficient.
It goes out when the handbrake in the superstructure is released and when a sufficient service
pressure is available in the chassis.
DANGER Only set the vehicle into motion when the warning lamps 2 "service brake,
superstructure" and 11 "service/parking brake, chassis" have gone out.
5.3.3.1 Acoustic warning device in brake system**)
The compressed air supply of circuits I and II of the service brake system is monitored by a warning lamp
(refer to item 5.3.3).
Moreover, an acoustic warning device is installed in the system. If the pressure level in the supply system of
the brake circuits drops below approx. 5,5 bar, a warning sound is emitted (this warning buzzer is installed in
the area of the dashboard).
DANGER When the warning buzzer sounds, the vehicle must be stopped immediately and the
reason for the pressure decrease must be determined.
5.3.4 Parking brake
If the vehicle is to be stopped or parked, actuate rocker switch 38 "parking brake".

The red warning lamp 11 "service and parking brake, chassis" goes on. The indicator lamp in the
rocker switch 38 “parking brake” goes out.

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5.3.5 Service brake - footbrake
- The foot-actuated brake pedal in the superstructure, which acts on all the wheels of the chassis, must be
used for slowing down and for stopping the vehicle from the superstructure.
- To this effect, the brake valve pedal must be actuated gently (item B2-2.1, pos. 28).
- In case of failure of the footbrake (service brake), the auxiliary brake (rocker switch "parking brake" 38)
must be actuated.
ATTENTION After starting to drive, perform brake tests immediately using the service and the
auxiliary brake (handbrake).
DANGER During operation from the superstructure, the handbrake in the chassis must not be
released. Analogically, the handbrake in the superstructure must not be released
during operation from the chassis.
DANGER If the handbrake valve in the chassis is not set to braking position, the handbrake in
the superstructure is inoperative, i.e. the parking brake in the chassis must be
engaged before the superstructure is set into operation.
5.4 Driving operation from the superstructure

5.4.1 Gearbox control
The vehicle can be driven from the superstructure in the gear steps "1st forward speed" and "1st reverse".
- Put the vehicle into operation as described under items 5.1, 5.2 and 5.3.
z The parking brake lever in the chassis and the rocker switch 38 "parking brake, superstructure" are in
"braking" position.
- To select the driving direction, turn the rotary switch 40 "gear selector, gearbox" from neutral "0" into the
desired driving direction, while the engine in the chassis is running at idle.
Turn rotary switch to the left = forward travel
Turn rotary switch to the right = reversing
- Actuate the service brake (foot brake).

- Release the handbrake (parking brake) in the superstructure.
- Release the service brake carefully.
- Accelerate gently.
ATTENTION Perform brake tests immediately after the vehicle has started to move.
Before resetting the rotary switch to neutral position "0", decelerate the vehicle to
standstill and engage the handbrake (parking brake).
Otherwise, the vehicle might start moving in an uncontrollable fashion.
DANGER Steering from the superstructure is only possible while the engine in the chassis is
running.
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5.4.2 Direction indicators, chassis
- Actuate rocker switch "direction indicators, chassis" (Fig. B2-2.1, item 23). The
direction indicators in the chassis are switched on.
Rocker switch to the right = direction indicators on the right are flashing
Rocker switch to the left = direction indicators on the left are flashing
While the direction indicators are flashing, the green pilot lamp 10 "direction indicators,
chassis" also flashes.
5.4.3 Steering from the superstructure
ATTENTION Before steering from the superstructure is commenced, the rear axles must be set to
straight-ahead position.
NOTE The steering from the superstructure is active if the boom is stowed over-front, or if
the boom is locked over-rear.
5.4.3.1 Steering the front axles from the superstructure
To change the direction of travel when driving from the

superstructure, actuate the steering control lever (1) installed
in the left-hand seat bracket.
Control lever to the right:

= Driving direction: to the right
Control lever to the left:

= Driving direction: to the left
The actual steering angle depends on the degree of actuation

of the steering control lever.
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5.4.3.2 Steering the rear axles from the superstructure
1. Rear axle steering, releasing the lock
• The front axles should be set to straight-ahead position.
- Actuate the rocker switch (Fig. 1, item 2) "rear axles unlocked" out of
its locking position; the steering locking cylinder is unlocked; the
yellow pilot lamp "rear axles unlocked" 20 is lit.
2. Actuating the rear steering
- To steer the rear axles when driving from the superstructure,

actuate the steering control lever (1) installed in the right-
hand seat bracket.
Control lever to the right:

= Rear steering, right-hand
Control lever to the left:

= Rear steering to the left
The front axles can be steered independently via the steering

control lever installed in the left seat bracket.
Fig. 1
ATTENTION Driving with rear axle steering is only admissible at minimum speed while
accelerating gently. The rear axles may only be unlocked and steered while the engine
is running and while there is a sufficient brake-air pressure in the brake system.
5.4.3.2.1 Locking the rear steering
- Check whether the steering locking cylinder of the rear axle is still unlocked; the yellow pilot lamp 20 "rear
axles unlocked" must be lit.
- The wheels must be steered in straight-ahead position by actuation of the steering control lever "rear
steering". To this effect, the vehicle should be moved at extremely low travelling speed.
- Actuate the rocker switch "unlock rear axles" and set it to "locking"; move the slide in the switch into
"locking" position.
If the steering locking cylinder has locked, the yellow pilot lamp 20 "rear axles unlocked" goes out.
- If the indicator lamp does not go out, the straight-ahead position of the wheels must be corrected.
DANGER The rear steering must be locked in straight-ahead position before the operator leaves
the superstructure, i.e. before he starts driving from the chassis. The yellow pilot lamp
20 "rear axles unlocked" must have gone out. The parking brake in the superstructure
must be engaged. Only then is travelling admissible from the chassis.
- Check that the vehicle is level before on-road travel begins and, if necessary, re-adjust.
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5.4.4 Connection of 2nd axle drive**) and differential locks
Observe the important instructions given in items B1-5.4.
ATTENTION Never drive on a firm road while the differential locks and the 2nd axle drive **) are
connected. When the inter-wheel locks are engaged, only-straight-ahead driving is
admissible. Connect the differential locks only if this is absolutely indispensable. The
differential locks in the axles are only engaged correctly if the appropriate yellow
indicator lamp goes on.
A driven 2nd axle is possible as optional equipment in the chassis. When the vehicle is driven from the
superstructure, it will then be possible to drive with the 2nd axle connected and with the differential locks
engaged.
5.4.4.1 Connecting the 2nd axle drive
The 2nd axle drive and the inter-axle differential lock cannot be connected from the superstructure.
Should it be necessary to perform these connections while driving from the superstructure, the operation
must be effected from the chassis.
To this effect, the same steps are required as are described under items B1-5.4.
5.4.4.2 Connecting the differential locks
The inter-axle wheel differential locks of the axles can be connected from the superstructure.
The connection of the inter-wheel differential locks from the chassis is described under item B1-5.4. For
connecting them from the superstructure, the same steps have to be performed analogously in the same
fashion.
- Actuate rocker tip switch 37 „inter-wheel differential locks, chassis”. The inter-
wheel differential locks in the axles are connected.
The yellow indicator lamp 14 "inter-wheel differential locks, axles" goes on.

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5.5 Driving from the superstructure with complete counterweight
DANGER Driving on the construction site with the complete counterweight mounted is only ad-
missible with the boom stowed over-front or over-rear, if possible, the superstructure
locking pin engaged and the swing brake actuated, on a firm, horizontal ground with
the suspension locked.
Driving must be effected at a low speed of max. 1.4 k.p.h., at the specified tire
pressure.
If possible, the outrigger beams should be extended and the outrigger floats be
located at a minimum distance from the ground.
Comply with the Notes referring to the load charts and item B2-7.
When the boom is deposited over-rear, the locking pin in the superstructure cabin can be inserted. Thus, the
front axle oscillation can be actuated.
- In uneven terrain, should a front wheel spin, the front axle oscillation can be engaged via the
rocker tip switch 35 "axle oscillation, chassis" in the superstructure.
- The rocker tip switch 35 “axle oscillation, chassis” must be kept pressed during driving
operation, until all wheels grip again.
- When the rocker tip switch is released, the axle oscillation is deactivated; the axle
suspension is locked again.
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5.6 Outrigger operation from the superstructure
NOTE
● Before actuating the outriggers, take all the necessary measures and perform all the checks
described under item B2-4.1. Comply with the instructions regarding outrigger operation (item B1-
6).
● The parking brake (handbrake lever) in the chassis and in the superstructure (rocker switch 38) is
in "braking" position.
- Set the key-actuated change-over switch in the chassis to position 2 and switch on the rocker switch 31
"ignition, chassis, ON" in the superstructure. The axle suspension is locked automatically.
● The yellow indicator lamp 15 "axle suspension lock engaged" must be lit in the superstructure.
● The position of the outrigger floats must be changed and the extended and retracted outrigger
beams must be secured with pins as described under item B1-6.
- Start the engine in the chassis from the superstructure and make it run at medium speed.
● The red warning lamp 3 "central warning, chassis" must not go on.
● Before outrigger operation, the operator must sound a warning signal (actuate horn).
DANGER While outriggers are being extended or retracted, nobody is allowed to stay close to
the outrigger beams and the outrigger cylinders. During extension and retracting, the
crane operator must constantly have unrestricted visibility of the moving outrigger
components. If necessary, have an assistant watch these components, for safety
reasons.
NOTE Driving with the crane on construction sites in full rig arrangement has been
described under item B2-7.4.
5.6.1 Outrigger operation
Actuation of the outriggers from the superstructure is effected via the preselector "A" and the four rocker tip
switches "B-C-D-E".
The four outrigger beams can only be extended and/or retracted one by one.
- Turn the preselector “A” switch to the direction of the rocker tip switch desired in the case in question.
To extend or retract the outrigger cylinders, actuate the preselector into position I (switch turned down).
Rotary switch 26 "Preselection of outriggers"
Switch positions:
0 = Outrigger operation OFF
I = Preselection, outrigger cylinders
B= Preselection, outrigger beam, front, right-hand
D= Preselection, outrigger beam, rear, right-hand
E= Preselection, outrigger beam, rear, left-hand
C= Preselection, outrigger beam, front, left-hand
Rocker tip switch, outrigger operation
25 = Rocker tip switch, outrigger beam / outrigger cylinder, front, left-hand

27 = Rocker tip switch, outrigger beam / outrigger cylinder, front, right-hand
29 = Rocker tip switch, outrigger beam / outrigger cylinder, rear, right-hand
28 = Rocker tip switch, outrigger beam / outrigger cylinder, rear, left-hand
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5.6.2 Extending the outrigger beams
- Change the position of the outrigger floats, as described under item B1-6.3.1, and secure them with pins.
- The areas where the outrigger floats are to be positioned must be propped with large-size, sturdy supports.
- Remove the locking pins from the four outrigger floats (refer to item B1-6.5).
- Set the ASLI program to the desired extension width according to the load chart.
- Set the preselector "A" from position "0" to the direction of rocker tip switch "C".
Actuate the rocker tip switch "C" to the left and keep it pressed until the front outrigger beam on the left is
extended to the desired extension width, and can be secured with pins.
- Set the preselector "A" to the direction of rocker tip switch "E".
- Actuate the rocker tip switch "E" to the left and keep it pressed until the rear outrigger beam on the left is
extended to the desired extension width, and can be secured with pins.
- The outrigger beams on the right side of the vehicle are extended in the same fashion, by actuating the
preselector "A" at a time to direction "B" or "D" while actuating the rocker tip switch "B" or "D" to the right.
- Reset preselector "A" to "0" position.
DANGER Make sure that the extended outrigger beams are secured with pins, as there is a risk
5.6.3 Extending the outrigger cylinders
Comply with the instructions specified under item B1-6.
- Turn preselector "A" from position "0" to position "I" (vertically down).
- To extend the outrigger cylinders on the left-hand side of the chassis, actuate the rocker tip switch "C" or
"E" to the left, and keep it pressed.
- To extend the outrigger cylinders on the right-hand side of the chassis, actuate the rocker tip switch "B" or
"D" to the right, and keep it pressed.
- Raise the machine just enough for all the tires to be clear of the ground. Do not prop the wheels with
supporting material.
- Align the vehicle in horizontal position (watch the spirit level). The air bubble must be in the center of the
reticule (max. deviation from the horizontal line: + 0.3°).
- When the crane is aligned in horizontal position, set the preselector switch "A" to "0" position.
- Actuate rocker switch 31 "Ignition, chassis" - stop the engine in the chassis.
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5.6.4 Retracting the outriggers
- Start the engine in the chassis from the superstructure and make it run at medium speed.
- The red warning lamp 3 "central - The yellow indicator lamp 15 "axle
warning, chassis" must not go on. lock engaged" must be lit.
5.6.5 Retracting the outrigger cylinders
- Set preselector "A" from position "0" to position "I" (vertically down). Actuate the
rocker tip switches "C" and "E" to the right, or the rocker tip switches "B" and
"D" to the left, and retract the outrigger cylinders uniformly.
- After all the outrigger cylinders have been retracted completely, set the
preselector "A" to "0" position (upwards).
5.6.6 Retracting the outrigger beams
- Remove the locking pins from the outrigger beams.
- Actuate the preselector "A" out of its position "0" by selecting the directions of the tip switches "C" and "E";
or "B" and "D" one by one; for each switch position, actuate the related rocker tip switch to "retracting
outrigger beams" (to the inside) and keep it pressed until the outrigger beams are retracted and can be
locked with pins.
- Reset preselector "A" to "0" position.
- Slip the outrigger floats on as specified for on-road travel, as described under item B1-6.3.1, fasten and
lock them.
- Lock the outrigger beams for on-road travel by means of pins (refer to item B1-6.5).
DANGER Make sure that the retracted outrigger beams are secured with pins, as there is a risk
- Actuate rocker switch 31 "Ignition, chassis" - stop the engine in the chassis.
For on-road travel, switch off the rocker switch 31 the superstructure, and set the key-actuated change-over
switch in the chassis to position 1. The axle suspension is automatically activated; the yellow pilot lamp 15
"axle lock engaged" in the superstructure goes out.
DANGER Do not change key-actuated change-over switch in the chassis over to position 1 until
all wheels are resting completely on the ground.
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Crane movements in no-load condition B2-6
DANGER To avoid operating errors during crane operation, please make sure that the safety
provisions contained in part B.0 are complied with!
6 Crane movements in no-load condition
● The checks required and the measures to be taken in the chassis

have been accomplished.
● The crane is supported by outriggers as specified.
● Key-actuated switch in the chassis in position 2, refer to part B1-
4.1.1.
● Start the engine in the superstructure as described under item B2-
4.5.
● The slewing gear brake is engaged via the switch (1) (rocker switch
actuated to the left - slewing gear brake engaged; rocker switch
actuated to the right - slewing gear brake released).
● The green pilot lamp 17 "Slewing gear locked" must not be lit.
6.1 Instructions regarding actuation of the crane control
The actuation of the crane control levers described in the following text applies to the standard
machine model. Any differing special models have not been taken into account.
For the crane operator, the instruction plates mounted in the cab will be decisive in any case.
●The speed of the working movements is controlled by gentle actuation of the crane control levers and by
varying the engine speed.
●All crane movements can be performed independently of the load pressure. Depending on the work cycle,
one or both crane control levers are moved in longitudinal direction, laterally or diagonally.
●The crane movements can be regulated precisely even when the engine is operating at idling speed.
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B2-6 Crane movements in no-load condition
6.1.1 High speed circuit (E)
NOTE To avoid control pressure peaks, the high speed must be connected before the crane
control levers are actuated.
By actuation of the push-button "E" in the right-hand crane control

lever, the high speed can be connected for the crane movements
"hoisting up/down", boom elevation "up" and "extending" telescopes.
Attention Only two working movements are possible at a

time when the fast speed is connected, i.e.
- Slewing gear and winch, or

- Slewing gear and tele sections, or
- Slewing gear and boom elevation
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6.2 Actuation of the hoisting gear (main hoisting gear)
Right-hand crane control lever

forward - bottom block moves down,
to the rear - bottom block moves up.
The hoisting speed can be controlled depending on the travel of the crane control lever and by varying the
engine speed.
The hoisting speed can be increased further by connection of the high

speed “E”, before actuation of the crane control lever.
When the highest bottom block position is reached, the hoisting gear
is switched off via the hoist limit switch. However, lowering is still
possible.
If the maximum admissible load per rope fall is reached in the course
of lifting, the system is also switched off. However, the bottom block
can still be lowered.
Before the rope end is reached on the hoist drum, the hoisting gear is
switched off by the rope limit switch (approx. 3 windings remain on the
rope drum).
DANGER If the hook block is lowered quickly without a load, it must be ensured in particular
that the rope does not get slack on the rope drum.
zMake sure that the load is not lifted or lowered by jerks.
zIf the load is decelerated or accelerated too quickly, this will cause an overload on
the drive elements and the rope, and may cause accidents, such as overturning.
Attention The high speed for "hoisting gear UP/DOWN" (regarding the hoisting gear and the
auxiliary hoisting gear) may only be connected at low or zero load. If 50% of the
maximum rope fall load are exceeded, the function “high speed” for the motion
“hoisting gear down” is interrupted.
The fast speed must be connected before a load is moved. The fast speed must not
be connected during the lifting or lowering procedure with a load fixed to the boom.
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6.2.1 Auxiliary hoisting gear (2nd hoisting gear)**)

6.2.1.1 Connecting the auxiliary hoisting gear
- Actuate the rocker switch (1) in position 1 (to the left). The auxiliary
hoisting gear is connected.
The pilot lamp "2nd winch is connected" must be lit in the

ASLI (Refer to part G2 "Operation of the Automatic Safe Load
Indicator").
The allocation of functions to the left-hand crane control lever is
changed as described under item 6.2.1.2.
Fig. 1
ATTENTION As long as the left-hand crane control lever's function allocation is changed, the
telescoping movement is not available.
6.2.1.2 Allocation of functions to the left-hand crane control lever and work using the
auxiliary hoisting gear:
Left-hand crane control lever

forward - bottom block moves down,
to the rear - bottom block moves up.
The hoisting gear speed can be controlled depending on the travel of the crane control lever and by
increasing the engine speed.
The auxiliary winch is mainly used during operation with a boom extension (arrangement with one rope fall).
In case of failure of the main winch, the rope falls of the auxiliary winch can also be fixed to the pulley head
of the main boom.
In this case, the hoist limit switch weight of the main winch must be
installed to the rope of the auxiliary winch.
When the highest bottom block position is reached, the hoisting gear is
switched off via the hoist limit switch. However, lowering is still possible.
If the maximum admissible load per rope fall is reached in the course of
lifting, the system is also switched off. However, the bottom block can still
be lowered.
Before the rope end is reached on the hoist drum, the hoisting gear is
switched off by the rope limit switch (approx. 3 windings remain on the rope
drum).

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cont'd.: 6.2.1.2 Allocation of functions to the left-hand crane control lever and work using the
auxiliary hoisting gear:
NOTE If work is only performed with the auxiliary winch via the jib, the
hoist limit switch on the pulley head of the main boom must be
set free via a clamping piece (2), as otherwise the hydraulic
system is switched off.
DANGER If the bottom block is lowered quickly without a load, it must be ensured that the rope
does not get slack on the rope drum.
Make sure that the load is not lifted or lowered by jerks.
If the load is decelerated or accelerated too quickly, this will cause an overload on the
drive elements and the rope, and may cause accidents, such as overturning.
6.2.1.3 Switching off the auxiliary hoisting gear
- Actuate rocker switch (1) into central position. The auxiliary hoisting gear is disconnected.
The standard allocation of the left-hand crane control lever - telescoping - is active again.
DANGER A double ladder must be positioned at the superstructure to enable placing the rope
of the 2nd winch. The double ladder is located below the driver's cab and secured by
means of supports (Refer to part B2, item 11.2).
6.2.2 Rope winch rotation indicator (D)
The integrated rotation indicator informs the crane operator about each motion of the rope drum. When the
right-hand crane control lever is actuated to position "hoisting gear raising/lowering" (or the left-hand crane
control lever, if the machine is equipped with an optional second hoisting gear), the pulse generator installed
in the handle vibrates as soon as the rope drum moves. The pulses are also indicated acoustically.
6.2.2.1 Actuation of rope winch rotation indicator
- Actuate the rocker switch 46 "rope winch rotation indicator". The function "rope winch
rotation indicator" is activated.
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6.3 Boom elevation
Right-hand crane control lever

to the left - boom is raised,
to the right - boom is lowered.
NOTE While the boom elevation is actuated, the telescopes must not be extended or
retracted.
The hoisting speed can be controlled depending on the travel of the crane control lever and by varying the
engine speed for raising the boom via the boom elevation.
To enable a faster boom elevation movement "up", the high speed “E”
can be connected, if at all possible, before the crane control lever is
actuated.
To increase the work radius ("boom down") under load, proceed

slowly and carefully, as the automatic safe load indicator (ASLI)
switches off as soon as the maximum work radius is reached (for a
description of the ASLI, please refer to part G2 Superstructure).
After switching off, only a movement tending to reduce the load

moment (boom elevation "up") can be performed.
Fast movements of the boom cause the load to swing out.
As the load swings away from the boom during the movement "boom
elevation down", the work radius is necessarily increased.
DANGER When the load swings out quickly and far, this implies an overload and can result in
accidents (tipping over).
ATTENTION The high speed for "boom elevation UP" may only be connected at low or zero load.
When the boom extension is mounted to the telescopic boom head, while the telesco-
pic boom is completely or partially extended, the fast speed must not be connected.
NOTE When performing the movement "boom elevation down" while actuating the hoisting
gear, the high speed can be connected for the hoisting gear.
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6.4 Telescoping (in the case of machines equipped with one rope winch)
Left-hand crane control lever

forward - telescopes are extended,
to the rear - telescopes are retracted.
The telescoping speed can be controlled depending on the travel of the crane control lever and by increasing
the engine speed.
To enable a faster telescope extension movement, the high speed (E)
can be connected, if at all possible, before the crane control lever is
actuated.
NOTE A load must not be fixed to the hook!
The telescopes are extended to the length being monitored by the

ASLI in accordance with the required rig arrangement and the ASLI
code no. to be selected to this effect (refer to load chart).
ATTENTION Work should not be performed with a longer

boom length than is actually required to perform
the crane operation.
The code numbers indicated in the load charts must be entered into
the ASLI control unit. The desired boom length must be determined
via the load charts and the hook height diagram.
NOTE The data for changing the counterweight variants or outrigger variants can only be
entered while the telescopes are retracted.
NOTE The boom elements must be extended to the desired length in no-load condition, and
subjected to load only afterwards.
NOTE During the telescoping process, the boom elevation must not be actuated.
DANGER In case of a deficiency in the length transmitter cable (break of a strand, etc.), which
implies failure of the ASLI, work must not be continued. Place the load on the ground
and retract the boom elements in manual mode, as described under item 6.4.2 and for
the ASLI. Repair any damage immediately.
Telescopable loads
DANGER When working with the option “telescopable loads”, make sure to comply with all the
instructions and provisions specified in this operating manual.
When „telescopable loads“ is used, a load of > 5 t can be telescoped using telescope 5. For the relevant
data, refer to the appropriate load charts.
However, the code numbers of the appropriate load charts for the standard mode must be entered in the
ASLI, e.g. 001010. In this case, 901010 will be displayed.
Now the appropriate loads can be telescoped by means of telescope 5, with telescoping being performed as
described above.
NOTE When telescoping in load condition, the pin locking procedure may be impossible.
If however, once the pin locking procedure has been accomplished, telescoping in load condition is
continued, the ASLI changes over to standard mode - refer to the code numbers appearing in the display.
If admissible values are exceeded in this process, the ASLI shut-off feature will be activated.
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6.4.1 Telescoping
DANGER Before starting crane work, the user must carefully read the ASLI operating manual
and familiarize himself thoroughly with its contents, and with the method of operation
of the ASLI.
In conjunction with the ASLI system, the telescoping control automatically ensures the correct telescoping
sequence.
ATTENTION During the telescoping process, the boom must be elevated at an angle of min. 45°.
Telescoping:
- Switch the ignition ON, start the engine.

The ASLI program is started.
The start menu appears.
- The data required for crane work (load, boom length etc.) must be
determined before crane work is started.
- The code number corresponding to this crane work must be determined
based on these data, via the load charts.
The ASLI guides the operator through the program in a user-friendly fashion.
- The ASLI must be programmed with the data determined previously as
described in the operator manual.
Attention In automatic telescoping mode, switch 51 must be in its central

position.
- Actuate the crane control lever.
The tele sections are automatically extended in the correct sequence, starting from the smallest tele section,
until the required telescoping configuration is reached.
Telescoping sequence: 5, 4, 3, 2 and 1.
NOTE If the "fast speed" pushbutton of the left-hand crane control lever is actuated during
the telescoping process, telescoping is interrupted. However, the boom in question is
extended to its final position.
NOTE The required boom length must be determined precisely before work is started.
Depending on the telescoping configuration, it may not be possible to change to another telescoping
configuration (e.g. from 100/100/50/50/0 to 100/100/100/50/0) without resetting the crane to its former rig
arrangement.
For further information, please refer to the notes regarding the load chart, or to the ASLI operating manual.
- Perform crane work as described in Part B2, items B2-6 and B2-7.
DANGER If a malfunction occurs in the control program during telescoping operation, proceed
as described under item 6.4.2.
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6.4.2 Emergency control
When telescoping the tele sections, make sure that the selected, automatically limited telescope lengths
according to the entered ASLI code are complied with.
If the operator notices, on telescoping the tele sections, that these are not extended completely to their
preselected position (malfunction in ASLI system regarding the length change-over point), the rocker tip
switch "emergency control" can be actuated to perform emergency control of the tele sections.
DANGER The emergency control feature may only be used to retract the tele sections (resetting
them to their former position). This requires maximum care and caution.
After activation of the emergency control, the functions "boom elevation", "telescope", "hoisting
gears 1 and 2**)" and "swing mechanism" can be controlled. The assignment of functions of the
crane control lever always corresponds to the EURO control system. All motions are controlled
digitally; the speed can be regulated within certain limits via the engine speed.
DANGER Only operate the swing mechanism at idle and while the boom is as short as possible.
To this effect, the vehicle must be supported by outriggers as specified.
Further explanations regarding the telescoping control

If the automatic system fails when the cylinder or a telescopic element is unlocked by removal of the
pin, it is recommended to release the telescope via the emergency control before the unit is reset by
hand to its former rig arrangement. To this effect, switch the emergency control on via the rocker
switch 52 and pull crane control lever for approx. 3 or 4 seconds backwards. Subsequently, switch
the emergency control off again. Now automatic operation can normally be resumed. If releasing
does not show the desired result, the boom must be returned to its former rig arrangement by hand.
ATTENTION In case of telescopes 1 to 3, the tele cylinder can be extended forward, beyond the
cylinder guide of the tele sections in question. However, under unfavourable circum-
stances, the proximity switches for the telescoping display ID might be damaged on
retracting. To reduce this risk to the largest possible extent, it is recommended to lift
the boom via the boom elevation as far as possible before retracting the elevation
cylinder.
In the case of boom lengths lower than approx. 18 m, the tele cylinder might push
through the boom head on extending.
During a telescoping movement, the bottom block must always be watched.

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6.4.2.1 Retracting the boom in manual mode
Prerequisite: The proximity switches for telescoping display ID and the locking mechanism appear on the
ASLI display.
Attention If no length transmitter signal is available, all movements must be performed at idle.
1. Activate emergency control: 52 (1) 51 50

Actuate the lock handle (1) down to unlock the rocker switch 52
"telescope emergency mode"; push rocker switch down and lock it.
The green function lamp in the switch is lit.
After switching on the emergency control, all locking mechanisms change initially over to position "pin
engaged" or "floating".
2. Check whether the tele cylinder is pin-fastened in one of the sections (displays, ASLI, pin securing
mechanism and valid telescoping indication ID) (refer to diagram).
In this case, continue as described under item 9.
Otherwise, proceed first of all as described under items 3 to 8.
3. Retract the pin from the tele cylinder; to this effect, move rocker switch 51 upwards and actuate rocker
tip switch 50, until complete releasing of the pin lock is signalled.
4. If the position of the tele cylinder with regard to the first telescope to be moved is unclear, retract tele
cylinder completely by moving the left-hand crane control lever back (also in case of FAUN control !)
until the cylinder length 0 is indicated. If the cylinder length transmitter has failed, watch the cable drum
on the boom underside.
5. Extend tele cylinder until one of the ID switches appears in the ASLI display for the tele section to be
reset to its former rig arrangement. To this effect, move left-hand crane control lever forward. Reduce
engine speed to idle approx. 1 m before the telescope reaches its pin locking position (table
value "boom pin locking positions for emergency operation"); stop approx. 0.5 m before the pin
locking position is reached and cover the residual stroke with short movements. When the first ID
proximity switch appears, a residual stroke of approx. 10 cm is left. Stop tele cylinder by releasing the
crane control lever immediately.
6. Lock the tele cylinder. To this effect, actuate the rocker switch 51 to its central position.
7. Subsequently, perform short extension movements via the crane control lever (max. total travel of 20 cm,
or until the first ID proximity switch shuts off). If complete locking is not achieved even after this proce-
dure, retract the tele cylinder. To this effect, actuate the left-hand crane control lever backwards (max.
total travel 20 cm, or until the first ID proximity switch shuts off). If necessary, repeat this procedure.
8. If complete locking is signalled and the complete telescoping display ID appears, the telescope can be
retracted.
9. Release the telescope. To do so, actuate the left-hand crane control lever forward and extend by approx.
2 cm. If the cylinder length transmitter has failed, watch the cable drum on the boom underside.
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(cont'd.) 6.4.2.1 Retracting the boom in manual mode
10. Unlock the telescope; to this effect, actuate the rocker switch 51 down and actuate rocker tip switch 50
until the telescope is completely unlocked.
11. If complete unlocking is not achieved, proceed once more as described as of item 9. If complete
unlocking is not achieved even after several attempts, the telescope must be locked once more. To do
so, move rocker switch 51 to central position while actuating the left-hand crane control lever several
times briefly to the rear while the engine is running at idle. Then, proceed again as described as of
item 9.
12. If the telescope is completely unlocked, it can be retracted; to this end, move left-hand crane control
lever back until the telescope has reached its final position. Reduce engine speed to idle approx. 1 m
before reaching the end position.
13. Lock the telescope; to this effect, move rocker tip switch 51 to its central position.
14. Retract the pin from the tele cylinder; to this effect, move rocker switch 51 upwards and actuate rocker
tip switch 50, until complete releasing of the pin lock is signalled. After all telescopes have been
retracted, continue as described under as of 15. Otherwise, proceed again as described as of item 5.
15. Retract tele cylinder completely; to this effect, move left-hand crane control lever to the rear until the
cylinder has been retracted.
16. Pin-fasten tele cylinder in a tele section (refer to items 6 and 7).
17. Shut off the engine, switch the ignition off.
18. Switch the emergency control off; to do so, actuate the rocker switch 52 upwards.
Items 15 to incl. 18 must be executed to re-initialize the telescoping control.
When the ignition is switched on again and the engine is started, the ASLI program is re-started. Items 17 to
18 must be performed to start the ASLI program.
Displays (refer also to part G2 - ASLI operating manual):
1. Load utilization rate

2. Operation mode
3. Tele cylinder locked by pins
4. Tele cylinder length
5. Boom length
6. % display of tele sections
7. Boom unlocked
8. Boom locked
9. Tele cylinder pin released.
10. Proximity switch, telescoping display ID
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(cont'd.) 6.4.2.1 Retracting the boom in manual mode
Telescoping display IDs
Each tele section is displayed individually in the (ID) display.
Tele section 1 Tele section 2 Tele section 3 Tele section 4 Tele section 5
Tele pin locking positions for emergency actuation:
0% 50% 100%
Tele section 1 0,00 m 3,75 m 7,50 m
6.4.3 Interruption of telescoping sequence
During the telescoping procedure, the tip switch “interruption of telescoping sequence T" in the left-hand
crane control lever can be actuated to interrupt telescoping.
- Tip switch "T" actuated while extending the telescopes:
The Telestop icon appears.
The current telescope is extended completely. Telescoping is finished if the current telescope no longer
appears in black (backlit) on the display.
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(cont'd.) 6.4.3 Interruption of telescoping sequence
- Tip switch "T" actuated while retracting the telescopes:
The Telestop icon appears.
The current telescope is retracted completely. The tele cylinder is completely extended and pin-fastened in
the next tele section. End of the telescoping procedure.
Subsequently, retracting or extending the telescopes can be continued by actuating the crane control lever
again.
6.4.4 Correction of pin fastening
If complete pin fastening is not detected at the end of a telescoping movement, the icon
"telescope correction" appears.
- Actuate the tip switch "T" to initiate the correction.
DANGER If the correction is performed during the extending procedure, the telescope is first retracted
by approx. 10 cm, which causes the load to move downwards.
Once correction is completed, the telescoping sequence interruption is active, i.e. the crane control lever
must be set briefly into its neutral position to continue the telescoping procedure.
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6.4.5 Sensor error in tele section
When sensor errors have been detected, the system should only be switched off if the tele section is pin-
fastened. Otherwise, it might be necessary to retract the tele section by hand before operation can be
continued.
If a sensor error occurs between the last tele movement and the moment the system is switched off, it may
also be necessary - depending on the operating state of the tele section - to retract the section by hand
before operation can be continued.
The sensor errors are subdivided into two groups:
6.4.5.1 ID errors
If an ID error occurs, the icon ID error appears. (Refer to part G2 Superstructure "Operation
of the Automatic Safe Load Indicator").
If a sensor triggers the error, the crane remains fully functional.

If sensors on both sides of the telescope trigger the error, refer to “tele stop” and “emergency control” as per
item 6.4.2.
6.4.5.2 Locking errors
If a “locking error” occurs, the icon "locking error" is displayed. (Refer to part G2
Superstructure "Operation of the Automatic Safe Load Indicator").
Locking errors are reset if the system is switched off.
If a sensor triggers the error, the telescoping speed is limited to 50%.

If sensors on both sides of the telescope trigger the error, refer to “tele stop” and “emergency control” as per
item 6.4.2.
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6.5 Slewing the superstructure
Move left-hand crane control lever gently

to the left - superstructure swings to the left.
DANGER Slewing the superstructure is only admissible while the crane is stabilized by
outriggers.
- Otherwise, the crane might tip over. -
DANGER The swing brake must be in automatic mode. Otherwise, the superstructure is not
braked automatically.
The green pilot lamp 17 "slewing gear locked" must not be lit.
- If necessary, pull the locking pin out of its lock assembly and put it to its upper position.
DANGER Before starting any swing movement, make sure that there are no
obstacles in the swing area.
The swing movement must be initiated and decelerated gently.
- While the swing brake is engaged, the movement is automatically

decelerated when the crane control lever is returned to central
position "0".
or:
while the swing brake is released (free wheeling), by gentle
deceleration via the swing mechanism foot-brake pedal.
ATTENTION When the brake is released, the swing movement

must be decelerated to standstill via the footbrake
pedal; only now may the swing brake be engaged
by operation of the rocker switch 1.
The swing speed can be controlled depending on the travel of the

crane control lever and by varying the engine speed.
Fig. 1
DANGER If the superstructure is slewed and decelerated abruptly, the load may start to
oscillate. The greater the load, or the greater the boom length, the lower the speed
must be at which slewing is commenced/decelerated.
ATTENTION The swing parking brake may only be released for slewing the superstructure.
In all the other working situations, the swing parking brake must remain engaged.
NOTE During crane work "free on wheels, to the rear", the pin locking device must always be
engaged. The superstructure must not be swung while a load is attached, as the
slewing gear is not shut off by the ASLI.
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6.6 Counterweights
) Important instructions to be observed

before commencing assembly and disassembly. (
zBefore the counterweight units are picked up or deposited, the vehicle must be supported by
outriggers and aligned in horizontal position, as specified.
zBefore commencing a slewing movement, make sure that the ballast cylinders are completely
retracted.
zThere must not be any persons or objects in the swing range - risk of accidents.
z When picking up the counterweights from the chassis, make sure that the counterweight cylinders
are inserted in the bore-holes of the counterweights without touching them. The boom should be
raised to approx. 30°. If necessary, check visually.
zBefore picking up, depositing the counterweights or slewing the superstructure, the operator must
sound a warning signal.
zThe counterweight units required for crane work must correspond precisely to the load chart in
question; there is a risk of accidents otherwise.
zWhen the basic boom is elevated and counterweights are mounted to the superstructure, the
outriggers must be fully extended; otherwise there is a risk of the superstructure tipping towards
the ballast side while it is being slewed.
zCounterweights which are transported by an auxiliary vehicle must be located as close as possible
to the supported chassis, so that they can be picked up with the crane's bottom block. To this
effect, a second crane may be used.
zThe legal regulations regarding “ropes and hosting gear” in force in the country where the crane is
to be registered must be observed.
zTo pick up or deposit counterweight units which have been transported by auxiliary vehicles using
the crane's bottom block, the pertaining "set-up program" must be programmed. The working radii
and boom lengths specified in it must not be exceeded. Risk of overturning, i.e. risk of accidents.
zDamaged counterweight units or retaining clips must not be used; they might fall to the ground and
involve a risk of accidents.
z The retaining clips are used to secure the weight units suspended from the superstructure.
zCounterweight units of other crane carriers must not be used.
zWhen depositing partial counterweights on the chassis, the locking pin must be actuated to secure
them better.
zWhen the counterweights are deposited, no ropes, wooden bars etc. must be located between
them, which would prejudice the safe support of the counterweights.
There is a risk of accidents due to slipping of weights.
zBefore commencing driving operation, check that the deposited counterweights are safely
fastened.
There is a risk of accidents due to slipping of weights.
zOnce crane work is finished, to prepare the crane for on-road travel, taking account of the legally
admissible axle loads, partial counterweights must be dismounted from the superstructure and
deposited on the chassis in the counterweight rest, or, with the fly jib mounted, transported on an
auxiliary vehicle. (For further details, refer to part B2, item 6.6.8 “Counterweight distribution
according to rig arrangement”).
zFor reasons regarding vehicle registration, the crane may only participate in public road traffic
when its rig arrangement has been changed accordingly.
(Refer to illustration of the weight versions according to EC approval, item 6.6.8).
0195_EN_FA043_B2_06_00_00_NEU
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cont'd.: 6.6 Counterweights
- Actuate the rocker switch (1) to position 2 (to the right).
ATTENTION As long as the left-hand control lever's function

allocation is changed, the movements
"telescoping" and "slewing of superstructure" are
not available.
The allocation of functions to the left crane control lever is changed as described below:
Left-hand control lever

forward - counterweight down,
backwards - counterweight up,
to the left - counterweight locked,
to the right - counterweight unlocked.
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6.6.1 Picking up counterweights
Counterweights which are transported by an auxiliary vehicle can be picked up by the crane itself, and
deposited in the counterweight rest of the chassis.
DANGER It is essential that the safety provisions in Chapter B0 are complied with to avoid
accidents.
Make sure that the Load Chart Counterweight Set-Up Program is used.
The counterweight elements may only be attached to the fastening points provided to
this effect.
When picking up or removing individual counterweights, there is a risk of crushing
between the counterweight elements and the vehicle components, especially when
swinging the superstructure.
When counterweights are lifted and lowered to the chassis, they must neither be
suspended aslant nor swing. There is a risk of accidents and of damage to vehicle
components.
The counterweights must be stowed safely and firmly in the counterweight rest.
Stowing counterweight elements in the counterweight rest of the chassis requires the
help of another well-instructed person. The crane operator must be in constant eye
contact with that person.
Before swinging the superstructure and before taking up crane work, the crane
operator must ensure that this person has left the crane and its working area.
The crane has been supported by outriggers as specified (see “Notes referring to the
Load Charts”).
- Fasten counterweights (1) to the eyelets (3)

provided to this effect using the approved, suitable
load securing devices, and lift them onto the
chassis.
- Carefully lower the counterweights (1) onto the
chassis as shown in the drawing. The centering
bore-holes of the counterweights must slip onto the
centering pins (2).
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6.6.1.1 Picking up and depositing the counterweights
Observe important instructions as per item B2-2.8 and B2-6.6.
Prerequisite:
● The counterweight variant required for crane work is deposited in the counterweight rest.
● The ballast cylinders are retracted; the "cylinder up / center" indicator is lit.
● The ballast cylinders are unlocked; the "counterweight unlocked" indicator is lit.
(Refer to part G2 Annex "Operation of the Automatic Safe Load Indicator").
- Start the engine in the superstructure; release the slewing gear brake.
- Swing the superstructure to the rear, in longitudinal direction, and lock it using the mechanical
superstructure locking device.
●Oberwagen ist über den Gegengewichten zentriert.
- Actuate crane control lever "counterweight up / down" (refer to item B2-2.8) forward to
↓
position "DOWN" and keep it pressed until the ballast cylinders are completely exten-
ded; the "downward movement" indicator in the ASLI is lit as long as the crane control
lever is actuated.
●The "counterweight down" indicator goes on when the ballast cylinders are
completely extended.
Actuate crane control lever "lock / unlock counterweight" (refer to item B2-2.8) to the left
in the position “locking” and lock the counterweight(s) deposited on the chassis; the
"counterweight locked" indicator in the ASLI is lit as long as the crane control lever is
actuated.
●The "counterweight locked" indicator goes on when the ballast cylinders are locked.
●The "counterweight unlocked" indicator goes out.
Attention If the "locking, center" indicator goes on while the counterweights

are picked up or removed, this indicates that the counterweights
are not correctly locked or unlocked.
NOTE The ballast cylinders can only be locked via the crane control lever, if the ballast
cylinders are completely extended downwards (the pilot lamp must be lit).
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cont'd.: 6.6.1.1 Picking up and depositing the counterweights
Actuate and hold crane control lever "counterweight up / down" (refer to item B2-2.8) to
the rear in position "UP", until the weight units or the locating tube are resting
↑
completely on the plate of the basic counterweight on the rotary platform of the
superstructure.
●The pilot lamp "upwards movement" is lit.
●The "counterweight down" indicator must have gone out.
●The "counterweight locked" indicator remains on.
NOTE After the counterweight package has been picked up, one of the
following indicators is lit, depending on the counterweight variant:
"Counterweight up + center" or
"Counterweight center".
Check visually.
6.6.2 Overriding the swing mechanism/counterweight (emergency control in case of

crane shut-off)
If the counterweight is raised to its stop, the indicator "counterweight DOWN" must have gone out.
If the indicator "Counterweight DOWN" goes on during crane operation (counterweight is not completely
raised), this may indicate a fault, e.g. a leakage in a hoist cylinder.
No rotary movement can be performed!
- Actuate rocker tip switch 45 „Swing mechanism/counterweight override“.

Now, the counterweight can be lifted again and the superstructure can be slewed.
DANGER To avoid damaging the chassis body components while the counterweight
has not reached its upper stop position, rotary motions must be
performed with extreme caution.
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6.6.3 Mounting the individual counterweight variants

6.6.3.1 Assembly of the 5.6 t or 7.0 t counterweight
DANGER For driving on the construction site with the counterweight mounted, refer to item B2-
7.
Picking up the 5.6 t or 7.0 t counterweight and fastening it to the superstructure
Prerequisite:
●The crane is supported by outriggers as specified.

● The weights (8) or (7 and 8) are located in the counterweight rest.
● Counterweight (1) is screw-fastened to the basic counterweight (3) and counterweight (2) is pin-fastened to
the winch frame.
●The ballast cylinders are retracted as described under item 6.6.1.
●The superstructure is slewed to the rear, in longitudinal direction, and locked by means of the mechanical
swing lock.
- Extend ballast cylinders completely, as described under item 6.6.1, and lock counterweight (8).
- Retract the locked counterweights (8), or (7 and 8) using the ballast cylinders, as described under item
6.6.1, until the counterweight’s (8) locating tube is completely touching counterweight (3). Check visually.
● The "counterweight down" indicator must have gone out.
Check visually.
NOTE Only the 5.6 t or 7.0 t load charts may be used to adjust the ASLI code for crane work.
NOTE The counterweights for the set-up program for picking up and depositing
counterweights from or on the superstructure are based on the counterweight variant
7,0 t, however without the counterweights units (7 and 8).
Observe the Load Charts !
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6.6.3.1 Assembly of the 5.6 t or 7.0 t counterweight (cont'd.)
5.6 t Counterweight variant 7.0t Counterweight variant
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6.6.3.2 Mounting the 12.5 t counterweight
ATTENTION Driving on public roads is prohibited with this counterweight distribution. No EC

approval.
Moreover, the appropriate national regulations of the country where the machine is to
be registered, or which apply to the field of application, must be observed.
7.
NOTE To be able to clamp counterweight (6) to the basic counterweight (3), counterweight
(5) must be picked up as well, and deposited once clamping is complete.
Picking up the 12.5 t counterweight and fastening it to the superstructure:
Prerequisite:

● The counterweight units (6, 5, 4, 7 and 8) are placed in the counterweight rest.
the winch frame.
swing lock.
- Retract the locked counterweights (6,5, 4, 7 and 8) using the ballast cylinders, as described under item
6.6.1, until counterweight (6) is completely touching the basic counterweight (3). Check visually.
● The "counterweight up" indicator must be lit.
Check visually.
Check visually.
0195_EN_FA043_B2_06_00_00_NEU
2003-01 23/46
cont'd.: 6.6.3.2 Assembly of the 12.5 t counterweight
Secure counterweight (6) with clamps to counterweight (3), and lock it:
DANGER For the counterweight variant 12.5 t, it is essential that counterweight (6) is secured to
the left and right of the basic weight (3) using the two retaining clips (H), and locked.
- Attach retaining clips (H) in the locating eyelets (F) of counterweight

(6) and insert retainers (C) through the locating eyelets (E) and
retaining clips (H) welded to the basic counterweight (3).
- Drive in retainers (C) until the spring clips (D) can be inserted in the
next full bore-hole of the retainers.
- Insert spring clips (D) between the locating eyelets (E) welded to the
basic counterweight (3) and the retaining clips (H), and lock them. To
this effect, the bore-hole of the retainers should be used which is as
close as possible to the locating eyelet (E).
DANGER Check counterweight for tight fit.
DANGER The spring clips (D) may only be inserted

between the locating eyelets (E) welded to the
basic counterweight (3), and the retaining clips
(H), and locked.
NOTE The opening (B) of the retaining clip must be used

for the counterweight version 12.5 t.
Now, the counterweight units (5, 4, 7 and 8) must be lowered are placed in the counterweight rest:
- Actuate crane control lever "counterweight up / down" (refer to item B2-2.8) forward to
↓
position "DOWN" and keep it pressed until the ballast cylinders are completely exten-
ded; the "downward movement" indicator in the ASLI is lit as long as the crane control
lever is actuated.
● The "counterweight down" indicator goes on when the ballast cylinders are
completely extended.
- Actuate crane control lever "lock / unlock counterweight" (refer to item B2-2.8) to the
right in the position “unlocking” and unlock the counterweights deposited in the
counterweight rest; the "unlock motion" indicator in the ASLI is lit as long as the crane
control lever is being actuated.
●The "counterweight unlocked" indicator is lit.
●The "counterweight locked" indicator goes out.
0195_EN_FA043_B2_06_00_00_NEU
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Retract ballast cylinders:
↑
- Actuate the crane control lever “counterweight up / down (refer to item B2-2.8) to the
rear in position “UP” and hold it in this position until the ballast cylinders have been
retracted, the pilot lamp “upwards movement” is lit.
●The "counterweight down" indicator must have gone out.
NOTE Depending on the counterweight variant, one of the following

indicators goes on:
Check visually.
- Fasten the counterweight (5) using suitable securing devices, and put it down, away from the vehicle.
●Now, the counterweight units (4, 7 and 8) are placed in the counterweight rest.
- Pick up the counterweights (4, 7 and 8) using the ballast cylinders, according to item 6.6.1, until the
counterweight’s (8) locating tube is completely touching counterweight (6). Check visually.
Check visually.
NOTE Only the 12.5t load charts may be used to adjust the ASLI code for crane work.
0195_EN_FA043_B2_06_00_00_NEU
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NOTE To be able to clamp counterweight (6) to the basic counterweight (3), counterweight
(5) must be picked up as well, and deposited once clamping is complete.
To obtain the 12.5 t counterweight variant, counter-

12.5 t Counterweight variant weight (5) must be picked up additionally and
deposited again once counterweight (6) has been
clamped.
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6.6.3.3 Mounting the 18.0 t counterweight **)
ATTENTION Driving on public roads is prohibited with this counterweight distribution. No EC

approval.
Moreover, the appropriate national regulations of the country where the machine is to
be registered, or which apply to the field of application, must be observed.
7.
NOTE For on-road travel, counterweight (4) must be clamped to the basic counterweight (3)
(see item 6.6.7).
Picking up the 18.0 t counterweight and fastening it to the superstructure:
Prerequisite:

the winch frame.
swing lock.
- Retract the locked counterweights (4, 6, 7 and 8) using the ballast cylinders, as described under item 6.6.1,
until counterweight (4) is completely touching the basic counterweight (3). Check visually.
● The "counterweight up" indicator must be lit.
Check visually.
Check visually.
NOTE Only the 18.0t load charts may be used to adjust the ASLI code for crane work.

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Secure counterweight (4) with clamps to counterweight (3), and lock it:
DANGER For on-road travel configuration, counterweight (4) must be fastened and secured on
the left and right to the basic counterweight (3) with both retaining clips (H).
-Attach retaining clips (H) in the locating eyelets (F) of counterweight

(4) and insert retainers (C) through the locating eyelets (E) and
retaining clips (H) welded to the basic counterweight (3).
-Drive in retainers (C) until the spring clips (D) can be inserted in the
next full bore-hole of the retainers.
-Insert spring clips (D) between the locating eyelets (E) welded to the
basic counterweight (3) and the retaining clips (H), and lock them. To
this effect, the bore-hole of the retainers should be used which is as
close as possible to the locating eyelet (E).
DANGER Check counterweight for tight fit.
DANGER The spring clips (D) may only be inserted

between the locating eyelets (E) welded to the
basic counterweight (3), and the retaining clips
(H), and locked.
NOTE The opening (A) of the retaining clip must be used

for the counterweight version 18.0 t.
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18.0 t Counterweight variant
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2003-01 29/46
6.6.4 Removal of the various counterweight variants
For removal, reverse analogically sequence of operations described under item 6.6.3.
Counterweight (4 or 6) remains mounted to the basic counterweight (3). To remove and deposit the
counterweights, proceed as described under item 6.6.5.
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6.6.5 Removing the counterweights from the superstructure, and stowing them
To obtain the specific counterweight variant or driving configuration required for the application in question,
various counterweight units must be removed from the superstructure and, if necessary, stowed.
DANGER No unauthorized persons may be in the danger zone. The danger zone (range of
rotation) must be free and within the full vision of the operator.
Prerequisite:
• The counterweight variants as described under item 6.6.3 are mounted to the superstructure.
• The vehicle is supported by outriggers as specified.
- Remove retaining clips depending on the counterweight variant required.
- Extend ballast cylinders as described under item 6.6.1, stow counterweight in counterweight rest.
- Unlock the ballast cylinders.
- Retract the ballast cylinders as described under item 6.6.1. The "counterweight up" indicator must have
gone out.
Attention The ballast cylinders must be retracted completely. Check visually.
- Release the superstructure lock, swing superstructure through 180°.

- Program the setup program in the ASLI.
- Fasten the counterweights using suitable securing devices and remove them from the vehicle as shown in
the following diagrams.
NOTE The legal regulations regarding “ropes and hosting gear” in force in the country
where the crane is to be registered must be observed.
To pick up and mount the counterweight units, proceed analogously by reversing the above procedure.
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6.6.6 Remove and attach complete counterweight (0.0 t counterweight)**)
If the 0.0 t counterweight variant is selected, the counterweight must be removed completely from the
superstructure.
Prerequisites: as described under item 6.6.5.

the winch frame.
● The ballast cylinders are retracted as described under item 6.6.1.
Retract the locked counterweights (4, 6, 7 and 8) using the ballast cylinders, as described under item 6.6.1,
until counterweight (4) is completely touching the basic counterweight (3). Check visually.
● The "counterweight locked" indicator remains on.
●The "counterweight up" indicator must be lit.
Check visually.
Check visually.
DANGER The locating tube of counterweight (8) must be secured in counterweight (3). Check
visually.

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cont'd.: 6.6.6 Remove and attach complete counterweight (0.0 t counterweight)
Disconnect counterweight (3) from the rope winch

frame.
- Remove the spring clip (9).
- Push pin (10) out of its bore-hole.
- Remove the cotter pin (11).
- Extend ballast cylinders as described under item

6.6.1, deposit counterweights (1, 3, 4, 5, 6, 7 and
8) in the counterweight rest.
- Unlock the ballast cylinders.
- Retract the ballast cylinders as described under
item 6.6.1. The "counterweight up" indicator must
have gone out.
Attention The ballast cylinders must be retracted

completely. Check visually.
Attention Before slewing the superstructure, close the

front window of the cab!
- Release the superstructure lock, swing superstructure through

180°.
- Program the set-up program 0.0 t in the ASLI.
- Deposit counterweights as described under item 6.6.5.
To pick up and mount the counterweight units, proceed

analogously by reversing the above procedure.
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cont'd.: 6.6.6 Remove and attach complete counterweight (0.0 t counterweight)
Attention When attaching the counterweight, make sure

that the guide pins (13) engage in the locating
bore-holes (12) of the rope winch frame.
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6.6.7 Distribution of counterweights depending on rig arrangement
Counterweight (t)
Model total front rear transport Remark
(deposited) (mounted) vehicle
with driver
40 t bottom block attached 3.5t 12t axle

Tires 16.00 R25 0.8t load
0.7t 0.3t
Drive 8 x 8 18.0t 0.3t 12.4t EU
approval
with fly jib 5.6t
6t bottom block in rest
Counterweight (t)
Tele section I extended by

approx. 300 mm.
3.5t
with driver 0.8t 12t axle
40 t bottom block attached 1.4t 0.3t load
18t 0.7t 0.3t 11.0t
Tires 16.00 R25 EU
7.0t approval
Drive 8 x 8
without fly jib
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2003-01 35/46
(cont'd.) 6.6.7 Distribution of counterweights depending on rig arrangement
Counterweight (t)

approx. 300 mm.
12t axle
with driver 3.5t load
40 t bottom block attached 0.7t 0.3t
17.2t 0.3t 12.4t EU
Tires 16.00 R25 approval
4.8t
Drive 8 x 8
with fly jib
with auxiliary winch
Counterweight (t)
with driver
3.5t
40 t bottom block attached 0.8t over
Tires 16.00 R25 3.7t 0.3t 12t axle
1.4t 0.3t load
Drive 8 x 8 18.0t 0.7t 1.8t 5.5t
no EU
with fly jib 12.5t approval
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(cont'd.) 6.6.7 Distribution of counterweights depending on rig arrangement
Counterweight (t)

approx. 300 mm. 3.5t
5.5t 0.8t
with driver 1.8t 0.3t over
40 t bottom block attached 1.4t 0.3t 12t axle
18.0t 0.7t 3.7t 0t load
Tires 16.00 R25
18.0t no EU
Drive 8 x 8 approval
with fly jib
DANGER While the boom is being extended, the bottom block must always be attached in
driving condition.
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6.7 Work involving metallic ropes
• On principle, the maximum admissible load bearing capacities of ropes must not be exceeded.
• When attaching ropes, make sure that the spreading angle of 120° is not exceeded. (The spreading angle
is the angle included by the ropes). In this case, the angle of inclination is 60°.
• With an angle of inclination of 60°, the tractive force, e.g. in the load securing ropes, has doubled. In this
case, the ropes must be designed for twice the load rating.
• Check ropes for wear, breakage of wires and breakage of a strand. Check the fastening of the rope socket.
• Never use old, cut-off load-lifting ropes as load-securing ropes.
• When attaching loads with sharp edges, make sure that rope protective devices are used, e.g. wooden
devices, to prevent the rope from being damaged.
DANGER Make sure that metallic ropes are not knotted.
• Precise specifications concerning the application and the design of ropes are laid down for Germany in the
"Guidelines for ropes used for hoisting applications".
• The end connections of ropes must correspond to the application concerned.
Moreover, the legal regulations of the country where the machine is to be used must be observed.
For "Care to the rope", refer to part "C2-6", item 6.6
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6.7.1 Rope reeving
The number of rope falls used depends on the load to be lifted.
The lifting and lowering speeds of the bottom block are necessarily
reduced by the same number by which the rope falls are increased.
The weights of the bottom block, the jib in transport position, the load-
securing ropes etc. are part of the load and must be deducted from the
lifting capacities.
The rope socket is fastened depending on the desired number of rope

falls.
with an even number of rope falls

on the boom head (Fig. 1),
Fig 1
with an odd number of rope falls

on the bottom block (Fig. 2).
ATTENTION Pin (3) must always be inserted in the direction of

the arrow, and be secured by the spring clip (4).
Otherwise, there is a risk of collision.
ATTENTION With all rope reeving arrangements, the rope end

must be guided through the releasing weight of the
hoist limit switch before it is secured to the rope
socket.
Fig 2
6.7.2 Rope fastening
When the mobile crane is equipped with its original components, a winch rope
with steel wire rope clamp (1) and a rope socket (2) are provided.
In the case of an even number of rope falls, the rope socket is fastened to the
boom head; in the case of an odd number of rope falls, it is fastened to the
bottom block (refer to item 6.7.1).
The steel wire rope clamp of the winch rope is attached in the rope socket as
shown in the illustration. If the locking pin is inserted (3) in the direction of the
arrow (refer to item 6.7.1, Fig. 1 and 2) and fastened to the boom head or the
bottom block, it is ensured that the steel wire rope clamp cannot be detached
from the rope socket. Once the pin has been inserted in the direction of the
arrow (refer to item 6.7.1, Fig. 1 and 2), it is essential to secure it by means of
the spring clip (4).
ATTENTION When installing a new rope socket or winch rope, make sure to use only original
TADANO FAUN spare parts (refer to data marked on the rope socket).
To enable also the use of conventional lifting ropes (without steel wire rope clamp), a conventionally
designed rope socket is also provided with the crane (rope end clamp) (refer to item 6.7.2.1).
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6.7.2.1 Conventional rope socket (rope end clamp)
If a conventional rope socket is used, the rope must be fastened as described below:
The rope end is fastened to the bottom block (in case of an odd
number of rope falls) or to the boom head (in case of an even number
of rope falls) using a rope socket.
As the rope socket (2) is actually a connecting device which is only

closed safely when subject to traction, the free rope end should be
secured against pulling through even if a rope key (3) with self-locking
function is provided.
The following important instructions must be observed:

• Insert the rope always so that the pulling rope moves in the traction
axis of the rope socket (Fig. item "A").
Should the rope be inserted incorrectly, it would be subject to
kinking, breaking and premature wear.
• It is not admissible to use implements as securing devices by means

of which the free rope end is connected so that force is transmitted
directly to the rope fall carrying the load.
• After the rope socket has been pin-fastened to the boom head or to
the bottom block, make sure that the load is gradually increased,
until the rope key has reached its end position.
correct incorrect
DANGER Avoid jerky load situations before the rope key is definitely fitted.
6.7.3 Placing the rope in the bottom block
NOTE The bottom block (1) comprises two sheet metal plates
(2 and 3) which can be folded off so that the winch
rope can be positioned.
To place the winch rope, remove the two split rivets (4 and 5).
Pull the two pins (6 and 7) out of the bottom block and fold down the sheet
metal plates at the sides.
After positioning the winch rope, fold the two plates on the left and right
back in place, insert the two pins and position the split rivets.
Fig. 3
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6.7.4 Mounting the releasing weight to the rope
After rope reeving has been finished and the rope socket has been secured to
the boom head or the bottom block, depending on the number of rope falls, the
releasing weight must be mounted to the rope again.
The releasing weight (1 and 1a) consists of two halves with a retaining device
(2).
- Fasten the shackle (3) of the chain in the thimble (4) of the hoist limit switch.
- Arrange the two halves of the releasing weight around the rope and secure
them so that the pins of one half of the weight can be inserted into the
boreholes of the other half of the weight.
- Press the weight halves together and push the retaining device (2) over the
releasing weight.
- Attach the snap hook (5) in the first chain link above the retaining device.
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6.7.5 Examples for rope reeving
Depending on the required hoisting load, the required bottom block and the number of rope falls required for
the case in question are indicated in the "Notes referring to the load chart".
The appropriate number of winch rope falls required must be arranged as follows:
NOTE As far as possible, the rope should be arranged in the bottom block - especially if few
rope falls are used - so that the bottom block is suspended vertically (refer to example
with four rope falls).
The winch rope is arranged as follows, depending on the number of rope falls required:
Bottom block, 7 - pulleys Bottom block, 7 - pulleys Bottom block, 7 - pulleys

arrangement with 15 rope falls arrangement with 14 rope falls arrangement with 12 rope falls

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(cont'd.) 6.7.5 Examples for rope reeving

Bottom block, 3 - pulleys Bottom block, 3 - pulleys Bottom block, 1 - pulley

Bottom block, 1 - pulley Bottom block

arrangement with 2 rope falls arrangement with 1 rope fall
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6.7.6 Attaching the bottom block for on-road travel
For on-road travel, the bottom block must be attached and secured in the front bumper crossmember
as specified.
- The machine is supported by outriggers.

- Depending on the rig arrangement concerned, either retract all tele sections completely or extend tele
section I by approx. 300 mm (see item B2-6.6.7).
- Raise the bottom block near the boom head.
- Swing the superstructure forward, in driving direction; engage the swing brake.
- Raise the basic mast via the boom elevation, until the bottom block is suspended vertically in front of the
Attach the rope loop in the towbar coupling (3).
- Lower the hook block carefully, until the hook (1) can be attached in the rope loop (2).
- Stow the basic mast in its end position, while winding up the winch rope (4) slowly and carefully until the
rope loop and the winch rope are no longer slack.
Attention To prevent damage to the bumper cross-member, do not tighten the rope more than
absolutely necessary. If necessary, have the procedure watched by an assistant.
6.7.7 Detaching the bottom block for crane operation
- Release the rope tension while raising the boom via

the boom elevation, until the hook of the bottom block
can be detached from the rope loop (2).
- Raise the hook block carefully.
- Stow the rope loop in the tool box.
NOTE Moreover, within the scope of the Federal Motor Vehicle Safety Standards (in
Germany: StVZO), the entries in the expert opinion required to obtain the operating
license must be complied with.
Please observe any specific regulations of the country where the machine is to be
used which might differ from those mentioned above.
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6.8 Inspection of the safety equipment
DANGER Before starting any crane work, make sure that the entire safety equipment of the
crane is checked for proper working order.
6.8.1 Inspection of the automatic safe load indicator (ASLI) and of its components
- Check the spring-loaded cable drums on the boom for proper working order.
- Check the length transmitter cables for damage.
- Check the ASLI indicator unit for proper working order (for further details, please refer to part G2
Superstructure, description of the automatic safe load indicator ASLI).
6.8.2 ASLI override key-actuated switch (Item B2-2.1, Pos. 13)
DANGER The key-actuated push-button may be used exclusively in case of a

malfunction of the system, in order to stop operation without delay;
by no means, however, to work with the crane in overload condition.
Overriding the system during normal crane operation can cause
serious damage and tremendous risk to persons and equipment.
The instruments of the indicator unit and the visual-acoustic warning signal are also operative after
overriding has been effected.
6.8.2.1 Warning device for "ASLI override" condition**)
If the ASLI override feature is activated by means of the key-actuated pushbutton (item B2-2.1, pos. 13), a
signal sounds outside of the cabin as long as the override condition is existing.
6.8.3 Inspection of the hoist limit switch
The hoist limit switch serves as a shut-off device to prevent the bottom block from knocking against the
boom head. The shut-off function must be checked before each crane operation by the working movement
"bottom block UP". The bottom block can be lowered as the control lever is actuated to "bottom block
DOWN".
NOTE The expression "hoist limit" is a crane-specific term which refers to a state which occurs
when the bottom block touches the boom head.
If this condition is not prevented, the lifting rope may break, causing the load to be dropped.
The "hoist limit" state may occur when the load is lifted up to the boom head, by lowering the boom
via the boom elevation or by extending the telescopic elements while the length of the winch rope
wound off is not sufficient.

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6.8.4 Key-actuated tip switch "Overriding hoist limit switch / set-up program"
Overriding the hoist limit switch for controlled further raising of the bottom block is possible
via the key-actuated tip switch 55 "Overriding hoist limit switch".
- To override the hoist limit switch, turn the key-actuated tip switch to the right.
DANGER This override function may only be actuated by authorized staff in cases of emergency,
and must be returned to normal position immediately afterwards. If this instruction is
not observed, this may result in material damage and/or damage to persons.
6.8.4.1 Key-actuated tip switch "Overriding in set-up program"
- To override the ASLI in the set-up program, e.g. extending the telescope, turn key-actuated switch (item
B2-2.1, pos. 13) to the right.
DANGER Overriding the system via the key-actuated push-buttons (part B2-2.1, item. 13) and 55
during normal operation involves an enormous risk of damage and incalculable
danger for persons and material.
6.8.5 Inspection of the rope limit switch
The rope limit switch which is mounted to the rope winch disconnects the winch drum rotation during the
working movement "bottom block down", when the rope is unwound. This may occur, e.g. in case the
maximum number of rope falls is used and with the telescopes extended. At least three safety rope windings
must remain on the rope drum. The rope can be wound up again by actuation of the control lever "bottom
block UP".
6.8.6 Over-unwinding cutout device for auxiliary winch**)
The over-unwinding cutout device prevents the wire rope from being damaged or improperly wound which
would be caused by lowering the hook block excessively and extra wraps of the wire rope required on the
winch drum cannot be maintained. When the wire rope left on the drum is reduced to 3 wraps, the over-
unwinding cutout function is activated and the operation toward the critical side (lowering the rope drum)
automatically stops.
DANGER When the bottom block has been removed, the winch rope may be wound up only
until its end reaches the hoist winch. If the winch rope is wound over the hoist winch
without a load being fastened, the setting of the dead-windings-on-the-rope detecting
switch is changed. The cutout device will not function correctly. Once winding it up to
the end has happened, readjust the detecting switch position.
**)Optional equipment
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Crane operation with a load fixed to the boom B2-7
7 Crane operation with a load fixed to the boom
After the crane operator has read the preceding chapters and familiarized himself with the control elements,
the safety instructions and the warning devices, he may start to perform crane work with the superstructure.
The crane operator must especially observe all the instructions for the various working conditions
described below and the "Notes concerning the load charts".
• Before commencing each crane operation, the operating safety of the machine must be checked.
• The safety instructions according to part B.0 must be adhered to.
In the load charts, the ranges indicating the strength of the components and the stability have been identified
by separating lines.
The ratings indicated above the separating line are based on the strength of the components (danger of
breaking in case of overload);
and the ratings below that line are based on the stability (danger of crane tipping in case of overload).
7.1 Crane operation with the machine stabilized by outriggers
The following actions and measures are required for crane operation "stabilized by outriggers".
• Check the ground condition.
• Block the suspension and align the machine stabilized by outriggers in horizontal position, according to the
instructions (watch spirit levels). The wheels must be clear of the ground.
• Make sure that the applicable load chart and the appropriate code no. are entered into the ASLI if the
outrigger beams are extended to half their supporting base.
• The weight of the load to be lifted must have been determined.
• The bottom block and the arrangement of rope falls must be dimensioned sufficiently.
• The admissible values specified in the load charts must be complied with precisely.
• The weights of the bottom block, the load securing ropes, the crossbeams etc. must be deducted from the
lifting capacities.
• The program selected in the ASLI (code no.) must be exactly identical with the desired working conditions.
• The wind speed must not exceed the values specified in the Notes referring to the load charts.
• The load surface exposed to the wind must not exceed the values specified in the Notes referring to the
load charts.
• The maximum admissible load must not be exceeded.
• The telescoping status indicated as a percentage value (%) in the load charts is controlled via the ASLI.
• The crane movements (speeds) must be selected so that work is effected without jerking, i.e. as smoothly as possible.
• Diagonal pulling is not admissible.
• Lifting the load and actuating the boom elevation with the load fixed to the boom is only admissible within
the range of the values specified in the load charts.
• During crane work, the instruments, warning, indicator and pilot lamps and the ASLI indicator unit must
always be monitored.
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B2-7 Crane operation with a load fixed to the boom
(cont'd.) 7.1 Crane operation with the machine stabilized by outriggers
• All crane work is to be performed with the minimum working radius possible.
• It must be checked whether the boom extension or the twin folding jib are correctly mounted and whether
the ASLI program is set to the rig arrangement required in the case in question.
DANGER Excessively fast initiation of lifting, slewing, braking and actuation of the boom
elevation may cause the load to oscillate. The greater the load, or the greater the
boom length, the more carefully the motion in question must be initiated.
! Perform all crane work with due care and attention. !
7.2 Crane operation "free on wheels"
For crane operation "free on wheels" (without outriggers), the following actions and measures are required:
• Perform work only on a level, solid ground free of inclinations (check ground quality and stability).
• Before slewing the superstructure to the rear, stabilize the vehicle by outriggers and swing superstructure
to the rear in the longitudinal direction of the vehicle while the telescopes are completely retraced, engage
the lock pin and apply the swing brake.
• Check tire pressure in all the tires; if necessary, inflate them to the specified pressure (the inflating
pressure is indicated in part "A2" or in the cabins).
• Lock the axle suspension and lower the vehicle (refer to items B1-4.7).
DANGER The yellow indicator lamp 15 "axle lock engaged" must be lit during crane operation.
If the pilot lamp is not lit, the suspension is not locked, or there is a fault in the axle
locking system.
In this case, work may only performed with the crane stabilized by outriggers;
however, all the wheels must be clear of the ground.
• The weight of the load to be lifted must have been determined.

• The bottom block and the arrangement of rope falls must be dimensioned sufficiently.
• The weights of the bottom block, the load securing ropes, the crossbeams etc. must be deducted from the
lifting capacities.
• During travelling, the following should be observed for safety reasons: extend outrigger beams and
outrigger cylinders as far as possible, place outrigger floats as close as possible to the ground.
ATTENTION When the ASLI program "free on wheels, to the rear" is selected, the ASLI switches off
the crane when the lock pin is removed. However, the swing mechanism is not shut
off.
• When the superstructure lock pin is not engaged, the program is not enabled.
• Select the ASLI program (code no.) (refer to load chart with the crane standing "free on wheels"). The
selected ASLI program must be identical with the desired rig arrangement.
• The telescoping status indicated as a percentage value (%) in the load chart is controlled via the ASLI.
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Crane operation with a load fixed to the boom B2-7
(cont'd.) 7.2 Crane operation "free on wheels"
• Crane work must be performed with the boom extended to its shortest possible length.
• The crane movements (speeds) must be selected so that work is effected without jerking, i.e. as smoothly
as possible.
• Diagonal pulling is not admissible.
• Lifting the load and actuating the boom elevation with the load fixed to the boom is only admissible within
the range of the values specified in the load charts.
• When driving with a load fixed to the boom, secure the load so that it cannot oscillate.
• During crane work, the instruments, warning, indicator and pilot lamps and the ASLI indicator unit must
always be monitored.
• The crane may only be driven at creeping speed (observe "Driving instructions").
NOTE To minimize any risk of accidents, it is advisable to perform crane work - as far as
possible - while the machine is stabilized by outriggers, even if the load chart would
allow for work with the crane standing "free on wheels".
! All crane work must be performed with due care and attention. !
7.3 Driving with a load
Driving with a load requires maximum care and caution.
- Perform driving operation with a load only with the boom over-rear and the locking pin completely inserted.
- The vehicle must be lowered, and the suspension locked.
Extend the outrigger beams and keep the outrigger floats just above the ground, to the extent that this is
possible in view of the available space.
Secure the load so that it cannot oscillate.
DANGER Driving with a load is only permitted when the vehicle has been lowered completely,
the suspension locked and the axle oscillation engaged.
DANGER Driving with a load is only admissible at the most reduced speed in the gears 1 and 1R
(Refer also to Notes concerning the Load Chart).
If it is necessary to drive the machine from the superstructure, this operation may only be performed on a
level ground because of a poor visibility and stability.
DANGER Watch out for possible obstacles at higher levels while the boom is raised.
NOTE The front axle oscillation is only operative with the locking pin completely inserted
(boom "directed to the rear").
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B2-7 Crane operation with a load fixed to the boom
7.4 Moving the crane in full rig arrangement on construction sites
For boom and counterweight combinations for moving the crane on construction sites, refer to the tables
below.
7.4.1 Boom deposited to the front of the crane
Instructions for moving the crane in full rig arrangement on construction sites:
Boom over carrier cab, swing brake engaged, solid, resistant, level and horizontal ground, suspension
locked, specified tire inflating pressure, at creeping speed max. 1.4 k.p.h., if possible with the outrigger
beams extended and the outrigger floats as close as possible above the ground.
Length of main Length of fly jib Boom Counterweights

boom angle
HA ( m ) SP ( m ) α(°) 5.6 t 7.0 t 12.5 t 18.0 t
10.8 9.0 / 16.0 m 0 X X X X
fly jib laterally in 30 X X X X
transport- 45 X X X X
position 60 X X X -
10.8 9.0 m fly jib 30 X X X X
mounted to 45 X X X X
boom head 60 X X X -
10.8 16.0 m fly jib 30 X X X X
boom head 60 X X X -
X = admissible
- = inadmissible
7.4.2 Boom deposited to the rear
Instructions for moving the crane in full rig arrangement on construction sites:
Boom over rear of vehicle and superstructure lock pin engaged, swing brake engaged, solid, resistant, level
and horizontal ground, suspension locked, specified tire inflating pressure, at creeping speed max. 1.4 k.p.h.,
if possible with the outrigger beams extended and the outrigger floats as close as possible above the ground.
Length of main Length of fly jib Boom Counterweights

boom angle
HA ( m ) SP ( m ) α(°) 5.6 t 7.0 t 12.5 t 18.0 t
10.8 9.0 / 16.0 m 0 X X X X
Fly jib laterally in 30 X X X X
transport- 45 X X X X
position 60 X X X X
10.8 9.0 m fly jib 30 X X X X
boom head 60 X X X X
10.8 16.0 m fly jib 30 X X X X
boom head 60 X X X X
X = admissible
- = inadmissible
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Emergency operation B2-8
8 Emergency operation
In case of failure or malfunctions of various control and operating elements, or in case of malfunctions of the
electric equipment, the functions which failed might be effected, e.g. via emergency controls. However, these
emergency control elements may only be used to complete the current crane movement and to reset the
crane to its former rig arrangement. Afterwards, the reason for the damage must be determined immediately
and the damage must be eliminated.
DANGER Emergency control elements must never be used instead of the controls for normal
operation. Any damage to the control and operating elements must be eliminated im-
mediately.
ATTENTION Do not actuate the push-button switches with rubber caps by means of sharp-edged
or pointed objects. Should the rubber caps be damaged, this may result in failure of
the valves.
Counterweight control
1 Counterweight down
2 Counterweight up
3 Unlock counterweight
4 Lock counterweight
Actuate
5 pressure supply
simultaneously.
Slewing the superstructure
Actuate:
6 Release slewing gear brake

7 Slewing to the right
8 Slewing to the left
Overriding the arm rest switch
9 Arm rest override feature
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B2-8 Emergency operation
Memo:
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Depending on the climatic conditions of the area where the crane is to be used, the weather conditions may
be more or less extreme during the winter months. Thus, the instructions mentioned below must definitely be
observed to ensure trouble-free and safe operation in winter.
DANGER Particular care is required when climbing up or using steps, ladders and platforms in
damp weather and snow.
• Access steps and platforms must be cleaned to remove dirt, oil, grease and smeary substances.
! Risk of slipping !
• Snow, frozen layers of snow and ice may form a dangerous coating on the boom surfaces, counterweights
and platforms of the superstructure.
• Snow and ice must be removed from the vehicle and the superstructure before the machine is set into
motion.
• Snow or lumps of ice which are blown down or which fall down during crane operation may endanger other
persons.
DANGER In case of extremely low freezing temperatures, do not touch metal surfaces with your
bare hands - danger of freezing to metal surfaces!
9.1 Engine
9.1.1 Engine oil
In order to ensure a sufficient lubrication in case the vehicle is to be started at low ambient temperatures, the
viscosity of the engine oil must be selected according to the ambient temperatures prevailing at the time
when the engine is started.
Refer to Operating Manual of engine manufacturer which is supplied with the vehicle!
9.1.2 Coolant
ATTENTION The engine must be filled with anti-corrosion - anti-freeze agent all the year round.
• The coolant must be checked for frost-proofness with a test instrument in good time before the cold
season.
• Normally, it must be frost-proof down to -37°C.

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9.1.3 Diesel fuels
In order to avoid operating malfunctions, the winter diesel fuel available on the market during the cold
season must be used. If only summer-type diesel fuel is available, or if winter-type diesel fuel is used at very
low ambient temperatures, a certain amount of petroleum, the quantity of which depends on the ambient
temperatures, must be added to the fuel in order to avoid segregation of paraffin.
The approximate values for the amounts of additive are indicated in the operating manual of the engine
manufacturer.
There is a simple method to check the diesel fuel for its suitability at the prevailing low temperatures:
- Fill diesel fuel in a flask and expose it to the ambient temperatures. If flakes (paraffin) develop in the fuel, it
is only suited for operation at higher temperatures.
9.1.4 Starting the engine at low ambient temperatures
For the steps to be taken and for further details, please refer to the operating manual of the engine
manufacturer.
9.2 Hydraulic oil
At low ambient temperatures, the hydraulic oils recommended in part "C2” Inspection, Service and
Maintenance - Superstructure must be used.
If the oils to be used at the appropriate ambient temperatures approach the limits (values of max. 10°C
below the minimum temperature limit are admissible), the hydraulic oil can be warmed up without requiring a
change of the oil type.
The hydraulic oil can be warmed up approximately to service temperature in a very short time by "retracting
the boom elevation cylinder" (to its mechanical stop) or by repeated extending or retracting the telescopes.
The admissible service temperature is approx. 70-80°C.
ATTENTION Avoid relatively high engine speeds while the hydraulic oil is still cold. Allow the oil to
warm up at least until it reaches the lower service temperature level.
If the hydraulic system is filled e.g. with hydraulic oil HLP 68 or HLP 46, the oil type must be replaced by the
specified pressure fluids at low ambient temperatures.
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9.3 Batteries
Well-charged batteries are a prerequisite for cold-starting the engine.
At ambient temperatures lower than -30°C, when the machine has been standing in the open air for an
extended period of time without being operated (e.g. at night), the batteries must be heated or removed from
the vehicle and stored in a warm room.
In winter, the current consumption should be kept as low as possible.
Check the acid density and the acid level as described in part "C2 Service and Maintenance -
Superstructure".
Discharged batteries freeze at temperatures starting from only -10°C.
The instructions of the battery manufacturer must be observed.
The adjustable air vents (refer to sect. B2-2.1, items 5 and 24) serve to direct the heated or fresh air flow.
During the winter months, a certain amount of anti-freeze agent for windshield washing systems, the quantity
of which depends on the temperature, must be added to the water of the windshield washing system.
The washer water is made frost-proof by adding washer additives (cleaning agent and anti-freeze agent for
windshield washing systems). Observe the manufacturer's instructions for use.
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Memo:
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Attachments, optional equipment and accessories B2-11
The optional equipment of the vehicle is listed and explained in this chapter. The following list is an overview
of the optional equipment which has been described and explained in other sections for logistic reasons.
Optional equipment mentioned in other sections:
● Assignment of functions to the left crane control lever in case of operation with a 2nd winch (auxiliary
hoisting gear). Refer to part B2, item: 2.8.
● Auxiliary hoisting gear. Refer to part B2-6, item: 6.2.1.
● Mounting the 12.5t counterweight. Refer to part B2-6, item: 6.6.3.2.
● Mounting the 18.0t counterweight. Refer to part B2-6, item: 6.6.3.3.
● Removing and attaching complete counterweight (0.0 t counterweight). Refer to part B2-6, item: 6.6.6.
● Over-unwinding cutout device for auxiliary winch. Refer to part B2-6, item: 6.8.6.
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B2-11 Attachments, optional equipment and accessories
11.1 Positioning the double ladder for mounting the jibs, and for access to the
crane superstructure
NOTE A double ladder is supplied with the vehicle for assembly and maintenance work on
the jib, or - provided the jib is folded to the boom - on the superstructure units. The
ladder is located below the driver's cab.
DANGER The ladder may only be positioned on solid, level ground. The safety instructions
provided for the use of ladders and access steps must be observed; otherwise, there
is a
RISK OF ACCIDENTS.
11.1.1 Fastening and securing the ladder on the vehicle:
- Slip the ladder (1) into the rear part of the angular
supports (2).
Note The struts (3) on the movable end of the

supports must be in full contact with a
rung of the ladder, to prevent the ladder
from slipping sideways.
- Attach eyelets of turnbuckle (a) in the locating cramps

(b), fold turnbuckles (4) down and secure them using
the catch lever.
- Fasten one of the two catch levers with the padlock
supplied with the machine.
DANGER Check the ladder at regular intervals for proper fastening and tight fit. Loss of the
ladder during travelling operation may result in serious accidents.
11.1.2 Positioning the ladder
- Remove the ladder from its supports

below the driver's cab.
- Open the ladder up completely and rest it
against the superstructure between the
handholds (refer to diagrams on the right).
To remove and stow the ladder, reverse the

above procedure.
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11.2 Boom extension
The jib consists of a lattice-type basic section and an extending box-type 2nd section. The jib can be adjusted
to 3 angular positions.
DANGER If working from an elevated position is absolutely necessary, use a platform or the
double ladder supplied with the crane to prevent falling and to ensure safety.
DANGER For safety reasons, before starting driving or crane operation with the jib folded to the
basic boom, all pin connections, securing devices and fasteners on the jib and the
basic boom must be checked.
When crane work is performed with the jib folded to the boom in transport position, or
during work over the main boom with the jib mounted to the boom head, the lifting
capacities indicated in the load charts are reduced by the values indicated in the
notes referring to the load charts.
DANGER The necessary safety precautions must be taken to ensure that no obstacles are in the
slewing range or danger zone of the jib.
Take the necessary precautions to ensure that no one enters the area over which the
jib will swing.
Anyone standing in this area could be injured.
DANGER Picking up loads which are resting on the ground by raising the boom via the boom
elevation may result in overload to the jib, the winch rope or the crane overturning.
There is a risk of OVERTURNING and BREAKING!
This movement "boom elevation - up" is not stopped by the overload safety device.
The following steps must be performed and the following instructions

must be observed before mounting is commenced:
• The crane is supported by outriggers as specified.

• All tele sections are retracted completely.
• The superstructure has been swung backwards, if possible, and
the mechanical swing lock has been engaged.
● The swing brake is engaged.
● The boom is set to an angle of 0°.
• While mounting and dismounting the jib, and when changing its offset angle, make sure that the 2nd section
is retracted into the lattice-type mast, and secured with pins.
• The appropriate rig arrangement for attachment of the jib must have been keyed-in in the ASLI
(code no., refer to load charts), depending on the counterweight and the extension width.
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11.2.1 Preparation for mounting the jib to the boom head
- Place the bottom block on the ground.

- Disconnect the rope socket from the bottom block or from the
boom head by releasing the pins.
- Remove the winch rope from the rope socket.
- Pull the winch rope out of the releasing weight of the hoist limit
switch.
- Remove the strands of the winch rope from the bottom block and
the boom head.
- Wind up the winch rope. Make sure that the winch rope is not
dragged on the ground.
- Pivot bearing bracket (1) upwards by folding over the link (2).
NOTE The link (2) must be touching the stowing pin (3).
11.2.2 Mounting the boom extension to the boom head
The steps described under item 11.2.1 have been accomplished.
Mounting the jib to the boom head at an offset angle of 5°:
- Fasten a strap (4) to the top end of the jib and to the specified
location (5) on the superstructure frame, and prevent it from
slipping.
- Remove the spring clip from the locking pin (6).

- Remove the lock pin (6) from the jib and the bracket (7).
DANGER Once the lock pins and the split rivet have been
removed from the jib, the boom angle must not
be changed any longer.
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11.2.2 Mounting the boom extension to the boom head (cont’d.)
- Pull jib to the outside on the bracket (7) until the lattice type fly jib
extension is touching the stop (9).
- Now the locating bore-holes of the adapter (10) must be aligned

with the bore-holes of the bearing bracket (1) and the shaft (8) on
the boom head.
- Insert the crank supplied with the machine into the threaded pin
(11) and turn the pins until the top and the bottom pin sections are
completely inserted in the bore-holes of the bearing bracket and
the shaft, and until the mark on the spindle is fully visible.
- Remove the crank from the threaded pin.
- Remove the split rivet (12) from the support bolt (13).
DANGER Before extending and pivoting, make sure that the top and bottom pin sections are
inserted in the bore-holes of the bearing brackets and the shaft on the boom head.
- Select ASLI program "telescope 1".

- Start the vehicle engine and extend telescope 1 carefully from its
initial position, until the support pins (13) are released from the
lateral transport support (14), or set free, and until the jib is no
longer in contact with the bracket (7).
Attention The jib may swing away from the boom.
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11.2.2 Mounting the boom extension to the boom head (cont’d.)
- Disconnect the strap (4) from the fastening and use it to swing the
jib forward, until the stopper (15) is engaged in the boom head.
The bore-holes of the adapter are aligned with the bore-holes of
the bearing bracket and the shaft on the left of the boom head.
red mark
- Insert the crank into the threaded pin (26) and turn the pin until the
pin sections are completely pushed into the bore-holes of the
bearing bracket and the shaft, and until the red mark is fully visible
on the spindle.
- Remove crank.
DANGER The red mark on the spindle must be visible

completely.
NOTE Due to the jib’s own weight, it

might not yet be possible to
turn the top threaded pin into
the upper bore-hole of the
bearing bracket.
In this case, perform the steps as per item

11.2.2.1.
DANGER If the jib is not correctly secured by pins, it might get

loose and fall to the ground.
Always make sure that the lock, stowing and pivot
pins are in position before starting any operation.
Failing this, the jib may fall off when an operation is
started.
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11.2.2.1 Turning the threaded pin into the upper bearing bracket
If it is not yet possible to turn in the top threaded pin, the following steps must be performed:
- Pull the winch rope over the top middle boom sheave and the sheaves of the jib, pass it through the
specific releasing weight (16) of the hoist limit switch and attach the releasing weight to the hoist limit
switch.
- Insert the three pins (17) securing the rope on the boom head, and lock them.
- Fasten the winch rope in the rope socket as specified, fasten the rope socket to the single hook and lock it,
or fasten it with the rope socket to the fixed point (18) of the jib.
- Keep the key switch 54 „hoist limit switch override” in its position during actuation.
- Tighten the winch rope carefully, until the single hook or the direct rope control raises the head of the jib.
- Lift the jib until the top threaded pin (19) can be turned in easily. Now the bore-holes of the adapter and of
the bearing bracket must be aligned.
- Insert the upper pin section by turning until the coloured mark (F) is visible completely on top (on the inner,
fine spindle).
- Lower single hook or rope control system.
- Insert the connectors into the plugbox on the boom head and the jib. Thus, the electrical connection of the
ASLI for the hoist limit switch on the jib is established.
DANGER If the key switch 54 “hoist limit switch override” is actuated, the hoist limit switch is
deactivated. Operate carefully and only without a load.
DANGER Before performing any

crane work with the at-
tached jib, it is essential
to verify whether the
pins are inserted proper-
ly in the bore-holes of
the bearing brackets,
and secured.
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11.2.3 Changing the boom elevation offset angle
Attention The jib offset angle may only be changed from the 5° initial position to the 20° or 40°
position or vice versa via the basic section. It is not admissible to change the offset
angle while the 2nd section is extended.
The following work must be performed and the following instructions observed before the offset angle of the
jib is changed:
y The crane is supported by outriggers as specified.

y The superstructure has been swung backwards, if possible, and the mechanical swing lock has been
engaged.
● The swing brake is engaged.
y All tele sections are retracted completely.
y No obstacle must be within the mounting area while the offset angle is being changed.
DANGER Persons are not allowed to stay in the jib swing range or in the danger zone.
Attention When changing the jib's offset angle, always raise the boom enough to make sure that
the jib head does not touch the ground.
Check that all pins and plugs are locked and that the cable connectors for the hoist
limit switch are correctly connected.
NOTE To change the jib offset angle, the winch rope may be secured to the fixed point (18),
or the jib may be offset with the winch rope remaining connected to the single hook.
- Remove single hook, hoist limit switch and releasing weight from the winch rope.
- Mount the rope socket to the fixed point (18) of the jib, lock it with the pin and secure it.
- Set the winch rope under slight tension (the jib is lifted
slightly in this process).
- Continue to wind up the winch rope slowly and carefully until
the two offset pins (20) are discharged.
- Remove the left-hand and right-hand retaining clips and
remove the two offset pins (20).
- Insert the left-hand and right-hand offset pins (20) into the
boreholes for the desired offset position (20° or 40°) and lock
them using the retaining clips.
- Unwind the winch rope carefully and slowly, if necessary, by
raising the telescopic boom via the boom elevation, until the
jib has reached the desired angular position.
- Set the crane to working position.
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11.2.4 Extending – retracting the 2nd section of the boom extension
- Lower the boom with the attached jib, until the head of the jib is located approx. 1.5 m above ground level.
- Disconnect the electrical plug-and-socket connectors of the hoist limit switch.
- Pull the single hook towards the jib; thus, the locking pin (21) is discharged.
- Remove spring clip, pull locking pin (21) out.
DANGER Protect the second section from being extended unintentionally using the strap.
- Raise the boom 45° via the boom elevation, and deposit single hook on the ground. Subsequently, lower
the boom again via the boom elevation.
- Remove strap and pull the 2nd section out to its stop by hand, using the two grips. The bore-holes (22) and
(23) must be aligned.
Attention To extend and retract the 2nd section, proceed with the due care and attention. There
must not be any obstacle in the area of movement, and nobody is allowed to be in the
area of movement or in the danger zone.
- Insert the locking pin (21) into the aligned bore-

holes (22) and (23) for the extended 2nd section,
and secure it.
- Insert the plugs into the plugboxes on the jib
and on the head of the 2nd section of the jib.
Thus, the electrical connection of the ASLI for
the hoist limit switch on the jib is established.
NOTE To extend and retract the 2nd section, the winch rope may be secured to the fixed
point (18) or remain fastened to the single hook.
11.2.4.1 Retracting the 2nd section of the boom extension
- Lower the boom via the elevating mechanism until the head of the 2nd section is approx. 1.5 m above the
ground.
- Disconnect the electrical plug-and-socket connectors of the hoist limit switch.
- Remove the locking pin.
- Wind up the winch rope carefully until the single hook is touching the head of the jib (if no single hook is
provided, the rope lock must be secured to the fixed point (18) of the jib).
- Continue to wind up the winch rope slowly, until the 2nd section has been retracted in the basic section.
- Insert the locking pins (21) into the aligned bore-holes (22) and (23), and secure them using a spring clip.
- Connect the electrical plug-and-socket connector for the hoist limit switch.
- Enter the rig arrangement into the ASLI for the short jib.
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11.2.5 Resetting the offset angle of the boom extension
Attention If working from an elevated position is absolutely necessary, use a platform or the
NOTE The telescopic boom must be retracted entirely to its stop, the 2nd section of the jib
must be retracted completely and secured with pins.
Attention First set the boom offset angle to its specified limit before pulling the jib upwards
using the winch rope. If the boom would be lowered even more when the jib has been
pulled up completely, this might overload the winch rope and the appropriate rope
fastening device!
The following steps must be performed and the following instructions observed before the offset angle of the
jib is returned to its previous setting:
y The crane is supported by outriggers as specified.

y The superstructure is slewed to the rear, if possible.
y The swing brake is engaged.
y All tele sections are retracted completely.
y The jib is mounted to the telescopic boom head correctly, and secured with pins.
y The 2nd section has been retracted into the jib base section, and secured with pins.
• Make sure that a sufficient length of winch rope is available to pass the winch rope over the head of the jib
and back to the fixed point (18) on the base section.
NOTE To return the jib offset angle to its previous setting, the winch rope may be secured to
the fixed point (18) or the offset angle can be returned to its previous setting with the
winch rope remaining connected to the single hook.
- Lower the telescopic boom via the elevating mechanism until the jib head is
placed just above the ground.
- If the load hook is still secured, remove the parts of line of the winch rope
from the load hook and the hoist limit switch weight.
- Place the winch rope (unless already placed there) in the sheave (24) of the
boom elevation head and secure it to the fixed point (18) of the jib’s base
section.
Insert the 3 rope locking pins and lock them using the locating dowels.
- Keep the key switch 54 „hoist limit switch override” in its position during
actuation.
- Wind up slack winch rope slowly until it is slightly tensioned.
- Continue to wind up the winch rope carefully, until the jib is lifted, so that the
angle between the jib and the telescopic boom is reduced.
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11.2.5 Resetting the offset angle of the boom extension (cont’d.)
DANGER Before the top jib is pulled against its stop via the winch rope, the boom elevation
cylinder of the telescope boom must be set to "blocked" position.
• While winding up the winch rope, the telescopic boom can be lowered via
the elevating mechanism, so that the head of the jib remains just above the
ground, as close as possible.
- Continue to wind up the winch rope carefully until the jib has reached the
desired offset position. Do not wind up the rope more than necessary.
- Remove the left-hand and right-hand retaining clips and pull out the two
offset pins (20).
- Insert the two offset pins (20) on the left and right into the bore-holes for the
desired angular position and lock them using the retaining clips.
- Wind off the winch rope carefully until the jib has reached the desired offset
position.
• When the jib has reached its desired offset position, discharge the winch
rope and release the rope socket from the fixed point on the jib base section.
DANGER Check that all pins and plugs are locked and that the cable connectors for the hoist
limit switch are correctly connected.
- Find the appropriate code from the rated load chart and enter it into the ASLI.
11.2.6 Dismantling the boom extension from the telescopic boom head
DANGER If the jib is not correctly secured by pins, it might get

loose and fall to the ground.
Always make sure that the lock, stowing and pivot pins
are in position before starting any operation. Failing
this, the jib may fall off when an operation is started.
DANGER Persons are not allowed to stay in the jib swing range or in the danger zone.
DANGER The necessary safety precautions must be taken to ensure that no obstacles are in the
slewing range or danger zone of the jib.
If the key switch 54 “hoist limit switch override” is actuated, the hoist limit switch is
deactivated. Operate very carefully and only without a load.
If working from an elevated position is absolutely necessary, use a platform or the
Use the attached pins and linch pins to secure the pivot pin, connecting pin, locking
pin, rope guide pins and stowing pin in position.
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11.2.6 Dismantling the boom extension from the telescopic boom head (cont’d.)
The following work must be performed and the following instructions observed before the jib is removed:
• The jib has been set to its initial position (5°).

• The 2nd section of the jib has been retracted into the base section and secured by pins.
• The telescopic boom is retracted completely and is in its 0° position.
• Make sure that a sufficient length of winch rope is available to guide the winch rope over the head of the jib
and back and fix it to the fixed point at the base section of the jib, if necessary. If the locking pin on top left
is hard to remove, the jib can be lifted slightly using the hoist winch.
- Retract the boom completely.

- Extend tele section 1 by approx. 0.5 m.
- Lower the boom to its horizontal position (0°) using the elevating mechanism, to enable work on the boom
head to be carried out from the ground, as far as possible.
- Release the winch rope from the load hook and remove it from the hoist limit switch weight.
- Release the cable connector of the hoist limit switch from the head of the jib and the connector from the
adapter of the boom elevation.
- Check that the stopper (15) is locked in and that the jib is
fixed to the telescopic boom head.
- Insert the crank handle on the left side of the telescopic

boom head into the lower threaded pin (25) and remove the
two pins (26) from the bearing bracket (27) and the shaft
(28) on the telescopic boom head.
NOTE If the upper locking pin is hard to remove or even cannot be removed from the bracket
on the telescopic boom at all, the jib must be raised by means of the rope winch.
Prerequisite: the rope thimble is secured to the fixed point (18) of the base section.
- Raise the boom elevation by means of the rope winch until the upper stowing pin (26) can be removed from
the upper bracket (27) easily.
• Remove upper and lower retaining pins completely.
- Unwind the winch rope slightly.
- Release the rope thimble from the fixed point of the base
section of the jib.
- Remove the winch rope from the sheave in the jib head and
from the rope sheave, and lower it to the ground on the left
side of the telescopic boom.
- Secure the strap (4) to the front end of the jib.
- Release the stopper (15) by means of the hook on the crank
handle (pull down).
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- Use the strap (4) to swing the jib carefully around, to the
longitudinal side of the telescopic boom.
NOTE Use the strap (4) to fix the jib so that the
position of the jib in front of the
transporting support (7) on the
superstructure is reached.
- Slowly and carefully elevate the telescopic boom, so that the

jib swings laterally to the telescopic boom, and stops at the
bracket.
NOTE Check whether the jib is folded in its

transport position.
- Carefully retract tele section 1 completely.

- The two support pins (13) must be inserted into the bore-
holes of the transport support (14) and the jib must be
pushed onto the bracket (7).
- Align boom horizontally.

- Extend telescope 5 until the tele cylinder is locked in the
telescope.
- Retract telescope 5 by actuating the crane control lever and
the tip switch "T" simultaneously.
- Lock jib by inserting the split rivet (12) into the support pin
(13).
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DANGER Before releasing the locking pins (11) on the right side of the telescopic boom, make
sure to check that:
- the boom is in 0° position,

- the two support pins (13) are completely inserted into the bore-holes of the transport
support (14) and locked using the split rivet (12),
- the jib is pushed onto the bracket (7).
If these prerequisites do not exist, there is a risk that the jib might fall to the ground
when the locking pins (11) are released.
- Insert the crank handle in the locking pin (11) on the right
side of the telescopic boom head and remove the two
stowing pins (29) from the bearing bracket or the shaft of the
telescopic boom head, so that the boom elevation is no
longer connected to the telescopic boom head.
NOTE The red marks on the threaded pins must match.
- Remove crank.
- Press jib onto the bracket (7) in the locking position.

- The lock pin (6) has been inserted through the bore-holes of
the clip (31) and the bracket (7).
- Secure the lock pin (6) using a spring clip (30).
- Remove strap.
- Fold the upper bracket (1) down using the mounting crank
handle by swinging the link (2) away from the stowing pin
(32).
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- Connect the hoist limit switch cable connector (33) to the

socket (34) on the telescopic boom head.
- Insert the winch rope in the rope guide sheave (35) on top of
the telescopic boom head and secure it by means of the
yoke (36).
- Attach the releasing weight of the hoist limit switch to the head
of the telescopic boom and to the hoist limit switch (37).
NOTE The upper bearing bracket (1) must be

pivoted downwards before the winch rope
is reeved.
- Reeve the winch rope in the telescopic boom head and in the bottom block as required.
- Return the crane to horizontal working position.
- Refer to the load chart for the appropriate code which depends on the counterweight and the extension
width, and enter it into the ASLI.
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11.3 2 m boom extension
The 2 m boom extension is a lattice-type design. The boom extension can be set to an angle of 4° or and
30°.
Attention Before starting traveling operation or crane work with the boom extension folded to
the basic boom, all bolt securing, locking and fastening devices on the boom
extension and on the basic boom must be checked for safety reasons.
In the case of crane work with the boom extension folded to the basic boom in
transport position, or during work via the main boom with the boom extension
mounted to the boom head, the lifting capacities specified in the load charts are
reduced by the values indicated in the "Notes referring to the load chart" in question.
NOTE A double ladder has been provided to facilitate assembly of the boom extension (refer
to part B2; item 11.1).
Before assembly, the following work must be effected and the following notes must be observed:
• The crane carrier has been supported by outriggers as specified.

• The superstructure has been slewed to the rear, the swing brake is engaged, the superstructure has been
locked using the locking pin.
• All telescopes have been retracted completely.
• During assembly and disassembly of the boom extension, there must not be any obstacle in the area of
motion.
• Do not move the crane during assembly of the boom extension.
• The rig arrangement of the boom extension must have been entered into the ASLI (code no., see
lifting capacity charts).
11.3.1 Preparation for mounting the boom extension to the boom head
- Lower the boom to horizontal position using the derricking

gear.
- Deposit the hook block on the ground.
- Disconnect the rope socket from the hook block or from the
boom head.
- Remove the rope clamp from the rope socket.
- Pull the rope out of the releasing weight of the hoist limit
switch.
- Release the rope falls of the hoisting rope from the hook
block and the pulley bracket on the boom head.
- Reel up the hoisting rope. The rope must not drag on the
ground.
- Pivot the bearing bracket (1) upwards by folding the link (2)
down.
NOTE The link must butt against the retaining

pin (3).
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11.3.2 Mounting the boom extension to the boom head
The steps as specified under item 11.3.1. have been performed.
Mounting the boom extension to the boom head at an inclination angle of 4°

- Swing the jib to the boom head by pressing on the point marked by an arrow until the locating bore-holes of
the adapter (2) are aligned with the bore-holes of the top bearing bracket (3) and of the lower bearing
bracket (4) on the boom head.
- Insert the crank supplied with the machine into the threaded pin (5) and turn the pin until the top and the
bottom pin sections are completely inserted into the bore holes of the bearing brackets, and the marks are
visible.
- Remove the crank from the threaded pin.
- Insert the crank into the threaded pin (6) and turn the pins until the top and the bottom pin sections have
been extended completely from the bearing brackets, so that the boom extension has been released.
Attention Before slewing, make sure that the top and

the bottom pin sections have been
inserted into the bearing brackets.
- Swing boom extension forward until the stopper (7) is

engaged at the boom head. The bore holes of the adapter
are aligned with the bore holes of the bearing brackets on
the boom head.
- Insert the crank into the threaded pin (8) and turn the pin
until the pin sections are completely inserted into the bore
holes of the bearing brackets, and the marks are visible.
NOTE Due to the proper weight of the boom extension, it may not yet be possible to turn the
top threaded pin into the top bore hole of the bearing bracket.
For information concerning the steps required to this effect, refer to item 11.3.2.1
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11.3.2.1 Turning the threaded pin into the top bearing bracket
If the top threaded pin still cannot be inserted, perform the following steps:
- Pull the hoisting rope via the middle boom pulley and the pulleys of the boom extension, guide it through
the specific releasing weight (1) of the hoist limit switch and attach the weight to the switch.
- Insert the three rope securing pins (3) and lock them.
- Fasten the hoisting rope in the rope socket as specified, and fasten and secure the rope socket to the
single hook, or fasten it to the fixed point (4) of the fly jib using the rope socket.
- Spool up hoisting rope carefully until the single hook or the direct rope pull lift the head of the boom
extension slightly.
- Lift the boom extension slightly, until the top threaded pin is easy to turn in. Now, the bore holes of the
adapter and of the bearing bracket must be aligned, the top pin section can be inserted.
- Lower the single hook or the rope.
- Insert the plug into the socket on the boom head and on the boom extension (now the electrical
connection of the ASLI for the hoist limit switch on the boom extension has been established).
Attention Before starting any crane work with

mounted boom extension, it is essential to
verify whether the pins have been inserted
correctly into the bore holes of the bearing
brackets.
Attention Before folding the boom extension to the

basic mast, the boom extension must be
set to the 4° position and the stopper (2)
must have been pulled out of its locking
position.
To dismantle or fold down the lattice-type fly jib, perform the

assembly procedure in reverse order.
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11.3.3 Changing the angle of the 2 m boom extension to the 4° or 30° position.
Before changing the angle, perform the following work and observe the following notes:
y The crane carrier has been supported by outriggers as specified.

y The superstructure has been slewed to the rear, the swing brake has been engaged.
y All telescopic elements have been retracted completely.
y When changing the boom angle, make sure that there are no obstacles in the area of assembly.
- Remove the single hook from the rope.

- Mount the rope shackle to the bracket (2) of the boom
extension, lock it by a pin and secure it.
- Put the hoisting rope under slight tension (while doing so,
the boom extension is lifted slightly).
- While the rope is still under slight tension, pull the spring
clip (3) and the locking pin (1) out of the 4° position.
- Lower the hoisting rope carefully; insert the locking pin in
the 30° angle position, lock it by a pin and secure it.
Attention The winch rope may only be fastened to the fixed point (2) of the boom extension for
pivoting or lifting the boom extension, but never for rope reeving!
11.3.4 Assembly of the rope socket for the 2 m boom extension in the case of an even
number of rope falls
In the case of an even number of rope falls, make

sure that the rope socket is fixed to the bracket of
the boom extension.
Attention Make sure that the rope socket

is fastened to the bracket only in
the position shown in the
illustration.
Correct Wrong
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11.3.5 Removing the support of the boom extension
To make sure that the 9.0/16.0 m boom extension can be mounted to the
vehicle, the 2 m boom extension must be removed including the support.
- Pull off the 4 spring clips (1) and remove the 4 pins (2).
Remove the boom extension including the support, and deposit it.
For assembly, perform this procedure in reverse order.
11.3.6 Alternate operation with 9.0/16.0 m and 2 m boom extension, and relocation of
the adapter
When crane work is being performed alternately with the two boom extensions, only one boom extension
can be mounted to the vehicle at a time.
Attention Before mounting the 9.0/16 m boom extension to the vehicle, make sure that the 2 m
boom extension incl. the support is removed (for notes on assembly and dis-
assembly, refer to part B2; item 11.5).
11.3.6.1 Relocation of the adapter
When changing the boom extension, make sure that the adapter is also
mounted to the required boom extension.
- Pull the 4 spring clips (1) and remove the 4 pins (2).
- Adjust the adapter to the required boom extension. The bore holes of the
boom extension and the adapter must be aligned.
- Insert the 4 pins (2) into the bore holes and lock them using the spring
clips (1).
11.3.7 Working with the 2 m boom extension
Attention When working with the 2 m boom extension in the 40 position alone, and when
working via the pulley head of the telescopic boom in conjunction with the 2 m boom
extension, the automatic safe load indicator will emit a warning in general when the
telescopic boom is at an angle of ≥ 750.
This warning regarding the telescopic boom angle only applies for operation with a
rope arrangement with 2 rope falls on the 2 m boom extension; in this case, the
telescopic boom angle of 750 must not be exceeded.
In case of non-observance of this angle limitation, the fixed rope fall of the hoisting
rope on the 2 m boom extension can be damaged, or damage the rope pulleys on the
telescopic boom head.
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If a centralized lubrication system is installed, various lubricators on the superstructure are supplied with
grease via the centralized lubrication.
For operating instructions and data regarding the lubricating points, please refer to the documents of the
unit's manufacturer (see Annex Part G).
11.4.1 Operation of the system
When the ignition is switched on, the piston pump assembly and the stirrer are activated by
actuation of the rocker switch 59 "centralized lubrication system". The points of lubrication are
supplied with grease. A pilot lamp in the switch goes on to indicate that lubrication is in progress.
To terminate the lubricating procedure, turn the rocker switch OFF; the pilot lamp in the switch
goes out. The lubrication time (contact time) and the duration of the regular lubrication intervals
depend on the frequency of working movements and can be determined by the operator.
However, it is recommended to adhere to the intervals specified in the maintenance scheme.
11.5 Heating of working mirror
- Actuate the rocker switch 58 "working mirror heating"; the green function lamp in the switch
goes on to indicate the heating process.
11.6 Aircraft warning lamp on the boom
- Actuate the rocker switch 57 "aircraft warning lamp"; the aircraft warning lamps on the boom
are switched on; the green function lamp in the switch goes on to indicate that the lamps are
switched on.
11.7 Working floodlight on the hoist winch
- Actuate the rocker switch 60 "working floodlight, hoist winch" down to switch the lights
ON/OFF.
11.8 Working floodlight on boom
- Actuate the rocker switch 61 "working floodlight on the boom" to switch this lamp ON/OFF".
11.9 Working floodlight - electrical adjustment
- Actuate the rocker tip switch 62 "working floodlight - electrical adjustment". The working
floodlight on the boom is adjusted.
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11.10 Emergency control of superstructure via hydraulic motor in the chassis
DANGER On principle, the superstructure emergency mode is only admissible to reset the
crane from a working position to its former rig arrangement in case of malfunction of
the power supply.
To supply the superstructure hydraulic system in case of engine failure in the superstructure, failure of the hydraulic
pump or the superstructure electrical system, the oil supply can be ensured by means of hose pipes equipped with
quick-locking coupling devices via a hydraulic motor which is driven by the hydraulic system in the chassis.
Due to the different sizes of the quick-locking coupling devices, these cannot be confused on connection.
Attention In the case of specific crane work which may require quick utilisation of the
emergency control feature, oil supply to the emergency control system must be
ensured before such work begins. At the same time, all possible procedures for
resetting the superstructure to its former rig arrangement must be checked for proper
function.
When slewing the superstructure, pay attention to any connected hydraulic hoses.
DANGER Only hoisting gear 1 can be reset to its former rig arrangement via the emergency
control.
Persons may only be transported by means of hoisting gear 1.
11.10.1 Establishing the oil supply between the chassis and the superstructure
In the chassis:
- Stabilize the vehicle by outriggers.

- Stop the engine in the chassis.
- Open the cover of the radiator housing.
During normal traveling operation, the 3/2-way cock (1)

provided for the oil supply of the superstructure emergency
control feature must always be in its initial position (refer to
Figure), and may only be set to emergency position for
emergency mode.
During normal driving operation, the change-over cock of the

engine cooling system is placed in its initial position
"independent of the engine speed", which is controlled by the
thermostatic valve, and must be turned to "emergency
position" (depending on engine speed) for emergency mode.
Emergency position Initial position
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11.10.1 Establishing the oil supply between the chassis and the superstructure (cont'd.)
- Move 3/2-way change-over cock (1) for oil

supply to the superstructure emergency control
feature from its initial position to the left into
emergency position.
- Remove the caps from the quick-locking
coupling devices (2, 3 and 4).
- Screw-fasten the hose pipes to the quick-
locking coupling devices (2, 3 and 4) by turning
them to their stops.
Emergency position
Attention The 3/2-way change-over cock (1) and the change-over cock "engine cooling system"
are used for change-over in the emergency position, and must be returned to their
initial position once work is finished.
Establishing the connection of the hydraulic hoses between the chassis and the superstructure
Prerequisite:
The three hose pipes in the chassis are safely
connected to the quick-locking coupling devices.
- Open engine lid in superstructure (on the right,

viewed in driving direction).
- Remove the caps from the quick-locking

coupling devices (2a, 3a and 4a).
- Screw-fasten the hose pipes to the three quick-

locking coupling devices (2a, 3a and 4a) by
turning them to their stop.
Attention All hose pipes must be screw-fastened safely to the quick-locking coupling devices,
as otherwise the hydraulic system may be damaged.
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11.10.2 Resetting the superstructure to its former rig arrangement
DANGER During superstructure emergency operation, any risks of overload or overturning to

which the crane might be exposed must be taken into account. Make sure that always
motions tending to reduce the load moment (lowering the load or raising the boom) are
performed, if possible. Retracting the telescopic boom is not possible.
While resetting the crane to its former rig arrangement, actuate the control levers
gently.
NOTE In emergency mode, as long as the superstructure power supply is available, the
information on the ASLI display remains visible and should be used to assess the
risk.
DANGER If there is a failure of the electrical power supply of the superstructure, the ASLI
information is no longer available. The prevailing risk must be judged on the basis of
other information.
Even if the electrical power supply is still available in superstructure emergency
mode, a dangerous motion (increasing the load moment) will not be stopped by the
automatic safe load indicator.
Prerequisite:
The hose connections between the chassis and the superstructure have been established.
In the chassis:
- Start the engine in the chassis and set the

speed to < 1500 r.p.m.
- Turn the 3/2-way cock (in the chassis) and the
change-over cock of the engine cooling system
(in the chassis) to its emergency working
position (refer to item 11.11.1).
All levers of the control cocks must be mounted

in their initial position. No crane movements are
possible.
Functions of the control cocks:
Control cock 1: Actuation of the pressure supply (oil supply).

ON / OFF.
Control cock 2: Actuation of hoist winch, winding up the rope.
Control cock 3: Actuation of hoist winch, winding off the rope.
Control cock 4: Actuation "raising the boom via the boom elevation".
Control cock 5: Actuation "lowering the boom via the boom elevation".
Control cock 6: Actuation "releasing swing brake".
Control cock 7: Actuation "slewing superstructure to the right".

Control cock 8: Actuation "slewing superstructure to the left".
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11.10.2 Resetting the superstructure to its former rig arrangement (cont’d)
After resetting the vehicle to its former rig arrangement, perform the following steps:
- Move the control cocks to their initial position.

- Disconnect and remove the hoses.
- Close the connectors of the quick-locking coupling devices by means of caps.
- Close lids and covers.
11.10.3 Putting the vehicle in its initial condition
After resetting the vehicle to its former rig arrangement, perform the following steps:
- Move the control cocks to their initial position.
- Disconnect and remove the hoses.
- Close the connectors of the quick-locking coupling devices by means of caps.
- Close lids and covers.
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11.11 Supplementary heating

Autonomous, gas-powered air heater unit (Truma gas heater unit)
11.11.1 Truma supplementary heater unit
The crane cabin is heated via the gas-operated supplementary heater

unit installed below the cabin. This supplementary heater unit is supplied
via a separate gas cylinder. Operation and checking are effected via the
control element (1).
For precise information on operation, service and maintenance of the

TRUMA heater unit, please refer to the enclosed operating manual of the
manufacturer of the heater unit.
DANGER Gas cylinders - even when emptied - must never be exposed to excessive heat
radiation; there is a
risk of explosion !
The instructions of the manufacturer of the heater unit or of the supplier of the gas
cylinder must be complied with.
- Actuate the rotary switch (1) to switch on the air

conditioner. During air conditioner operation, the
pilot lamp (2) is lit.
For further details on operation, care and mainten-

ance of the air conditioner, refer to the documents of
the manufacturer of this unit in Annex G2.
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11.13 Switch "Emergency OFF, superstructure

engine”
To stop the running engine in the chassis in cases of emergency,

press the push-button.
To re-start the engine, first turn the releasing ring in the push-button
to the right, in the direction of the arrow; then the push-button will
return to its original position.
Engine stop
11.14 Checking the wind velocity via the anemometer
After entry of the number "14" into the keypad (1) of the ASLI, the wind
velocity appears in m/sec in the display section (2).
DANGER If the admissible wind velocity value specified in the

"notes referring to the load charts" is exceeded, the
boom must be retracted or deposited, and crane
operation must be stopped immediately.
Attention During traveling operation, the anemometer must be

deactivated or removed.
11.14.1 Removal of the anemometer
- Remove the plug (5) from the plugbox (4).

- Remove the anemometer (2) with its retaining device (3).
To mount the anemometer, reverse the above procedure.
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11.15 Front-end pulley
The front-end pulley is always used with one rope fall; it is secured via the telescopic boom's ASLI program
for the counterweight actually mounted to the machine, and for the existing supporting base.
The total load to be lifted - consisting of the load securing equipment and the hook blocks at the front-end
pulley and the telescopic boom head, and of the load to be lifted at the front-end pulley - must not exceed the
maximum specified lifting capacities of the telescopic boom as indicated in the load charts for the prevailing
rig arrangement of the crane.
DANGER The appropriate code number of the telescopic boom according to the prevailing
crane configuration, as regards the counterweight and the supporting base, and the
number of rope falls "1" must be entered into the automatic safe load indicator.
Picking up loads deposited on the ground by lifting the boom via the derricking gear
may result in overload of the front-end pulley, of the hoisting rope or in overturning of
the crane.
This upward movement of the derricking gear is not stopped by the overload safety
device.
Attention The load and radius values appearing in the automatic safe load indicator (ASLI)
deviate slightly from the actual values, as the ASLI does not take account of the
geometric conditions of the front-end pulley.
DANGER When working with two winch ropes, make sure that the ropes are guided via the rope
pulleys as shown under item 11.15.1, Fig. 2. Otherwise, there is a risk that the winch
ropes might cross and chafe.
11.15.1 Mounting the front-end pulley to the boom head
• Fold down the bearing bracket as it is shown in Fig. 2, item

12.
• Pull out the spring clip (Fig. 1, item 1) so that the locking pin
(Fig. 1, item 2) of the front-end pulley can be released from
the boom head.
• Swing the front-end pulley (Fig. 1, item 2) into the support

on the boom head and secure it by means of the spring clip
(Fig. 1, item 1).
This measure should be taken to ensure that the locking pin

and the spring clip are not lost. Fig. 1
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11.15.1 Mounting the front-end pulley to the boom head (cont'd.)
• Fasten the front-end pulley with pin (Fig. 2, item 4) to the

boom head and lock it using the spring clip (Fig. 2, item 5).
• Place the rope of the second hoist winch (auxiliary winch)

over the front-end pulley and lock it using the securing yokes
(Fig. 2, item 8).
• Fasten the releasing weight to the hoisting rope of the

second hoist winch and the hoist limit switch (Fig. 2, item 9).
• Pull electric plug-and-socket connector from the blind socket

(Fig. 2, item 10) and insert it into the plugbox (Fig. 2, item
11).
• Before the plug-and-socket connector can be inserted, the

blind plug must be removed from the plugbox (Fig. 2, item
11).
• To store the blind plug, insert it into the blind socket (Fig. 2,
item 10).
• After work with the second hoist winch has been finished,
reverse the above procedure to reset the front-end pulley to
its initial state.
Fig. 2
11.15.2 Operation with two hooks and the boom extension
means of supports. (Refer to part B, item 11.1).
Provided that the crane is equipped with two hoisting gears, the use of the boom extension or of the
front-end pulley offers the possibility to locate loads accurately which are positioned accordingly, or
to turn loads.
Prerequisite: The boom extension or the front-end pulley is mounted correctly to the telescopic boom head
as described, and the crane is stabilized by outriggers as specified.
DANGER On principle, loads must be lifted or lowered by means of the component featuring the
least load bearing capacity. Thus, the load must always be lifted clear or lowered
completely by means of this component.
The overload safety device must be set to the correct ASLI code number which
corresponds to the configuration of the boom extension, and to the counterweight and
the supporting base.
The lifting capacities at the boom extension which are admissible in this case correspond to the maximum
lifting capacities indicated in the appropriate load charts for the boom extension. The total load incl. hook
block and all the load securing equipment must not exceed the lifting capacities specified for the rig
arrangement of the crane.
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11.15.2 Operation with two hooks and the boom extension (cont'd.)
DANGER The number of rope falls attached to the boom head must never be smaller than the
number of rope falls attached to the boom extension. On principle, it must be at least
identical with or greater than the number of rope falls fixed to the boom extension. If
this regulation is not observed, this may cause failure of the hoisting gear or of the
hoisting rope of the telescopic boom head.
On principle, each load may only be lifted completely clear of the ground with the hook which is at the
greatest horizontal distance from the center of rotation.
DANGER When the hook block at the telescopic boom head is put under load condition while a
load is being lifted, incorrect load values will appear on the automatic safe load
indicator.
DANGER When working with main and auxiliary winch, the winch rope of the main winch must
always be guided over the boom head, and the winch rope of the auxiliary winch must
be guided over the boom extension (single top, heavy-lift fly jib, etc.). Otherwise, there
is a risk that the winch ropes might cross and chafe.
When a load is suspended on both hook blocks, the telescopic boom must on no account be lowered
via the derricking gear.
All crane work must be performed with the required care.
1. Use the 2nd winch to lift the 1. Use the second winch to lower
load clear of the ground the load
2. Use the main winch to hoist the 2. Use the main winch to deposit the
load load
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11.16 Mounting and dismounting the 2nd hoist winch
DANGER The 2nd hoist winch is part of the counterweight mass. Crane work with disassembled
2nd hoist winch is prohibited.
! RISK OF ACCIDENTS!
Balancing counterweights can be mounted after having consulted the vehicle
manufacturer and obtained his approval and release.
Dismounting the 2nd hoist

winch:
- Disconnect electrical and

hydraulic connections.
- Raise the hoist winch until the
securing pins are set free.
- Remove spring clips (1) from
the pins (2).
- Remove the pins (2) with
washers and split pins.
- Fasten hoist winch using
appropriate load securing
devices, and remove it from
the vehicle.
The setscrews (3) have been

adjusted by the factory and
must not be adjusted!
For assembly, proceed
analogously by reversing the
above sequence of operations.
11.17 Warning in case of ASLI shut-off
The during crane work, an ASLI shut-off is performed due to overload, an acoustical and/or visual warning -
depending on the crane model - will be issued (horn/flashing beacon).
A separate hourmeter (item B2-2.1, pt. 42) has been installed to monitor the service
hours of the hoisting winch 1. The hourmeter operates as soon as the hoisting winch is
put into operation.
A separate hourmeter (item B2-2.1, pt. 43) has been installed to monitor the service
hours of the hoisting winch 2. The hourmeter operates as soon as the hoisting winch is
put into operation.
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If the vehicle's batteries are discharged or if their capacity is insufficient, the

engine can be started with power supplied from an external source.
Such an external power source are the batteries of another vehicle with 24 V
system, or the batteries of the superstructure or the chassis of the vehicle in
question.
However, this requires that the vehicle supplying power is equipped with a
plugbox for starting via an external power source.
The plugbox for starting via an external power source (1) of the vehicle to be supplied
with power is installed on the right-hand side on the battery box (see Fig.).
The batteries of the vehicle supplying power should have the same or a higher capacity (Ampere) than the
vehicle to be supplied with power.
To avoid damage to the alternator, make sure that the following sequence of operations is observed.
Vehicle to be supplied with power Vehicle supplying power

1. The ignition is switched OFF. The ignition is switched OFF.
2. The battery main switch is turned OFF. The battery main switch is turned OFF.
3. Connect jumper cable to plugbox. Connect jumper cable to plugbox.
6. Start the engine and make it turn at half-load.
(Do not switch the battery main switch ON.)
10. Stop the engine, switch the ignition OFF;
Switch the battery main switch OFF.
11. Disconnect the jumper cables Disconnect the jumper cables
Attention Make sure that the engine is never running without connection to the battery (either to
the vehicle's own battery, or to the battery of another vehicle). (Destruction of the
rectifier diodes in the three-phase alternator).
NOTE Current can also be supplied via the plugbox for starting the vehicle by means of an
external power source, i.e. another vehicle can be started.
11.21 Battery charging plugbox (1))
The battery charge condition is checked by measurement of the acid density.
If the acid density is below 1.21 kg/l - referred to a temperature of 20°C and the
specified acid level - the battery must be charged.
The battery may only be charged with direct current.
To charge the batteries, connect the charging plugbox directly to the charger via
a cable; it is not necessary to remove the batteries.
For further details, please refer to the brochures of the battery manufacturer.
Attention The charging plugbox must not be used for starting the vehicle with externally
supplied power while the charger is connected. The plugbox only serves to charge the
battery.
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12 Instrument panel
12.1 Monitoring the superstructure and the chassis, driving and outrigger operation from the superstructure, ASLI control
unit
12.1.1 Indicator, pilot and 12.1.3 Other components
warning lamps
Item Item
1 free 30 ASLI indicator and control unit

2 (rt) Service brake, superstructure
3 (rt) Central warning, engine in chassis 12.1.4 Switches, rocker
6 (rt) Generator (alternator) switches (WS), rocker tip
7 (rt) Engine malfunction
8 (rt) Engine oil level switches (WT)
9 (ge) Engine air cleaner
10 (gn) Direction indicators, chassis 25 WT - Extending/retracting outriggers VL
11 (rt) Service - parking brake, chassis 26 Rotary switch - preselection - outrigger
13 free beams / outrigger cylinders
14 (ge) Inter-wheel differential locks in 27 WT - Extending/retracting outriggers VR
axles 28 WT - Extending/retracting outriggers HL
15 (ge) Axle suspension lock engaged 29 WT - Extending/retracting outriggers HR
16 (rt) Hydraulic oil filter 31 WS*) Ignition chassis ON
17 (gn) Swing mechanism locked 32 WT - Engine start, chassis
19 free 33 free
20 (ge) Rear axles unlocked 34 WS - Lighting system, chassis
23 (rt) Hydraulic oil temperature 35 WT - Axle oscillation, chassis
24 free 36 free
37 WT - Inter-wheel differential locks,
12.1.2 Instruments chassis
38 WS*) parking brake, chassis
4 Engine temperature indicator 40 Rotary switch, gear selector, gearbox,
5 Fuel level indicator chassis
21 Air pressure gauge
22 Hourmeter superstructure
Pilot lamps = (gn) green UW = Chassis, OW = superstructure
Indicator lamps = (ge) yellow WS = Rocker switch
(or) orange WS*) = Rocker switch with function lighting
(bl) blue WT = Rocker tip switch
Warning lamps = (rt) red VL = front, left-hand VR = front, right-hand
HL = rear, left-hand HR = rear, right-hand
0220_EN_FA043_B2_12_00_00
2003-01 1/4
12.2 Operation of the superstructure
12.2.1 Indicator, pilot and Item

warning lamps
Item
12.2.2 Switches, rocker

switches (WS), rocker tip
switches (WT)
Item 51 WT - Engine stalling device
52 Rotary switch - ignition ON/OFF - engine
39 free start
40 free 53 Key-actuated switch “Hoist limit switch
41 free override feature”
42 free 54 free
43 WS - Swing / counterweight override
feature
44 WS - Rope winch rotation indicator
45 free
46 free
47 free
48 WT - Emergency control - Release tele-
scope locking mechanism
49 WS - Emergency control - Lock tele-
scope preselection
50 WS*) Emergency control telscope
Pilot lamps = (gn) green UW = Chassis, OW = superstructure

Indicator lamps = (ge) yellow WS = Rocker switch
(or) orange WS*) = Rocker switch with function lighting
(bl) blue WT = Rocker tip switch
Warning lamps = (rt) red VL = front, left-hand VR = front, right-hand
HL = rear, left-hand HR = rear, right-hand
0220_EN_FA043_B2_12_00_00
2/4 2003-01
cont: 12.2.2 Switches, rocker switches (WS), rocker tip switches (WT)
57 WS*) Aircraft warning lamp **)*)

58 WS*) Mirror heating **)
59 WS*) Centralized lubrication **)
60 WS Working floodlight, hoist winch **)
61 WS Working floodlight on boom **)
62 WT - Working floodlight - electrical
adjustment **)
63 WS - Working floodlight on basic boom
64 WS - Instrument illumination, working
floodlight on the crane cabin
65 WS - Wiper, skylight
66 WS - Windscreen wiper
67 WT - Windscreen washing system
68 WT - Windscreen adjustment
69 WT - Seat adjustment
70 WS*) - Battery main switch
12.2.3 Other components

71 Timer, heating
**)
Optional equipment
0220_EN_FA043_B2_12_00_00
2003-01 3/4
Memo:
0220_EN_FA043_B2_12_00_00
4/4 2003-01
Part C
Service and Maintenance
0225_EN_ALLGE_C_00_00_00
General Instructions concerning Service and Maintenance C1-1
1 General Instructions concerning Service and Maintenance

Regular cleaning, careful servicing and maintenance will ensure that your machine is ready to work perfectly
through a long lifetime.
All the operations required have been described in the following part "C" and must be effected at the
intervals specified in the maintenance schedules for the chassis and the superstructure.
Service and maintenance work may only be performed by qualified, well-trained and authorized specialist
staff.
These instructions do not include any particular work on the engine and the gearbox requiring special
knowledge. For further details, please refer to the enclosed Operating Manuals of the manufacturers of the
assemblies in question.
The machine must be cleaned thoroughly at least every 3 months. At the same time, rust should be removed
from all defective parts of the paint, which must be re-painted.
When the vehicle is out of operation for an extended period of time, all metallic parts must be greased to
protect them against corrosion. Corrosion protection must be ensured especially as regards the piston rods
of the working cylinders.
1.1 Before starting service and maintenance work
Absolute cleanness and reasonable planning are prerequisites to all work.
• Maintenance work may only be performed while the engine is at a standstill.

• Protect the machine against rolling away.
• Use only non-fibrous cloth for all work to be carried out, in particular at the hydraulic system.
• Check oil levels only while the machine is standing in horizontal position.
NOTE During oil level inspections, the safety prescriptions according to § 6 "Regulation for
the prevention of accidents to drive assemblies" must be observed. (Please observe
any specific regulations of the country where the machine is to be used which might
differ from those mentioned above.)
• Oil changes should only be effected when the systems and assemblies have their service temperature.
DANGER Danger of scalding in case of uncontrolled seepage of hot lubricant or hydraulic oil.
DANGER Systems, such as: hydraulic system, piping, radiator, compressed air tanks,
expansion vessels, pressure accumulators etc., must be depressurized before they
are opened.
• In case of a visible loss of oil, check the oil level of the assembly in question at shorter intervals; determine
the reason and eliminate it. Check the hose clamps possibly installed for tight fit at regular intervals; if
necessary, re-tighten them.
• Disconnect the batteries before performing work at the electrical equipment during which tools etc. might
get into contact with the electrical equipment. First disconnect the negative, then the positive terminal
(when reconnecting, start with the positive terminal, subsequently connect the negative terminal).
• Before greasing, clean the lubricators; then lubricate according to the maintenance schedule.
• Grease all joints, all movable and rotating parts which are not equipped with grease nipples using an oil
can, according to the maintenance schedule.
0230_EN_FA043_C1_01_00_00
2001-06 1/4
C1-1 General Instructions concerning Service and Maintenance
cont'd.: 1.1 Before starting service and maintenance work
• Eliminate any leakage in the piping systems immediately.

• When mounting covers, plugscrews etc., pay attention to good condition and perfect fit of the seals, if
necessary, replace sealing element.
• All filter elements and/or filter cartridges must be replaced at the specified intervals, unless cleaning is
expressly admitted.
• If the oil or grease type is to be changed for technical or operational reasons, make sure that only the
recommended qualities and viscosities are selected.
• Only use clean oils and lubricants stored in closed vessels.
• For filling and transferring oil, use only clean vessels; the use of a fine-meshed strainer is recommended.
• Use only clean tools when handling lubricants.
• Before re-using fastening and securing elements, e.g. screws and bolts, nuts, spring washers, discs etc.,
check and, if necessary, replace them. Do not re-use lock nuts.
• Before disassembly, mark all cables and lines to prevent them from being mixed up on reassembly once
repair has been completed. Check for proper working order. Check compressed air, hydraulic oil and
coolant lines for leakage.
1.2 Welding and straightening work
Welding work, thermal treatment and straightening work on supporting components are absolutely
prohibited (refer to part E-1, item 1).
As high-tensile steels are used, there is a risk that the material properties might be lost due to inexpert
welding work, thermal treatment or straightening work.
1.3 Inspection of screw couplings
Check the tight fit of all connecting and securing bolts, incl. the assemblies, as well as all hose clamps at
regular intervals of 3 months; if necessary, re-tighten them.
When checking these components for tight fit, observe the specified tightening torques.
The corresponding standard „FN 10009“ referring to tightening torques is available via the TADANO-FAUN
After-Sales Service.
1.4 Checking the hydraulic system and its screw couplings for leakage
Leaking hydraulic screw couplings - if they have come loose - may only be retightened when the system is
depressurized. If safely fastened screw couplings are leaking, the screw coupling must be replaced.
Damaged pipes must not be repaired but replaced by new ones.
Hydraulic hoses and hose pipes must be checked at regular weekly intervals and replaced immediately if
damage - e.g. abrasions, cuts, fissures, deformations are detected or they move out of their fittings, so that
damp spots are visible.
The utilization period of hose pipes should not exceed 6 years as from the date of commissioning (refer to
DIN 20 066, ZH 1/74) (please observe any specific regulations of the country where the machine is to be
used, which might differ from the value mentioned before).
0230_EN_FA043_C1_01_00_00
2/4 2001-06
General Instructions concerning Service and Maintenance C1-1
1.5 Cleaning the machine
In order to avoid damage to the electrical equipment, the brake pipes and the paint, the machine should be
cleaned during the first three months using cold water only. After three months, water temperatures in
excess of 70°C should be avoided; aggressive cleaning substances should not be used.
Spray nozzles should not be closer to the vehicle than 30 cm. Do not use "Power Jet" nozzles.
When the machine is cleaned using a high-pressure cleaning unit (steam jet unit), make sure that the steam
jet is neither directed immediately on rubber or electrical components, nor on joints and the length
compensation of propeller shafts and breathers. Maximum pressure of cleaning units = 80 bar. Preferably,
fan nozzles should be used.
1.6 After having finished service and maintenance work
After having finished these operations, re-install the protective equipment properly. Check the machine for
proper operation.
Attention When disposing of oil, grease, detergents or components containing oil, e.g. filters,
observe the provisions for pollution control. Used oil must be disposed of according
to the applicable requirements.
Besides, please observe the “Instructions for avoiding damage" specified under item 4.1 of the
Preface.
1.7 Configuration of electronic components
In the case of replacement of the engine, gearbox and ABV electronics (control system) and on replacing the
engine and the gearbox, the control parameters must be configured anew. Such work may only be
performed by well-trained specialists.
For further information, please contact the TADANO FAUN After-Sales Service.
0230_EN_FA043_C1_01_00_00
2001-06 3/4
C1-1 General Instructions concerning Service and Maintenance
Memo:
0230_EN_FA043_C1_01_00_00
4/4 2001-06
Part C1
Chassis
0235_EN_ALLGE_C_01_00_00
Maintenance intervals C1-2
The maintenance intervals depend on the vehicle’s operating conditions; the next maintenance will be due
after:
- a certain number of operating hours,

- a certain number of kilometers traveled, or
- a defined period of time.
NOTE The value which is reached first shall be decisive.
The kilometers traveled are indicated in the tachograph in the driver’s cab (see item B1-4.6.6), and the
operating hours in the hourmeter (see item B1-4.6.2.9).
Maintenance work which must be performed earlier than the regular maintenance works, or in a different
fashion, is indicated in the maintenance schedule in the column “Initial maintenance after”, e.g.
commissioning of the machine or replacement of components.
After these maintenance works have been effected, the column „Regular maintenance every 125 / 250 /
500 / 1000 / 2000 / operating hours“ shall apply.
Maintenance work which must be performed daily or before commissioning the vehicle has been marked by
an “X” in the maintenance schedule in the column “Daily, before start-up”.
The number of operating hours expiry of which calls for the specified maintenance work to be performed
repeatedly have been marked by an “X“ in the columns “Regular maintenance every 125 / 250 / 500 /
1000 / 2000 / operating hours”.
e.g. “every 500 operating hours“ i.e. after 500, 1000, 1500 etc. operating hours have been reached,
“every 2000 operating hours“ i.e. after 2000, 4000, 6000 etc. operating hours have been reached.
NOTE The maintenance intervals apply for machines which are subject to normal operating
and environmental conditions. If the machines are used in particular applications, the
maintenance intervals must be adapted to the prevailing operating conditions.
NOTE Whenever major maintenance work is performed, it is obvious that also maintenance
work required to be done at shorter intervals which coincides with this date must be
performed as well.
NOTE In the inspection and maintenance plans, item C1-27 to C1-30, the maintenance works
are shown in terms of assemblies.
If the test and maintenance schedules call for tests on several identical parts (e.g.
axles, propeller shafts, suspension cylinders etc.), only one item is positioned in
terms of example for the assembly.
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2003-01 1/18
C1-2 Maintenance intervals
Memo:
0240_EN_FA043_C1_02_00_00_NEU
2/18 2003-01
Initial Regular maintenance every

Refer to Daily; Minimum
Assemblies / Maintenance mainten-
Part "C1", before 125 250 500 1000 2000 intervals Remark
work and inspections ance
item start-up
after operating hours
Hydraulic piping
Check hydraulic hoses / hose 1.4 Once per
lines for damage. week
Replace hydraulic hoses. 1.4 every 6 years
Engine
Inspection for leakage. 3 X Simultaneously with each oil
level inspection and with each
oil change
Check hose clamps of the 3 X
coolant hoses for tight fit and
tightness.
Oil level inspection. 3.1 X
Oil change, oil filter 3.2 600 Once per Every 40,000 km traveled, every
replacement. op. year 600 operating hours, at least,
hour however, once per year.
s
Inspection of tight fit of the 3.3 X
hose clamps of the charge
air hoses.
Fuel tank; drain condensed 3.4.1 X Once per If necessary, earlier.
water. year
Fuel tank; clean fuel strainer 3.4.2 X
in the filler socket.
Fuel strainer; drain 3.4.3.1 X If necessary, earlier.
condensed water.
Fuel strainer, replace filter 3.4.3.2 X Once per Every 100,000 km traveled.
cartridge. year If necessary, more frequently,
depending on the fuel quality.
Replacement of coolant. 3.5 X Every 2
years
Inspection of coolant level. 3.5.1 X
0240_EN_FA043_C1_02_00_00_NEU
2002-12 3/18

item start-up
Cleaning the cooler. 3.6 X If necessary, earlier.
Air cleaner
Monitoring the air cleaner. 3.7 X During operation via the air
cleaner indicator lamp.
Check air cleaner housing for 3.7 Simultaneously with each
damage and cracks. maintenance of the air cleaner.
Replacement of air cleaner 3.7.1 X Every 2 And when the air cleaner
cartridge. 3.7.2 years indicator goes on.
Clean air cleaner housing. 3.7.1 Simultaneously with each
maintenance of the air cleaner.
If necessary, earlier, depending
on dust collected.
Check air intake pipes and 3.7.3 X
hoses.
Servicing switch "Air cleaner 3.7.4 X Once per And if the indicator does not go
monitoring" - check for year on in spite of contamination of
proper working order the air cleaner.
Cleaning the louvred grill, 3.7.5 Simultaneously with each
coarse filter. maintenance of the air cleaner.
on dust collected.
Gearbox
Inspection for leakage. 4.1 X Simultaneously with each oil
level inspection and each oil
change.
First oil change. 4.2 360000
km; at
least after
3 years
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4/18 2001-06

item start-up
Subsequent oil changes. 4.2 For oil types and oil change
intervals, refer to the ZF Chart of
Approved Lubricants in the
Annex G1.
Transfer box
Inspection for leakage. 5.1.1 X Simultaneously with each oil
change
Inspection of control 5.1.1 X Simultaneously with each oil
cylinders for on-road/off-road level inspection; at the latest
gear for leakage. with each oil change.
Check pressure lines for 5.1.1 X Simultaneously with each oil
leakage and chafe marks. level inspection; at the latest
with each oil change.
Check breather; if necessary, 5.1.1/9 X Simultaneously with each oil
clean. level inspection; at the latest
Check electrical switches for 5.1.1 X Simultaneously with each oil
proper working order. level inspection; at the latest
Oil level inspection / check 5.1 X Every 3
visually. 5.1.1 months
Oil change. 5.2 1000 to Once per At regular intervals of 10,000 km
1500 km year traveled.
Clean oil cooler. 5.3 X If necessary, earlier.
Axles
Oil level inspection. 6.1 Once per
month
Oil change. 6.2 100 op. X Once per Every 10,000 kilometers travel-
hours year ed, at least, however, once per
year.
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2002-12 5/18

item start-up
Greasing the intermediate 6.3 1000 op. X Once per Every 10,000 kilometers travel-
bearings of the propeller hours year ed, at least, however, once per
shafts of the non-driven year.
axles.
Greasing the stub axle 6.4 X Once per Every 10,000 kilometers travel-
bearings. year ed, at least, however, once per
year.
Double propeller shafts (if 6.4 X Once per Every 10,000 kilometers travel-
provided with grease fittings). year. ed, at least, however, once per
year.
Replacement of grease filling 6.4.1 1000 op. Every 2 Every 50,000 km traveled.
in the wheel hubs of the non- hours years
driven axles.
Inspection for leakage. 6.5 X X Simultaneously with each oil
change.
Visual inspection and check 6.5 X Simultaneously with each oil
of control functions. level inspection and each oil
change
Inspection of axial play. 6.6 X In a specialist workshop.
Inspection of wheel bearing 6.6 100 op. Once per
backlash. hours year
Check screws and bolts on 6.7 50 op. X Once per
axles, drop arms, thrust rods, hours, then year
etc. for tight fit; if necessary, after
re-tighten. reaching
100 op. hs.
Preservation of axle and 6.8 As required, and after an ex-
planetary gearings. tended period of standstill of the
vehicle.
Check flange screws of 6.9 50 op. X Once per
propeller shafts for tight fit, if 7.3 hours, then year
necessary, re-tighten. after
reaching
100 op. hs
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item start-up
Propeller shafts
Inspection of backlash. 7.1 50 op. X Once per
hours, then year
after
reaching
100 op. hs
Inspection for noise. 7.2 X During operation.
Eddy-current brake **)

Check backlash between 8 X Once per
stator and rotors. year.
Check air gap. 8 X Once per
year.
Checking the propeller shaft 8 50 op. X Once per
flange screws for tight fit. hours, then year.
after
reaching
100 op. hs.
Check tightening torque of 8 X Once per
screws and bolts. year.
Check shaft packing rings on 8 X Once per
axle. year.
Check insulating sleeves, 8 X Once per
cabling, fasteners and year.
supports for good condition.
Check terminals/pole units 8 X Once per
and pole shoes for corrosion. year.
Check cable lugs and ground 8 X Once per
connection for proper year.
fastening and tight fit.
Check contacts in relay box 8 X Once per
for good condition. year.

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item start-up
Check the cable connections 8 X Once per
and connecting clamps in the year.
relay box for tight fit.
Check control levers for good 8 X During traveling operation.
condition.
Check pilot lamp for proper
function.
Breathers
Check, clean and – if neces- 9 X and simultaneously with every
sary - replace breathers at oil change.
the gearbox, transfer box,
axles, fuel tank (superstruc-
ture), hydraulic tank (chassis
and superstructure) and
swing drive.
Check and, if necessary, 9 X If necessary, earlier.
clean breather / vent holes
on the brake cylinders.
Check, clean and – if neces- 9 X If necessary, earlier.
sary – replace silencers /
breathers on the brake
valves.
Hydraulic system
Check hydraulic system for 10 X
leakage. C2-3.6
Replace filter cartridges. 10.2 125 op. X Once per Simultaneously with each
hours year. hydraulic oil change and if the
filter contamination indicator
lamp is lit.
Replacement of the 9/10.2.1 X If necessary, earlier, if
ventilation filter. contaminated.
0240_EN_FA043_C1_02_00_00_NEU
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item start-up
Oil change. 10.3 X Every 2 Take and analyse an oil sample
years at regular intervals.
Check working pressure of 10.5.3 125 op. X
the hydraulic system of the 10.6.4 hours
chassis; if necessary, have it 10.7.3
re-adjusted by specialists.
Hydraulic system of
steering assembly
Hydraulic oil change. 10.5.1 Simultaneously with each
hydraulic oil change.
Inspection of miter gear of 10.5.2 X
steering system for leakage.
Checking the steering gear 10.5.4 X
and the steering system for
leakage.
Hydraulic system of
suspension
Check for proper working 10.6.2 X
order and leakage
Check the preload pressure 10.6.3 50 operat- X Once per And, if necessary, more fre-
of the hydraulic accumula- ing hours, year. quently.
tors. then once
more after
4 months
Hydraulic system of
outriggers
Bleeding the hydraulic 10.7.1 X If necessary, more frequently, if
cylinders. the machine is standing
outdoors.
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item start-up
Checking the hydraulic sy- 10.7.4 X Before each outrigger operation.
stem of outriggers / the hy-
draulic cylinders for leakage.
Brake system
Check compressed air 11.1 X
system for leakage.
Actuate drainage valves of 11.1 X Every 2
air tanks. weeks
Cleaning drainage valves of 11.1 X Once per
air tanks. year.
Functional check of air drier. 11.2.1 X
Replacement of air drier 11.2.1 Every 2 If necessary, earlier.
cartridge. 11.2.2 years
Pressure governor - check 11.3 X Inspection according to the legal
for proper working order and regulations of the country where
visual inspection of its the machine is to be registered.
internal components.
Inspection and cleaning of 11.4.3 X And whenever the spreading
the diaphragm cylinders. device is checked.
Inspection according to the legal
regulations of the country where
the machine is to be registered.
Checking wheel brakes for 11.5 X Inspection according to the legal
proper working order and regulations of the country where
wear. the machine is to be registered.
Inspection of brake lining 11.5.1 X
thickness.
Inspection of air gap. 11.5.2 X
Wheel brakes - Maintenance 11.6 X
Inspection for wear of the 11.6.1 X Every 2 Inspection according to the legal
spreading device; greasing of years regulations of the country where
movable components. the machine is to be registered.
0240_EN_FA043_C1_02_00_00_NEU
10/18 2001-06

item start-up
Checking the pressure sett- 11.7 X Simultaneously with each
ing of the pressure reducing inspection of the brake system,
valves. and after replacement of a
valve.
Inspection according to the legal
regulations of the country where
Correct functioning of the 11.8 X When starting driving operation,
ABV system. and/or while driving: check the
pilot lamps for proper working
order.
Check mechanical compo- 11.8 X
nents of ABV system.
Check the entire ABV 11.8 X In a specialist workshop.
system.
Checking function and 11.9 X Observe specifications of engine
setting of engine brake and 11.9.1 manufacturer.
exhaust flaps.
Inspection of the compressed 11.10 X Inspection according to the legal
air system. regulations of the country where
Electrical equipment
Check the batteries. 12.1 X Once per
month.
Batteries, grease terminals. 12.1 As required.
Check the three-phase 12.2 X Pay attention to correct Vee belt
generator. tension.
Check the starter. 12.3 X Refer to the instructions of the
engine manufacturer.
Check lamps and indicator 12.4 X
lamps for proper function.
Clean lamp glasses and 12.4 X If necessary, earlier in case of
check them for damage. contamination.
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2002-12 11/18

item start-up
Wheels and tires

Check rims for good condi- 13 X Immediately in case of damage
tion and tires for wear. (accident).
Check wheels for parallelism. 13 X X In a specialist workshop.
Check toe-in (0° + 0.5) 13 X In a specialist workshop.
Check wheel nuts for tight fit. 13.2 50 km, X Subsequently, after 500, 1000
then after and every 5000 km or after 50,
reaching a 100 and every 500 operating
mileage of hours.
100 km
and 200
km.
Check tire inflating pressure. 13.4 X
Interchanging wheels in case 13.6 Every 5,000 Depending on wear pattern.
of tire wear. to 10,000 km
Outriggers
Outrigger floats - grease and 14 X Once per And after every crane cleaning
lubricate support (ball). month operation using the high-
pressure steam jet blower.
Outrigger beams - lubricate 14.1 X
sliding surfaces.
Outrigger beams - check 14.1.1 X
and, if necessary, adjust
guide pads.
Check cable drag chain - 14.2 X
check securing bolts for tight
fit and perform a visual
inspection.
Driver’s cab
Lubricate joints, pins, hinges 15 X Every two And after every crane cleaning
and all movable components. weeks operation using the high-
0240_EN_FA043_C1_02_00_00_NEU
12/18 2001-06

item start-up
Treat door locks (closing 15 X Once per
cylinders), door seals. year
Grease support of the double 15 X If necessary, more often.
ladder.
Warm water heating unit: 15.1 X Twice per
lubricate shaft bearings, year.
articulations of levers and all
movable parts.
Warm water heating unit. 15.1 X Every 3 Simultaneously with a replace-
Clean heat exchanger. years ment of the coolant in the
engine.
Warm water heating unit. 15.1.2 X Twice per
Heat exchanger: Clean air year.
fins.
Blower fan: Clean electric
motor and fan wheel.
Warm water heating unit. 15.1.3 X Every 15,000
Inspection and/or replace- km or every 3
ment of the air cleaner. months.
Clean wiper-blade elements. 15.2 X Once per If necessary, more frequently.
month
Replace the wiper-blade 15.2 X Once per Or if damaged.
elements. year
Checking the fluid level and 15.2 X Once per If necessary, more frequently.
replenishing fluid in tank of month
washing system.
Air conditioning system**). 15.3.3 X If necessary, more often.
Clean evaporator, heat 15.3.4
exchanger and blower fan.
Air conditioning system**). 15.3.6 X Every 15,000
Replace air cleaner. km or every
3 months.

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2002-12 13/18

item start-up
Air conditioning system**). 15.3.9 X If necessary, more often.
Replace drier of air
conditioning compressor.
Air conditioning system**). 15.3.10 Whenever performing work on
Replenish compressor oil the air conditioner.
filling.
Miscellaneous; other
points of lubrication,
service and maintenance
Other points of lubrication
Oil/grease joints and pins, 16.1 X Every two And after every crane cleaning
hinges and other movable weeks operation using the high-
components. pressure steam jet blower.
Supplementary heater unit
**)
Replace strainer of fuel pipe. 16.2 X Once per
year.
Trailer coupling device**)
Rockinger
Greasing the trailer coupling 16.3.1 X And after each vehicle cleaning
device. operation using a high-pressure
steam jet unit.
Checking the trailer coupling 16.3.1 X
device.
Check compressed air 16.3.3 X And simultaneously with each
coupling heads. inspection of the brake system.
Trailer coupling device**)
Ringfeder
Greasing the trailer coupling 16.3.2.1 X And after each vehicle cleaning
device. operation using a high-pressure
steam jet unit.

0240_EN_FA043_C1_02_00_00_NEU
14/18 2001-06

item start-up
Checking the trailer coupling 16.3.2 X
device.
Clean and grease coupling 16.3.2 X And after each vehicle cleaning
bolt. operation using a high-pressure
steam jet unit. If necessary, ear-
lier, depending on dust
collected.
Check compressed air 16.3.3 X And simultaneously with each
coupling heads. inspection of the brake system.
Sliding coupling
Checking the sliding coupling 16.4 X
Steering
Grease the bearing points of 16.5 X
the guide levers.
Suspension
Grease suspension cylinders 16.6 X
at the bottom and on top.
Check bellows. 16.6 X If necessary, more frequently.
Centralized lubrication
system
Check fluid level in supply 16.7 As required.
tank; if necessary, replenish.
Check pipes and screw 16.7 X
couplings for damage.
0240_EN_FA043_C1_02_00_00_NEU
2002-12 15/18
Memo:
0240_EN_FA043_C1_02_00_00_NEU
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Memo:
0240_EN_FA043_C1_02_00_00_NEU
2003-01 17/18
Memo:
0240_EN_FA043_C1_02_00_00_NEU
18/18 2003-01
Engine C1-3
3 Engine
The following general inspection, servicing and maintenance operations at the engine, such as
• Engine oil level inspection,

• Engine oil change,
• Replacement of lubricating oil filters,
• Replacement of fuel filter cartridges,
• Cleaning of fuel pre-filter cartridges,
• Inspection of Vee belts for good condition,
• Inspection of tappet clearance, etc.
• Troubleshooting
are described in the enclosed operating manual of the engine manufacturer.
- Check engine for leakage at regular intervals.
DANGER When handling fuel or consumables, do not smoke, do not use open flames!
DANGER Maintenance work may only be performed while the engine is at a standstill.
DANGER Depressurize systems such as the radiator, expansion vessels etc. before opening
them.
NOTE Checking the oil level and replenishing oil

can be effected via the maintenance port in
the engine cover.
For oil level inspection and oil filling, refer to the specifications
of the engine manufacturer.
While the engine is at a standstill, the oil level of the engine

can be monitored by a warning lamp.
0245_EN_FA043_C1_03_00_00
2003-01 1/8
C1-3 Engine
Attention Oil change and replacement of oil filter after every 40000 km travelled, 600 service
hours at least, however, once per year.
However, these intervals apply only for the use of oils with DB release 228.5.
The specifications of consumables of the engine manufacturer must be complied
with.
NOTE To facilitate collection of the used oil during engine oil

changes, the oil drain plug installed as standard
equipment can be released during the first oil change,
and replaced by a drain valve provided with the tool
kit.
To this effect, first drain the used oil, then mount the
above-mentioned drain valve incl. packing ring instead
of the oil drain plug.
During subsequent oil changes, only the cap (1) of the drain valve (2) must be
released and replaced by the oil drain hose (3) which is also supplied in the tool box.
As the hose is fastened, the drain valve opens and the oil can be drained through the
hose into the collecting vessel provided to this effect.
After these operations have been finished, remove the drain hose, clean the thread
using a clean piece of cloth and re-tighten the cap screw.
! Used oil and filters must be disposed of in an environmentally responsible fashion !

Attention The hose clamps of the charge-air hoses are equipped with cup springs on the screw
casing. When re-tightening the hose clamps, make sure that the max. tightening
torque of 10.2 Nm is not exceeded.
• The hose clamps of the engine charge air hoses must be checked for tight fit according to the maintenance
schedule.
0245_EN_FA043_C1_03_00_00
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Engine C1-3
3.4 Fuil tank

3.4.1 Draining condensed water from the fuel tank
Under extreme weather conditions, condensation may form in the

fuel tank.
Operate the vehicle until the tank is emptied to reserve; unscrew the
drain plug (1) from the tank bottom and drain condensed water into
an appropriate vessel. The drain port must be left open until fuel
flows out free of water.
Before retightening the drain plug, clean the sealing surface using a
lint-free cloth. If necessary, replace sealing element.
3.4.2 Fuel strainer in the filler socket of the fuel tank**)
Remove the fuel strainer (1) and clean it in a clean vessel using a
cleaning agent or diesel fuel. Subsequently, blow out using
compressed air.
3.4.3 Fuel filter

3.4.3.1 Draining condensation water
- Open the drain valve (1) and allow the collected condensation water to
drain into an appropriate vessel.
NOTE Before the cold season begins, the condensate

must be drained. If necessary, repeat this step
several times.

0245_EN_FA043_C1_03_00_00
2003-01 3/8
C1-3 Engine
3.4.3.2 Replacement of fuel filter
- Drain the entire filter contents as described under item C1-3.4.3.

- Disconnect the filter (4) from the filter top (5) together with the filter base (2).
- Disconnect the filter base (2) from the filter (4); clean the filter base (e.g. using diesel fuel).
- Clean the sealing surfaces.
- Grease new sealing elements with diesel fuel and insert them into the gaskets (3).
- Screw-fasten filter base (2) by hand to new filter cartridge, and screw-fasten filter cartridge (4) to filter top
(5).
- Tighten all components securely.
- Bleed system, as described in part B item B1-4.5.3.
3.5 Coolant
3.5.1 Inspection of coolant
DANGER The cap of the filler socket may only be opened carefully at coolant temperatures
lower than 90°C.
The cooling system is filled to the correct level when the

coolant reaches the edge of the filler socket (Fig. 1, item 2) of
the expansion tank.
If necessary, add a type of anti-freeze agent approved by the
engine manufacturer, or renew this filling.
Check the anti-freeze protection using a test unit. The frost-
proofness must be -37°C all over the year.
The valve cover (Fig. 1; item 1) has been provided with a lead
seal in the factory.
When the coolant is renewed or the cooling system has to be
refilled after repair, the whole cooling system must be bled.
NOTE In case of possible seepages at the radiator hose couplings, do not only re-tighten or
replace the hose clamps, but check the proper function of the pressure relief valve in
the valve cover as well. A defective valve may cause excess pressure in the cooling
circuit and consequently leakages.
0245_EN_FA043_C1_03_00_00
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Engine C1-3
3.5.2 Drainage of coolant
NOTE Before the coolant is renewed, the vehicle's warm water heating must be open.
The drain cock is installed below the engine on the right side. It located
mounted in the lowermost position of the cooling system.
- Open the drain cock (1) and the cover of the expansion tank; drain the
coolant into an appropriate vessel.
- Close the drain cock and pour in coolant mix via the expansion tank.
- Start the engine; make it run at various speed levels for approx. 1
minute.
- Stop the engine and check the coolant level in the expansion tank; if
necessary, top up (see item 3.5.1).
! Coolant must be disposed of in an environmentally responsible fashion !

NOTE For instructions how to drain the entire coolant from the engine, refer to the engine
3.6 Clean radiator
Clean the cooler fins of the charge-air cooler (1) and of

the water cooler (3) at regular intervals, according to
the maintenance schedule, by blowing-out with
compressed air or using a paint-brush.
0245_EN_FA043_C1_03_00_00
2003-01 5/8
C1-3 Engine
3.7 Air cleaner
DANGER The air cleaner may only be serviced while the engine is not running. Switch battery
main switch off.
Attention Do not start the engine while the cleaner element is not installed.
NOTE In addition to the normal replacement intervals, the air cleaner cartridge needs only
cleaning if the pilot lamp "air cleaner" goes on while the engine is running (refer to
part "B1", item 4.6.2.10). However, the air cleaner housing may have to be cleaned at
shorter intervals as an intermediate measure, depending on the operating conditions
and on the dust collected.
Attention The air cleaner housing must be checked for damage and cracks whenever the air
cleaner is serviced.
3.7.1 Removal / installation of the filter cartridge
- Release retaining clips (1).

- Remove the cover (3) from the filter housing.
- Remove the air cleaner (2) out of the filter housing.
- Clean the filter housing and the sealing surfaces of the
filter housing and the cover carefully, using a lint-free
piece of cloth.
ATTENTION Do not use compressed air to clean out !

Make sure that no dust enters into the engine's air intake system while the air cleaner
housing is being cleaned!
- Carefully insert the new or cleaned filter cartridge (2) in the housing.
- Check the filter cartridge for correct fit.
- Place the cover (3) onto the housing and fasten it by means of the retaining clips. Correct installation must
be ensured („⇑ TOP“).
! Air cleaner cartridges must be disposed of in an environmentally responsible fashion !
0245_EN_FA043_C1_03_00_00
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Engine C1-3
3.7.2 Cleaning the filter cartridge
Attention If no new cleaner element is available, the cartridge can be cleaned in cases of
emergency.
The cleaner cartridge must NEVER cleaned by washing, brushing or knocking it
against a hard surface to remove the dirt. Blowing-out is only admissible in cases of
emergency, making sure that no dust gets to the inside of the filter cartridge.
Attention Cleaning an element in case of an emergency does not affect the usual replacement
intervals.
- To this effect, a tube with a 90° bent end section should be placed on the
compressed-air gun. It must be long enough to reach down to the bottom of the
cartridge. Clean cleaner cartridge carefully by blowing from the inside to the
outside using dry compressed air (max. 5 bar), by moving the tube in the
cleaner cartridge up and down repeatedly, until no more dust is raised.
Attention The tip of the tube must not get too close to the filter paper.
Attention Before reinstalling the cleaned cleaner element, check it carefully for damage to the
paper bellows and to the seals.
- After every cleaning operation, check every pleat of the paper bellows for
damage (cracks and holes), using an inspection lamp (flashlight). To ensure
that minor defects are also detected, this check should not be performed in
direct sunlight, but e.g. in a dark room.
- Any damage is shown by a bright flare.
- Check rubber filter seal for crushing and damage.
Attention Any damaged filter cartridges must be replaced.
3.7.3 Check air intake pipes and hoses
- Check all hose connections between the filter and the engine and the charge air hoses for tight fit. Use
screw-type hose clamps only.
- Check hoses and pipes for porosity and cracks.
0245_EN_FA043_C1_03_00_00
2003-01 7/8
C1-3 Engine
3.7.4 Air cleaner monitoring - check for proper working order
- Engine running, reduce air cleaner intake opening gradually by covering it (e.g. using cardboard or sheet
metal), until the air cleaner indicator lamp goes on.
ATTENTION After the air cleaner indicator lamp has gone on, the intake opening must not be
reduced further.
Risk of damage!
NOTE The air intake duct, the air cleaner housing

and the filter cartridge are located on the
radiator housing on the right side of the
vehicle.
ATTENTION The protective grill of the air intake duct

must not be covered. It must be kept free
from dirt.
3.7.5 Cleaning the rain cap of the air cleaner
- Whenever the air cleaner housing is cleaned, unscrew the rain cap (item 1) of
the air intake socket and clean it with compressed air or wash it out.
3.8 Exhaust system
The exhaust system, which simultaneously functions as spark arrester, consists of special steel. It does not
require any particular service or maintenance.
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Gearbox C1-4
4 Gearbox
DANGER Lack of oil in the gearbox will result in damage to the gearbox.
DANGER OF ACCIDENTS!
- Check gearbox for leakage at regular intervals.
Prerequisite:
● The oil level inspection must be performed while the transmission oil has cooled down (<40°C).
● The vehicle is parked on a plane surface (horizontally).
● The handbrake (parking brake) is engaged.
● The gearbox is set to neutral „N“.
● The engine has been stopped.
● The vehicle has been protected against rolling away by means of wheel chocks.
NOTE Whenever checking the oil level, check the gearbox simultaneously for seeping fluid.
Any leakage must be located and eliminated. In case of oil loss, add a corresponding
quantity of oil.
In case of leakage at the gearbox, the breather on top of the gearbox must also be
checked for proper functioning.
For information on the oil level inspection, refer to the enclosed documents of the gearbox manufacturer
(Part G1, chassis).
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2003-01 1/4
C1-4 Gearbox
Attention The oil may only be stored in and transferred from clean containers. If this rule is not
observed, the gearbox might be contaminated and even damaged.
Make sure that containers or filling devices which have been used for anti-freeze or
engine coolant fluids are not used for transmission oil.
DANGER Danger of scalding when oil is hot.
Touching hot gearbox components may cause burns.
NOTE To facilitate collection of the used oil dur-

ing transmission oil changes, the oil drain
plug installed as standard equipment can
be removed during the first oil change, and
replaced by a drain valve provided with the
tool kit.
drain valve specified above including the packing ring
instead of the oil drain plug.
During subsequent oil changes, only the cap (1) of the
drain valve (2) need to be removed and replaced by the oil
drain hose (3) which is also supplied with the tool kit.
As the hose is fastened, the drain valve opens and the oil can be drained through the hose into the
collecting vessel provided to this effect.
After these operations have been finished, remove the drain hose, clean the thread using a clean
piece of cloth and retighten the cap screw.
For information regarding oil types, oil changes, replacement of oil filters, pouring in oil and oil level inspec-
tion, please refer to the enclosed operating instructions and the gearbox manufacturer’s list of approved lu-
bricants (Part G1, chassis).
NOTE Dirt particles:
During each oil change, check the drained oil for traces of dirt. Make sure to eliminate
any deposited mud or soft dirt in the oil sump completely.
Metal particles:
Metal particles in the oil indicate a damage which has occurred in the gearbox. If such
particles are detected in the oil sump, the gearbox must first be disassembled and in-
vestigated thoroughly, to determine the cause. Metallic impurities require complete
disassembly and cleaning of the gearbox.
! Used oil must be disposed of in an environmentally responsible fashion !
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Gearbox C1-4
4.4 Clutch, and clutch control mechanism
The gearbox is adapted to the engine via a standard dry clutch.

The clutch and the clutch actuating assembly do not require any maintenance.
In case of wear of the clutch and if replacement of the clutch linings is imminent, a corresponding message
appears in the display of the instrument panel.
>> CW << = Clutch wear indication.

The vehicle must be taken to a specialist workshop before long to have the clutch
replaced.
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2003-01 3/4
C1-4 Gearbox
Memo:
0250_EN_FA043_C1_04_00_00
4/4 2003-01
Transfer box C1-5
5 Transfer box
Attention An insufficient oil level results in insufficient lubrication and reduces the service life; an
excessive oil level results in overheating of the transfer box.
Prerequisites for oil level inspection:
The oil level should be checked after a driving operation, after the oil has settled.
z The vehicle is parked on a horizontal surface.
z The handbrake (parking brake) is engaged.
z The gearbox is set to neutral „N“.
z The transfer box is set to on-road travel.
z The vehicle is supported by outriggers.
z The engine has been stopped.
- Unscrew oil level inspection plug (1).

The oil level must reach the lower edge of the bore-hole.
If necessary, add oil via the oil filler plug (2).
To this effect, proceed as described under item 5.2 "Oil
change".
- Fasten oil level inspection plug (1) safely after having fitted a
new seal.
5.1.1 Visual check during each oil level

inspection
- Check housings and shafts for leakage

- Check gearbox suspension for stability
- Check breather for contamination, if necessary, clean it (refer
to item C1-9).
- Check condition of compressed air lines and function of
gearshift system.
- Check electrical cables and cable connections.
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2003-01 1/4
C1-5 Transfer box
5.2 Oil change
NOTE Perform oil change when the transfer box has reached its service temperature. The
vehicle must be supported by outriggers, until the wheels are clear of the ground.
Attention During an oil change, the oil in the transfer box, the oil cooler and the hydraulic lines
must be drained on principle.
Prerequisites for oil change:

z The transfer box is set to on-road travel.
- Unscrew breather (item 5.1.1).

- Remove the oil filler plug (2).
- Unscrew both drain plugs (3 and 4) and drain the used oil into
an appropriate tank.
- If there is no oil leaving through the drain plugs (3 and 4),
release the hydraulic lines leading to and coming from the
transfer box downstream of the check valves (5 and 6);
bleeding makes the residual oil leave the hydraulic lines and
the oil cooler. Drain the used oil in an appropriate vessel.
! Used oil must be disposed of in an

environmentally responsible fashion !
- After the used oil has been drained completely, retighten drain
plugs (3 and 4) safely with new packing rings and reconnect
hydraulic line to the check valves (5 and 6).
- Pour in new oil via the oil filler plug (2). For the correct oil
quantity, refer to item C1-24.
- After pouring in the required quantity of oil, install the oil filler
plug (2) using a new seal.
- Clean breather (item 5.1.1) and re-tighten it (refer to item C1-
9).
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Transfer box C1-5
cont'd.: 5.2 Oil change
- Set transfer box to “neutral position” (2):
The change-over cock is installed on the left side of the vehicle,

between axles 2 and 3.
Lever positions:
Move lever forward in driving direction (2) = neutral position.

Move lever backwards, contrary to the driving direction (1) = driving
position.
Before the lever can be actuated, the securing yoke (3) must be
bent upwards.
- Start the engine and set gearbox to "D". (Select high gear in manual mode.)
DANGER Caution – wheels are turning.
- Increase the engine speed to approx. 1,200 r.p.m. and make the engine run for one minute; thus, the hose
lines are filled with oil.
- Set the engine to idle and change the gearbox to “N”.
- Shut off the engine.
- Shift transfer box to on-road gear (driving position) and bend securing yoke (3) back.
- Check oil level on level inspection plug (1); if necessary, correct it.
zThe transfer box is filled correctly if the oil level reaches the oil level inspection plug (1) after overflowing.
zIf necessary, check the oil level and repeat the steps described above.
Clean the cooler fins of the oil cooler (2) at regular

intervals, according to the maintenance schedule, by
blowing-out with compressed air or using a painter's
brush.
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2003-01 3/4
C1-5 Transfer box
Memo:
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4/4 2003-01
Axles C1-6
6 Axles
DANGER For all maintenance operations on the axles, the vehicle must be aligned in horizontal
position. If the vehicle is standing on wheels (without outriggers), e.g. during oil level
inspections or oil changes to the axle drive assemblies, it must be protected against
rolling away by means of wheel chocks; the parking brake must be engaged and the
engine must be shut off.
DANGER Drain the oil only in warm condition.
6.1 Oil level inspection in the axle drive assemblies of the driven steering
axles, and in the planetary gears
NOTE For oil level inspection and filling of the planetary gears, the oil drain port (2) (item C1-
6.2.1 and C1-6.2.2) must be in its lowest position. To this effect, lock the axle
suspension; support the vehicle by outriggers and place it in horizontal position. Turn
the wheels so that the oil drain port is placed in its lowest position.

- Remove the plugscrews (item C1-6.2.1 and C1-6.2.2) of the oil level inspection and filler ports (1).
The oil level must reach the rim (bottom edge) of the inspection and filler ports (1).
- If necessary, add oil via the inspection and filler ports port until overflow occurs.
- Check the sealing elements for damage, clean and, if necessary, replace them.
- Insert the plugscrews with the sealing elements, and tighten them.
- Check the breather (4) (item C1-6.2.1 and C1-6.2.2), clean and - if necessary - replace it (refer to item C1-
9). Check the sealing elements for damage, clean and, if necessary, replace them
0260_EN_FA043_C1_06_00_00
2003-01 1/8
C1-6 Axles
6.2 Oil change in the axle drive assemblies and planetary gears

6.2.1 Drive 8 x 6
Drain the oil:
- Remove the plugscrews from the inspection and filler ports (1).
- Remove the plugscrews from the drain ports (2).
- Drain the oil completely in a suitable vessel.
- Check the packing rings for damage and, if necessary, replace them. Clean the plugscrews.
- Position plugscrews on drain ports (2) incl. sealing element, and tighten them.
Pour in oil:
- Add oil via the oil level inspection and filler ports (1) until overflow occurs.
- Wait a few minutes; then add oil, if necessary, until the oil level remains constant.
The oil level must reach the rim (bottom edge) of the inspection and filler port (1).
- Check the sealing elements for damage, clean and, if necessary, replace them. Clean plugscrews.
- Position plugscrews of oil level inspection and filler ports (1) incl. the sealing elements, and tighten them.
- Check and clean the breather (4), if necessary, replace it (refer also to item C1-9). Clean, check and, if
necessary, replace the sealing element.
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Axles C1-6
(cont'd.) 6.2.1 Drive 8x6
1st driven axle 2nd non-driven axle
3rd driven axle with countershaft assembly 4th driven axle
Planetary gears in wheel hubs
Item 1 Oil level inspection and filler port - Item 2 Oil drain port - Item 3 Lubricator - Item 4 Breather
= Driving direction.
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2003-01 3/8
C1-6 Axles
6.2.2 Drive 8 x 8**)
Drain the oil:
- Remove the plugscrews from the inspection and filler ports (1).
- Remove the plugscrews from the drain ports (2).
- Drain the oil completely in a suitable vessel.
- Check the packing rings for damage and, if necessary, replace them. Clean the plugscrews.
- Position plugscrews on drain ports (2) incl. sealing element, and tighten them.
Pour in oil:
- Add oil via the oil level inspection and filler ports (1) until overflow occurs.
- Wait a few minutes; then add oil, if necessary, until the oil level remains constant.
The oil level must reach the rim (bottom edge) of the inspection and filler port (1).
- Check the sealing elements for damage, clean and, if necessary, replace them. Clean plugscrews.
- Position plugscrews of oil level inspection and filler ports (1) incl. the sealing elements, and tighten them.

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4/8 2003-01
Axles C1-6
(cont'd.) 6.2.2 Drive 8x8**)
1st driven axle

2nd driven axle - 8x8 drive **)*)
3rd driven axle with countershaft assembly 4th driven axle
Planetary gears in wheel hubs

Item 1 Oil level inspection and filler port - Item 2 Oil drain port - Item 4 Breather
= Driving direction.

0260_EN_FA043_C1_06_00_00
2003-01 5/8
C1-6 Axles
6.3 Greasing the intermediate bearings of the propeller shafts of the non-
driven 2nd axle (8x6 standard version)
NOTE When greasing the intermediate bearings of the propeller shafts, make sure not to apply
high pressure or hard lubricating strokes to force in the lubricant. The maximum
admissible lubricating pressure must not exceed 30 bar.
- The intermediate bearings must be greased at regular intervals, according to the maintenance schedule, via
the lubricator (3).
6.4 Greasing the axles
Attention Greasing by means of high-pressure grease guns must be effected carefully and slowly.
Otherwise the grease - in particular at relatively low temperatures - cannot flow fast
enough through the grease grooves of the bushings and through the bearings. This
might result in such a high back-pressure that the dust caps at the axle kingpins are
pressed through.
- The stub axle bearings must be greased at regular intervals,

according to the maintenance schedule.
- Check bearings of the joints, etc. for wear and good condition.
- Grease the articulated heads of the drop arms and guide levers
(steering linkage), (provided that they are equipped with
lubricators).
Lubricator
Grease filling in the wheel hubs
NOTE The double propeller shafts in the driven axles Driven planetary axles
are maintenance-free.
6.4.1 Replacement of grease filling in the wheel

hubs of the non-driven 2nd axle
The wheel hubs of the 2nd axle (in case of 8x6 standard version) are
provided with a grease filling.
These grease fillings must be replaced at regular intervals according

to the maintenance schedule.
Non-driven 2nd axle
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6/8 2003-01
Axles C1-6
6.5 Check for leakage / visual inspection / inspection of the control function
- Check the axle drive assemblies and the planetary gears in the wheel hubs at regular intervals according to
the maintenance schedule.
- Check the control functions of the differential locks and the connection of the 3rd axle (in case of 8x8
drive**)*) by actuating the switches or tip switches in the instrument panel while the ignition is switched on,
at regular intervals, according to the maintenance schedule.
6.6 Checking the axial play of the steering axle bearings and the planetary
bearings; check the wheel bearing backlash.
NOTE THESE OPERATIONS REQUIRE SPECIAL KNOWLEDGE AND SHOULD ONLY BE

PERFORMED IN A SPECIALIZED SERVICE STATION.
- Check the axial play and the bearings of the planetary gears at regular intervals according to the
maintenance schedule.
- Check the wheel bearing backlash at regular intervals, according to the maintenance schedule; if
necessary, re-adjust.
- Check the locking condition of the wheel bearing adjusting nuts.
6.7 Checking screws and bolts on axles for tight fit; check axle fastening,
drop arms, thrust rod fastening, etc.
- Check nuts on track rods and steering rods for tight fit.
- Check securing bolts of steering and track rods and, if necessary, re-tighten (observe specified tightening
torques).
- Re-tighten thrust rod fastenings of axle suspension systems (observe specified tightening torque).
• Screws secured by means of Loctite must not be re-tightened.
6.8 Preservation of axle and planetary gearings.
• In order to maintain the operating safety of the vehicle, corrosion must not be allowed to develop on
supporting components.
• In order to avoid damage due to corrosion when the vehicle is not operated for an extended period of time,
move the vehicle over a distance of approx. 100 m while the axles are cold, to supply cold oil on all parts of
the axle drive assemblies. The axles must be protected against penetration of water.
6.9 Checking the propeller shaft flange screws for tight fit
- Check screws and nuts of the propeller shaft drive flanges for tight fit and, if necessary, re-tighten at regular
intervals, according to the maintenance schedule.

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2003-01 7/8
C1-6 Axles
Memo:
0260_EN_FA043_C1_06_00_00
8/8 2003-01
Propeller shafts C1-7
7 Propeller shafts
DANGER Wherever there is a potential danger to persons and material, the crane operating
company has to provide for appropriate safety precautions. Only specialized staff are
allowed to install or replace propeller shafts at the vehicle.
7.1 Inspection of backlash
- Check backlash of the gudgeon assemblies and the splined shaft connections at regular intervals.
Attention If a noticeable backlash is detected, replace the propeller shaft (repair).
7.2 Noise test
- Perform a noise test at regular intervals. If the noise is different from that noise known from normal opera-
tion, look for the reason and repair any possible deficiency.
- Check the balancing plates or the counter-balancing pieces.
7.3 Checking the flange couplings
- Check the flange couplings for tight fit.
Max. tightening torque of screws and bolts for a thread size of M14 = 180 ±10 Nm.
0265_EN_FA043_C1_07_00_00
2003-01 1/2
C1-7 Propeller shafts
Memo:
0265_EN_FA043_C1_07_00_00
2/2 2003-01
Eddy-current brake **) C1-8
8 Eddy-current brake **)
NOTE The eddy-current brake must be checked completely by an authorized specialist

workshop at least once per year. The regular maintenance operations and tests de-
scribed in the maintenance schedule should also be performed in a specialist work-
shop.
DANGER These checks must be performed by a specialist workshop.
8.1 Servicing
Regular servicing of the eddy-current brake is indispen- Rotors

sable to ensure its reliable operation.
Washing
• The eddy-current brake must be washed at least twice

per year to eliminate grease and dirt.
• The cleaning may only be effected when the machine
has cooled down and when the electrical equipment is
switched off.
• Clean rotors of the eddy-current brake at regular in-
tervals on the outside using a steam jet unit, to re-
move grease and dirt and to ensure heat dissipation.
Attention Do not use detergents or solvents.
Coils Stator
• To avoid damaging the insulation of the electrical cables, do not direct the steam jet immediately onto the
electrical cables and connections.
• The stator and the electrical connections may only be washed with very low pressure.
• For drying, compressed air should be preferably used.
• Inspection of the mechanical and electrical components at regular intervals in a specialist workshop.
Attention Under aggravated operating conditions, (e.g. during operation on construction sites),
the cleaning intervals can be reduced to once per week in case of severe dust accu-
mulation.
Check the mechanical and electrical components according to the maintenance schedule.

0270_EN_FA043_C1_08_00_00
2003-02 1/2
C1-8 Eddy-current brake **)
8.1.1 Test and setting values
Luftspalt über den gesamten Umfang = Air gap over entire circumference
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2/2 2003-02
Breather C1-9
9 Breather
A defective breather may result in leakage at the gearbox, transfer box or a drive axle.
Engine malfunctions may also be due to a faulty ventilation filter of the fuel tank (superstructure).
Malfunctions of the hydraulic system can be due to a faulty ventilation filter of the hydraulic oil tank (chassis
and superstructure).
Malfunctions in the eddy-current brake**) can be due to a faulty breather.
Malfunctions of the superstructure swing mechanism may be due to a faulty breather.
However, other malfunctions in the brake and compressed air systems - valves which deaerate insufficiently,
wheel brakes which are sliding or releasing slowly - may be due to a contaminated breather or a clogged
breather hole.
The brake valves have been provided with a combined silencer / venting device. The wheel brake cylinders
are equipped with vent/breather holes.
• Check breathers for proper condition.
• Clean contaminated breathers on the outside.
• Vent/breather holes on the wheel brake cylinders must be free from contamination.
• The breather cap must be easy to turn (not in the case of venting devices on the brake valves).
• Check breathers for tight fit.
• Replace breathers if they have been loosened or lost, or if they are faulty.
• If it is suspected that the oil - especially the oil of the axles, of gearbox and transfer box - contains water,
make sure that an oil change is performed.
• During painting work, cover the breathers well. Once painting work is finished, it is essential to remove the
cover.
• When spray-cleaning the assemblies, make sure that the breathers are not directly exposed to the jet of
water. Penetrating water may cause damage.
• If it is suspected that the hydraulic oil (chassis and superstructure) contains water, make sure that the hy-
draulic oil is examined, and - if necessary - clean and change the oil.
• If water is suspected of having entered the fuel tank (chassis and superstructure), drain the water from the
fuel tank, as described. If necessary, drain condensed water from the fuel strainer as described, and if nec-
essary replace the fuel filter as described.

0275_EN_FA043_C1_09_00_00
2003-01 1/2
C1-9 Breather
(cont'd.) 9 Breather
Breather installed on the gearbox Breather, brake cylinder.
Breather, brake valves
Breather at the eddy-current brake **)
For an illustration and the mounting location of the breather to the transfer box, refer to item -C1-5.1.1.
For an illustration and the mounting location of the breathers on the axles, refer to item C1-6.
For an illustration and the mounting location of the breather on the fuel tank, refer to item C2-2.4.2.1 (super-
structure).
For an illustration and the mounting location of the breather on the hydraulic oil tank, refer to item C1-10.2.1
(chassis) and item C2-3.2.1 (superstructure).
For an illustration and the mounting location of the breather on the swing drive, refer to item C2-4.2.2 (super-
structure).
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Hydraulic system C1-10
10 Hydraulic system
DANGER Work on the hydraulic system may only be performed while the engine is at a
standstill.
• Check hydraulic system for leakage at regular intervals.

• Checking and retightening the screw couplings of the hydraulic assemblies and pipes, see item C2-3.6.
10.1 Checking the hydraulic oil level
NOTE The steering, the outriggers and the suspension are supplied from a common oil tank.
NOTE Check oil level when the engine is at a standstill, while the outrigger cylinders are
retracted.
• The oil level depending on the oil temperature is

indicated at the sight glass (2).
• The oil level depends on the oil temperature; refer to
plate (3).
• Oil is poured in via the port of the ventilation filter
(1).
- Unscrew the ventilation filter and pour in oil through

the port.
- Reposition and fasten the ventilation filter.
Attention Make sure that only new oil is

poured in from clean vessels.
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2003-01 1/10
C1-10 Hydraulic system
DANGER Replace the filter cartridges only while the engine is at a standstill.
NOTE The individual components installed in the valves, pumps and hydraulic motors have
deliberately narrow tolerances. Even very small impurities penetrating the hydraulic
system may cause malfunctions.
The two filter cartridges must be replaced during each hydraulic oil change, and when
the red warning lamp 34 "hydraulic filter" goes on, and according to the maintenance
schedule.
Do not clean filter cartridges.
- Unscrew the two filter covers (1).

- Fold the yokes (2) of the filter cartridges (3) up. Turn the
filter cartridge to the left by 90° and unlock it.
- Remove the filter cartridges (3).
- Insert new filter cartridges carefully in the housing. Lock
them by a 90° rotation and fold down the yoke (2).
- Clean, check and, if necessary, replace the seals in the
caps.
- Clean the seals of the filter covers (1) using a non-fibrous
cloth.
- Re-fasten the filter covers (1).
10.2.1 Replacement of the ventilation filter
- If the ventilation filter is contaminated or clogged, unscrew the ventilation filter (refer to Fig. 10.1, item 1)
and replace it by a new one.
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10.3 Oil change to the hydraulic tank
DANGER Perform oil change only while the engine is not running.
• The outrigger cylinders are retracted.

- Remove the caps (3) from the drain plugs.
- Release drain plugs (1 and 2) - do not unscrew them - until
oil is leaving. Drain the oil completely into a suitable
container.
- Close the drain plugs. Reposition the caps.
- Replace the filter cartridges.
- Replace the filter cartridges as described under item C1 -
10.2.
- Pour in new oil as described under item 10.1.
NOTE It is recommended to have the oil analysed by the oil supplier before carrying out a
scheduled oil change, or at regular intervals, to see whether an oil change is necessary. The
purity degree must comply with ISO 4406 grade 18/16/13. Only clean oil must be poured in
during the oil changes. Depending on the degree of contamination and the thermal load the
hydraulic oil is subject to, shorter oil change intervals than those specified in the
maintenance schedule may be required.
!Filters and used oil must be disposed of in an environmentally responsible fashion !

The hydraulic system can be converted to biodegradable oils according to VDMA 24568.
Attention When changing over the hydraulic system from oils based on mineral oil to
biodegradable oils, compliance with the directives of VDMA 24569 must be ensured.
(Use the recommended oil types.)
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2003-01 3/10
10.5 Hydraulic system of steering assembly

10.5.1 Hydraulic oil change in steering system
NOTE After having filled the hydraulic oil tank with new oil, perform maintenance work
individually on each steering cylinder.
- Start the engine, support the machine by outriggers.

- Release the screw couplings (1) of the steering cylinder.
- Turn the steering wheel alternately and slowly against the stops on the
left and right.
- Drain approx. 1 l of used oil per cylinder via the screw coupling, until a
solid stream of oil flows out free of bubbles.
- Close the cylinder screw couplings; check the oil level in the oil tank
and, if necessary, re-adjust.
NOTE When replacing the oil filling in the rear axle steering cylinders, actuate the rocker tip
switch "rear axle steering".
10.5.2 Miter gear of steering system
The miter gear of the steering system has been provided with a life-time
lubrication in the factory (oil filling). Thus, it normally does not require any
service or maintenance. Should nevertheless any leakage be detected,
the vehicle must be taken immediately to a specialized workshop where
the reason for the leakage is eliminated - i.e. if necessary, the miter gear
of the steering system may have to be replaced.
- Check the miter gear for leakage at regular intervals, according to the
10.5.3 Checking the hydraulic system of the steering assembly for correct pressure
NOTE The test points (measuring connectors "M") and the measurement values of the entire
hydraulic system of the chassis are listed up under item 10.9.
In case of an operating malfunction in the steering system, the set-point pressure can be checked by screw-
fastening a hydraulic pressure gauge to the measuring sockets (M1), (M2) and (M5).
To ensure precise measurement results, increase the engine speed to maximum and actuate the steering
from the chassis or the superstructure to its stop at the left or right, and hold it in this position.
NOTE The specified values are only reached when the system is deaerated. The oil
temperature should be in the range from approx. +30°C to + 40°C.
10.5.4 Check steering gear / steering system for leakage
- Check the steering system for leakage at regular intervals, according to the maintenance schedule.
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10.6 Hydraulic system of the suspension

10.6.1 Oil replacement in the hydraulic system of the suspension
By lowering the chassis before each hydraulic oil change, an essential part of the oil flows from the
suspension cylinders and hydraulic accumulators into the oil tank. After a hydraulic oil change, the
suspension system is filled automatically with new oil via the level control system.
DANGER When lowering the vehicle, and when the axle suspension is locked, make sure that
nobody stays under or on the vehicle.
10.6.2 Checking the suspension system for proper working order and leakage
• Check the valves, sleeves and connectors for leakage.

• Check system for proper operation and correct pressure.
• Check hydraulic hoses at regular intervals visually for fissures and damage.
Checking the hydraulic accumulators, refer to item 10.6.3.
10.6.3 Checking the hydraulic accumulators
DANGER Before working on the suspension system, lower the vehicle completely.
The pre-load pressure of the hydraulic accumulators must be set and checked especially during the winter
months and after every installation or repair work.
The inspection intervals specified in the maintenance schedule must absolutely be observed.
) The first inspection must be performed already after 50 service hours. (

Check the pressure of the individual hydraulic accumulators separately while the engine is not running. The
oil-bearing end of the accumulators must have been drained previously via the measuring screw couplings
on the accumulators (refer to part "B1", item 4.7.3.2).
THIS CHECK MUST BE PERFORMED IN A SPECIALIST WORKSHOP.
- Check the pre-load pressure by measurement with a filling and test equipment, and correct it , if necessary.
DANGER Make sure to use only nitrogen for filling or for pressure correction. Never use oxygen
or air.
Explosion hazard !
- After the pressure test has been effected, actuate the push-button switch "level control" to restore the
vehicle's suspension to working order (for further details, refer to part "B1", item 4.7.3.1).
Attention During the levelling process, the rear axle steering must be locked.
The axle suspension must not be locked while the level control is actuated.
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10.7.1 Oil change of the outriggers
After having changed the hydraulic oil in the oil tank (with the outrigger and
extension cylinders retracted), no oil change is required in the outriggers. The
cylinders are automatically supplied with new oil.
- When replacing a cylinder or after a repair work, actuate the appropriate

selector switch while the engine is running at idling speed, so that new oil is
pressed into the cylinders.
- Release the breather (2) on the piston end and the screw coupling (1) on the
ring end and actuate the outrigger selector switch until oil flows out free of
bubbles.
This serves simultaneously to bleed the cylinder.
10.7.2 Maintenance instructions for hydraulic cylinders
• Before commissioning, make sure that the hydraulic cylinders are bled.
• Bleeding may only be finished when no more bubbles appear.
• Bleeding must be repeated whenever hydraulic components or pipelines have been assembled or
disassembled.
• When machines are operating outdoors, bleed the hydraulic cylinders at regular intervals.
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10.7.3 Pressure check
NOTE The test points (measuring connectors "M") and the measurement values of the entire
hydraulic system of the chassis are listed up under item 10.9.
The pressure check of the level control and the inclination adjustment (suspension), the outrigger cylinders,
outrigger beams and the fan drive is effected via the measuring connector M 3.
The measuring connector M 3 is located on the right-hand side of the vehicle, underneath the fan box,
behind the driver's cab.
Pressure check of suspension and outriggers:

- Connect a hydraulic pressure gauge to the measuring connector
M 3.
- actuate the desired hydraulic circuit to its mechanical stop while the
engine is running at idling speed.
Pressure check of the fan drive:

- Connect a hydraulic pressure gauge to the measuring connector
M 3.
- at engine idling speed, fan dragging speed 800 r.p.m.
Change-over cock opened (notch parallel to the piping). Change-over cock
- at maximum engine speed, coolant temperature 92°C; fan speed 2250 r.p.m., change-over cock closed
(notch transverse to the piping).
NOTE The specified values are only reached when the system is deaerated. The oil
temperature should be in the range from approx. +30°C to +40°C.
10.7.4 Checking the hydraulic system of outriggers / cylinders for leakage
- Check the hydraulic system of the outriggers and the cylinders for leakage at regular intervals according to
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10.8 Test connectors and measured values
NOTE The pressure setting is to be effected after deaeration of the system at a hydraulic oil
temperature of +30 to +40°C and at an engine speed which corresponds to the values
specified for the individual working movements.
After the pressure setting, the pressure measurements must be repeated three times.
No measured value must exceed the tolerance range.
The level clearance must be measured 1x.
Level and inclination position Set-point Tolerance Meas. point Engine speed
Level control and inclination adjustment 220 bar + 10 bar M3 at idle
Level clearance
front 270 mm ± 5mm 1200 min-1
Axle center - bottom edge of chassis frame rear 470 mm ± 5mm 1200 min-1
Outriggers Set-point Tolerance Meas. point Engine speed

Extending outrigger beams, rear axle steering 130 bar + 5 bar M3 at idle
Retracting outrigger beams 220 bar + 10 bar M3 at idle
Extending the outrigger cylinders 220 bar + 10 bar M3 at idle
Retracting the outrigger cylinders 220 bar + 10 bar M3 at idle
Steering Set-point Tolerance Meas. point Engine speed

Circuit I 130 bar +8.5 bar M1 Max.
Circuit II 130 bar +8.5 bar M2 Max.
Steering Set-point Tolerance Meas. point Engine speed

Steering, rear axles 150 bar + 5 bar M5 1000 min-1
Steering, front axles from superstructure 140 bar + 5 bar M1 Max.
Fan drive Set-point Tolerance Meas. point Engine speed

Fan speed 800 r.p.m., engine cold 30 bar + 5 bar M3 1000 min-1
Fan speed (cock closed) 2250 r.p.m. 230 bar +10 bar M3 Max.
Hydraulic suspension Set-point Tolerance

Pre-load pressure, nitrogen accumulators 70 bar ± 2 bar
Optional - operation with dolly: Pre-load pressure 50 bar ± 2 bar
nitrogen accumulators
99707017032_B/1005
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10.9 Location of the hydraulic measuring points on the vehicle
Measuring connectors have been provided in easily accessible locations on the vehicle to enable functional
inspections of the vehicle's hydraulic system.
The locations of the measuring connectors on the vehicle are shown in the diagram to the right.
Names and functions of the measuring connectors:
M1= Measuring connector "steering circuit I".

M2= Measuring connector "steering circuit II".
M3= Measuring connector "hydraulic pressure, fan drive and outriggers".
M5= Measuring connector "rear axle steering".
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Memo:
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Brake system C1-11
11 Brake system
DANGER Prior to all types of work on the brake system, protect the vehicle against rolling by
means of wheel chocks.
11.1 Drainage valves in the compressed air tanks
- Pull or push the actuator bolt (toggle valve 1) to check

carefully whether condensed water is blown off.
Make sure that no condensed water is blown off.
• If condensed water is found to be blown off, check the air

drier (filter element) for proper working order, and the
compressed air system for leakage.
NOTE A leaky compressed air system affects the operating time of the air compressor and
the efficiency of the air drier. Check compressed air system for leakage at regular
intervals. Locate and eliminate any leakage immediately.
11.2 Air drier

11.2.1 Functional check of the air drier
- Actuate the drainage valves as described under item C1-

11.1.
• If no condensed water is blown off, the desiccant cartridge of

the air drier may only be replaced when condensed water
escapes several times successively during the regular
inspections of the air tank valves as specified in the
11.2.2 Replacement of the desiccant cartridge

of the air drier
• The desiccant cartridge may only be replaced during the

pressure governor's shut-off phase.
- Unscrew the desiccant cartridge (1).

- Fasten the new cartridge.
- Check the packing ring and tighten the cartridge with approx. 15 Nm.
NOTE Replace dessicant cartridge at intervals of 2 years.

Besides, the system must be monitored as described under items C1-11.1 and C1-
11.2.2.
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C1-11 Brake system
11.3 Pressure governor with tire inflator socket (integrated in the air drier)
11.3.1 Inflating tires via the tire inflator socket at the pressure governor
NOTE In order to avoid damage to the air compressor, it may be used to fill only the tires
mounted to the vehicle with compressed air. Other work, such as painting by means
of a spray gun, is prohibited.
• Before inflating the tires, the pressure of the compressed air

system must be reduced below the switch-on point of the
pressure governor.
- Start the engine.

- Remove the valve cap (2).
- Fasten the tire inflator socket onto the valve.
- Fill tires to the specified pressure (for tire pressure, refer to
part A2, item 2.6.4).
DANGER Check tire pressure at regular intervals.
11.3.2 Setting the pressure governor's switch-off pressure
DANGER In order not to prejudice the traffic and operating safety of the vehicle, make sure that
adjustment and maintenance work at the entire brake system as described below
(also in the wheel brake system) is only performed by well-trained specialized staff in
an authorized specialist workshop (brake repair service).
DANGER AN Y TIME B EFOR E PER FORMIN G WORK AT TH E BRAKE SYSTEM ,

PLAC E WH EEL CHOCK S UNDER TH E VEHICLE'S WH EELS TO PREVEN T
IT FRO M RO LL IN G AWA Y.
The pressure governor must be checked visually and for

proper working order in the scope of the legal regulations of
the country in question (in FRG, according to § 29 StVZO). If
deficiencies are detected, the unit must be removed and
checked for proper function of its internal components, or be
replaced.
After an extended period of operation, a deviation from the
specified switch-off pressure may occur.
- When the engine is running, turn the setscrew (1) until the
specified switch-off pressure is reached.
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Brake system C1-11
11.4 Brake cylinders
Attention In order not to prejudice the traffic and operating safety of the vehicle, make sure that
adjustment and maintenance work at the entire brake system (also in the wheel brake
system) is only performed by well-trained specialized staff in an authorized specialist
workshop (brake repair service).
DANGER ANY TIME BEFORE WORK IS PERFORMED AT THE BRAKE SYSTEM, WHEEL
CHOCKS MUST BE PLACED UNDER THE VEHICLE'S WHEELS TO PREVENT THE
VEHICLE FROM ROLLING AWAY.
11.4.1 Releasing the air accumulator section of the air accumulator diaphragm
cylinders
The combined air accumulator diaphragm cylinder is equipped with a mechanical releasing device for the air
accumulator section. In case of a complete pressure drop (e.g. major leakage in the air accumulator section),
the piston, due to the spring load, is in braking position.
- Turn the releasing bolts (1) out of the threaded sleeves of the air accumulator brake cylinders, until the
brakes are released.
11.4.2 Establishing the braking function of the air

accumulator section
- Ventilate the air accumulator section (min. 7 bar).

- Screw-in the releasing bolts and tighten them safely (tightening
torque approx. 45 Nm).
- Check braking function; if necessary, re-adjust.
11.4.3 Cleaning the diaphragm brake cylinders
Even if the diaphragm cylinders operate perfectly (response

pressure does not exceed 0.5 bar, no leakage etc.), they must be
cleaned at regular intervals.
- Remove, disassemble and clean the cylinders.

- Replace the wear parts.
In the scope of the inspection of the internal parts of the spreading wedge brake actuation mechanism, which
must be effected at intervals of two years, the brake cylinders (diaphragm and Tristop cylinders) must also
be checked for leakages and proper working order.
Attention After mounting the brake cylinders, check that the breather hole is directed
downwards and that the other bore-holes are closed with rubber plugs.
After mounting, the brake cylinders must not touch any vehicle components. For
inspection, it may be necessary to move the suspension in and out, and to actuate the
steering to its stops on the left and right.
Brake hoses must not chafe or be kinked.
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C1-11 Brake system
11.5 Inspection of the wheel brakes
NOTE The wheel brakes are adjusted automatically, depending on the wear of the brake
linings. Manual readjustment is not required.
However, it is necessary to check them at regular intervals.
11.5.1 Inspection of brake lining thickness
- To check the brake lining thickness visually, remove the rubber plugscrew from the inspection holes of the
cover plates.
• The brake linings have to be replaced if the wear marking provided has been reached, or if their thickness
has decreased to the minimum value of 4 mm.
Attention When brake linings are to be replaced, make sure to renew all linings of one axle.
Use only original TADANO-FAUN spare parts.
11.5.2 Inspection of the air gap
- Check the air gap between the brake drum and the brake
lining using a feeler gauge.
• During the inspection, make sure that both brake shoes are
applied evenly to the brake drum. For that purpose, actuate
the service brake.
The air gap for each brake shoe must be 0.4 to 1.2 mm.
The max. air gap must not exceed 1.2 mm.
• If the air gap needs to be readjusted, actuate the brake several times in quick succession while travelling at
low speed.
After approx. 30 braking operations, the air gap must have been reduced. If the air gap is not reduced, check
the spreading mechanism for proper operation.
NOTE The air gap of the brake can only be readjusted while the wheels are turning.
Attention If only one brake shoe touches the brake drum, the vehicle must be taken to a repair
workshop without delay.
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Brake system C1-11
11.6 Wheel brakes - Maintenance
Perform the regular maintenance work according to the maintenance schedule.
• Check all components for damage or wear.

• Replace defective components; renew contaminated or hardened grease.
• After assembly, make sure that the brake is re-adjusted.
11.6.1 Spreading device - Maintenance
• Disassemble spreading device at regular intervals, according to

the maintenance schedule, and check it for wear; if necessary,
repair it using the repair kits specified in the spare parts list.
• Visual inspection of internal components: specified at intervals

of two years.
• All movable parts must be greased previously.
11.7 Check pressure limiting valve
A pressure limiting valve is installed in brake circuit I (BBA I) of the brake system to limit the rear axle
pressure (item 15 in the brake system).
• Whenever the brake and compressed air system is examined, or on

replacing valves, the setting value of the pressure limiting valve must be
checked.
• When the valve is replaced, the pressure must be set to the specified
value.
For setting and measured values, refer to item 11.11.
• The correct setting value can be obtained on valve (1) by turning the
setscrew (2).
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C1-11 Brake system
11.8 Automatic anti-block system (ABV) - Maintenance
The pilot lamps in the instrument panel enable checking of the function during driving operation.
- Check sensors for correct fit, electrical cables for correct installation, damage, kinks and chafing.
- Check electrical plug-and-socket connectors.
- Have the ABV system (electronic system) checked by a specialist workshop.
NOTE Various components of the ABV system are used for ABV control as well as for
gearbox control. The components are also installed if the vehicle is not equipped with
an ABV system.
DANGER Faulty components may lead to gearbox malfunctions.
11.9 Engine brake
For a functional check of the engine brake, the reserve pressure in the brake system must be at least 7 bar.
11.9.1 Functional test of the engine brake
For precise instructions regarding the checks for proper function, good condition and adjustment of the engine
brake, please refer to the brochure of the engine manufacturer.
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Brake system C1-11
11.10 Test connectors
The brake system must be checked according to the testing

instructions by a brake repair service workshop as required by
the legal provisions of the country in question (in FRG:
"special brake inspection service" pursuant to § 29 StVZO).
To this effect, a portable tester is required.
The test connectors are provided on a test panel, on the left

side of the vehicle, between the 2nd and 3rd axles.
NOTE After the testing operations have been completed, make sure to close the test
connectors with the protective caps pertaining to them.
Item Scope of test and inspection work

A Supply line connecting the air compressor to the four-circuit protection valve (supply line).
B Supply pressure, service brake circuit I (BBA I).
C Supply pressure, service brake circuit II (BBA II).
D Supply pressure, secondary and parking brake (HBA/FBA).
E Supply pressure, auxiliary equipment (NVA).
F Line pressure, service brake circuit I (BBA I) (3rd and 4th axles) upstream of pressure limiting
valve (pressure not reduced).
G Cylinder pressure, air accumulator cylinder, 2nd axle (pressure limited).
H Cylinder pressure, air accumulator cylinder, 3rd and 4th axles (pressure limited).
NOTE The air accumulator cylinders can be filled - as described under item B1-5.10.4 - via
the filler socket installed under item K in the test panel.
Test connectors on 2nd axle on the left and right (diaphragm cylinders), brake pressure, circuit II.
Test connectors on the 4th axle on the left and right (air accumulator cylinder), brake pressure, circuit I.
Test and setting values of the brake and compressed air system, refer to item 11.11.
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C1-11 Brake system
11.11 Test and setting values
When replacing valves and pressure switches and in the scope of the regular inspection operations -
pursuant to the specific regulations of the country where the machine is to be registered - the following
pressure settings must be checked or re-set.
11.11.1 Brake system
Valve / pressure switch Test Measuring connector Measured value

Pressure governor
(Brake system diagram,
item 2) Fill empty brake system Test panel, connectors 10.0 ± 0.2 bar
Switch-off pressure: until switch-off pressure is B and C.
reached.
Switch-on pressure: Reduce pressure in brake Test panel, connectors 8.5 – 9.5 bar
system until it is B and C.
replenished.
Pressure switch
(Brake system diagram, Fill empty brake system.
item 20) The warning lamp "service
(4 each). and parking brake" and the
warning lamp "parking
Control pressure: brake" in the instrument Test panel, connectors 5.5 ± 0.5 bar
panel must go out. B, C, D and K.
Pressure limiting valve

(Brake system diagram,
item 15) Actuate service brake
(depress brake pedal Test panel:
Setting value: completely). Connector F. ≥ 6.5 bar
Test sockets on the 5.5 to 5.7 bar

brake cylinders of axle
4.
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11.12 Locations of the measuring and test connectors
Measuring connectors are provided in easily accessible locations of the vehicle to enable the functional
inspection of the brake and compressed air system.
The locations of the measuring connectors on the vehicle are shown in the following illustration.
Designations and functions of the measuring and test connectors:
1 = Test connector, auxiliary equipment 20l compressed air tank between 2nd and 3rd axles on the left.
2 = Test connector, auxiliary equipment 10l compressed air tank between 2nd and 3rd axles on the left.
3 = Test connector, brake cylinders of 2nd axle, right-hand and left-hand.
4 = Test connector, brake cylinders of 4th axle, right-hand and left-hand.
5 = Test panel, connectors A - K between the 2nd and the 3rd axles on the left (assignment, see item C1-
11.10).
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C1-11 Brake system
Memo:
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Electrical equipment C1-12
Attention When work is effected at the electrical equipment, or during welding work on the
chassis, the current circuit must be interrupted by disconnecting the negative
terminal "-" cable from the batteries (marked with a minus sign [-] on the battery).
Never disconnect the batteries while the engine is running. This might destroy
electronic components.
12.1 Batteries
DANGER When checking the acid level, do not smoke; do not use open flames!
Due to chemical reactions, batteries emit highly explosive hydrogen gas!
Spilled battery acid must not touch the skin, the clothes or the vehicle's paint. Battery
acid may cause injuries. Wear protective glasses!
If acid has got on your skin or in your eyes, wash these areas immediately with ample
quantities of tap water and, if necessary, consult a doctor!
Attention Used batteries must be disposed of according to the regulations.
The batteries are located behind the lateral cover in the battery box on the vehicle's platform, on the left,
behind the driver's cab. If the vehicle operates under normal conditions, the batteries require only little
maintenance.
A well-charged battery helps improve the starting process and has a longer service life.
• The acid level must be checked at regular intervals (visual inspection). The acid level must be approx. 10 to
15 mm above the top edge of the cells.
• Only top up distilled or demineralized water. After replenishing, wait approx. 30 minutes, then check the
acid.
• The acid density in the individual cells must be measured using an acidimeter.
Discharge batteries freeze at -10°C.
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C1-12 Electrical equipment
12.1.1 Specific gravity and charge condition of the battery at an acid temperature of
+20°C
Specific gravity Volts per cell Charge condition of battery

Normal Tropics at test instrument
1.28 1.23 2.4 charged
1.20 1.12 2.0 semi-discharged; re-charge
1.12 1.08 1.75 discharged - recharge immediately
NOTE When the vehicle is to be used under tropical climate conditions, it is essential to take
the fluctuations of the acid density into consideration. During the charging process,
the acid temperature must be monitored continuously.
• During the cold season, a good charging condition must be permanently ensured. If the vehicle is standing
for an extended period of time, the batteries must be re-charged.
• The charging current must not exceed 1/10 of the battery capacity.
- The connecting terminals must be greased with acid-free and acid-resistant grease (e.g. Vaseline).
• Due to the danger of short circuits, parts conducting current, such as tools, etc., must not be placed on the
batteries.
• If the battery charging pilot lamp does not go out at increased engine speed, this indicates that the batteries
are not charged. Find out the reason immediately (governor or alternator).
12.1.2 Installation of new batteries
• When installing new batteries, first connect the positive cable (+), and then the negative cable (-).
• For removal, reverse sequence of installation operations.
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12.1.3 Starting the engine by means of jumper cables
Should the engine fail to start due to an uncharged battery, the engine can be started with energy supplied
by the batteries of another vehicle, by means of a jumper cable. However, only jumper cables provided
specifically to this effect with a sufficient cable cross section may be used for this starting process.
The two vehicles must be equipped with 24V systems. The total capacity (Ah) of the starter batteries must
not be essentially lower.
To avoid any current conduction between the vehicles, these must not be in connection in any way.
The batteries must be connected to the vehicle's electrical systems as specified.
The jumper cables must be connected by the following sequence of operations:
• Start the engine of the vehicle supplying power and make it run at medium speed level.
• Connect one end of the positive cable (+) to the positive terminal (+) of the discharged battery. Connect the
other end of the cable to the positive terminal (+) of the battery of the vehicle supplying power. The plus (+)
and minus (-) signs are marked on the battery.
• Connect one end of the negative cable (-) to the negative terminal (-) of the discharged battery. The other
end of the cable must be connected to the negative terminal (-) of the battery of the vehicle supplying
power. The plus (+) and minus (-) signs are marked on the battery.
• Now start the engine of the vehicle to be started by an external power source, as described under item 3.3.
• After starting the engine, disconnect the jumper cables again.
DANGER Do not touch the metallic parts of the cable clamps and make sure that the positive
cable (+) does not touch any metallic part of the vehicle's body.
The service life of the three-phase generator depends considerably on the bearings. Thus, make sure that
the Vee belts have always the proper tension (refer to Operating Manual of the engine manufacturer).
• The generator should be checked in a specialist workshop at regular intervals. In case of operation in very
dusty ambient conditions or at high ambient temperatures, the inspection should take place
correspondingly earlier.
• Operate the generator only when the batteries are connected.
• When connecting the batteries, pay attention to correct polarity, as incorrect connection might destroy the
diodes in the generator.
• Make sure that the batteries are disconnected and that the engine is not running when assembly work is
performed which involves live components (precaution)!
• Tipping against the mass in order to find out whether voltage is "on" is not admissible.
• Pre-excitation of the generator is effected from the batteries via the battery charging pilot lamp. To ensure
correct excitation, a defective battery charging pilot lamp must be replaced immediately.
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12.3 Starter
Refer to the instructions of the engine manufacturer.
Defective lamps, indicator and warning lights must be replaced immediately. Make sure to use lamps having the
same wattage.
12.4.1 Mounting location, voltage/wattage and designation of the lamps and lights in
the chassis
Mounting location DIN Design Voltage/

Wattage
Main headlights 72601 H4 24V 75/70W
Parking light 72601 R19/5 24V 5W
Front flasher lamps 72601 P25-1 24V 21W
Rear flasher lamps 72601 P21W 24V 21W
Stop lights 72601 P21W 24V 21W
Rear foglight 72601 P21W 24V 21W
Reversing light 72601 P21W 24V 21W
Foglights 72601 YC 24V 70W
License plate lamp 72601 R19/10 24V 10W
Rear lamps 72601 R10W 24V 10W
Lateral lights 72601 R10W 24V 5W
Lateral lights, rear 72601 W10/3 24V 3W
Cab roof, bordering lights 72601 R19/10 24V 10W
Driver's cab, ceiling lamp 72601 K 24V 10W
Instrument panel - switch illumination 72601 W5/1,2 24V 1,2W
Instrument panel - indicator lamps 72601 W5/1,2 24V 1,2W
Outriggers, lighting of control box 72601 L 24V 5W
Outriggers - switch lighting 72601 W5/1,2 24V 1,2W
Flashing beacon 72601 H1 24V 70W
Tachometer lighting 72601 W10/3 24V 3W
Lighting of revolution counter 72601 W10/3 24V 3W
Rear light 72601 R5W 24V 5W
Working floodlight above the outriggers 72601 H3 24V 70W
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12.5 Fuse / relay arrangement
The fuse box is installed in the driver's cab, on the right side of the instrument panel.
DANGER Before replacing any faulty fuses, turn the ignition off. Replace defective fuses only
by fuses having the same power rating. Do never use a jumper wire or a similar
device.
Fuse arrangement
F001 = Gearbox, starter interlock F017 = Differential lock F033 = Radio, trailer plugbox**),
7.5 A 10 A plugbox
10 A
F002 = Gearbox F018 = Mirror heating, mirror adjust- F034 = Hazard warning flasher lamp
10 A ment, refrigerator box**) 10 A
10 A
F003 = Suspension F019 = Eddy-current brake**), F035 = Rotary beacons**)
15 A continuous service brake, 15 A
Cruise Control
10 A
F004 = Suspension F020 = ABV F036 = Fog lights**), rear fog light,
15 A 5A cab light, headlamp flashers
10 A
F005 = Steering F021 = ABV, trailer **) F037 = Battery main switch
15 A 5A 10 A
F006 = Outriggers F022 = Free F038 = Supplementary heater unit**),
10 A Thermo 90 S**)
15 A
F007 = Direction indicators F023 = Immobilizer**) F039 = Supplementary heater unit **)
7.5 A 5A 7.5 A
F008 = Wiper, washer, electric horn, F024 = Free F040 = Relay, generator D+
super-tone horn**) 7.5 A
10 A
F009 = Stop lights, air drier F025 = Bordering light, rear light, F041 = ADM electronic system, FR-
10 A license plate lamp, parking electronics
lights, left-hand 10 A
7.5 A
F010 = Reversing light, water level F026 = Instrument illumination, F042 = Diagnostic connector
indicator, centralized bordering light, rear light, 10 A
lubrication system**) license plate light, parking
10 A light, right-hand
7.5 A
F011 = Instruments, indicator lights, F027 = Supplementary bordering F043 = Gearbox
relays, engine malfunction light, lateral light on crane 10 A
buzzer 7.5 A
10 A
F012 = Heater fan, supplementary F028 = Dimmed light, left-hand, relay F044 = ABV
heating**) fog lights**) 10 A
15 A 10 A
F041 = MR electronic system, ADM F029 = Dimmed light, right-hand F045 = ABV
electronics, FR electronics 10 A 10 A
10 A
F014 = Free F030 = High-beam light, left-hand F046 = ABV, trailer **)
10 A 25 A
F015 = Diagnostic connector F031 = High-beam light, right-hand, F047 = Immobilizer**)
10 A indicator high-beam light 5A
10 A
F016 = Working floodlight, F032 = Air conditioning**) F048 = >Tachograph, revolution
outriggers**) 20 A counter
15 A 5A
MR / ADM / FR = Electronic system, engine F = Fuse:

ABV = Automatic anti-lock system A = Ampere

0290_EN_FA043_C1_12_00_00
2003-01 5/10
cont'd.: 12.5 Fuse / relay arrangement
The relay panels are installed in the driver's cab, on the right side of the instrument panel.
Relay arrangement
A 009 = Pulse generator
K 065 = Automatic connection of K 601 = Change-over UW-OW
fan**)
K 1 W**) K 066 = Working floodlight, right K 719 = Engine stalling device
side**)
K 002 = Wiper, interval action K 067 = Working floodlight, left side**) K 721 = Central warning OW
K 004 = Generator D+ K 311 = Gearbox, starter interlock K 722 = MR / ADM
K006 = Fog light**) K 312 = Reversing light K 726 = Ignition, chassis, ON
K 007 = High-beam light, headlamp K 313 = Gearbox, neutral K 730 = Lighting from superstructure
flashers
K 008 = Rear fog light K 329 = Gearbox, neutral K 731 = Lighting from superstructure
K 010 = Direction indicators and K 334 = Switch, engine brake
hazard warning flashers
K 013 = Battery main switch K 401 = Crane directed to the rear
K 024 = Telma and eddy current K 402 = Change-over proximity V 003 = Buzzer
retarder **) switch, axle lock
K 032 = Off-road gear (torque K 410 = Normal level, front left-hand V 401 = Depressurized circulation
limitation)
K 033 = Supplementary heating **) K 411 = Normal level, rear left-hand V 419 = Leveling ”all down”
K 037 = Air conditioning system**) K 412 = Normal level, front right-hand V 508 = Steering
K 038 = Coupling, air conditioning K 413 = Normal level, rear right-hand V 711 = Ignition
system**)
K 039 = Condenser, air conditioning K 512 = Floating position V 712 = Group of diodes
system**)
K 040 = Holding circuit, rear fog light K 516 = Rear axles locked V 713 = Group of diodes
K 041 = Door contact switch K 518 = Gearbox control
K 042 = Stop light, superstructure K 519 = Pulse generator Ground point
OW = Superstructure UW = Chassis
ADM / MR = Electronic system, engine; MPKT = Ground point
V = Diode K = Relay
0290_EN_FA043_C1_12_00_00
6/10 2003-01
cont'd.: 12.5 Fuse / relay arrangement
0290_EN_FA043_C1_12_00_00
2003-01 7/10
12.5.1 Fuses in battery box
1 = Fuse, eddy-current brake**)*) 250 A

2 = Fuse, batteries 100 A
3 = Fuse, chassis 50 A
4 = Fuse, superstructure 50 A
5 = Fuse, battery charging plugbox**) 25 A

0290_EN_FA043_C1_12_00_00
8/10 2003-01
12.7 Relay arrangement in the distribution box
The relay panels are installed in the distribution box, centrally on the left vehicle side (behind the control box
for outrigger actuation).
7770990
070501
12.7.1 Electronic system of 12.7.2 Differential locks

outriggers
Diodes
Relays
V 714 = Group of diodes, indication, diff. locks
K 602 = Change-over, outr. beam/outr. cylinder V 715 = Group of diodes, indication, diff. locks
K 605 = Change-over, outr. beam/outr. cylinder
K 607 = Change-over, outr. beam/outr. cylinder 12.7.3 Electrical system of steering
K 608 = Change-over, outr. beam/outr. cylinder assembly
Relays
Diodes K 513 = Relay, front axle steering from super-
V 604 Group of diodes, outriggers structure
V 605 Pressure limitation, extend outrigger K 514 = Relay, front axle steering, right-hand
beams K 515 = Relay, front axle steering, left-hand
V 623 Free
Diodes
V 505 = Group of diodes, steering
0290_EN_FA043_C1_12_00_00
2003-01 9/10
Memo:
0290_EN_FA043_C1_12_00_00
10/10 2003-01
Wheels and tires C1-13
13 Wheels and tires
DANGER The wheel is an important safety component at the vehicle and must be checked at
regular intervals with regard to:
• lateral or vertical movement of the rim,

• wear and deterioration of the tires,
• tire pressure,
• toe-in,
• parallelism of the wheels (immediately in case of a deficiency), racks in the rim and the wheel nave,
• traces of corrosion,
• damaged wheel bolts or wheel nuts,
• deformation of rims,
• tight fit of wheel nuts etc.
NOTE Refer also to chapter B0, item 1.1 „Important instructions regarding the load ratings of
tires depending on the maximum travelling speeds and the stress to which the rims
are subject“.
13.1 Measures to be taken to avoid accidents caused by the wheels
• Check the wheels for good condition and wear.

• When the vehicle operates under heavy load, it might be necessary to reduce the intervals specified in the
• Do not repair or weld damaged wheels, misshapen and broken rims and bolt boreholes.
• Re-paint rim to prevent the development of corrosion and tension cracks.
• The surface protection of the rim must be checked and, if necessary, renewed at certain intervals and when
a tire is mounted.
• Whenever tires are mounted, clean the rims to remove corrosion, dirt and rubber residues and provide the
rims with a new protective paint.
DANGER In order to avoid severe accidents, make sure that only parts of the same make, the
same system and the same size are combined. Pay attention to the marked
identification figures.
0305_EN_FA043_C1_13_00_00
2003-03 1/4
C1-13 Wheels and tires
13.2 Checking the wheel nuts on the disc wheel for tight fit
• Wheel nuts of recently mounted wheels must be checked for tight fit repeatedly, according to the
maintenance schedule, until all nuts remain evenly tightened.
• Re-tighten wheel nuts vigorously, without applying force.
NOTE Make sure to tighten the wheel nuts in crosswise order. Use a torque wrench.
Do not damage the threads of the wheel bolts.
DANGER In order to prevent the wheels from getting loose due to subsiding and abrasion of the
painted contact surfaces, which would result in ovalization of the rim holes or in
breaking of the wheel bolts, make sure that the wheel nuts are checked for tight fit at
regular intervals.
13.3 Tightening torque of wheel nuts (with thrust plate)
Wheel nuts M22x1.5, blackened with phosphorus = 650 Nm.
13.4 Tire pressure
Check the tire pressure at regular intervals, according to the maintenance schedule. It is possible to inflate
tires via the tire inflation socket on the pressure governor (for further details, refer to item C1-11.3.1). The tire
inflating pressures are specified in part "A", item 2.7.4.
0305_EN_FA043_C1_13_00_00
2/4 2003-03
Wheels and tires C1-13
13.5 Replacement of a disc wheel
DANGER Two persons should perform mounting and moving the wheels (weight of wheel and
tire approx. 300 kg). Risk of accidents!
- Park the vehicle.

- Actuate the parking brake.
- Gearbox set to „Neutral“.
- Shut off the engine.
- Prevent the vehicle from rolling away by placing wheel chocks under the wheels.
- After a case of damage, which might cause an accident hazard when removing the wheel, check the tire,
rim and hub.
- Release wheel nuts by approx. 2 turns.
- Jack-up the axle - e.g. by supporting the chassis by outriggers - until the tire has some ground clearance.
- Unscrew the wheel nuts, remove the wheel from the hub and put it down, without laying it on the ground.
- Clean wheel hub, bolts, nuts and contact surfaces of wheel; check them for wear and deficiencies.
- Replace defective components. Use only genuine TADANO-FAUN spare parts!
NOTE To facilitate mounting, the wheel can be lifted to the level of the wheel hub by means
of appropriate equipment, e.g. a forklift truck.
- Check new wheel for proper working order, then position it on the hub.
- Do not damage the threads of the wheel bolts.
- Screw-on the wheel nuts so that they are uniformly applied; then tighten them to the specified torque using
a torque wrench.
- If necessary, check tire inflating pressure.
- Set vehicle in driving condition. If necessary, perform leveling as described under item B1-4.7.
- Check wheel nuts for tight fit at regular intervals according to the maintenance schedule.
13.6 Interchanging wheels in view of tire wear
To ensure a uniform wear pattern on all tires, it is recommended to interchange the wheels of the vehicle.
This exchange is due as soon as an irregular wear pattern is visible. In this context, intervals ranging from
5,000 to 10,000 km have proved to be useful.
The wheels should be interchanged cross-wise, i.e. to the other side of the vehicle, and the locations should
be selected so that tires with a uniform wear pattern are mounted in locations showing an irregular wear
pattern.
These measures enhance the driving comfort and the service life of the tires.
0305_EN_FA043_C1_13_00_00
2003-03 3/4
C1-13 Wheels and tires
Memo:
0305_EN_FA043_C1_13_00_00
4/4 2003-03
Outriggers C1-14
14 Outriggers
The sliding surfaces of the outrigger beams and the support of the outrigger float in the outrigger cylinder
must be cleaned and lubricated with multi-purpose grease at regular intervals.
14.1 Adjusting the guide pads
- Raise outrigger beams - by extending the outrigger cylinders - until dimension (A) between the force
transmission plates on the outrigger casing and the top flange, outrigger beam I and on the outrigger beam
I and the top flange, outrigger beam II, amounts to 1 to 3 mm.
- Release the lock nuts (1); turn in the setscrews (2) to push the guide pads against the outrigger beams (3).
- Tighten the lock nuts (1) securely again.
- Retract the outriggers completely.
Check the setting; if necessary, repeat adjusting process.
14.1.1 Inspection and, if necessary, re-adjustment of the guide pads
Three guide pads are located on each outrigger. One each (1/2) is provided at the bottom behind the
outrigger float and two of them (5) on the opposite side of the corresponding outrigger.
- Extend all outrigger beams completely (refer to item B1-6.5).

The clearance (A) between the outrigger casing and the outrigger beam must not exceed 3 mm.
0310_EN_FA043_C1_14_00_00_NEU
2003-03 1/2
C1-14 Outriggers
14.2 Check cable drag chain
A cable drag chain is located in each outrigger casing. The cable drag chain accommodates the cables,
pipes and line for the outriggers.
- Check securing bolts at the two ends of the cable drag chain for tight fit.
- Check visually. The cable drag chain, including the hose lines and cables, must run correctly; they must not
be damaged, kinked or show areas of chafing.
0310_EN_FA043_C1_14_00_00_NEU
2/2 2003-03
Driver’s cab C1-15
15 Driver’s cab
Grease joints and pins and all movable components with lubricating oil. Make sure that these parts run freely
and are easy to operate.
These components are, e.g.:

• Joints of the folding access steps on the left and right;
• Hinges of the cover lid below the driver's cab,
• Hinges of the engine servicing lid.
The mechanical components of the door locks also require regular care. The closing cylinders should be
treated with a graphited agent, preferably before the cold season begins.
It is better to treat door seals and other rubber components with acid-free grease or French talc before the
cold season begins.
15.1 Warm water heating

15.1.1 Heat exchanger
After having removed the rear panel, lifted off the cover with air distributor and released the hose connec-
tions, the heat exchanger can be pulled upwards and out. It is advisable to rinse it thoroughly on the water
end at all main servicing intervals (approx. 3 - 5 years) to ensure that chalk and iron deposits are removed.
The air fins should be blown out at regular intervals of 500 service hours using compressed air in the direc-
tion opposite to the air supply. This can be performed while the heat exchanger remains mounted. However,
the air cleaner and the blower fan must be removed previously.
15.1.2 Blower fan
The blower fan slide-in module can be pulled out to the back after the rear panel has been removed. To
reach an optimum service life, the electric motor and the fan wheel must be blown out gently with com-
pressed air at regular intervals of 500 service hours. (Contamination reduces the electric motor's service life
and, due to imbalances on the fan wheel, may result to vibrations and consequently to development of
noise).
Attention Make sure that the position of any balancing clips on the impeller is not changed!
15.1.3 Air cleaner
The air cleaner can be replaced through the fresh air port when the flap is set to "fresh air". It must be
checked for contamination at regular intervals. A servicing interval of approx. 3 months or 15,000 km trav-
elled is recommended for filter replacement.
The servicing intervals depend on the local operating conditions and may be subject to fluctuations.
A severely contaminated air cleaner may result in insufficient demisting of the windows.
0315_EN_FA043_C1_15_00_00
2003-03 1/4
C1-15 Driver’s cab
15.2 Wiper-blade elements

15.2.1 Replacement of wiper-blade elements
The wiper-blade elements must be cleaned at regular intervals to work properly.

For safety reasons (good visibility), it is recommended to replace the wiper-blade elements immediately if
their cleaning effect decreases. The wiper-blade elements should be replaced at least once per year.
Replacement of wiper-blade elements:
- Lift wiper arm (1), push down the spring (2) and slip wiper-
blade element (3) towards the wiper arm.
- Remove wiper-blade element and reverse the above proce-
dure to mount new wiper-blade element.
The wiper-blade element is correctly mounted when it is

locked in its support.
The supply tank of the windshield washing system is located below the front lid of the driver's cab, on the
right (refer to part "B1", item 2.3.3).
15.3 Air conditioner **)
DANGER All sorts of repair, replenishing or overhaul work on the air conditioner system may
only be performed in an authorized workshop by well-trained staff.
Work on the air conditioner requires specific extraction and filling stations, recovery
stations, electronic leak detectors and special tools which are only available in spe-
cialist workshops. Correct disposal of fluids is also only ensured in a specialized
workshop.
In the scope of the maintenance operations which are to be performed at least twice per year by the vehicle's
operator, all movable parts, such as shaft bearings and articulations of levers, must be lubricated sufficiently
with a commercially available grease, and actuated.
15.3.1 Functional check of air conditioner
The air conditioner should be put into operation for approx. 10 minutes at regular intervals, also in winter, to
keep it in proper working order.

0315_EN_FA043_C1_15_00_00
2/4 2003-03
Driver’s cab C1-15
15.3.1.1 Inspection for correct fluid level and leakage
- Start the engine of the vehicle.

- Switch on the air conditioner (for further details, refer to part "B1", item 4.4.5 and 10.14).
• When the system is perfectly tight, the white ball will float in the inspection glass of the fluid tank, thus indi-
cating the correct fluid level. (Refer to item 15.3.9)
• If air inclusions appear in the inspection glass, the system is leaky. It must be checked or repaired in a
specialist workshop. (Electronic leakage detector)
• If traces of corrosion or precipitation appear in the inspection glass, or if the refrigerant is turbid, the fluid
tank and the drier must be replaced in a special workshop.
15.3.2 Condenser
The condenser is installed below the driver's cab.

• Clean condenser at regular intervals to remove dust, insects, etc. (blowing out or washing down).
15.3.3 Evaporator
The evaporator is installed centrally in the driver's cab.

• Check discharge of condensed water.
• The evaporator fins must be blown out using compressed air together with the heat exchanger fins, with the
air jet directed contrary to the air-supply side. To this effect, the evaporator and the heat exchanger can
remain in their installation position. However, the blower fan and the air cleaner must be removed previ-
ously.
15.3.4 Heat exchanger
• It is advisable to rinse it thoroughly on the water end at all main servicing intervals to ensure that chalk and
iron deposits are removed.
For cleaning of heat exchanger fins, refer to item 15.3.3 "Evaporator".
15.3.5 Blower fan
• To reach an optimum service life, the electric motor and the fan wheel must be blown out gently with com-
pressed air at regular intervals of 500 service hours.
Attention Make sure that the position of any balancing clips on the impeller is not changed!
15.3.6 Air cleaner
• The air cleaner can be replaced through the fresh air port when the flap is set to "fresh air". It must be
checked for contamination at regular intervals. A severely contaminated air cleaner may result in insuffi-
cient demisting of the windows.
0315_EN_FA043_C1_15_00_00
2003-03 3/4
C1-15 Driver’s cab
15.3.7 Hoses and hose clamps
• Check hoses for leakage, areas of abrasion and cracks.

• Hose clamps: Check hose couplings for tight fit.
15.3.8 Checking the Vee belt of the air conditioning compressor
• Check Vee belt for good condition, cracks, fouling and wear.
• Check the Vee belt tension.
Refer to operating manual of the engine manufacturer.
15.3.9 Drier of air conditioning compressor
The collector drier is installed centrally on the front end, below the driver's
cab. There is an inspection glass in the collector drier.
Two beads are located in the inspection glass.
1.: For fluid level indication; colour: white. (Refer to item 15.3.1.1)
2.: For moisture indication; colour: blue: dry.
Colour: pink: damp.
If the 2nd bead indicates "pink", this means that the collector drier must be
replaced by a specialist workshop.
However, the drier of the air conditioning compressor should be replaced at
intervals of max. 2 years.
15.3.10 Oil level inspection of air conditioning compressor
The oil level in the compressor can only be checked after a repair, or every time before the air conditioning
system is filled with new refrigerant. No refrigerant may be present in the circulation or the oil level inspec-
tion.
On principle, the oil volume extracted from the refrigerating circulation plus an additional quantity of 10 cm3
must be poured into the circuit on re-filling. If parts have been replaced during repair, then the quantities
specified for the replaced component must be added additionally (adhere to the current information by the
various manufacturers).
15.4 Supplementary heater unit **)
For instructions on operation, service and maintenance of the heater unit, please refer to the documents of
the unit's manufacturer. Make sure that the manufacturer's instructions are observed.
15.5 Engine pre-heating unit **)
the unit's manufacturer. Make sure that the manufacturer's instructions are observed.

0315_EN_FA043_C1_15_00_00
4/4 2003-03
Miscellaneous; other points of lubrication, servicing and maintenance C1-16
16 Miscellaneous; other points of lubrication, servicing and main-

tenance
Grease joints and pins and all movable components with lubricating oil. Make sure that these parts move
unrestrictedly and are easy to operate.
• Threads of the star-shaped handles which serve to lock the lateral coverings;
• Hinges of the lateral coverings;
• Joints of the folding access steps on the left and right sides;
• Hinges of the cover lid below the driver's cab,
• Hinges of the lid of the engine serivicing port;
• Hinges and pin securing devices of the tool kit **)
The mechanical components of the door locks also require regular care. The closing cylinders should be
16.2 Replacement of filter in the fuel pipe of the supplementary heater unit**)
The supplementary heating is supplied with fuel from the

fuel tank of the chassis.
It is recommended to replace the fuel filter once per year to

ensure trouble-free heater operation.
- Loosen the hose clamps (1), remove the fuel filter (2),
install a new filter and tighten the hose clamps safely.

0320_EN_FA043_C1_16_00_00
2003-03 1/6
C1-16 Miscellaneous; other points of lubrication, servicing and maintenance
16.3 Trailer coupling device **)

16.3.1 ROCKINGER
16.3.1.1 Servicing
The trailer coupling device must be lubricated with multi-purpose grease

via the lubricator (1).
NOTE The coupling device may only be greased in open

condition (coupling bolt on top) to prevent the auto-
matic unit from being supplied with excessive grease.
Subsequently, the automatic unit must be actuated
several times.
16.3.1.2 Inspection and adjustment

no longitudinal bearing backlash
The trailer coupling device must be checked at regular
intervals, for safety reasons.
6.3.1.3 Inspection of the longitudinal bear-

ing backlash.
• Move the coupling head (not the coupling jaw funnel)

with both hands in longitudinal direction.
Make sure that no longitudinal backlash is noticeable.
16.3.1.4 Inspection of the vertical bearing backlash.
• Open the coupling (hand-actuated lever in 1st locking position).

• Insert a bent tire lever so that the top side of the lever touches the cou-
pling jaw, and its underside rests against the coupling body (not of the
lower bushing).
• Push the rod upwards while watching the movement of the coupling de-
vice. If the backlash due to wear exceeds 1 mm, the coupling device
must be removed on all accounts, and the bearing must be checked.

0320_EN_FA043_C1_16_00_00
2/6 2003-03
16.3.1.5 Inspection of the coupling bolt for wear.
• The wear of the coupling bolt must be determined by measuring it with a

sliding caliper.
• The diameter of the ball-shaped part must not fall below 36.5 mm. Oth-
erwise, the coupling bolt must be replaced.
16.3.1.6 Inspection of the vertical backlash.
• The maximum vertical backlash must not exceed 4 mm.
16.3.1.7 Inspection of the lower bushing for wear.
• The admissible inside diameter of the lower bushing in the coupling jaw
must not exceed 31.2 mm.
16.3.1.8 Pre-load of the rubber springs.
The axial torque of the coupling, when new, is at least 100 Nm.
• Turning the coupling head by hand must require considerable effort.
16.3.1.9 Adjustment of the coupling jaw.
To enable coupling, the coupling jaw (coupling bolt on top) must be locked
automatically in its central position. Failing this, the central position must be
corrected as follows:
• Open the coupling (hand-actuated lever in 1st lock).

• Loosen the screws at the bottom part.
• Push the coupling jaw to the right/left, until the release lever is engaged.
• Tighten the screws (tightening torque: 49 Nm).
• To engage, press the hand lever into the 2nd lock position.
16.3.1.10 Inspection
• Close the coupling device (hand lever down).

• Push the coupling jaw slightly to the left or right.
• Open the coupling (hand-actuated lever in 2nd lock).
• Release the coupling jaw: The release lever must lock the coupling jaw again in its central position.
0320_EN_FA043_C1_16_00_00
2003-03 3/6
16.3.2 RINGFEDER
16.3.2.1 Greasing
- Grease the entire coupling head on the knob locking device at regular
intervals, according to the maintenance schedule, via the lubricator
(1). 1
To minimise wear on the coupling bolt and the towing eyelet, clean and
grease these parts at regular intervals.
The pull rod bearing does not require any maintenance.

The castle nut below the protective cap has a tightening torque of 400
to 500 Nm.
16.3.3 Coupling heads
The pneumatic coupling heads must be free of leakage in coupled and in uncoupled condition (no sound of
air escaping). The sealing surfaces must be kept clean and free of damage. In uncoupled condition, the cov-
ers must be folded over the sealing surfaces.
0320_EN_FA043_C1_16_00_00
4/6 2003-03
16.4 Sliding coupling
Check the sliding coupling according to the maintenance schedule.
16.5 Steering
Grease the bearing points of the guide levers according to the maintenance schedule.
16.4 Suspension
Grease the suspension cylinders at the top and bottom according to the maintenance schedule.
- Check bellows for correct fit and condition (no cracks, holes etc.). Fasten bellows correctly. If damage is
detected, do not repair, but replace them.
16.7 Centralized lubrication system**)
For instructions on operation, service and maintenance along with the data regarding lubricants and the
lubricating points, please refer to the information supplied by the unit's manufacturer (see Part G1, Chassis).
Make sure that the manufacturer's instructions are observed.

0320_EN_FA043_C1_16_00_00
2003-03 5/6
Memo:
0320_EN_FA043_C1_16_00_00
6/6 2003-03
Summary of oil types and filling capacities C1-24

(Recommended oil types)
NOTE The filling capacities specified below are approximate values. For precise measuring
results, the oil level inspection plugs, the oil dipsticks or inspection glasses are al-
ways decisive. Only those qualities may be used which are listed in the chart of ap-
proved consumables of the assembly manufacturer, or which are indicated on the
nameplate of the assemblies.
Maintenance point Oil type / Filling type Filling capacity
Engine Engine oils according to the DC consumables specification. Refer to DC Oper-

ating Manual
Initial filling with SAE 15W-40
Coolants / anti-freeze Coolants according to the DC Operating Manual approx. 50 l

agents Anti-freeze agents according to the DC fuel specifications
Fuel tank Diesel fuel EN 590 approx. 400 l
Gearbox For oil types and oil change intervals, refer to the ZF Chart of Refer to ZF Oper-
approved Lubricants in Part G1, Annex, Chassis. ating Manual in the
Annex.
Initial filling with ECOFLUID M 75W-80
Transfer box Hypoid gear oil SAE 90 according to approx. 7,5 l

Mil-L-2105 d und API-GL 5
in case of
complete
oil change
approx. 10,5 l
0325_EN_FA043_C1_24_00_00
2003-03 1/4
C1-24 Summary of oil types and filling capacities
cont'd.: 24 Summary of oil types and filling capacities

Axles
Drive 8 x 6
Planetary gears
1st axle approx. 1.2 l each
Axle drive assembly
1st axle approx. 19 l
Planetary gears Hypoid gear oil SAE 90 according to
3rd axle MIL-L- 2105 B / API-GL 5 approx. 1.2 l each
Axle drive assembly Hypoid gear oil with multigrade
3rd axle properties according to approx. 21 l
Planetary gears MIL-L- 2105 C / D / API-GL 5
4th axle SAE 90 or multigrade oils at normal outside temperatures approx. 1.2 l each
Axle drive assembly SAE 75 W – 90, SAE 75 W – 85 at
4th axle outside temperatures below -10°C approx. 19 l
SAE 140 or multigrade oils
at over +30°C
Drive 8 x 8**)
Planetary gears
1st axle approx. 1.2 l each
Axle drive assembly
1st axle approx. 19 l
Planetary gears **)
2nd axle approx. 1.3 l each
Axle drive assembly **)
2nd axle approx.17,5 l
Planetary gears
3rd axle approx. 1.2 l each
Axle drive assembly
3rd axle approx. 21 l
Planetary gears
4th axle approx. 1.2 l each
Axle drive assembly
4th axle approx. 19 l

0325_EN_FA043_C1_24_00_00
2/4 2003-03

Maintenance point Oil type / Filling type Filling ca-

pacity
Hydraulic system Ambient temperature Mineral oils accord- Biodegradable approx. 220 l
ing to oils according to
DIN 51524-2 VDMA 24568
over +30° C HVLP 68 HEES 68
Oil tank from + 5° C to + 25° C HLP 46 HEES 46 approx. 147 l
for below + 5° C to - 15° C HLP 32 HEES 32
steering from - 15° C to -25° C HLP 22 HEES 22
outriggers, below - 25° C HLP 10
Suspension.
Initial filling with HLP 46
Air conditioning sys-

tem**) Refrigerator oil: ND-Öl 8 210 cm3
Refrigerator oil and Refrigerant : R134a 1,65 kg
refrigerant.

0325_EN_FA043_C1_24_00_00
2003-03 3/4
Memo:
0325_EN_FA043_C1_24_00_00
4/4 2003-03
Summary of lubricating grease types (recommended grease types) C1-25
25 Summary of lubricating grease types (recommended grease

types)
Maintenance point Grease type Filling capacity
Grease filling in wheel Lubricating grease, lithium-saponified, as

bearings according to DIN 51825-KP2K-20 required
2nd axle
(For drive 8x6)
Lubricators
on
steering knuckle Lubricating grease, lithium-saponified, as
bearings, according to DIN 51825-KP2K-20 required
suspension cylinders,
guide levers,
propeller shaft
intermediate bearings,
greasing points equip-
ped with lubricators.
Other points of
lubrication
Outriggers
Sliding surfaces Lubricating paste containing MoS2-, Cu or Al- as

required
Outrigger floats Makraflon HSII
Centralized lubrication Lubricating grease, lithium-saponified,

system**) according to DIN 51825-KP2K-20 as
Grease tank required
Batteries Terminal grease as
required
Spreading device Renoplex EP2, manufacturer: Fuchs approx. 25 g per
box
Door locks Graphite powder as
required

0330_EN_FA043_C1_25_00_00
2003-03 1/2
C1-25 Summary of lubricating grease types (recommended grease types)
Memo:
0330_EN_FA043_C1_25_00_00
2/2 2003-03
Chart of approved consumables and lubricants C1-26
Recommended greases and lubricants for greasing points equipped

with lubricators, sliding surfaces and ball bearing slewing devices, as
well as ringgear and slewing gear pinion.
Symbols used in Symbols

the lubricating used in the
schedule Table
First-class lubricating grease, lith-

ium-saponified, penetration grade
2
Special lubricant, adhesive, hydro-

phobic with sufficient temperature
characteristics
248 K to 403 GULF CROWN 243 K to 393

Rolexa 2
K Grease No. 2 K
263 K to 393 GULF LUBCOTE 253 K to 333

Engrenage 3
K No. 2 K
243 K to 393 243 K to 403

Aralub HL 2 MOBILUX 2
K K
253 K to 403 243 K to 393

Aralub LFZ 1 MOBILTAC 81
K K
243 K to 393 243 K to 403

BP Energrease LS 2 Alvania Fett R 2
K K
243 K to 353 255 K to 333

BP Energol WRL Cardium Fluid C
K K
Castrol Spheerol 253 K to 393 253 K to 393

Glissando FL 20
AP 2 K K
253 K to 353 253 K to 393

Castrol Grippa 33 S Crater 2 X Fluid
K K
Chevron Dura-Lith 248 K to 398 253 K to 393

VALVOLINE LB-2
Grease 2 K K
Chevron Pinion 273 K to 398 VALVOLINE Dipper 253 K to 493

Grease MS K Stick K
243 K to 403
BEACON 2 Fritz Manke
K Technische
Artikel
Fichtestr. 72
253 K to 333 40233 Düsseldorf Voler Compound 243 K to 343
SURETT Fluid 4 K
K 2000 E K
0335_EN_FA043_C1_26_00_00
2003-03 1/2
C1-26 Chart of approved consumables and lubricants
Memo:
0335_EN_FA043_C1_26_00_00
2/2 2003-03
Inspection scheme/8x8 drive**) (before start-up, daily) C1-27
27 Inspection scheme/8x8 drive**) (before start-up, daily)

Check before start-up
= Refer to
Part C1), item …
= Inspection
K = Coolant

0340_EN_FA043_C1_27_00_00
2002-12 1/2
C1-27 Inspection scheme/8x8 drive**) (before start-up, daily)
Memo:
0340_EN_FA043_C1_27_00_00
2/2 2001-06
Inspection and cleaning scheme/8x8 drive**) C1-28
28 Inspection and cleaning scheme/8x8 drive**)

Inspection, refer to maintenance
schedule
Cleaning, replacement, refer to
maintenance schedule
= Refer to Part C1), item

…..
F = Cleaning and/or replace-

ment of filters, refer to
E = Breathers
= Inspection
= Cleaning
Inspection, refer to maintenance

schedule
Cleaning, replacement, refer to

0345_EN_FA043_C1_28_00_00
2002-12 1/2
C1-28 Inspection and cleaning scheme/8x8 drive**)
Memo:
0345_EN_FA043_C1_28_00_00
2/2 2001-06
Oil/coolant level inspection and change scheme/8x8 drive**) C1-29
29 Oil/coolant level inspection and change scheme/8x8 drive**)

Oil change, refer to mainte-
nance schedule
Oil level inspection, refer to
= Refer to Part C1),

item ...
F = Filter change, refer to

Engine oil*)
Hypoid gear oil *)
Hydraulic oil *)
Refrigerator oil and re-

frigerant*)
~Corrosion-protective anti-
freeze agent
*) Use the recommended oil
types
Oil change, refer to main-

tenance schedule
Oil level inspection, refer to

0350_EN_FA043_C1_29_00_00
2002-12 1/2
C1-29 Oil/coolant level inspection and change scheme/8x8 drive**)
Memo:
0350_EN_FA043_C1_29_00_00
2/2 2001-06
Lubricating scheme/8x8 drive**) C1-30
30 Lubricating scheme/8x8 drive**)

Lubrication, refer to
= Refer to Part C1)

Item …
Universal grease**)
Special grease*)
*) Use recommended
grease types
Clean lubricators before

greasing. Grease all the
other parts using an oil
can.

0355_EN_FA043_C1_30_00_00
2002-12 1/2
C1-30 Lubricating scheme/8x8 drive**)
Memo:
0355_EN_FA043_C1_30_00_00
2/2 2001-06
Part C2
Superstructure
0360_EN_ALLGE_C2_00_00_00
The maintenance intervals depend on the vehicle’s operating conditions; the next maintenance will be due
after:
- a certain number of operating hours, or

- a defined period of time.
NOTE The value which is reached first shall be decisive.
The operating hours are indicated on the hourmeter in the crane cabin (refer to item B2-2.1).
Maintenance work which must be performed earlier than the regular maintenance works, or in a different
fashion, is indicated in the maintenance schedule in the column “Initial maintenance after”, e.g.
commissioning of the machine or replacement of components.
After these maintenance works have been effected, the column „Regular maintenance every 125 / 250 /
500 / 1000 / 2000 / operating hours“ shall apply.
Maintenance work which must be performed daily or before commissioning the vehicle has been marked by
an “X” in the maintenance schedule in the column “Daily, before start-up”.
The number of operating hours expiry of which calls for the specified maintenance work to be performed
repeatedly have been marked by an “X“ in the columns “Regular maintenance every 125 / 250 / 500 /
1000 / 2000 / operating hours”.
e.g. “every 500 operating hours“ i.e. after 500, 1000, 1500 etc. operating hours have been reached,
“every 2000 operating hours“ i.e. after 2000, 4000, 6000 etc. operating hours have been reached.
NOTE The maintenance intervals apply for machines which are subject to normal operating
and environmental conditions. If the machines are used in particular applications, the
maintenance intervals must be adapted to the prevailing operating conditions.
NOTE Whenever major maintenance work is performed, it is obvious that also maintenance
work required to be done at shorter intervals which coincides with this date must be
performed as well.
NOTE In the maintenance plans, items C2-18 to C2-21, the maintenance works are structured
by assemblies.
The maintenance works are shown, as an example, only for one part of an assembly;
if a part occurs more than just once, the maintenance works must be performed on all
such parts (e.g. batteries etc.).
0365_EN_FA043_C2_01_00_00
2003-01 1/12
Memo:
0365_EN_FA043_C2_01_00_00
2/12 2003-01

Refer to Daily;
Assemblies / Maintenance mainten- Minimum
Part "C2", before 125 250 500 1000 2000 Remark
work and inspections ance intervals
item start-up
after Operating hours
Hydraulic piping
Check hydraulic hoses / hose C1-1.4.1 Once per
lines for damage. week
Replace hydraulic hoses. C1-1.4.1 every 6 years
Engine
Inspection for leakage. 2 X
Oil change, oil filter 2.2 900 Once per
op.
replacement. year
hours
Inspection of tight fit of the 2.3 X
hose clamps of the charge
air hoses.
Fuel tank; drain condensed 2.4.1 X Once per If necessary, earlier.
water. year
Fuel tank, clean fuel 2.4.2 X If necessary, earlier.
strainer**) in the filler socket.
Fuel tank; check ventilation 2.4.2.1 X Once per If necessary, earlier.
filter year
Fuel strainer; drain 2.4.3.1 X If necessary, more often.
condensed water.
Fuel strainer, replace filter 2.4.3.2 X Once per If necessary, more frequently,
cartridge. year depending on the fuel quality.
Check hose clamps of the 2.5.1 X
coolant hoses for tight fit and
tightness.
Inspection of coolant level. 2.5.1 X
Replacement of coolant. 2.5.2 X every 2 years
Cleaning the cooler. 2.6 X If necessary, earlier.

0365_EN_FA043_C2_01_00_00
2002-12 3/12
C2-1 Wartungsintervalle

Refer to Daily;
item start-up
Air cleaner
Monitoring the air cleaner 2.7.4 X During operation via the
indicator lamp "air cleaner".
Servicing switch "Air cleaner 2.7.4.1 X
monitoring" - check for
proper working order
Replacement of air cleaner 2.7.1 X And when the indicator lamp "air
cartridge. cleaner" goes on.
Clean air cleaner housing. 2.7 X Simultaneously with each
maintenance of the air cleaner.
on dust collected.
Check air cleaner housing for 2.7 Simultaneously with each
damage and cracks. maintenance of the air cleaner.
Check air intake pipes and 2.7.3 X
hoses.
Check electrical vacuum 2.7.4 If the pilot lamp “air cleaner”
switch on the air cleaner does not go on in spite of
housing. contamination of the air cleaner.
Exhaust system
Silencer spark arrester**) 2.8 X Empty and clean 2 or 3 times
per year.
Hydraulic system
Check hydraulic system for 3/3.6 X
leakage.
Replace the filter cartridges. 3.2 125 oper- X Once per Simultaneously with each hy-
ating year draulic oil change and if the
hours indicator lamp warning about
contamination of the filter is lit.

0365_EN_FA043_C2_01_00_00
4/12 2001-06

Refer to Daily;
item start-up
Replacement of the 3.2.1 X If necessary, earlier, if
ventilation filter. contaminated.
Replace sinter filters (if 3.2.2 If an operating malfunction
installed; refer to hydraulic occurs.
piping diagrams).
Oil change. 3.3 X Every 2 Take and analyse an oil sample
years at regular intervals.
Replacement of filter insert of 3.5 X
pressure filter.
Oil cooler / supplementary oil 3.7 X
cooler; clean cooler fins.
Oil cooler/supplementary oil 3.7 X
cooler; check fan and
thermostatic valve for proper
working order.
Check working pressure of 3.9 125 X
the hydraulic system of the 3.10 operating
chassis; if necessary, have it hours
re-adjusted by specialists.
Swing mechanism
Check gearbox visually. 4 Every 3 Inside and outside
years
Inspection for leakage. 4.1 X
Check oil level in gearbox. 4.1 X While gearbox is at a standstill.
Change oil in gearbox. 4.2 200 op. X Once per Analyse an oil sample simulta-
hours, then year. neously with every oil change.
after 1000
op. hs.
Check hydraulic oil level in 4.3 X
the supply tank of the swing
brake.
Checking the swing brake for 4.3.2 X Once per
proper working order and year.
leakage.
0365_EN_FA043_C2_01_00_00
2002-12 5/12

Refer to Daily;
item start-up
Check tooth face backlash 4.4 Once per
on swing motor gearbox year.
drive shaft.
Grease ring gear and pinion 4.5 X If necessary, at shorter intervals,
of swing mechanism. depending on slewing
frequency.
Grease ball bearing slewing 4.6 X If necessary, at shorter intervals,
device of race system. depending on slewing
frequency.
Grease the lock pin. 4.7 X
Check mechanical super- 4.8 X
structure lock and proximity
switch for proper working
order.
Check connecting bolts of 4.10 100 to 125 X Comply with tightening torque.
ring gear, securing bolts of operating
hydraulic motor and gearbox hours
flange screws for tight fit.
Check tipping backlash of 4.11 As required.
slewing device.
Hoisting gear and auxiliary

hoisting gear**)
Check gearbox visually. 5 Every 3 Inside and outside
years
Inspection of rope drum. 5 X and simultaneously with each
rope replacement.
Inspection for leakage. 5.1 X
Oil level inspection. 5.1/5.3 X
Oil change. 5.2/5.4 200 ope. X Once per Analyse an oil sample simulta-
hours, then year. neously with every oil change.
after 1000
op. hs.

0365_EN_FA043_C2_01_00_00
6/12 2001-06

Refer to Daily;
item start-up
Check tooth face backlash. 5.5 X Once per
year.
Grease drum bearings. 5.6 X Twice per And after each cleaning
year. operation using a steam jet unit.
Hoisting gear brake - check 5.8 X Once per
disc package and free year.
wheeling.
Check hoist limit switch for 5.9 X During operation.
proper function.
Check rope limit switch for 5.10 X and simultaneously with each
proper function. rope replacement.
Check length transmitter 5.11 X
cable.
Winch rope
Visual inspection. 6.1 X Once per Before and after each operation.
week.
Cleaning. 6.2 If seriously soiled.
Lubrication and servicing of 6.2 X If necessary, earlier, and after
the rope. each cleaning operation.
Check rope drum for wear. 6.4 X Before placing the new winch
rope.
Electrical equipment
Check the batteries. 7.1 X Once per
month.
Batteries, grease terminals. 7.1 As required.
Check the three-phase 7.2 X Pay attention to correct Vee belt
generator. tension.
Check the starter. 7.3 X Refer to the instructions of the
engine manufacturer.
Check lamps and indicator 7.4 X
lamps for proper function.
0365_EN_FA043_C2_01_00_00
2002-12 7/12

Refer to Daily;
item start-up
Clean lamp glasses and 7.4 X If necessary, earlier in case of
check them for damage. contamination.
Check the automatic safe 7.5 X
load indicator for proper
working order.
Check automatic safe load 7.6 X
indicator.
Crane cab
Lubricate/oil joints, pins, 8 X Every two And after every crane cleaning
hinges and all movable weeks operation using the high-
components. pressure steam jet blower.
Treat door locks (key 8 X Once per
cylinders). year
Air conditioning system.**) 8.1 X Once per At the beginning of a cooling
Perform inspection. year. period.
In a specialist workshop.
Clean wiper-blade elements. 8.2.1 X Once per If necessary, more frequently.
month
Replace the wiper-blade 8.2.1 X Once per Or if damaged.
elements. year
Checking the fluid level and 8.2.2 X Once per If necessary, more frequently.
replenishing fluid in tank of month
washing system.
Replace fuel filter of auxiliary 8.3.1 X Once per Before heating operation begins.
heating. year.
Replacement of dust filter of 8.3.1 Depending on dust collected.
Check recirculated air filter. 8.5 As required, i.e. when air flow in
recirculation mode decreases.
Other points of lubrication,

service and maintenance

0365_EN_FA043_C2_01_00_00
8/12 2001-06

Refer to Daily;
item start-up
Telescopic boom
Grease and oil slide pieces, 9.1 X
slideway linings, slide
bars, cross-heads and
guide rollers.
Grease basic boom bearing. 9.1 X
Boom elevation cylinder
Grease cylinder bearing. 9.2 X If necessary, earlier.
Bottom block
Grease the hook cross- 9.3 X
beam.
Counterweight
Check locking cylinders for 9.4 X
leakage.
Jib**)
Grease and lubricate rope 9.5 X
pulley support, bearings and
bolt securing mechanisms.
system **)
Check fluid level in supply 9.6 As required.
tank; if necessary, replenish.
Check pipes and screw 9.6 X
couplings for damage.
Other points of lubrication
Lubricate joints, pins, hinges 9.7 X Every two And after every crane cleaning
and all movable components. weeks. operation using the high-
Cable drum
Spray-coat contact surfaces 9.8 X If necessary, more frequently.
of collector rings.
Rope supporting pulleys

0365_EN_FA043_C2_01_00_00
2002-12 9/12

Refer to Daily;
item start-up
Grease the rope supporting 9.9 X
pulleys
0365_EN_FA043_C2_01_00_00
10/12 2001-06
Memo:
0365_EN_FA043_C2_01_00_00
2003-01 11/12
Memo:
0365_EN_FA043_C2_01_00_00
12/12 2003-01
Engine C2-2
2 Engine
DANGER A double ladder must be positioned at the superstructure to enable maintenance work
to be performed on the engine (with the fly jib mounted and folded to the boom). The
double ladder is located below the driver's cab and secured by means of supports
(see part B2, item 11.1).
DANGER When handling fuel or consumables, do not smoke, do not use open flames!
DANGER Maintenance work may only be performed while the engine is at a standstill.
DANGER Depressurize systems such as the radiator, expansion vessels etc. before opening
them.
The following general inspection, servicing and maintenance operations at the engine, such as:
• engine oil level inspection,

• engine oil change,
• replacement of lubricating oil filter,
• replacement of fuel filter cartridges,
• cleaning of fuel prefilter cartridges,
• inspection of Vee belt for good condition,
• inspection of tappet clearance,
• troubleshooting, etc.,
have been described in the Operating Manual of the engine manufacturer which has been supplied with the
machine.
- Check engine for leakage at regular intervals.
Access to the oil dipstick (2) and the oil filler port (3) is possible after
opening the engine cover (1).
Oil level inspection, refer to the Operating Manual of the engine

manufacturer.
While the engine is at a standstill, the oil level of the engine can be
monitored by a warning lamp.
0370_EN_FA043_C2_02_00_00
2003-01 1/10
C2-2 Engine
Attention Oil change and oil filter replacement every 900 operating hours; at least, however,
once per year.
However, these intervals apply only in conjunction with oils according to DB approval
228.5.
The specifications of consumables of the engine manufacturer must be complied
with.
NOTE To facilitate collection of the used oil during engine

oil changes, the oil drain plug installed as standard
equipment can be removed during the first oil change,
and replaced by a drain valve provided with the tool
kit.
drain valve with packing ring instead of the oil drain
plug.
During subsequent oil changes, only the cap (1) of the drain valve (2) need be
removed and replaced by the oil drain hose (3) which is supplied with the took kit. As
the hose is fastened, the drain valve opens and the oil can be drained through the
hose into the collect vessel provided to this effect.
After these operations have been finished, remove the drain hose, clean the thread
using a clean piece of cloth and retighten the cap screw.
! Used oil and filters must be disposed of in an environmentally responsible fashion !
Attention The hose clamps of the charge air hoses are equipped with cup springs on the
threaded housing. When re-tightening the hose clamps, make sure that the maximum
tightening torque of 10.2 Nm is not exceeded.
• The hose clamps of the engine charge air hoses must be checked for tight fit according to the maintenance
schedule.
0370_EN_FA043_C2_02_00_00
2/10 2003-01
Engine C2-2
2.4 Fuel tank

2.4.1 Draining condensation water
Under extreme weather conditions, condensation may form in the fuel tank.
Operate the vehicle until the tank is emptied to reserve; unscrew the drain
plug (1) from the tank bottom and drain condensed water into an approp-
riate vessel. The drain port must be left open until clean fuel flows out.
Before retightening the drain plug, clean the sealing surface using a lint-
free cloth. If necessary, replace sealing element.
2.4.2 Clean fuel strainer**) in the filler socket
The filler socket for fuel is located on the left side, behind the super-
structure cabin.
- Open the cover, remove the fuel strainer (1) and clean it in a clean vessel
using a cleaning agent or diesel fuel; check and if necessary, replace it.
- Subsequently, blow the fuel strainer (1) out using compressed air.
- Reposition the fuel strainer (1) and mount cover.
2.4.2.1 Ventilation filter
- Check ventilation filter (1) for damage / contamination; clean, if

necessary, replace.

0370_EN_FA043_C2_02_00_00
2003-01 3/10
C2-2 Engine
2.4.3 Fuel strainer
2.4.3.1 Draining condensation water
- Open the drain valve (1) and allow the collected condensation
water to drain into an appropriate vessel.
NOTE Before the cold season begins, the condensate

must be drained. If necessary, repeat this step
several times.
2.4.3.2 Replacement of fuel strainer
- Drain the entire filter contents as described under item 2.4.3.1.

- Disconnect the filter (4) from the filter top (5) together with the filter base (2).
- Disconnect the filter base from the filter; clean the filter base (e.g. using diesel fuel).
- Clean the sealing surfaces.
- Grease new sealing elements with diesel fuel and insert them into the gaskets (3).
- Screw-fasten filter base (2) by hand to new filter cartridge, and screw-fasten filter cartridge (4) to filter top
(5).
- Tighten all components securely.
- Bleed system, as described in part B2, item 4.5.3.
0370_EN_FA043_C2_02_00_00
4/10 2003-01
Engine C2-2
2.5 Coolant
2.5.1 Check coolant level
DANGER Open cover of filler socket carefully and only at a coolant temperature below 90°C.
The cooling system is filled correctly if the coolant level is

between the "Max. and Min." marks (1) on the expansion tank
(2).
If necessary, add or replace the anti-freeze agent approved by

the engine manufacturer.
Check the anti-freeze protection using a test instrument. The
components must be frost-proof down to -37°C all the year
round.
When the coolant is replaced or the cooling system has to be

refilled after repair, the whole cooling system must be bled.
NOTE In case of possible leakage at the radiator hose couplings, do not only retighten or
replace the hose clamps, but check also the pressure relief valve in the valve cover
for proper working order. A defective valve may cause excess pressure in the coolant
circuit and consequently leakage.
0370_EN_FA043_C2_02_00_00
2003-01 5/10
C2-2 Engine
2.5.2 Drainage of coolant
NOTE Before the coolant is replaced, the vehicle's warm water heating must be open.
The drain plug is located at the bottom of the radiator. It is

located in the lowest position of the cooling system.
- Open the drain plug (1) and the cover of the overflow tank;
drain coolant into a suitable container.
- Fasten the drain plug and pour in coolant mix via the
overflow tank.
- Start the engine, make it run at various speed levels for
approx. 1 minute.
- Stop the engine and check the coolant level in the overflow
tank; if necessary, top up.
! Coolant must be disposed of in an environmentally responsible fashion !

NOTE For instructions on how to drain the entire coolant from the engine, refer to the engine
Depending on the dust collected, the cooler fins of the charge air and water cooler must be cleaned by
flushing with compressed air or using a paint brush.
0370_EN_FA043_C2_02_00_00
6/10 2003-01
Engine C2-2
2.7 Air cleaner
DANGER The air cleaner may only be serviced while the engine is not running. Switch battery
main switch off.
Attention Do not start the engine while the cleaner element is not installed.
NOTE In addition to the normal replacement intervals, the air cleaner cartridge need only be
replaced if the pilot lamp "air cleaner" in the instrument panel goes on while the
engine is running (refer to part "B2", item B2-4.6.2.5). At the same time, the air cleaner
housing must also be cleaned.
Attention The air cleaner housing must be checked for damage and cracks whenever the air
cleaner is serviced.
The air cleaner is installed in front of the superstructure engine

(viewed in driving direction). It is accessible after the lid of the
servicing port, has been opened.
2.7.1 Removal / installation of the filter cartridge
- Open the retaining clips (1) of the cover.

- Remove the cover (2) from the filter housing.
- Pull the air cleaner (3) out of the filter housing.
- Clean the filter housing and the sealing surfaces of
the filter housing and the cover carefully using a lint-
free piece of cloth.
- Insert new filter cartridge carefully into the housing.
Make sure that the sealing surfaces are in perfect
condition.
- Mount the cover. To this effect, place the cover onto
the housing and fasten it by means of the retaining
clips (1).
- During assembly, perfect fit of the filter cartridge and the housing cover must be ensured.
Attention Do not blow-clean using compressed air!

Make sure that no dust can enter the engine's air intake system while the air cleaner
housing is being cleaned!
2.7.2 Check filter cartridge
Check new filter cartridge before installation.
Attention On no account may a filter cartridge be used which shows visible damage - dents,
deteriorated filter surface etc.
Replace damaged filter cartridges immediately.
0370_EN_FA043_C2_02_00_00
2003-01 7/10
C2-2 Engine
2.7.2.1 Maintenance instructions
Filter servicing requires absolute precision and reliability. Inappropriate filter servicing may damage the
engine.
Do NOT perform maintenance depending on the result of the visual inspection of the cartridge. If a filter
cartridge is functioning properly, it must look dirty.
Never clean the filter cartridge by

• knocking,
• washing,
• blowing,
• or other cleaning procedures.
2.7.2.2 Disposal
Filter cartridges must be disposed of normally, and never be incinerated.
2.7.3 Check air intake pipes and hoses
- Check all hose connections between the filter and the engine and the charge air hoses for tight fit. Use
screw-type hose clamps only.
- Check hoses and pipes for porosity and cracks.
2.7.4 Inspection of electric vacuum switch on the clean air end of the air cleaner
housing
If the pilot lamp "air cleaner" does not go on despite the air cleaner being contaminated, the electric vacuum
switch must be checked for proper working order. The pilot lamp may also be defective.
2.7.4.1 Monitoring of air cleaner - check for proper working order
- Once the engine is running, reduce air cleaner intake opening gradually by covering it (e.g. using
cardboard or sheet metal), until the air cleaner pilot lamp goes on.
Attention After the air cleaner pilot lamp has gone on, the intake opening must not be reduced
further.
Risk of damage!
0370_EN_FA043_C2_02_00_00
8/10 2003-01
Engine C2-2
2.8 Exhaust system
The exhaust system consists of special steel. It does not require any particular service or maintenance.
2.8.1 Servicing the silencer spark arrester**)
Cleaning the soot collector
To remove the soot particles collected in the soot collector (1),

remove the cap (2).
To ensure that the spark arrester is always in proper working

order, the soot recipient must be emptied at regular intervals.

0370_EN_FA043_C2_02_00_00
2003-01 9/10
C2-2 Engine
Memo:
0370_EN_FA043_C2_02_00_00
10/10 2003-01
3 Hydraulic system
DANGER Work on the hydraulic system may only be performed while the engine is at a
standstill.
• Checking and retightening the screw couplings of the hydraulic assemblies and pipes, see item C2-3.6.
•Check hydraulic system for leakage at regular intervals.
Attention The shut-off cocks may only be closed in case of repair work (e.g. at the hydraulic
pumps).
3.1 Inspection of hydraulic oil level
NOTE Check the oil level while the engine is at a standstill and while the telescope cylinders
and the boom elevation cylinder are retracted.
• The oil level is indicated at the inspection glass (6). The oil level
must not exceed the black - maximum - mark, and it must not
drop below the red - minimum - mark.
• The oil level should be in the center of the inspection glass (6).
• Oil is poured in via the port of the ventilation filter (5). For this
purpose, unscrew the filter and pour in oil through the port.
• Subsequently, fasten the ventilation filter again.
Attention Make sure that only new oil is poured in from clean vessels.
0375_EN_FA043_C2_03_00_00
2003-01 1/6
3.2 Replacement of hydraulic filter cartridge
DANGER Replace the filter cartridges only while the engine is at a standstill.
NOTE The individual components installed in the valves, pumps and hydraulic motors have
deliberately narrow tolerances. Even very small impurities penetrating the hydraulic
system may cause malfunctions.
The filter cartridge must be replaced during every oil change to the hydraulic system,
when the “hydraulic oil filter contamination” warning lamp goes on and according to
Do not clean the filter cartridge.
• The tele and boom elevation cylinders are retracted.
- Release the securing bolts (1) and remove the filter cover (2).
- Fold the clip (3) of the filter cartridge (4) up. Turn the filter cartridge
to the left by 90° and unlock it.
- Remove the filter insert (4); allow the residual oil to drip.
- Insert new filter cartridge carefully into the housing. Lock them by a
90° rotation and fold down the clip (3).
- Check and, if necessary, replace the cover seal.
- Clean the filter cover seal (2) and the sealing surfaces using a lint-
free cloth.
- Make sure that the packing ring fits correctly.
- Position the filter cover (2) and re-tighten the securing bolts (1).
3.2.1 Replacement of the ventilation filter
- If the ventilation filter is contaminated or clogged, unscrew the ventilation filter (5) and replace it by a new
one. Check and clean the sealing element, if necessary, replace it (refer to item C1-9).
3.2.2 Replacement of sinter filters
Depending on the design of the hydraulic system, sinter filters are installed in the valves and control blocks.
The installation position of the filter in question is specified in the appropriate hydraulic piping diagram.
NOTE Whenever an operating malfunction occurs in a function circuit (loss of power etc.),
replace the sinter filters before taking other action.
! Filters must be disposed of in an environmentally responsible fashion !
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3.3 Oil change in the hydraulic system
DANGER Perform oil change only while the engine is not running.
• The tele and boom elevation cylinders are retracted.
- Close the stop cock (1) in the suction pipe.

- Remove the cap (2) from the drain plug (3). Fix the hose.
- Release drain plug (3) - do not unscrew it - until oil is
leaving. Drain the oil completely into a suitable container.
- Once work is finished, close drain plug (3), remove the hose
and reposition cap (2).
- Replace the filter cartridge as described under item 3.2.
- Pour in new oil as described under item 3.1.
- Remove any impurities which might be present.
- Clean sealing surfaces, clean sealing element, check and - if
necessary - replace it.
- Re-open the stop cock (1) in the suction pipe.
Attention Before starting the engine, check whether the stop cock in the suction pipe of the oil
tank is opened (lever transverse with reference to the piping).
NOTE It is recommended to have the oil analysed by the oil supplier before carrying out a
scheduled oil change, or at regular intervals, to see whether an oil change is
necessary.
The purity degree must comply with ISO 4406 grade 18/16/13. Only clean oil must be
poured in during the oil changes.
Depending on the degree of contamination and the thermal load the hydraulic oil is
subject to, shorter oil change intervals than those specified in the maintenance
schedule may be required.
! Filters and used oil must be disposed of in an environmentally responsible fashion. !

The hydraulic system can be converted to biodegradable oils according to VDMA 24568.
Attention When changing over the hydraulic system from oils based on mineral oil to
biodegradable oils, compliance with the directives of VDMA 24569 must be ensured.
(Use the recommended oil types.)
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3.5 Replacement of filter insert of pressure filter
- Unscrew the filter housing (1) and replace the filter insert.
- Clean sealing surfaces before assembly using a lint-free cloth.
3.6 Checking and retightening the screw couplings of the hydraulic

assemblies and pipes
• Check piping systems for leakage according to the maintenance schedule.

• In case of leakage of the adjustable screw couplings and assemblies, proceed as follows: first release the
cap nuts on the piping systems or hose pipes, then tighten the adjustable screw couplings in the
assemblies safely, finally fasten the cap nuts of the piping systems and hose pipes again.
• A perfectly sealing condition is only ensured if the above sequence of operations is observed and complied
with.
• In case of leakage at the cap nuts of the piping systems, check cap nuts for tight fit; if necessary, replace
the screw coupling.
3.6.1 Check screw couplings on the piping systems
Release the cap nut and check whether the gap between the packing ring and
the retaining ring is closed.
If necessary, replace the screw coupling.
3.7 Oil cooler / additional oil cooler**)
• Clean cooler fins with compressed air, depending on dust accumulated.

• Check fan and thermostatic valve for proper working order.

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3.8 Maintenance instructions for hydraulic cylinders
• Before commissioning, make sure that the hydraulic cylinders are bled.
• Bleeding may only be finished when no more bubbles appear.
• Bleeding must be repeated whenever hydraulic components or pipelines have been assembled or
disassembled.
• When machines are operating outdoors, bleed the hydraulic cylinders at regular intervals.
3.9 Speeds of the working hydraulics of the superstructure
The table indicates the specified speed set-point of the working hydraulics in sec./min., at max. engine
speed, for testing purposes.
NOTE Precise measurements are only possible after the system has been rinsed and bled.
The hydraulic temperature should be approx. + 30 to + 40°C and the engine speed
should be 2300 rpm. Setting tolerances: Pressure and time values +5%, engine speeds
-5%.
Speeds Set-point
Boom elevation "up" Normal 48 sec.
"up" High speed 27 sec.
"down" Speedy, smooth movement
Telescopes "extending" Normal 360 ± 35 sec.
"extending" High speed 270 ± 25 sec.
"retracting" Normal 350 ± 35 sec.
"retracting" High speed 270 ± 25 sec.
Winch Lifting, normal 0 – 49 min-1
Lifting, high speed 0 – 66 min-1
Auxiliary winch **) Lifting, normal 0 – 49 min-1
Lifting, high speed 0 – 66 min-1
Swing mechanism 29 sec./rot.
7009056/F/0505
3.10 Pressure check in the hydraulic system of the superstructure
In the case of an operating malfunction of the hydraulic system of the superstructure, the set-point pressures
of the various pressure ranges can be checked by unscrewing the pipes from the measuring connectors on
the valves and control blocks, which are marked with "M" in the figure, and by fastening hydraulic pressure
gauges to these connectors.
The pipes on measuring connectors M 3, M 4, M 5 and M 6 must be unscrewed and connected to the
hydraulic pressure gauges.
When M 3, M 4, M 5 and M 6 are activated individually during crane work, their pressures appear on the
ASLI indicator unit. When several working movements are activated, the ASLI display always indicates the
highest pressure value.
NOTE Precise measurements are only possible after the system has been rinsed and bled.
The hydraulic oil temperature should be approx. + 30 to + 40°C and the engine speed
should be 2300 rpm. Setting tolerances: Pressure and time values +5%, engine speeds
-5%.
For pressure values for the hydraulic system of the superstructure, refer to item 3.10.1.

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3.10.1 Set-point pressures in the hydraulic system of the superstructure
Pressure ranges Set value in bar Measuring

connector
Control oil supply, max. 50 M6
Control oil, telescope cylinder 100 M7
Control block, tele/boom elevation/auxiliary winch, 330 M4
primary
Tele cylinder, secondary "retracting" 315 M4
Tele cylinder, secondary "extend- 165 M4
ing"
Boom elevation, secondary "down" 35 M4
Winch, secondary "down" 150 M4
Winch, secondary "up" 310 M4
Control block, hoisting gear, primary 310 M3
Hoisting gear, secondary "down" 150 M3
Control block, slewing/counterweight 250 M5
Counterweight, secondary "down" 80 M8
7009056/F/0505
3.12 Measuring connectors
NOTE The measuring connectors are marked with an "M" in the hydraulic piping diagram for
the superstructure.
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Swing mechanism C2-4
4 Swing mechanism
DANGER Perform works on the swing mechanism only when it is at a standstill and not subject
to load.
Before commencing the works, take precautions to prevent unintended start-up.
Before starting the vehicle after maintenance or repair works, make sure that there is
no person within the danger zone.
To enhance safety, the swing mechanism should be checked visually (inside and
outside) at intervals of three years.
• Check the swing mechanism for leakage at regular intervals, according to the maintenance
schedule.
• Defective seals may affect the service life of the swing mechanism considerably.
• Loss of oil or an insufficient oil level in the gearbox may result in damage.
• Check oil level at regular intervals according to the maintenance

schedule, while the gearbox is not moving and after the oil has cooled
down.
• After removal of the inspection plug (4) (M 10x1), the oil level in the
gearbox must reach the inspection port or the inspection glass (5); if
necessary, add an appropriate amount of oil via the expansion tank (1)
using a funnel or a hose. To this effect, remove the ventilation filter (2)
and the plugscrew (3).
• Check oil level once more, if necessary, replenish.
Attention Different oil types – even if from the same

manufacturer – must not be mixed! Moreover, mineral
and synthetic oil must not be mixed!
4.2 Oil change
Perform the oil change at regular intervals according to the maintenance

plan when the system has its service temperature.
DANGER Risk of scalding.
- Drain oil into an appropriate vessel through the drain port by removing the oil drain plug R ¼“ (6).
- Clean, check and, if necessary, replace the seal. Close drain port again.
- Pour in new oil via the expansion tank (1) after removing the ventilation filter (2) and the plugscrew (3), until
the oil escapes through the inspection port (4) or until the oil level is visible in the center of the inspection
glass (5). Immediately after start-up, check the oil level once more and, if necessary, add oil.
- Clean sealing surfaces, clean sealing elements, check and - if necessary - replace them.
- Close inspection and filler ports again.
NOTE Check oil for foreign matter whenever an oil change is performed.
Drain oil when it has its service temperature. Caution - risk of scalding!
If e.g. coarse impurities are detected, they may be due to excessive stress or
improper operation. Determine the cause and eliminate it. Dismantle the hoisting gear,
check it for damage. If necessary, have a general overhaul be performed by the
manufacturer.
Check oil for possible blackening and foreign matter, if necessary, reduce oil change
intervals.
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C2-4 Swing mechanism
4.2.1 Inspection of the swing mechanism
DANGER Before or after any extended continuous operation, and in case the maximum load is
reached frequently, the screws and bolts located within the power flow must be
checked for tight fit.
- Check all screw couplings for tight fit.

- Check swing mechanism for abnormal sounds.
4.2.2 Ventilation filter
- Check the aeration filter (item 4.2, pos. 2) for damage and contamination; clean and, if necessary, replace
it (refer also to item C1-9).
4.3 Inspection of the hydraulic oil in the working brake circuit of the swing
mechanism
• The supply tank (3) must be filled with hydraulic oil up to the measurement mark.
Attention Do not use brake fluid. In case of a loss of oil (e.g. leakage), eliminate the damage
immediately, fill the supply tank and deaerate the brake system.
4.3.1 Bleeding (deaerating) the service brake circuit
The working brake must be bled after repairs to the hydraulic components of the
working brake circuit, before putting the gearbox into operation again.
- Fill supply tank (3) in the crane cabin with hydraulic oil.
- Remove protective cap from bleeder valve (1).
- Place transparent hose on the bleeder valve and open valve by approx. 1 turn.
- Hang the hose into a vessel which is half-full with hydraulic oil.
- Actuate pedal (2) until bubble-free oil flows out of the hose.
NOTE During this deaeration, the oil level in the supply tank (3)
must be checked or topped up continuously.
- With the pedal depressed, close breather valve, remove the hose and
reposition the protective cap.
- The pedal must not be released until the breather valve is closed.
- Check hydraulic oil level in supply tank once more.
Function test: The pedal must not have an inadmissibly long "dead
travel" or an excessively long travel, or rebound during actuation; if
necessary, the system must be bled once more.
! Used oil must be disposed of in an environmentally responsible

fashion !
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4.3.2 Inspection of the swing brake
Check for proper working order and leakage during operation. Once per year, the internal parts should be
checked for wear.
Please do not hesitate to contact your TADANO FAUN After-Sales Service in case of queries or problems.
They will be pleased to perform for you all the servicing, maintenance and repair work required.
4.4 Check tooth face backlash on swing motor gearbox drive shaft
The swing motor and the brake should be removed

and the splined shaft connections on the drive end
checked at regular intervals.
No excessive tooth face backlash is admissible.
gearing in good condition step gearing damaged
After the running-in period, the tooth faces show a smooth, bright surface in case of normal wear. If there are
other phenomena, such as scrub marks, seizing, pits, flaking, blistering, cracks and plastic deformations, the
gear wheels must be replaced.
4.5 Swing mechanism - greasing ring gear and pinion
The lubrication intervals depend on the slewing frequency. The special lubricant is applied to the gearing
using a paint-brush or a spray gun. It must be ensured that no blank areas are left on the tooth faces.
NOTE After each cleaning operation of the machine - especially after using a steam-jet unit -
check the lubrication of the ring gear and pinion of the swing mechanism. The ring
gear and the pinion must always be supplied with lubricant.
4.6 Greasing the ball bearing slewing ring
• Grease the ball-bearing slewing ring at regular intervals, according to the maintenance schedule, via the
lubricators installed in the superstructure platform.
• Shorter lubricating intervals may be required in tropical areas, at a high relative humidity, under ambient
conditions entailing lots of dust or dirt, and in the case of significant temperature fluctuations.
• Before the crane is put out of operation for an extended time, and before it is restored to operating
condition, re-greasing is essential.
• Caution when cleaning the crane - make sure that no water enters into the raceways.
• Once cleaning is finished, lubricate the crane thoroughly.
• The grease filling is to prevent friction, to seal and to protect the assembly against corrosion.
• Sufficiently ample amounts of grease must be used, so that a grease bead forms around the whole
circumference of the bearing grooves.
• To achieve uniform grease distribution, support the crane by outriggers and slew the superstructure while
re-greasing.
DANGER CAUTION during slewing operation ! Nobody is allowed to stay on the chassis ! For
slewing, it is essential that the crane is supported by outriggers!
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4.7 Greasing the swing lock pin
• The lock pin of the superstructure locking system must always be easy to operate.
• Grease the pin at regular intervals.
4.8 Check mechanical superstructure lock and proximity switch for proper
working order.
The superstructure is locked mechanically by means of the locking pin. Checking is possible via a proximity
switch provided in the chassis. The functions of the lock assembly and the proximity switch should be
checked before each crane operation.
For locking the superstructure, refer to part B2-2.9.
If the green pilot lamp 17 "swing mechanism locked" does not go on while the manual lever in the
superstructure is actuated correctly, the following options are available:
• The pilot lamp 17 "swing mechanism locked" is faulty.

• The proximity sensor in the chassis is faulty.
4.9 Lubrication of the swing mechanism multi-disc

compartment
To ensure corrosion-protection inside the multi-disc compartment and to obtain a

constant friction value, 0.1 l of hydraulic oil must be poured in before assembling
the motor.
The multi-disc compartment does not require an oil change.
However, it must be ensured that the same type and quantity of oil are poured in
after repair or after replacement of the disc package, before the motor is
assembled.
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4.10 Checking the ring gear connecting bolts, the securing bolts of the
hydraulic motor and the gearbox flange bolts for tight fit
• Check screws of rotary coupling, of hydraulic motor and gearbox flange bolts for tight fit according to the
maintenance schedule; if necessary, re-tighten.
ATTENTION It is essential to use a torque wrench for checking or re-tightening the screws and
bolts.
Tightening torques of
• ring gear connecting bolts M 27 = 1400 Nm,
• hydraulic motor securing bolts M 10 = 79 Nm,
• gearbox flange bolts M 16 = 280 Nm.
4.11 Checking the slewing device for wear
During the many years of operation, the wear of the raceway system, and consequently the tipping backlash
of the slewing device increase.
The maximum admissible increase of the bearing backlash, measured below the raceway, is 2.3 mm.
The specified value is not an absolute value, but indicates the increase of the backlash, referred to the
bearing backlash of the component when new.
DANGER If an inadmissible increase of the tipping backlash or advanced wear is suspected,

please contact the TADANO-FAUN After-Sales Service.
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Memo:
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Hoisting gear and auxiliary hoisting gear**) (2nd winch) C2-5
5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)
DANGER A double ladder must be provided on the superstructure to enable maintenance work
to be performed on the main or auxiliary winch. The double ladder is located below
the driver's cab and secured by means of supports. (Refer to part B2, item 11.1).
DANGER Perform works on the hoisting gear or on the auxiliary hoisting gear**) only when the
hoisting gears is at a standstill and in no-load condition.
Before commencing the works, take precautions to prevent unintended start-up.
Before starting the vehicle after maintenance or repair works, make sure that there is
no person within the danger zone.
To enhance safety, the hoisting gear and the auxiliary hoisting gear should be
checked visually (inside and outside) at intervals of three years.
• Check the hoisting gear for leakage at regular intervals, according to the maintenance schedule.
• Defective seals may affect the service life of the hoisting gear considerably.
• Loss of oil or an insufficient oil level in the gearbox may result in damage.
• Check oil level at regular intervals according to the

maintenance schedule, while the gearbox is not moving and
after the oil has cooled down.
• Once the inspection plug (2) has been removed, the hoisting
gear must be filled with oil up to the inspection port. If
necessary, add an appropriate quantity of oil via the filler
opening (1).
• Check oil level once more, if necessary, replenish.
• Clean sealing surfaces, clean sealing elements, check and -
if necessary - replace them.
• Close filler plug again.
Attention Different oil types – even if from the same manufacturer – must not be mixed!
Moreover, mineral and synthetic oil must not be mixed!

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C2-5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)
5.2 Oil change
• Perform the oil change at regular intervals according to the maintenance plan when the system has its
service temperature.
DANGER Risk of scalding.
- Remove the filler plug (1), the inspection plug (2) and the drain plug (3).
- Drain oil in an appropriate vessel.
- Check the seal of the drain plug and re-tighten the drain plug (3) safely.
- Pour in new oil via the oil filler port (1), until the oil flows out of the inspection port (2).
- Clean the sealing surfaces, check seals of filler and inspection plug, and re-tighten the two plugs.
- Check oil level once more, if necessary, replenish.
NOTE Check oil for foreign matter whenever an oil change is performed.
Drain oil when it has its service temperature. Caution - risk of scalding!
If e.g. coarse impurities are detected, they may be due to excessive stress or
improper operation. Determine the cause and eliminate it. Dismantle the hoisting gear,
check it for damage. If necessary, have a general overhaul be performed by the
manufacturer.
Check oil for possible blackening and foreign matter, if necessary, reduce oil change
intervals.
5.5 Check tooth face backlash on hoisting gear motor gearbox drive shaft
The hoisting gear motor and the brake should be removed and the splined shaft connections on the drive
end checked at regular intervals.
No excessive tooth face backlash is admissible.
After the running-in period, the tooth faces show a smooth,

bright surface in case of normal wear. If there are other
phenomena, such as scrub marks, seizing, pits, flaking,
blistering, cracks and plastic deformations, the gear wheels
must be replaced.
gearing in good condition step gearing damaged
5.6 Greasing of hoisting gear drum bearing bush
- Grease the bearing bush on the bearing end via lubricators (4) according to the maintenance schedule.
Make sure to apply only just as much grease until it leaves uniformly at the bearing bush (Use recommended
grease type).
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Hoisting gear and auxiliary hoisting gear**) (2nd winch) C2-5
5.7 Preservation of the hoisting gear drive
If the machine is to be decommissioned for an extended time, preservation of the hoisting gear is
recommended.
- Drain the used oil and pour in half the quantity of preservative oil.
- Actuate the hoisting gear for approx. 5 to 10 minutes, winding the rope on and off without load, with a high
number of rope falls fixed to the boom.
- On re-commissioning the machine, drain the preservative oil and pour in the specified oil type.
Only such types of preservative oil may be used as emulgate with the lubricating oil, according to the oil
manufacturer's specifications (Use the recommended oil types.)
5.8 Inspection of the hoisting gear brake
The hydraulic multi-disc brake of the hoisting gear is subject to a certain wear. For inspection, unscrew the
hoisting gear flange (5) together with the engine. In case of wear, the complete set of brake discs must be
replaced.
At the same time, the free wheeling of the hoisting gear brake must be checked.
To this effect, proceed as follows:
To check the free wheeling, pick up a load which amounts to 125 % of the max. rope pull force via the boom
elevation using the "short boom", and suspend it just above the ground. The distance which is now existing
between the lifted load and the ground must not change within 15 minutes.
However, it must be taken into consideration that the angle included by the boom elevation cylinder does not
change due to temperature influences. If the load moves down, the free wheeling must be replaced.
5.9 Check hoist limit switch for proper function
The hoist limit switch prevents the bottom block from hitting against the
rope sheaves.
- Raise the bottom block carefully, until the releasing weight (1) is lifted and
the spring-loaded limit switch (2) is set free.
Now, the crane movements "hoisting gear up", "extending

telescopes" and "boom elevation down" must be switched off.
- Lower the bottom block until the releasing weight is suspended freely;
now all crane movements are possible again.
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C2-5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)
5.10 Checking the hoist limit switch on the hoisting gear
The rope limit switch is set so that at least three safety rope windings remain on the drum.
- Extend the telescopes and wind off the rope until at least three rope windings remain on the drum.
Now, the hoisting gear must shut off.
NOTE Before winding up the rope, check the rope drum and the rope grooves for wear. While
spooling up, check the rope and, if necessary, grease it.
5.10.1 Setting the rope limit switch
- Wind up at least three rope windings on the drum.

- Unscrew the cover (1).
- Turn the gearbox cam plate (2) via the setscrew (3) until the
cam (4) actuates the micro switch (5). (Clicking sound in the
switch).
The gearbox cam plate does not require any maintenance.
5.11 Length transmitter rope

5.11.1 Checking the rope for correct winding-up and adjustment
• Check the length transmitter rope for good condition and

correct winding-up according to the maintenance schedule.
If the length transmitter rope is not correctly wound on the

drum or hangs loosely down from the drum, wrong data are
transmitted to the ASLI.
In this case, the length transmitter device must be readjusted
as follows:
- Retract the boom completely.
- Wind the rope on the drum.
NOTE The rope must be slightly tensioned.
Re-adjustment of the length transmitter unit
- Open the cover of the length transmitter unit (10 ea. hex. bolts SW 10).
- Turn potentiometer to the left to its stop at the setscrew (1) using a screwdriver.
- Check the boom length displayed in the ASLI. The ASLI must indicate 10.9 m.
- Position the cover and fasten it by means of the screws.
• On assembly, pay attention to the correct fit of the cover seal.
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Winch rope C2-6
6 Winch rope
NOTE The winch rope servicing and maintenance operations specified under item 6 must
also be performed for the rope of the 2nd hoisting gear.
means of supports (see part B2, item 11.1).
6.1 Inspection of the rope
• The rope must be checked visually before and after each application.
• When the ropes are evaluated and inspected at regular intervals, the legal regulations (in FRG: according
to DIN 15020, page 2, and VBG 9a) must be observed scrupulously.
• Ropes must be discarded if one of the following deficiencies occurs: breakage of a rope, breakage of a
strand, stepping up, bruising, traces of corrosion, wear, reduction of the rope diameter, lasting deformation,
etc. (for more details, refer to Part “E Crane Testing Instructions", item 3, Inspection of winch ropes).
• The ropes must be checked along their whole length, even at the fastening devices.
6.2 Cleaning and lubrication of the rope
• To prolong the service life of the ropes, wash severely soiled ropes down with clear water at regular inter-
vals, and grease them after drying. To protect the ropes against humidity and corrosion, grease them at
regular intervals using an adhesive grease.
• It is not sufficient to grease the rope only on the outside. The lubricant must penetrate into the rope.
• Use the recommended types of lubricants.
ATTENTION To increase the rope's service life, keep it tidy; do not drag it over the ground.
6.3 Removal (replacement) of the rope
- Place the bottom block on the ground.

- Detach the rope socket from its bolt fastening devices and
remove it.
- Remove the rope from the hoist limit switch weight and de-
tach the rope falls from the bottom block and the guide pul-
leys.
- Wind off the rope until the rope limit switch shuts off.
- Loosen the residual rope windings.
- Detach the rope end by releasing the threaded pins from the
clamping bar (1);
- remove the rope.
6.4 Inspection of rope drum
• Before placing a new rope of the same type (refer to crane inspection booklet), check the rope drum.
• Clean the drum thoroughly, removing dirt, old paint and foreign matter.
• Check the rope drum grooves for wear.
• If necessary, check the oil level via the inspection glass (2).
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C2-6 Winch rope
6.5 Placing a new winch rope
NOTE The service life of a rope depends essentially on the way how it is handled on posi-
tioning. For replacement, make sure that only metallic ropes of the same type,
strength and diameter are used.
• If possible, place a reel stand below the boom head when performing this work.
• The technical data of ropes are specified in the crane inspection booklet.
(The corresponding pages are available via the TADANO-FAUN After-Sales Service.)
- Pass the rope end over the boom head and pull it through to the rope drum.
- Pass the rope end through the bore-hole of the clamping piece (1), tighten the threaded pins.
- Wind up approx. 6 rope windings; wind off the rope until the rope limit switch shuts off as soon as 3 wind-
ings are reached; if necessary, re-adjust the switch.
- Wind up the rope slowly on the winch drum (place rope under a certain pretension).
- Tap the rope into its proper position using only a hammer of brass or lead.
• The rope is only wound up properly on the drum when the correct turn directions are selected.
• When winding up the rope, make sure that it is under tight tension (if necessary, grease the rope).
- Route the rope through the weight in the hoist limit switch, reeve the various rope falls in the bottom block
and fasten the rope to the rope socket.
ATTENTION Initially, the new rope may only be moved under moderate load and the load must be
increased gradually to its maximum rating, so that the rope is allowed to run in, to set-
tle and to lengthen.
6.6 Care to the winch rope
• Regular care to the rope helps ensure safety during crane operation and is essential for enhancing the
rope's service life considerably.
• Metallic ropes must be re-greased at regular intervals, depending on the operating conditions, this is espe-
cially important in the bending areas at the drum and the pulleys. The agents used for re-greasing must be
compatible with the original rope lubrication.
• Under identical test conditions, well-greased ropes provide four times the fatigue strength under reversed
bending stress than non-greased ropes.
• Metallic ropes which are subject to severe dirt accumulation should be cleaned at regular intervals, best
using a brush and washing with clear water.
• If the lower rope layers on the drum are nearly not used or not used at all, they must be unwound from time
to time and re-positioned under pre-load. A rope will operate with optimum economic efficiency if its entire
length is always used. Therefore, it is recommended to use a rope length suitable for the work to be per-
formed if crane operation will take an extended period of time.
• The rope must be checked visually at regular intervals, especially during the first time after placing. More-
over, it must be checked visually after extraordinary stress, in case of supposed, but not visible damage or
if there are first signs of damage at the rope.
• If the same hoisting movement is executed frequently, the winch rope may be dislocated longitudinally from
time to time.
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ATTENTION When work is effected at the electrical equipment of the superstructure, the current
circuit must be interrupted by disconnecting the negative terminal "-" cable from the
batteries (marked with a minus sign [-] on the battery).
Never disconnect the batteries while the engine is running. This might destroy
electronic components.
7.1 Batteries
DANGER When checking the acid level, do not smoke; do not use open flames!
Due to chemical reactions, batteries emit highly explosive hydrogen gas!
Spilled battery acid must not touch the skin, the clothes or the vehicle's paint. Battery
acid may cause injuries. Wear protective glasses!
If acid has got on your skin or in your eyes, wash these areas immediately with ample
quantities of tap water and, if necessary, consult a doctor!
ATTENTION Used batteries must be disposed of in an environmentally responsible fashion.
The batteries are installed on the right side of the superstructure (viewed in driving direction), on the front
end, below the cover. For battery maintenance, open the servicing lid and remove the battery cover. If the
vehicle operates under normal conditions, the batteries require only little maintenance.
A well-charged battery helps improve the starting process and has a longer service life.
• The acid level must be checked at regular intervals (visual inspection). The acid level must be approx. 10 to
15 mm above the top edge of the cells.
• Only top up distilled or demineralized water. After replenishing, wait for approx. 30 minutes, then check the
acid.
• The acid density in the individual cells must be measured using an acidimeter.
Discharged batteries freeze at -10°C.
0395_EN_FA043_C2_07_00_00
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7.1.1 Specific gravity and charge condition of the battery at an acid temperature of
+20°C
Specific gravity Volts per cell Charge condition of battery

Normal Tropics at test instrument
1.28 1.23 2.4 well charged
1.20 1.12 2.0 semi-discharged; re-charge
1.12 1.08 1.75 discharged - recharge immediately
NOTE When the vehicle is to be used under tropical climate conditions, it is essential to take
the fluctuations of the acid density into consideration. During the charging process,
the acid temperature must be monitored continuously.
• During the cold season, a good charging condition must be permanently ensured. If the vehicle is standing
for an extended period of time, the batteries must be re-charged.
• The charging current must not exceed 1/10 of the battery capacity.
- The connecting terminals must be greased slightly with acid-free and acid-resistant grease (e.g.Vaseline).
• Due to the danger of short circuits, parts conducting current, such as tools, etc., must not be placed on the
batteries.
• If the battery charging pilot lamp does not go out at increased engine speed, this indicates that the batteries
are not charged. Eliminate the reason immediately (governor or alternator).
7.1.2 Installation of new batteries
• When installing new batteries, first connect the positive cable (+), and then the negative cable (-).
• For removal, reverse sequence of installation operations.
The service life of the three-phase generator depends considerably on the bearings. Thus, make sure that
the Vee belts have always the proper tension (refer to Operating Manual of the engine manufacturer).
• The generator must be checked in a specialist workshop at regular intervals. In case of operation in very
dusty ambient conditions or at high ambient temperatures, the inspection should take place
correspondingly earlier.
• Operate the generator only when the governor and the batteries are connected.
• When connecting the batteries, pay attention to correct polarity, as incorrect connection might destroy the
diodes in the generator.
• Make sure that the batteries are disconnected and that the engine is not running when assembly work is
performed which involves live components (precaution)!
• Tipping against the mass in order to find out whether voltage is "on" is not admissible (destruction of semi-
conductors).
• Pre-excitation of the generator is effected from the batteries via the battery charging indicator lamp. To
ensure correct excitation, a defective battery charging pilot lamp must be replaced immediately.
7.3 Starter
Refer to the instructions of the engine manufacturer.
0395_EN_FA043_C2_07_00_00
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Defective lamps, indicator and warning lights must be replaced immediately. Make sure to use lamps having the
same wattage.
7.4.1 Mounting location, voltage/wattage and designation of the lamps and lights in
the superstructure
Mounting location DIN Design Power

Working floodlights (cabin, boom) 72601 YC 24V 70W
Working floodlight (boom) G 6,35 24V 250W
Rotary beacon 72601 H1 24V 70W
Instrument panel (switches) 72601 W5/1,2 24V 1.2W
Instrument panel (indicator lamps) 72601 W5/1,2 24V 1.2W
Fuel level indicator 72601 H 24V 2W
Compressed air pressure gauge, 72601 J 24V 3W
thermometer
Cab light 72601 K 24V 10W
Lateral lights on the boom head 72601 H 24V 2W
7.5 Load moment limiter (ASLI - Automatic Safe Load Indicator)
The automatic safe load indicator consists to a major part of electronic components of modular
design which must be serviced exclusively by qualified service staff.
Every time before the crane operator puts the machine into operation, he must make sure that:
• the ASLI is not restricted in its functionality by external destruction;

• the hoist limit switch, its weight and chain are correctly mounted,
• the electric cable connections are inserted;
• the cables are correctly wound up and tensioned in the electric cable drum, and properly routed in the
cable drum;
• the cables are neither damaged nor any strands are broken.
7.6 Inspection of the ASLI at regular intervals according to the legal

regulations
• The systems must be checked with calibrated weights according to the legal regulations.
• If an essential difference compared to the original setting is detected, re-adjustment must be effected by a
specialist.
Tampering with the electronic system of the ASLI by unauthorized persons is prohibited.
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Memo:
0395_EN_FA043_C2_07_00_00
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7.7 Fuse arrangement

The fuse box is located at the rear of the crane cabin.
DANGER Before replacing any defective fuses, turn the ignition off. Replace defective fuses only by fuses having the same power rating. Do
never use a jumper wire or a similar device.
F 801 Windshield wipers, F 809 Crane control F 817 Telescope control F 825 Battery main switch F 833 ADM F 841 Supplementary F 849 Chassis
10 A windshield washing 10 A -hoist winch, 5 A -Length transmitter 10 A 10 A 20 A heater unit 10 A -Engine start,
system -Armrest switch -Ignition ON,
-Indicator lamps
F 802 Seat adjustment, F 810 Crane control F 818 Emergency control F 826 Instrument F 834 Diagnostic connector F 842 Supplementary F 850 Chassis
15 A Windscreen 10 A -Swing brake, 10 A -Telescopes, 15 A illumination, 10 A -Engine 5 A heater unit 7,5 A - Parking brake
adjustment -High speed -Counterweight Working floodlight,
crane cabin
F 803 Mirror heating**), F 811 Crane control F 819 Counterweight F827 Working floodlight F 835 Generator F 843 Air conditioning**) F 851 Chassis
10 A Centralized 10 A -PDC output 7.5 A 10 A -Basic boom 7.5 A 15 A 15 A - Direction indicators,
lubrication system**) (25A) (working floodlight, - Lighting system
el. adjustable**))
F 804 Instruments, F 812 Precontrol F 820 Dead man’s F828 Working floodlight F 836 Hydraulic oil cooler F 844 free F 852 Chassis
10 A indicator lamps, 10 A transmitter 5 A control**) 15 A - Boom head 20 A 5 A -Inter-axle differential
buzzer, ADM locks
F 805 ADM, MR F 813 ASLI F 821 Light barrier, F 829 Working floodlight F 837 Plugbox F 845 free F 853 Chassis
10 A 10 A -Length transmitter, 3 A Extending 7.5 A -Rope winch 10 A -Inspection lamp 10 A -Front and rear axle
-Angle transmitter, telescopes steering
-Swing brake,
-Pressure sensor,
-Anemometer,
-Indicator lamps
F 806 free F 814 ASLI F 822 free F 830 Aircraft warning lamp F 838 Crane control F 846 free F 854 Chassis
7.5 A -Solenoid valve, 3 A **) 10 A Emergency mode 10 A - Outriggers
-Hoist winches
F 807 Diagnostic connector F 815 ASLI F 823 Heater fan F 831 Cab light F 839 free F 847 free F 855 free
10 A -Engine 7.5 A -Override feature 15 A 3A
F 808 Electric horn F 816 Telescope control F 824 free F 832 Radio, F 840 free F 848 free F 856 Chassis
7.5 A 10 A 15 A voltage reduction 7.5 A -Ignition ON
24/12V,
Crane control
Emergency mode
MR / ADM = Electronic system, engine PCD = Control electronics ASLI = Automatic Safe Load Indicator 99707700854/18
E/0402
Attention *) Depending on the vehicle model and the design of the optional equipment in question, fuses with different amperage ratings may be used.
The fuse to be exchanged may only be replaced by a fuse of the same type and amperage.

0395_EN_FA043_C2_07_00_00
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7.7.1 Fuses in the battery box, proximity switches for counterweight control
1 = Battery 25 A
2 = Fuse, chassis 50 A
3 = Fuse, battery 80 A
4 = Fuse, charging plugbox 25 A
For designations of the switches for the

counterweight control system, refer to the
electric circuit diagram for the
superstructure.
Sicherungsdose - Batterie = fuse box - battery

Gegengewcht-Zyl. = Counterweight cylinder
7.7.2 Hydraulic control block behind the crane cabin
For the functions of the solenoid valves,

please refer to the electric circuit diagram
and the hydraulic piping diagram for the
superstructure.
Fahrtrichtung vorne - Driving direction, front
0395_EN_FA043_C2_07_00_00
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7.8 Relay arrangement

The relay panels are located at the rear of the crane cabin.
free K 709 K 811 K 810 K 951 K 950 V 912 V913
Direction indicator Heating system Heating system Crane control Crane control Crane control Crane control
transmitter Vehicle fan Instrument illumination emergency mode emergency mode emergency mode emergency mode
V 702 free K 815 K 818 V 914 V 911 K 962**) K 963
Differential locks Heating system Heating system Crane control Crane control Crane control Hydraulic system
in axles, inter-wheel Vehicle fan Vehicle fan emergency mode emergency mode emergency mode Pumpe I
locks Auxiliary hoisting gear
up
K 503 free K 814 K 803 K 964 K 966 K 960 K 961**)
Steering enable Electric horn Wiper system Crane control Extending telescopes Crane control Crane control
Interval action emergency mode emergency mode emergency mode
Slewing superstructure Auxiliary hoisting gear
to the right down
K 501 K 504 K 813 K 802 K 817 K 816 K 958 K 959
Steering change-over Steering enable 15+ Wiper system Generator D+ Air conditioning system Crane control Crane control
ADM/MR Interval action emergency mode emergency mode
Retracting telescopes Slewing superstructure
to the left
V 501 K 502 K 809 V 801 free free K 956 K 957
Steering Steering change-over Battery main switch Generator D+ Crane control Crane control
emergency mode emergency mode
Lowering boom Extending telescopes
Ground point V 701 free K801 V 907 K 942 K 954 K 955
Axle locking assembly Radiator control ASLI override feature Electric horn Crane control Crane control
Crane over-rear activated ASLI override feature emergency mode emergency mode
activated Raising boom Lowering boom
K 706 K 702 K 808 K 806 K 965**) K 913 K 952 K 953
Ignition, superstructure Enable ignition Working floodlight Battery main switch Auxiliary hoisting gear Hoisting winch up Crane control Crane control
ON up emergency mode emergency mode
Hoisting gear "down" Hoisting gear "up".
99707700854/19
K = Relay , V = Diodes, OW = Superstructure F/1202

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Memo:
0395_EN_FA043_C2_07_00_00
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Memo:
0395_EN_FA043_C2_07_00_00
2003-01 9/10
Memo:
0395_EN_FA043_C2_07_00_00
10/10 2003-01
Crane cabin C2-8
8 Crane cabin
Grease joints and pins and all movable components with lubricating oil. Make sure that these parts move
unrestrictedly and are easy to operate.
• Hinges of the covers and servicing lids.
The mechanical components of the door lock also require regular care. The closing cylinder should be
It is most useful to treat door seals and other rubber components with acid-free grease or French talc before
the cold season begins.
For further information concerning the crane cabin, refer to the documents of the machine manufacturer in
part G2 Superstructure.
8.1 Air conditioner**)
The air conditioner for the crane cabin is MAINTENANCE-FREE. It must only be taken to a special workshop
in case of malfunctions.
Attention All sorts of repair, replenishing or overhaul work on the air conditioner system may
only be performed in an authorized workshop by well-trained staff.
Work on the air conditioner requires specific extraction and filling stations, recovery
stations, electronic leak detectors and special tools which are only available in
specialist workshops. Correct disposal of fluids is also only ensured in a specialized
workshop.
Oil level inspection of air conditioning compressor:
The oil level in the compressor can only be checked after a repair, or every time before the air conditioning
system is filled with new refrigerant. No refrigerant must be present in the circuit at the time the oil level in-
spection is performed.
On principle, the oil volume extracted from the refrigerating circuit plus an additional quantity of 10 cm3 must
be poured into the circuit on re-filling. If parts have been replaced during repair, then the quantities specified
for the replaced component must be added additionally (adhere to the current information by the various
manufacturers).
8.1.1 Functional check of air conditioner
The air conditioner should be put into operation for approx. 10 minutes at regular intervals, also in winter, to
keep it in proper working order.
The system should be checked in a specialist workshop once per year at the beginning of the cooling period.
For further details on operation, care and maintenance of the air conditioner, refer to the documents of the
manufacturer of this unit in Part G2, Superstructure.

0410_EN_FA043_C2_08_00_00
2003-01 1/4
C2-8 Crane cabin
8.2 Wiper-blade elements / washing system

8.2.1 Replacement of the wiper-blade elements
The wiper-blade elements must be cleaned at regular intervals to work properly.

2 1
For safety reasons (good visibility), it is recommended to replace the wiper-blade
elements immediately if their cleaning effect decreases. The wiper-blade elements
should be replaced at least once per year.
3
Replacement of wiper-blade elements:
- Lift wiper arm (1), remove the nut (2) and the securing bolt (3) and remove the wiper
blade.
- To mount the new wiper blade, reverse disassembly procedure.
8.2.2 Windshield washing system
The tank of the windshield washing system is accessible after opening of the windshield.
8.3 Replacement of dust filter and fuel filter
The supplementary heating is supplied with fuel from the

vehicle's fuel tank.
It is necessary to replace the fuel filter (3) of the supple-
mentary heater unit at regular intervals according to the
maintenance schedule to ensure trouble-free heater
operation.
- Remove the cover (1).
- Loosen the hose clamps (2), remove the fuel filter (3),
install a new filter and tighten the hose clamps safely.
The dust filter in the intake duct of the supplementary heater unit must be replaced, depending on the dust
collected.
For instructions on operation, care and maintenance of the superstructure cabin, refer to the documents of
the manufacturer of this unit in Part G2, Superstructure.
8.4 Heating system
the unit's manufacturer.
0410_EN_FA043_C2_08_00_00
2/4 2003-01
Crane cabin C2-8
8.5 Cleaning the recirculated air filter
The recirculated air filter (3) for the fan and the air conditioning is located between the protective grille (2) in
the floor assembly (1) behind the seat.
If the recirculated air filter (3) is visibly clogged by relatively big particles, it must be cleaned.
The cleaning intervals required depend greatly on the crane’s application.
The clogged filter element can be washed in water and re-installed after drying.
Before installing the filter element, check it for damage.
Attention In case of visible damage, the

filter element must be replaced.
- Lift off the protective grille (2) and remove the filter
element (3).
- Install the filter element, once cleaned and dried,
by reversing the above sequence of operations
analogously.
0410_EN_FA043_C2_08_00_00
2003-01 3/4
C2-8 Crane cabin
Memo:
0410_EN_FA043_C2_08_00_00
4/4 2003-01
Other points of lubrication, servicing and maintenance C2-9
9 Other points of lubrication, servicing and maintenance

9.1 Telescopic boom
• Grease or lubricate sliding surfaces, slideway liners, guide elements and guide rollers etc. at regular
intervals, according to the maintenance schedule (use recommended grease types).
• Grease the telescopic boom and basic boom bearings via the top lubrication port on the basic boom at
regular intervals, according to the maintenance schedule.
NOTE Whenever the crane has been cleaned - especially using a steam jet cleaning unit - check
the lubrication of the slide surfaces, slideway liners, guide elements etc. of the telescopic
elements and, if necessary, renew the grease applied. These components must always be
provided with a sufficient grease filling.
9.2 Boom elevation cylinder
• Grease the bearing of the top and bottom boom elevation cylinder securing pin at regular intervals, accord-
ing to the maintenance schedule.
9.3 Bottom block
• The load hook cross-beam and the load hook bearings must be greased via the lubricators at regular inter-
vals, according to the maintenance schedule. The lubricating intervals depend on the number of service
hours; under extreme operating conditions, lubrication may have to be effected earlier than specified in the
DANGER Welding on any components of the hook block is not admissible.
9.4 Counterweight
• Check locking cylinders for leakage according to the maintenance schedule. Check the locking mechanism
for proper working order and the cylinders for correct fastening.
9.5 Boom extension**)
• Grease and lubricate bearings, bushings, bolt securing mechanisms and lubricators.
• Grease the pin securing mechanisms which serve to mount the adapter to the boom head.
9.6 Centralized lubrication system **)
For instructions on operation, service and maintenance and data regarding the lubricating points, please
refer to the documents of the unit's manufacturer (see Annex).

0415_EN_FA043_C2_09_00_00
2003-01 1/2
C2-9 Other points of lubrication, servicing and maintenance
Grease joints, pins and all movable components, such as:

hinges of the engine servicing lid, hinges of the servicing lid for the air cleaner and the batteries, hinges of
the working floodlight adjusting device etc. by means of lubricating oil. Make sure that these parts move un-
restrictedly and are easy to operate.
The mechanical components of the door lock require regular care. The closing cylinder should be treated
with a graphited agent before the cold season begins.
9.8 Rope drum
- Remove rope drum cover.

- Coat the running and contact surfaces of the collector rings with contact
spray.
- Reposition the rope drum cover.
9.9 Rope supporting pulleys
• Grease rope supporting pulleys on the boom head at regular intervals, according to the maintenance schedule.
0415_EN_FA043_C2_09_00_00
2/2 2003-01

results, the oil level inspection plugs, the oil dipsticks or inspection glasses are
always decisive. Only those qualities may be used which are listed in the chart of
approved consumables of the assembly manufacturer, or which are indicated on the
Engine Engine oils according to the DC consumables specification. Refer to DC

Operating Manual
Initial filling with SAE 15W-40
Fuel tank Diesel fuel EN 590 approx. 220 l
Coolants / anti-freeze Coolants according to the DC Operating Manual approx.17,5

agents Anti-freeze agents according to the DC fuel specifications
Ambient temperature Mineral oils Biodegradable

according to oils according
DIN 51524-2 to
VDMA 24568
Hydraulic system over +30° C HVLP 68 HEES 68 approx. 590 l
from + 5° C to +25° C HLP 46 HEES 46
below + 5° C to - 15° C HLP 32 HEES 32
Oil tank from - 15° C to - 25° C HLP 22 HEES 22 approx. 480 l
below - 25° C HLP 10
Hoisting gear gearbox Hypoid gear oil according to MIL-L-2105 d (API-GL5) approx. 3,4 l
SAE 80 API-GL5
Initial filling with ARAL DEGON BMB 220
0420_EN_FA043_C2_15_00_00
2003-03 1/2

results, the oil level inspection plugs, the oil dipsticks or inspection glasses are
always decisive. Only those qualities may be used which are listed in the chart of
approved consumables of the assembly manufacturer, or which are indicated on the
Gearbox of swing Hypoid gear oil according to MIL-L-2105 d (API-GL5) approx. 3,3 l
mechanism SAE 90 GL5
Viscosity grade according to ISO-VG 220, DIN 51519
Initial filling with ARAL DEGON BMB 220
Swing mechanism ATF II D 0,1 l

Multi-disc compartment
Swing brake Ambient temperature Mineral oils Biodegradable approx. 0.5 l

expansion tank according to oils according to
DIN 51524-2 VDMA 24568
over +30° C HLP 68 HEES 68
from + 5° C to +25° C HLP 46 HEES 46
below + 5° C to - 15° C HLP 32 HEES 32
from - 15° C to - 25° C HLP 22 HEES 22
below - 25° C HLP 10
( ! Do not use brake fluid ! )
Air conditioning
system**) Refrigerator oil: ND-Öl 8 210 cm3
Refrigerator oil and Refrigerant : R134a 1,65 kg
refrigerant

0420_EN_FA043_C2_15_00_00
2/2 2003-03
Summary of lubricating grease types (recommended grease types) C2-16
16 Summary of lubricating grease types (recommended grease

types)
Maintenance point Grease type Filling capacity
Ring gear pinion and

gearing of the Preservation lubricant, specification BB as
ball bearing slewing (DIN 51513) or bituminous cogwheel spray for ring gears required
device
Swing
lock pin;
Other points of Lubricating grease, lithium-saponified, as

lubrication; according to DIN 51825-KP2K-20 required
Lubricators on:
Ball bearing slewing
device,
boom elevation
cylinder,
rope supporting pulley,
bottom blocks,
basic boom bearing
telescope boom
bearing
hoisting gear drum
bearing
Boom extension**)
Winch rope Corrosion-protective oil or anti-corrosion agent, lubricating

grease or lubricating adhesive or cogwheel spray as
Lubricating properties ensured from –20°C to +120°C required
Dropping point 200°C DIN 51801;
consistency grade 2 DIN 51818
Telescopes: Long-term lubricant: We recommend: FAUN-LUB

Sliding surfaces
slideway liners,
guide elements from -40° to +125°C from -30°C to +150°C as
NLGI grade no. 1 NLGI grade no. 2 required
Penetration 310/340 Penetration 265/295
Dropping point +180°C Dropping point +185°C
Centralized lubrication Lubricating grease, lithium-saponified, as
system **) according to DIN 51825-KP2K-20 required
Grease tank
Batteries Terminal grease as
required
Door locks Graphite powder as
required

0425_EN_FA043_C2_16_00_00
2003-03 1/2
C2-16 Summary of lubricating grease types (recommended grease types)
Memo:
0425_EN_FA043_C2_16_00_00
2/2 2003-03
Chart of approved consumables and lubricants C2-17
Recommended greases and lubricants for greasing points equipped

with lubricators, sliding surfaces and ball bearing slewing devices, as
well as ringgear and slewing gear pinion.
Symbols used in Symbols

the lubricating used in the
schedule Table
First-class lubricating grease, lith-

ium-saponified, penetration grade
2
Special lubricant, adhesive, hydro-

phobic with sufficient temperature
characteristics
248 K to 403 GULF CROWN 243 K to 393

Rolexa 2
K Grease No. 2 K
263 K to 393 GULF LUBCOTE 253 K to 333

Engrenage 3
K No. 2 K
243 K to 393 243 K to 403

Aralub HL 2 MOBILUX 2
K K
253 K to 403 243 K to 393

Aralub LFZ 1 MOBILTAC 81
K K
243 K to 393 243 K to 403

BP Energrease LS 2 Alvania Fett R 2
K K
243 K to 353 255 K to 333

BP Energol WRL Cardium Fluid C
K K
Castrol Spheerol 253 K to 393 253 K to 393

Glissando FL 20
AP 2 K K
253 K to 353 253 K to 393

Castrol Grippa 33 S Crater 2 X Fluid
K K
Chevron Dura-Lith 248 K to 398 253 K to 393

VALVOLINE LB-2
Grease 2 K K
Chevron Pinion 273 K to 398 VALVOLINE Dipper 253 K to 493

Grease MS K Stick K
243 K to 403
BEACON 2 Fritz Manke
K Technische
Artikel
Fichtestr. 72
253 K to 333 40233 Düsseldorf
Voler Compound 243 K to 343
SURETT Fluid 4 K
K 2000 E K
0430_EN_FA043_C2_17_00_00
2003-03 1/2
C2-17 Chart of approved consumables and lubricants
Memo:
0430_EN_FA043_C2_17_00_00
2/2 2003-03
Inspection scheme (before start-up, daily) C2-18

Check before start- up
= Refer to
Part C2), item …
= Inspection
K = Coolant
0435_EN_FA043_C2_18_00_00
2002-12 1/2
C2-18 Inspection scheme (before start-up, daily)
Memo:
0435_EN_FA043_C2_18_00_00
2/2 2001-06
Inspection and cleaning scheme C2-19
19 Inspection and cleaning scheme

Inspection, refer to main-
tenance schedule
Cleaning, replacement,
refer to maintenance
schedule
= Refer to Part C2)

Item …
F = Cleaning and/or re-

placement of fil-
ters, refer to main-
tenance schedule
E = Breathers
= Inspection
= Cleaning
Inspection, refer to main-

tenance schedule
Cleaning, replacement,
refer to maintenance
schedule
0440_EN_FA043_C2_19_00_00
2002-12 1/2
C2-19 Inspection and cleaning scheme
Memo:
0440_EN_FA043_C2_19_00_00
2/2 2001-06
Oil/coolant level inspection and change scheme C2-20

tenance schedule
Oil level inspection, refer
to maintenance schedule
= Refer to Part C2)

Item …
F = Filter change, refer

Engine oil*)
Hydraulic oil *)
Refrigerator oil and

refrigerant*)
~Corrosion-protective
anti-freeze agent
*) Use the recommend-

ed oil types

tenance schedule
Oil level inspection, refer
0445_EN_FA043_C2_20_00_00
2002-12 1/2
C2-20 Oil/coolant level inspection and change scheme
Memo:
0445_EN_FA043_C2_20_00_00
2/2 2001-06
Lubricating scheme C2-21
21 Lubricating scheme
= Refer to Part C2)

Item …
Universal grease**)
Special grease*)
*) Use recommended
grease types
Clean lubricators before

greasing. Grease all the
other parts using an oil
can.
0450_EN_FA043_C2_21_00_00
2002-12 1/2
C2-21 Lubricating scheme
Memo:
0450_EN_FA043_C2_21_00_00
2/2 2001-06
Part D
Circuit and piping diagrams
0455_EN_ALLGE_D_00_00_00
Diagrams D-0
0 Diagrams * A924 Control electronics, * E039 Rotary beacon, right-hand F012 Fuse
deadman sensor, right-hand * E042 Bordering light, front, left-hand (France) * F012 Fuse
*) For optional equipment “warning buzzer service
B001 Electric horn * E043 Bordering light, front, right-hand (France) F013 Fuse
brake”, refer to separate module!
* B002 Supertone horn * E044 Heater unit * F014 Fuse
A001 Radio
* B003 Buzzer, reversing signal M1 Motor F015 Fuse
A002 Voltage reduction device 24 V/12 V
* B005 Temperature sensor, room thermostat E Heater plug * F015 Fuse
* A005 Control unit, centralized lubrication system
B006 Inductive pickup, tachograph B3 Temperature sensor * F016 Fuse
* A009 Pulse distributor (only in case of AMOT control) B2 Temperature sensor
B007 Loudspeaker, left-hand F017 Fuse
A013 MR * E048 Marker lamp (France)
B008 Loudspeaker, right-hand F018 Fuse
Engine control system
B009 Buzzer, engine malfunction * E049 Marker lamp (France) F019 Fuse
Electronic system
B011 Fuel level transmitter E053 2nd side marker lamp, left-hand F020 Fuse
A014 ADM
* B012 Timer, heating E054 2nd side marker lamp, right-hand * F021 Fuse
Adaptation module
B101 Inductive pickup ABV 2A left-hand L2 E055 3rd side marker lamp, left-hand * F022 Fuse
Vehicle engine control
B102 Inductive pickup ABV 2A right-hand L1 E056 3rd side marker lamp, right-hand * F023 Fuse
A017 FR
Vehicle control B105 Inductive pickup ABV 4A left-hand A1 E057 6th side marker lamp, left-hand F025 Fuse
* A031 Refrigerator box B106 Inductive pickup ABV 4A right-hand A2 E058 6th side marker lamp, right-hand F026 Fuse
A101 Electronic module ABV B306 Buzzer, warning, gearbox E059 1st side marker lamp, left-hand F027 Fuse
A303 Gearbox electronics B801 Electric horn E060 1st side marker lamp, right-hand F028 Fuse
A801 Radio * B802 Fuel level transmitter, bio diesel E061 4th side marker lamp, left-hand F029 Fuse
A802 Voltage reduction device 24V / 12 V B802 Fuel level transmitter E062 4th side marker lamp, right-hand F030 Fuse
A803 Heater unit, control unit B806 Buzzer, engine malfunction E070 Reversing light F031 Fuse
A804 MR B807 Loudspeaker, left-hand * E091 Working floodlight, outriggers front left-hand * F032 Fuse
Engine control system B808 Loudspeaker, right-hand * E092 Working floodlight, outriggers front right-hand F033 Fuse
Electronic system B809 Timer, heating * E093 Working floodlight, outriggers rear left-hand F034 Fuse
A805 ADM B904 Rotation transmitter, hoisting gear 1 * E094 Working floodlight, outriggers rear right-hand F035 Fuse
Adaptation module * B905 Buzzer, AML shut-off feature E601 Instrument illumination, outriggers, right-hand F036 Fuse
Vehicle engine control * B908 Rotation transmitter, hoisting gear 2 E602 Instrument illumination, outriggers, left-hand F037 Fuse
* A807 Electrical thermostat control * B909 Anemometer E701 Rotary beacon rear, left-hand * F038 Fuse
A901 PDC indicator and control unit * B909 Connector, anemometer E704 Rotary beacon, rear, right-hand * F039 Fuse
A902 ASLI angle transmitter, boom E001 Dimmed light, left-hand E705 Lateral light, front right, on boom F040 Fuse
A903 ASLI length transmitter, boom E002 High-beam light, left-hand E706 Lateral light, front left, on boom F041 Fuse
A905 Pressure sensor, piston end "ACTUAL VALUE" E003 High-beam light, left-hand E707 Clearance lamp rear, left-hand, on the F042 Fuse
A906 Pressure sensor, rod end "COMPENSATION" * E004 Fog light, left-hand counterweight F043 Fuse
* A907 Pressure sensor, hydraulic system pressure E005 Bordering light on roof, left-hand E708 Clearance lamp rear, right-hand, on the F044 Fuse
A908 Length transmitter, telescope cylinder E006 Bordering light, front, left-hand (Parking light) counterweight F045 Fuse
A917 Remote control transmitter, left-hand * E007 Bordering light, lateral, left-hand (France) E801 Heater unit * F046 Fuse
a extending/retracting the telescopes E008 5th side marker lamp, left-hand E802 Working floodlight on the crane cabin * F047 Fuse
b slewing left-hand/right-hand * E009 Bordering light, rear, left-hand (France) E803 Working floodlight on the crane cabin F048 Fuse
c direction extending telescope E010 Rear light, left-hand E804 Working floodlight 70W F058 Fuse
d direction retracting telescope E011 License plate lamp basic boom F059 Fuse
e direction slewing left-hand E012 Direction indicator, front, left-hand * E804 Working floodlight 250 W F060 Fuse
f direction slewing to the right E013 Direction indicator, lateral, left-hand basic boom, adjustable via motor F061 Fuse
g stop telescoping, rated length E014 Direction indicator, rear, left-hand E805 Cab light * F062 Fuse
h2 swing brake E015 Stop light, left-hand * E807 Working floodlight on boom head F801 Fuse
i electric horn E016 Rear fog light, left-hand * E808 Working floodlight 70W F802 Fuse
j rotation transmitter, hoisting gear 2 E018 Cab light, left-hand basic boom F803 Fuse
k deadman sensor * E808 Working floodlight 250 W
* E019 Rotary beacon, left-hand F804 Fuse
l deadman sensor basic boom, adjustable via motor
E021 Dimmed light, right-hand F805 Fuse
A918 Remote control transmitter, right-hand * E810 Working floodlight on rope winch
E022 High-beam light, right-hand * F806 Fuse
a hoisting gear 1 - up/down * E811 Aircraft warning lamp
E023 High-beam light, right-hand F807 Fuse
b boom elevation - up/down * E811 Connector, aircraft warning lamp
c direction hoisting gear 1 - down * E024 Fog light, right-hand F808 Fuse
* E812 Condenser blower with pressure switch
d direction hoisting gear 1 - up E025 Bordering light on roof, right-hand F809 Fuse
* E813 Air conditioning compressor
e direction boom elevation - up E026 Bordering light, front, right-hand (Parking light) F810 Fuse
* E901 SCK alarm, visual/acoustic
f direction boom elevation - down * E027 Bordering light, lateral, right-hand (France) F811 Fuse
F001 Fuse
g high speed E028 5th side marker lamp, right-hand F812 Fuse
F002 Fuse
h1 hoisting gear 2 * E029 Bordering light, rear, right-hand (France) F813 Fuse
F003 Fuse
h2 counterweight E030 Rear light, left-hand F813 Fuse
F004 Fuse
i electric horn * E031 License plate lamp F814 Fuse
F005 Fuse
j rotation transmitter, hoisting gear 1 E032 Direction indicator, front, right-hand F815 Fuse
k deadman sensor F006 Fuse
E033 Direction indicator, lateral, right-hand F816 Fuse
l deadman sensor F007 Fuse
E034 Direction indicator, rear, right-hand F817 Fuse
A921 PDC central unit F008 Fuse
E035 Stop light, right-hand F818 Fuse
* A922 Swing angle transmitter, swing mechanism F009 Fuse
E036 Rear fog light, right-hand F819 Fuse
* A923 Control electronics F010 Fuse
E037 Reversing light F820 Fuse
deadman sensor, left-hand F011 Fuse
E038 Cab light, right-hand F821 Fuse
0457_EN_FA043_D_00_00_00
2001-06 1/8
D-0 Diagrams
* F822 Fuse H101 Indicator lamp, ABV, tractor vehicle K602 Relay, change-over, outrigger beams / outrigger crane control , emergency mode, brake, boom
F823 Fuse * H103 Indicator lamp, ABV, trailer cylinders elevation
* F824 Fuse H307 Indicator lamp, gearbox malfunction K603 Relay, change-over, outrigger beams / outrigger K956 Relay, brake, boom elevation
F826 Fuse H401 Axle lock indicator lamp cylinders K957 Relay,
F827 Fuse H402 Indicator lamp, normal level K604 Relay, change-over, outrigger beams / outrigger crane control, emergency mode, extending
* F827 Fuse H405 Indicator lamp, axle locking system engaged cylinders telescopes
F828 Fuse H501 Indicator lamp, rear axle unlocked K605 Relay, change-over, outrigger beams / outrigger K957 Relay, extending telescopes
F829 Fuse H511 Indicator lamp, rear axle unlocked cylinders K958 Relay,
F830 Fuse H701 Indicator lamp, central warning, engine K606 Relay, change-over, outrigger beams / outrigger crane control, emergency mode, retracting
F831 Fuse H702 Direction indicator pilot lamp cylinders telescopes
F832 Fuse H703 Indicator lamp, service brake, superstructure K607 Relay, change-over, outrigger beams / outrigger K958 Relay, retracting telescopes
F833 Fuse H704 Indicator lamp, service / parking brake, chassis cylinders K959 Relay,
F834 Fuse H707 Indicator lamp, inter-wheel differential lock K608 Relay, change-over, outrigger beams / outrigger crane control, emergency mode, slewing left-
F835 Fuse H713 Indicator lamp "swing mechanism locked" cylinders hand
F836 Fuse H801 Generator indicator lamp K609 Relay, change-over, outrigger beams / outrigger K959 Relay, swing mechanism left-hand
F837 Fuse H802 Indicator lamp, air cleaner cylinders K960 Relay,
F838 Fuse H805 Indicator lamp, hydraulic oil filter K702 Relay, enabling ignition crane control, emergency mode, slewing right-
K706 Relay, ignition, chassis ON hand
* F839 Fuse H806 Indicator lamp, hydraulic oil temperature
K709 Direction indicator transmitter K960 Relay, swing mechanism right-hand
* F840 Fuse H807 Indicator lamp, engine malfunction
K719 Relay, engine stalling device K961 Relay, crane control, emergency mode “hoisting
F841 Fuse K002 Relay, intermittent wiper operation
K721 Relay, central warning, superstructure gear 2 - down”
F842 Fuse K003 Electr. battery main switch
K722 Relay, MR/ADM K961 Relay, “hoisting gear 2 - down”
* F843 Fuse K004 Relay, generator D+
* K730 Relay, lighting from superstructure K962 Relay, crane control Emergency mode “hoisting
* F844 Fuse * K006 Relay, fog-light
* K731 Relay, lighting from superstructure gear 2 - up”
* F845 Fuse K007 Relay, high-beam light / headlamp flashers
K801 Relay, radiator control K962 Relay, hoisting gear 2 - UP
* F846 Fuse K008 Relay, rear fog light
K802 Wiper interval action relay K963 Relay, pump I
* F847 Fuse K010 Direction / hazard warning flasher transmitter
K803 Wiper interval action relay K964 Relay, crane control, emergency mode
* F848 Fuse K013 Relay, battery main switch
K805 Electric battery main switch K965 Relay, hoisting gear 2 - UP
F849 Fuse K013 Timing relay, battery main switch
K806 Timing relay, battery main switch K966 Relay, extending telescopes
F850 Fuse * K016 Relay box
K808 Relay, working floodlight * L001 Eddy-current brake
F851 Fuse K024 Relay, Telma
K809 Relay, generator D+ M001 Starter
F852 Fuse K032 Relay, off-road gear (torque limitation)
K810 Relay, heating, instrument illumination M002 Heater fan
F853 Fuse * K033 Relay, heater unit 58
K811 Relay, heating / vehicle fan (Thermostatic switch only in case of air
F854 Fuse * K037 Relay, air conditioner conditioner!)
* F855 Fuse * K038 Relay, clutch, air conditioner K811 Relay, vehicle fan
K813 Relay 15+ ADM/MR * M002 Collector drier with pressure switch
F856 Fuse * K039 Relay, condenser, air conditioner * M002 Magnetic clutch
F860 Fuse K040 Relay, holding circuit NES K814 Relay, electric horn
K815 Relay, heating / vehicle fan * M002 Condenser fan
F861 Fuse K041 Relay, door contact switch M003 Wiper motor
* F862 Fuse K042 Relay, stop light, superstructure K815 Relay, vehicle fan
* K816 Relay, air conditioner M005 Washer motor
F863 Fuse * K065 Relay, * M006 Fan
G001 Battery automatic connection of fan * K817 Relay, generator D+
K818 Relay, heating / vehicle fan M801 Starter
G002 Battery * K066 Relay, working floodlight, left side
K913 Relay, hoisting gear 1 - UP * M802 Radiator motor I
G003 Generator * K067 Relay, working floodlight, right side
* K942 Relay, M803 Motor, windscreen wiper
G801 Battery K311 Relay, gearbox starter interlock
electric horn, M804 Wiper motor, skylight
G802 Battery K312 Relay, reversing light
AML override actuated * M805 Windshield washer motor
G803 Generator K313 Relay "Gearbox, neutral"
K950 Relay, crane control, emergency mode * M806 Fan
H001 Generator indicator lamp K329 Relay "Gearbox, neutral"
K951 Relay, M807 Ventilation/heating fan
H005 Indicator lamp, MR/ADM malfunction K334 Relay "Engine brake"
crane control, emergency mode, swing brake M807 Ventilation/heating/air conditioning fan
H006 Indicator lamp, oil level, engine K401 Relay, crane directed to the rear
K952 Relay, * M808 Servomotor, working floodlight
H007 Indicator lamp, coolant level K402 Relay, change-over, proximity switch, axle lock
crane control , emergency mode “hoisting gear - * M809 Refrigerator motor II
H008 Indicator lamp, air cleaner K410 Relay, normal level front, left-hand
down” M810 Motor, seat adjustment
H009 Indicator lamp, hydraulic filter K411 Relay, normal level rear, left-hand
K952 Relay, “hoisting gear 1 - down” M811 Motor
H010 Indicator lamp, high-beam light K412 Relay, normal level front, right-hand Windscreen adjustment
K953 Relay,
H011 Direction indicator I pilot lamp K413 Relay, normal level front, right-hand crane control Emergency mode “hoisting gear - P001 Fuel level indicator
* H012 Direction indicator II pilot lamp K501 Relay, change-over of steering up” P003 Air pressure gauge
H014 Service brake indicator lamp K502 Relay, change-over of steering K953 Relay, hoisting gear 1 - UP P004 Engine temperature indicator
H015 Parking brake indicator lamp K503 Relay, steering enable K954 Relay, P005 Speed indicator with hourmeter
H016 Indicator lamp, steering pump K504 Relay, steering enable crane control emergency mode, boom elevation P006 Tachograph
H018 Indicator lamp, off-road gear K512 Relay, rear axle „floating“ up P008 Air pressure gauge
H020 Indicator lamp, inter-wheel differential lock K513 Relay, front axle steering from superstructure K954 Relay, boom elevation up P310 Display for gearbox
* H021 Indicator lamp, 2nd axle drive ON K514 Relay, front axle steering, right-hand K955 Relay, P703 Air pressure gauge
H022 Indicator lamp, on-road gear K515 Relay, front axle steering, left-hand crane control emergency mode, boom elevation P801 Fuel level indicator
* H026 Indicator lamp, centralized lubrication K516 Relay, rear axle locked down P802 Hourmeter
H028 Indicator lamp "Continuous service brake" K518 Relay, gearbox control K955 Relay, boom elevation down P804 Engine temperature indicator
H032 Indicator lamp, front inter-axle differential lock K519 Pulse generator K956 Relay, P820 Diagnostic connector
H035 Indicator lamp, rear fog light K601 Relay, chance-over, chassis/superstructure
0457_EN_FA043_D_00_00_00
2/8 2001-06
Diagrams D-0
P821 Diagnostic connector S051 Switch, front inter-axle differential lock hand locking mechanism
* P902 Hourmeter, hoisting gear 1 S052 Switch, reserve, circuit I S618 Rocker tip switch, engine speed regulation S910 Rocker tip switch,
* P903 Hourmeter, hoisting gear 2 S053 Switch, reserve, circuit II S621 Rocker switch with indicator lamp, preselection telescope emergency control,
R001 Rearview mirror, left-hand, heated, adjustable * S054 Switch, stop light of outrigger beam/outrigger cylinder left-hand releasing the lock
R002 Rearview mirror, right-hand, heated, adjustable S056 Switch, on-road gear S622 Rocker tip switch, extending/retracting front, left- S924 Rocker tip switch, counterweight overriding
R003 Rearview mirror, right-hand, heated S058 Switch, hydraulic filter hand feature
* R005 Rearview mirror, right-hand, heated S059 Switch, hydraulic filter S623 Rocker tip switch, extending/retracting rear, S925 Rocker switch with indicator lamp, telescope
* R006 Rearview mirror, right-hand, heated S063 Door contact switch, left-hand right-hand emergency mode
R010 Foot-actuated accelerator transmitter S064 Door contact switch, right-hand S624 Rocker tip switch, extending/retracting rear, left- * S933 Key-actuated switch, change-over, load charts
R013 Resistor, 120 Ω S075 Mushroom-head emergency off push-button, left- hand S938 Limit switch “hoisting gear 1 - down”
R014 Resistor 680 Ω , air cleaner hand S625 Rocker tip switch, extending/retracting front, left- * S939 Limit switch “hoisting gear 2 - down”
R015 Resistor 150 Ω, coolant level S076 Mushroom-head emergency off push-button, hand S941 Proximity switch, counterweight down, right-hand
right-hand S628 Rocker tip switch, engine speed regulation S942 Proximity switch, counterweight down, left-hand
R016 Resistor 3.3 kΩ, ambient temperature
S100 Rocker tip switch - switching ABV ON / OFF * S676 Rocker switch “working floodlight” on outrigger, S943 Proximity switch “TOP”, counterweight cylinder
R702 Hand-actuated accelerator, chassis
S301 Gear selector, gearbox left-hand not on top right
R802 Foot-actuated accelerator transmitter
S302 Gear selector, gearbox * S677 Rocker switch “working floodlight” on outrigger, S944 Proximity switch “TOP”, counterweight cylinder
* R804 Mirror, heated
S319 Switch, gearbox in neutral position right-hand not on top left
R910 Resistor HES (hoist limit switch), main boom
S401 Rocker switch, axle lock S701 Rocker switch with indicator lamp, chassis S945 Proximity switch, counterweight locked, left-hand
R911 Resistor dummy plug, HES control system engaged
S402 Rocker tip switch "leveling" S946 Proximity switch, counterweight locked, right-
* R912 Resistor HES, fly jib S702 Rocker tip switch, engine start, chassis
S403 Rocker tip switch, inclination adjustment, front hand
* R913 Resistor dummy plug, HES S703 Rocker switch, driving headlights
left-hand S947 Proximity switch, counterweight unlocked, left-
* R915 Resistor HES, heavy-lift fly jib S704 Rocker switch, direction indicators hand
* R916 Resistor dummy plug, HES S404 Rocker tip switch, inclination adjustment, rear
left-hand S707 Rocker switch with indicator lamp, parking brake S948 Proximity switch, counterweight unlocked, right-
* R917 Resistor S713 Rocker switch, inter-wheel differential lock hand
HES single top S405 Rocker tip switch, inclination adjustment, front
right-hand S714 Rocker tip switch, axle oscillation S951 Proximity switch S1
* R918 Resistor cylinder lock mechanism left-hand locked
S406 Rocker tip switch, inclination adjustment, rear S722 Switch, service brake, superstructure
dummy plug HES S952 Proximity switch S2
right-hand S801 Rocker switch, windscreen wipers
S002 Ignition starter switch cylinder lock mechanism right-hand locked
S411 Proximity switch on locking pin, crane directed to S802 Rocker switch, wiper skylight
S004 Rocker switch, mirror heating S953 Proximity switch S3
the rear S803 Rocker tip switch, washer
S005 Switch, heating / air conditioner cylinder lock mechanism left-hand unlocked
S412 Switch, front axle, left-hand, axle lock S804 Rocker switch
S006 Light switch S954 Proximity switch S4
S413 Switch, front axle, right-hand, axle lock Instrument illumination
S007 Steering column switch, Working floodlight cylinder lock mechanism right-hand unlocked
S414 Switch, rear axle, left-hand, axle lock
intermittent wiper action, S957 Proximity switch S5
S415 Switch, rear axle, right-hand, axle lock * S805 Rocker switch, working floodlight on boom
washer cylinder lock mechanism left-hand locked
S429 Rocker tip switch, leveling, ALL down * S807 Rocker switch with indicator lamp, aircraft
S008 Steering column switch S958 Proximity switch S6
S437 Magnetic switch, normal level, front, left-hand warning lamp
High-beam / dimmed light cylinder lock mechanism right-hand locked
S438 Magnetic switch, normal level, rear, left-hand S808 Rocker switch with indicator lamp, battery main
horn S959 Proximity switch S7
S439 Magnetic switch, normal level, front, right-hand switch
S009 Steering column switch, direction indicators cylinder lock mechanism left-hand unlocked
S440 Magnetic switch, normal level, rear, right-hand S809 Rocker switch with indicator lamp, centralized
* S010 Rocker switch, super-tone horn S960 Proximity switch S8
S501 Rocker switch, unlock rear axle lubrication
* S011 Rocker switch, fog light cylinder lock mechanism right-hand unlocked
S502 Control switch, rear axle steering S810 Ignition starter switch
S012 Rocker switch with indicator lamp, hazard S962 Hoist limit switch, main boom
S503 Control switch, rear axle steering * S814 Rocker switch, working floodlight on rope winch
warning flasher system * S963 Hoist limit switch, fly jib
S506 Switch on slipring, crane directed to the rear S815 Rotary switch , ventilation/heating
S013 Key-actuated switch, carrier - superstructure S964 Proximity switch 1a
S511 Rocker switch with indicator lamp, rear axle * S817 Rocker switch with indicator lamp, mirror heating
S014 Rocker tip switch, rear fog light Tele pin locking mechanism
unlocked S818 Rocker switch, working floodlight on basic boom
S015 Rocker switch with indicator lamp, rotary beacon Detection of telescope section
S512 Rocker tip switch, rear axle steering, left- * S819 Rocker tip switch, variable working floodlight,
S016 Rocker tip switch, on-road / off-road gear 1 a left-hand on top
hand/right-hand basic boom
S019 Rocker tip switch, inter-wheel differential locks S965 Proximity switch 1
S517 Switch, rear axle locked S823 Mushroom-head emergency off push-button
* S020 Manual control switch (with eddy-current brake) Tele pin locking mechanism
S601 Rotary switch, preselection of outriggers * S824 Mushroom-head emergency off push-button
S021 Rocker switch, battery main switch Detection of telescope section
S602 Rocker tip switch, extending/retracting front, left- S824 Mushroom-head emergency off push-button
* S022 Rotary switch, differential locks 1 right-hand on top
hand * S825 Air conditioning switch with temperature control
S026 Rotary switch, mirror adjusting switch S966 Proximity switch 2a
S603 Rocker tip switch, extending/retracting rear, * S826 Rotary switch, ventilation/heating/air conditioning
S030 Rocker switch, working speed Tele pin locking mechanism
right-hand S827 Rocker tip switch, seat adjustment
* S031 Rocker switch, reversing signal Detection of telescope section
S604 Rocker tip switch, extending/retracting rear, left- S828 Rocker tip switch
S037 Switch, coolant level 2a left-hand, center
hand Windscreen adjustment
S038 Switch, air cleaner S967 Proximity switch 2
S605 Rocker tip switch, extending/retracting front, left- S829 Rocker tip switch, engine stalling device
S039 Switch, steering pump Tele pin locking mechanism
hand S830 Switch, air cleaner Detection of telescope section
S041 Switch, stop light S831 Switch, hydraulic oil filter
S611 Rocker switch with indicator lamp, preselection 2a right-hand, center
S042 Switch, parking brake brake-air pressure * S832 Temperature switch, radiator control
of outrigger beam/outrigger cylinder right-hand S968 Proximity switch 3a
S043 Switch, parking brake S836 Switch, hydraulic oil temperature
S612 Rocker tip switch, extending/retracting front, left- Tele pin locking mechanism
S044 Switch, parking brake hand * S840 Thermo probe NTC
S045 Switch, off-road/manoeuvring gear Detection of telescope section
S613 Rocker tip switch, extending/retracting rear, S903 Key-actuated push-button, hoist limit switch 3a left-hand, bottom
* S046 Switch, 2nd axle drive ON right-hand S904 Key-actuated push-button, AML
* S047 Switch, inter-wheel differential lock, 1st axle S969 Proximity switch 3
S614 Rocker tip switch, extending/retracting rear, left- S909 Rocker switch, Tele pin locking mechanism
* S048 Switch, inter-wheel differential lock, 2nd axle hand telescope emergency control, Detection of telescope section
S049 Switch, inter-wheel differential lock, 3rd axle S615 Rocker tip switch, extending/retracting front, left- telescope preselection, 3 right-hand, bottom
S050 Switch, inter-wheel differential lock, 4th axle
0457_EN_FA043_D_00_00_00
2001-06 3/8
D-0 Diagrams
S972 Proximity switch “CENTER”, counterweight not * X903 Plug on fly jib to main boom Y605 Solenoid valve, outrigger cylinders, rear, right-
on top right * X904 Plug on fly jib to hoist limit switch hand: retracting
S973 Proximity switch “CENTER”, counterweight not * X905 Plug on stinger, rear Y606 Solenoid valve, outrigger beams, rear, left-hand:
on top left * X906 Plug on stinger, front, to hoist limit switch extending
S974 Light barrier, receiver, extending tele section * X911 Plug Y607 Solenoid valve, outrigger beams, rear, left-hand:
S975 Light barrier, emitter, extending tele section on single top retracting
* S981 Hoist limit switch, single top to main boom Y608 Solenoid valve, outrigger cylinders, rear, left-
* S985 Hoist limit switch, heavy-lift fly jib * X913 Plug hand: extending
S990 Rocker switch, rope winch rotation transmitter on heavy-lift jib Y609 Solenoid valve, outrigger cylinders, rear, left-
V003 Group of diodes, buzzer to main boom hand: retracting
V012 Group of diodes Y002 Pneum. solenoid valve, transfer box, off-road Y610 Solenoid valve, outrigger cylinders, front, left-
V401 Group of diodes, depressurized circulation gear hand, extending
V413 Canceling diode * Y006 Solenoid valve, 2nd axle drive ON Y611 Solenoid valve, outrigger cylinders, front, left-
V414 Canceling diode Y007 Solenoid valve, inter-wheel differential locks hand, retracting
V415 Canceling diode Y011 Solenoid valve PN, parking brake Y612 Solenoid valve, outrigger cylinders, front, left-
V416 Canceling diode Y014 Pneum. solenoid valve, transfer box, on-road hand: retracting
V419 Group of diodes, leveling, ALL down gear Y613 Solenoid valve, outrigger beams, front, left-hand:
V501 Group of diodes, steering * Y016 Fuel pump retracting
V505 Group of diodes, steering Y019 Solenoid valve, front inter-axle differential lock Y614 Solenoid valve, outrigger cylinders, front, right-
V506 Group of diodes, steering Y101 Solenoid valve, ABV 2A left-hand L2 hand: extending
V508 Group of diodes, steering Y102 Solenoid valve ABV 2A right-hand L1 Y615 Solenoid valve, outrigger cylinders, front, right-
V509 Group of diodes, steering Y105 Solenoid valve, ABV 4A left-hand A1 hand: retracting
Y106 Solenoid valve, ABV 4A right-hand A2 Y616 Solenoid valve, outrigger beams, front, right-
V510 Group of diodes, steering
Y307 Pneum. solenoid valve, engine brake hand: extending
V603 Group of diodes, outriggers
Y311 Pneum. solenoid valve, engine brake Y617 Solenoid valve, outrigger beams, front right-
V604 Group of diodes, outriggers
Y401 Solenoid valve, inclination adjustment, front left- hand: retracting
V605 Group of diodes, outriggers (sol. Y619)
hand, down Y618 Solenoid valve, depressurized circulation
V701 Group of diodes, axle lock, crane directed to the
Y402 Solenoid valve, inclination adjustment, front left- Y619 Solenoid valve, pressure limitation, extending
rear
hand, up outrigger beams
V702 Group of diodes, inter-wheel differential lock
Y403 Solenoid valve, inclination adjustment, rear left- Y801 Fuel pump
V711 Group of diodes, ignition, chassis
hand, down Y901 Solenoid valve, crane control, control pressure
V713 Group of diodes
Y404 Solenoid valve, inclination adjustment, rear left- Y902 Solenoid valve, boom elevation “down”
V714 Group of diodes, differential locks
hand, down Y903 Solenoid valve “hoisting gear 1 - down”
V801 Group of diodes, generator D+
Y405 Solenoid valve, inclination adjustment, front Y904 Solenoid valve “hoisting gear 1 - up”
V907 Group of diodes, AML override feature activated
right-hand, down Y905 Solenoid valve, extending tele sections
V911 Group of diodes, crane control, emergency mode
Y406 Solenoid valve, inclination adjustment, front Y906 Solenoid valve “hoisting gear 2 - down”
right-hand, up Y907 Solenoid valve “hoisting gear 2 - up”
Y407 Solenoid valve, inclination adjustment, rear right- Y908 Solenoid valve, retracting tele sections
V914 Group of diodes, crane control, emergency
hand, down Y909 Solenoid valve, boom elevation up
mode, swing brake
Y408 Solenoid valve, inclination adjustment, rear right- Y910 Solenoid valve, swing brake released
W001 Antenna
hand, up Y914 Solenoid valve, high speed
W701 Slipring (chassis/superstructure)
Y411 Pneum. solenoid valve, suspension Y918 Solenoid valve, swing mechanism left-hand
W801 Antenna
Y412 Solenoid valve, axle oscillation Y919 Solenoid valve, swing mechanism, right-hand
* W802 Cable drum, working floodlight
Y501 Solenoid valve, front axle steering from Y925 Solenoid valve, pump I
W901 Cable drum, length angle transmitter, slip ring
superstructure Y926 Solenoid valve, pump II
W905 Cable drum, tele control
Y502 Solenoid valve, front axle steering from Y927 Solenoid valve, counterweight activ.
X Remove connection in case of optional
superstructure Y931 Solenoid valve, counterweight "down"
equipment
Y503 Solenoid valve, front axle steering from Y932 Solenoid valve, counterweight "up"
X001 Cigarette lighter (plugbox)
superstructure Y933 Solenoid valve, locking counterweight
* X002 Battery charging plugbox
Y504 Solenoid valve, front axle steering from Y934 Solenoid valve, unlocking counterweight
* X003 Plugbox for starting the engine with current superstructure
supplied from an external source Y939 Solenoid valve, brake, boom elevation
Y505 Solenoid valve, actuation of rear axle steering, Y941 Solenoid valve, ASLI
* X004 Trailer plugbox N left-hand
* X005 Trailer plugbox S Y971 Solenoid valve, control oil, locking mechanism
Y506 Solenoid valve, actuation of rear axle steering, Y972 Solenoid valve, soft change-over, locking tele
X050 Diagnostic connector right-hand cylinder
* X101 Trailer plugbox, ABV Y509 Solenoid valve, front axle steering from Y973 Solenoid valve, lock, keeping locking state
X21 Diagnosis superstructure
X301 Plug, vehicle electric system I Y510 Pneum. magnetic valve, rear axle unlocked
X801 Plugbox 24V/10A inspection lamp Y515 Solenoid valve, front axle steering, left-hand
* X802 Battery charging plugbox Y516 Solenoid valve, front axle steering, right-hand
* X803 Plugbox for starting the engine with current Y602 Solenoid valve, outrigger beams, rear, right-
supplied from an external source hand: extending
* X837 Plugbox 12V/10A Y603 Solenoid valve, outrigger beams, rear, right-
X901 Plug-and-socket connectors, fly jib hand: retracting
X901 Plug-and-socket connectors, fly jib Y604 Solenoid valve, outrigger cylinders, rear, right-
X902 Dummy plug, main boom hand: extending
0457_EN_FA043_D_00_00_00
4/8 2001-06
Diagrams D-0
Key for diagrams Diff.-quer Inter-wheel differential lock

Diode Diode
German English Diode Zündung UW ein Diode, ignition chassis ON
(Option) (Optional equipment) Diodengruppe Group of diodes
2. A. Antr. Diff. VA-lae. 2nd axle drive, front inter-axle differential lock Display Display
ab "down" Dollybetrieb Dolly operation
Abstützträger 1 ausfahren Extend outrigger beam 1 Drehbereich Swing area
Abstützträger 1 einfahren Retract outrigger beam 1 Drehdurchführung Rotary coupling
Abstützträger 2 ausfahren Extend outrigger beam 2 Drehen links Slewing to the left
Abstützträger 2 einfahren Retract outrigger beam 2 Drehen rechts Slewing to the right
Abstützträger 3 einfahren Retract outrigger beam 3 Drehwerk Swing mechanism
Abstützträger 3. ausfahren Extend outrigger beam 3 Drehwerksblock Swing block
Abstützträger 4 ausfahren Extend outrigger beam 4 Drehwerksmotor Swing motor
Abstützträger 4 einfahren Retract outrigger beam 4 Drehwerksmotor Einspeisung Swing motor, supply
Abstützung Outriggers Drehwinkel Swing angle
Abstützzyl. ausfahren Extend outrigger cylinder Drehzahlverstellung Engine speed regulation
Abstützzyl. einfahren Retract the outrigger cylinder ein Retracting – or - ON
Abtriebsdrehzahl Output speed Einf. Retract.
Achsblockierung Axle locking assembly entr. - entriegeln Unlocked - unlocking
Achse Axle EURO-Steuerung EURO control
Achspendelung Axle oscillation Fahrersitz Driver's seat
Anschl. Kuppl. Connection coupling Fahrschalt. Gear selector switch
Anschluss Connector Fahrtrichtung Driving direction
Anschluss Funk Connection, radio Fahrzeugseite rechts Right side of the vehicle
Anschluss Heizung Connection, heating FAUN-Steuerung FAUN control system
Anschluss Konstantdrossel Connector, constant throttle valve FBA - Federspeicherbremsanlage Air accumulator brake system
Anschlussplan ABV-Stecker Connection diagram ABV connector Federung / Straßenfahrt Suspension / on-road gear
Antr. aus Drive assembly OFF Federung OW Superstructure suspension
Antr. ein Drive assembly ON Federungszylinder Suspension cylinder
Antrieb 2. Achse 2nd axle drive Funktion Function
Anz. Ind. Fussbremse Footbrake
Anz. Achsblock. ein Ind. „axle lock ON“ Gangsch. Gearbox control system
Anz. Diff.-quer Ind. ”inter-wheel differential lock” Gebläse Fan
Anz. Festst.bremse Ind. “parking brake“ Geg.zyl. auf / ab Counterweight cylinders up /down
Anz. Zentralw. Motor Ind. “central warning, engine“ Geg.zyl. entrieg./verrieg. Unlock / lock counterweight cylinders
auf “up” Gegengewicht Counterweight
aus Extending – or - OFF Geländegang Off-road gear
Ausf. Extend. Getriebe Gearbox
Ausfahrzyl. ausfahren extending the extension cylinder Getriebeausgang Gearbox output
Ausfahrzyl. einfahren retracting the extension cylinder Getriebeeingang Gearbox input
Ausg. Output Getriebeölkühlung Gearbox oil refrigeration
Ballast heben / senken Lift / lower ballast HA entriegeln Unlock rear axle
Ballast verriegeln / entriegelen Lock / unlock ballast HA entriegelt Rear axle unlocked
BBA - Betriebsbremsanlage service brake system HA-Lenkung / HA-Lenk. Rear axle steering
Bedien. operation Handfahrgeber Hand-actuated accelerator
Beifahrersitz Passenger seat Hauptschalter Main switch
Beleucht. Display Lighting of display heben Raising / lifting
Beleuchtung / Bel. Lighting hinten / hi. rear
Blinker links Direction indicators, left-hand hinten links absenken Lowering, rear, left-hand
Blinker rechts Direction indicators, right-hand hinten links anheben Raising, rear, left-hand
Bordnetz Kl. ... Vehicle's electrical network, terminal … hinten rechts absenken Lowering, rear, right-hand
Bremslicht Brake light hinten rechts anheben Raising, rear, right-hand
Bremsventil Brake valve Hinterachslenkung Rear axle steering
D.S. (Drehschalter) Rotary switch HL Rear, left-hand
D.S. 2.VA-Antrieb Rotary switch, 2nd front-axle drive Hochschaltsperre Upshift lock
D.S. Feststellbr. Rotary switch, parking brake HR Rear, right-hand
dauergeschaltet (d. OW-Lenkung) Continuously connected (via superstructure steering) Hubw. 1 / 2 ab / auf Hoisting gear 1 / 2 ab / auf
Diagnose Diagnosis Hubwerk Hoisting gear
Diff. VA-lae. / Diff.-laengs Front inter-axle differential lock Hubwinde Hoist winch
0457_EN_FA043_D_00_00_00
2001-06 5/8
D-0 Diagrams
Hydraulik Hydraulic system Rahmendurchbruch Frame breakthrough

Hydraulikanlage Hydraulic system re. Right-hand
Hypl - Hydraulikplan Hydraulic piping diagram Rechtseinschlag Actuation of steering, right-hand
je nach Fahrzeugtyp Depending on vehicle type Rel. (Relais) Rel. (Relais)
Klima Air conditioner Relais PTO1 Relay, PTO1
Kolbenseite Piston end Reserve Reserve
konst. const. R-Signal R signal
Kraftstoffbehälter Fuel tank Rücklauf Return line
Kranstellung hi. Crane over-rear Rücklauf vom Ölkühler Return line from the oil cooler
Kreis Circuit Rückleitung Return pipe
Kühlanlage Cooling system Rücklicht Rear light
Kühlbox Refrigerator box Rundumleuchte Rotary beacon
Lecköl Leakage oil Sammelleitung Manifold line
Leerlaufschalter Idle switch Sammeltrockner mit Druckschalter Collector drier with pressure switch
Leitungsenden isolieren Insulate cable ends Saugleitung Suction pipe
Lenksäule Steering column Schalt. Drehwerksfreisch. Switch, swing lock out
Lenkung Steering Schalter OW ein Switch, superstructure, ON
Lenkungspumpe Steering pump Schalter OW ein Switch, superstructure, ON
Lenkungsverriegelung Steering locking mechanism Schalter UW ein Switch, chassis, ON
li. Left-hand schematische Anschlussdarstellung Schematic connection diagram
Lieferumfang „MOTOR“ Scope of supplies “MOTOR” Schlaucharmatur Hose fitting
Linkseinschlag Actuation of steering, left-hand Schlüsselschalter Key-actuated switch
Lüfter Fan Seitenleuchten Lateral lamps
Lüfterpumpe Fan pump senken Lowering
Luftfederung Air suspension Set + / - Set + / -
Mag. Achspendelung Solenoid valve, axle oscillation Sicherung Fuse
Mag. druckl. Uml. Solenoid valve, depressurized circulation siehe BGR Refer to module
Mag. Handbremssich. Solenoid valve, handbrake locking mechanism siehe Stromlaufplan OW Refer to electric circuit diagram for superstructure
Magnetventil Solenoid valve Sign. 1./2./3./N/R-Gang Signals, 1st, 2nd, 3rd/N/rev. gear
Masse Ground Speicherladeventil Accumulator load valve
Masse Deckenleuchte usw. li. / re. Ground, ceiling lamp etc., left-hand / right-hand Speichervorfülldruck Accumulator pre-load pressure
Masse FH/Inst.T. Ground, driver's cab/instrument panel SPK - Br. (Spreizkeilbremse) Spreading wedge brake
Masse Scheinwerfer usw. li. / re. Ground, headlamp etc., left-hand / right-hand St.tr. Outrigger beam
minus Minus St.zyl. / Stützzyl. Outrigger cylinder
Mot.-Start UW Engine start, chassis Standard Standard
Motor Engine Stangenseite Rod end
Motor Start Engine start Start-Sperr-Relais Starter-interlock relay
Motor Stopp Engine stop (stalling device) Steuerblock Control block
Motorbremse Engine brake Steuersch. Control switch
Näh.schalter Proximity switch Straßengang On-road gear
Niveauregulierung Leveling Stufe (Heizung: - / Teleskopieren: _) Stage (heating: level / telescoping: section)
Notlenkpumpe Steering emergency pump Stützzylinder 1 einfahren Retracting outrigger cylinder 1
np bei ... km/h np at … km/h Stützzylinder 1. ausfahren Extending outrigger cylinder 1
NV - Nebenverbraucher Auxiliary equipment Stützzylinder 2 ausfahren Extending outrigger cylinder 2
NVA - Nebenverbraucheranlage Auxiliary equipment Stützzylinder 2 einfahren Retracting outrigger cylinder 2
oben top Stützzylinder 3 ausfahren Extending outrigger cylinder 3
Ölbeh. (Ölbehälter) Oil tank Stützzylinder 3 einfahren Retracting outrigger cylinder 3
opt. Hupe Optical horn Stützzylinder 4 ausfahren Extending outrigger cylinder 4
Option Optional equipment Stützzylinder 4 einfahren Retracting outrigger cylinder 4
OW - Oberwagen Superstructure Tank Tank
P.St. (Pumpensteuerung) Pump control Tank Pumpen Enb Tank, pump assembly
Pneum. Schaltung für Federung / Pneumatic control for suspension / axle lock Tank Tele Tank, tele sections
Achsblockierung Taster Abst. HL ausf. Pushbutton, extending outriggers rear left-hand
Pneumatikventile Pneumatic valves Taster Abst. HL einf. Pushbutton, retracting outriggers rear left-hand
PTO1 Anforderung PTO1 request Taster Abst. HR ausf. Pushbutton, extending outriggers rear right-hand
PTO1 Rückmeldung PTO1 feedback signal Taster Abst. HR einf. Pushbutton, retracting outriggers rear right-hand
Pumpe Pump Taster Abst. VL ausf. Pushbutton, extending outriggers front left-hand
Pumpen Enb Pump assembly Taster Abst. VL einf. Pushbutton, retracting outriggers front left-hand
Quit Quit Taster Abst. VR ausf. Pushbutton, extending outriggers front right-hand
0457_EN_FA043_D_00_00_00
6/8 2001-06
Diagrams D-0
Taster Abst. VR einf. Pushbutton, retracting outriggers front right-hand

Tele aus Extend tele section Text blocks
Tele ein Retract tele section
Teleskopverriegelung Telescope lock Re. Chapter D1-2, page 1/2
Telesteuerung Telescope control system
Temp aus Cruise control OFF List of functionalities (not for materials planning)
Temposet Temposet Item Designation Qty.
Thermoventil Thermostatic valve 01 Two-cylinder air compressor 1
Türschalter Door switch 02 Pressure governor / air drier 1
Umluft Recirculated air 03 Four-circuit protection valve 1
Umsch. Stützzyl. Change-over, outrigger cylinders 04 Dual-circuit brake valve 1
Umschaltventil Change-over valve 05 Handbrake valve 1
unten Bottom 07 Compressed air tank 5 l 1
Unterwagen – UW Chassis 08 Compressed air tank 20l 1
VA-Lenk. Front axle steering 08.1 Compressed air tank 40l 5
Ventil-Anordnung Prototyp Valve disposition, prototype
08.2 Compressed air tank 10l 1
09 Drainage valve 7
Ventilblock Valve block
10 Brake cylinder 20 6
Ventilgruppe Valve group
11 Air accumulator cylinder 20/24 6
verr. - verriegeln Lock - locking
15 Pressure limiting valve 1
Verstellpumpe Variable-rate pump
15.1 Quick release valve 1
Verteilergetr. Transfer box
16 Relay valve 3
Vierkreisschutzventil Four-circuit protection valve
16.1 Overload protection valve 2
VL Front, left-hand 17 Check valve 1
von L Hubwinde from L hoist winch 18 Shuttle valve 3
Vorderachslenkung (von Oberwagen) Front axle steering (from superstructure) 19 Pressure gauge 2
Vorlauf zum Ölkühler Pressure line to the oil cooler 20 Pressure switch 6
vorne Front 21 Pressure switch 1
vorne links absenken Lower, front, left-hand 24 Silencer 5
vorne links anheben Raise, front, left-hand 24.1 Silencer 1
vorne rechts absenken Lower, front, right-hand 24.2 Silencer 1
vorne rechts anheben Raise, front, right-hand 28 Test socket 10
VR Front, right-hand 28.1 Test socket 4
W.S. (Wippschalter) Rocker switch 30 Filler socket 1
W.T. (Wipptaster) Rocker tip switch 31 3/2 way valve 1
W.T. Achspendelung Rocker switch, axle oscillation 33 Rod-type sensor 2
Warnsummer, Störlampe Warning buzzer, malfunction indicator lamp 34 Rod-type sensor for drive var. 8x6 2
Widerstand Resistor Rod-type sensor for drive var. 8x8 2
Widerstand Kl. 1-2 entfällt bei Betrieb mit 2 Resistor, terminal 1 - 2, deleted in case of two-winch operation 35 ABV solenoid valve 4
Winden 36 Trailer control valve 1
Winde Winch 37 Coupling head B (brake) 1
Wippe Boom elevation 38 Coupling head V (supply) 1
Wippe ab Boom elevation "down" 39 Single-circuit brake valve 1
Wippe auf Boom elevation “up” 40 Pressure gauge 1
zum Filter to the filter
Zündung UW ein Ignition, chassis ON TECHNICAL DATA OF BRAKE SYSTEM
Zusatzheizung Supplementary heater unit
Zusatzsymbol an der Schlauchleitung Additional symbol on the hose pipe Switch-off pressure: 9.8 to 10.2 bar - circuits 1 and 2
Zuschaltung Connection Switch-on pressure: 8.5 to 9.5 bar - circuits 1 and 2
Zuschaltventil Sequence valve Design pressure: 8.5 bar – 1st axle
Zylinderverriegelung Cylinder lock Pressure limitation of 3rd and 4th axles: 5.5 to 5.7 bar
Pressure limitation of circuits 3 and 4: 8.1 to 8.5 bar
Brake circuit 1 = 3rd and 4th axles.
Brake circuit 2 = 1st and 2nd axles.
The brake system has been equipped with polyamide tubes according to DIN 74324.
(KG) = Connector for clutch and gearbox
(NV) = Connector or auxiliary equipment
Y011 = Parking brake actuation from the superstructure
0457_EN_FA043_D_00_00_00
2001-06 7/8
D-0 Diagrams
Re. Chapter D1-2, page 2/2 Re. Chapter D2-3, page 2/12
List of functionalities (not for materials Functions of valves according to

planning) designation of electr. connector Overview of switches
Item Designation Qty. Y002 = Transfer box - off-road gear
001 3/2 way valve 6 Y007 = Inter-wheel differential lock in S831 Hydr. oil filter
axles S 832 Connecting hydr. oil cooler Y914 High speed
002 3/2 way valve 2 Y011 = Parking brake actuation from S836 Max. hydr. oil temperature Y918 Swing mechanism, left-hand
the superstructure S961 Swing brake engaged Y919 Swing mechanism, right-hand
003 5/2 way valve 1 Y014 = Transfer box - on-road gear Y925 Pump 1
004 Compressed air tank 20l 1 Y019 = 4th axle - inter-axle lock Overview of solenoid valves Y926 Pump 2
005 Drainage valve 1 Y307 = Constant throttle valve Y901 Control pressure shut-off Y927 Activating the counterweight
006 Test socket 1 Y311 = Engine brake Y902 Boom elevation "down" Y931 Counterweight down
007 Quick release valve 1 Y411 = Axle lock / suspension Y903 Winch „down“ Y932 Counterweight up
008 Unloading valve 1 Y510 = Unlock rear axle (steering) Y904 Winch “up” Y933 Lock counterweight
009 4/2 way valve 1 Connector for supply of auxiliary Y905 Extend tele section Y934 Unlock counterweight
equipment, refer to module 16/00 Y906 2nd winch “down” Y939 Brake valve, boom elevation
010 Shuttle valve 1 Optional equipment: Y907 2nd winch “up” Y941 ASLI shut-off feature
Y006 = Connection of 2nd axle Y908 Retract tele section Y971 Control oil, locking mechanism
Y909 Boom elevation “up” Y972 Change-over, telescopic cylinder lock
Y910 Release swing brake Y973 Keeping locking state
Re. Chapter D2-1, page 34/36
Leitungsfarben - Cable colors

BG beige beige
BL blau blue
BR braun brown
GE gelb yellow
GN grün green
GR grau grey
OR orange orange
RS rosa pink
RT rot red
SW schwarz black
TR transparent transparent
VI violett violet
WS weiß white
S= Shield
*= Optional equipment
according to customer’s request
Ground cables: brown
Cable colours unless otherwise specified: white
Cable cross sections, unless otherwise specified: 1,5 ∅
0457_EN_FA043_D_00_00_00
8/8 2001-06
Part D1
Chassis
0460_EN_ALLGE_D1_00_00_00
Electric circuit diagrams (diagrams of chassis) D1-1
1 Electric circuit diagrams (diagrams of chassis)

1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 1/32
D1-1 Electric circuit diagrams (diagrams of chassis)
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2/32 2001-06
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 3/32
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
4/32 2001-06
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 5/32
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
6/32 2001-06
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 7/32
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
8/32 2001-06
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 9/32
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
10/32 2001-06
cont'd.: 1.1 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 11/32
1.2 ABV (99707782423)
0465_EN_FA043_D1_01_00_00
12/32 2001-06
1.3 Gearbox control (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 13/32
cont'd.: 1.3 Gearbox control (99707782423)
0465_EN_FA043_D1_01_00_00
14/32 2001-06
1.4 Chassis (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 15/32
1.5 Axle suspension (99707782423)
0465_EN_FA043_D1_01_00_00
16/32 2001-06
cont'd.: 1.5 Axle suspension (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 17/32
cont'd.: 1.5 Axle suspension (99707782423)
0465_EN_FA043_D1_01_00_00
18/32 2001-06
1.6 Steering (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 19/32
cont'd.: 1.6 Steering (99707782423)
0465_EN_FA043_D1_01_00_00
20/32 2001-06
1.7 Outriggers (99707782423)
0465_EN_FA043_D1_01_00_00
2001-06 21/32
cont'd.: 1.7 Outriggers (99707782423)
0465_EN_FA043_D1_01_00_00
22/32 2001-06
0465_EN_FA043_D1_01_00_00
2001-06 23/32
0465_EN_FA043_D1_01_00_00
24/32 2001-06
0465_EN_FA043_D1_01_00_00
2001-06 25/32
1.8 *Eddy-current brake (99707782423)
0465_EN_FA043_D1_01_00_00
26/32 2001-06
1.9 Slipring (99707792047)
0465_EN_FA043_D1_01_00_00
2001-06 27/32
1.10 Outrigger actuation, left-hand (99707778632)
0465_EN_FA043_D1_01_00_00
28/32 2001-06
1.11 Outrigger actuation, right-hand (99707778633)
0465_EN_FA043_D1_01_00_00
2001-06 29/32
1.12 Webasto heating, type Air Top 3500 (99707782215)
0465_EN_FA043_D1_01_00_00
30/32 2001-06
1.13 * Emergency OFF Engine Stop (99707764338)
0465_EN_FA043_D1_01_00_00
2001-06 31/32
Memo:
0465_EN_FA043_D1_01_00_00
32/32 2001-06
Pneumatic diagrams (diagrams of chassis) D1-2
2 Pneumatic diagrams (diagrams of chassis)

2.1 Pneumatic diagram - compressed air system (99707784011)
0470_EN_FA043_D1_02_00_00_ABFZ02
2001-06 1/2
D1-2 Pneumatic diagrams (diagrams of chassis)
2.2 Pneumatic diagram - auxiliary equipment (99707784011)
0470_EN_FA043_D1_02_00_00_ABFZ02
2/2 2001-06
Hydraulic piping diagrams (diagrams of chassis) D1-3
3 Hydraulic piping diagrams (diagrams of chassis)

0475_EN_FA043_D1_03_00_00
2001-06 1/8
D1-3 Hydraulic piping diagrams (diagrams of chassis)
3.2 Steering (99707783480)
0475_EN_FA043_D1_03_00_00
2/8 2001-06
3.3 Water separator (99707769783)
0475_EN_FA043_D1_03_00_00
2001-06 3/8
3.4 Engine (99707783479)
0475_EN_FA043_D1_03_00_00
4/8 2001-06
3.5 Fan drive (99707783478)
0475_EN_FA043_D1_03_00_00
2001-06 5/8
3.6 Oil tank (99707785893)
0475_EN_FA043_D1_03_00_00
6/8 2001-06
3.7 Transfer box (99707783485)
0475_EN_FA043_D1_03_00_00
2001-06 7/8
3.8 Outriggers (99707775506)
0475_EN_FA043_D1_03_00_00
8/8 2001-06
Part D2
Superstructure
0480_EN_ALLGE_D2_00_00_00
Electric circuit diagrams (diagrams of superstructure) D2-1
1 Electric circuit diagrams (diagrams of superstructure)

0485_EN_FA043_D2_01_00_00
2001-06 1/36
D2-1 Electric circuit diagrams (diagrams of superstructure)
1.2 Chassis control – differential lock (99707792063)
0485_EN_FA043_D2_01_00_00
2/36 2001-06
1.3 Chassis control - lighting (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 3/36
1.4 Chassis control - gearbox control (99707792063)
0485_EN_FA043_D2_01_00_00
4/36 2001-06
1.5 Chassis control - steering (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 5/36
1.6 Chassis control - outriggers (99707792063)
0485_EN_FA043_D2_01_00_00
6/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 7/36
cont'd.: 1.7 Chassis control (99707792063)
0485_EN_FA043_D2_01_00_00
8/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 9/36
cont'd.: 1.8 Superstructure (99707792063)
0485_EN_FA043_D2_01_00_00
10/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 11/36
0485_EN_FA043_D2_01_00_00
12/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 13/36
0485_EN_FA043_D2_01_00_00
14/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 15/36
1.9 Crane control (99707792063)
0485_EN_FA043_D2_01_00_00
16/36 2001-06
cont'd.: 1.9 Crane control (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 17/36
0485_EN_FA043_D2_01_00_00
18/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 19/36
0485_EN_FA043_D2_01_00_00
20/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 21/36
1.10 Telescope control (99707792063)
0485_EN_FA043_D2_01_00_00
22/36 2001-06
cont'd.: 1.10 Telescope control (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 23/36
0485_EN_FA043_D2_01_00_00
24/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 25/36
0485_EN_FA043_D2_01_00_00
26/36 2001-06
1.12 ASLI (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 27/36
cont'd.: 1.12 ASLI (99707792063)
0485_EN_FA043_D2_01_00_00
28/36 2001-06
0485_EN_FA043_D2_01_00_00
2001-06 29/36
1.14 *Extensible fly jib (99707792063)
0485_EN_FA043_D2_01_00_00
30/36 2001-06
1.15 *Heavy-lift fly jib / single top (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 31/36
1.16 Webasto heating, type Thermo 90S (99707792063)
0485_EN_FA043_D2_01_00_00
32/36 2001-06
1.17 *Air conditioning system (99707792063)
0485_EN_FA043_D2_01_00_00
2001-06 33/36
0485_EN_FA043_D2_01_00_00
34/36 2001-06
1.19 * Emergency OFF Engine Stop (99707764226)
0485_EN_FA043_D2_01_00_00
2001-06 35/36
Memo:
0485_EN_FA043_D2_01_00_00
36/36 2001-06
Hydraulic diagrams (diagrams of superstructure) D2-3
3 Hydraulic diagrams (diagrams of superstructure)

0490_EN_FA043_D2_03_00_00
2001-06 1/12
D2-3 Hydraulic diagrams (diagrams of superstructure)
cont'd.: 3.1 Hydraulic system (99707017035)
0490_EN_FA043_D2_03_00_00
2/12 2001-06
3.2 Valve group (99707017205)
0490_EN_FA043_D2_03_00_00
2001-06 3/12
3.3 Pump assembly (99707785539)
0490_EN_FA043_D2_03_00_00
4/12 2001-06
0490_EN_FA043_D2_03_00_00
2001-06 5/12
3.5 Swing mechanism (99707017051)
0490_EN_FA043_D2_03_00_00
6/12 2001-06
3.6 Telescopic cylinder (99707766793)
0490_EN_FA043_D2_03_00_00
2001-06 7/12
3.7 Boom elevation cylinder (99707766792)
0490_EN_FA043_D2_03_00_00
8/12 2001-06
3.8 Hoist winch (99707775369)
0490_EN_FA043_D2_03_00_00
2001-06 9/12
3.9 Auxiliary hoisting gear (99707775372)
0490_EN_FA043_D2_03_00_00
10/12 2001-06
3.10 Emergency control (99707771869)
0490_EN_FA043_D2_03_00_00
2001-06 11/12
Memo:
0490_EN_FA043_D2_03_00_00
12/12 2001-06
Part E
Crane testing instructions
0495_EN_ALLGE_E_00_00_00
Recurrent crane inspections E-1
Recurrent crane inspections
Every FAUN crane is tested before delivery according to the DIN standards or the Regulations for the Pre-
vention of Accidents according to BGV D6 valid in the Federal Republic of Germany.
The accident prevention provisions valid in the Federal Republic of Germany specify that inspections be
effected at yearly intervals; corresponding regulations are valid abroad and have to be observed.
If no appropriate regulations are existing in the country of use, it is recommended to perform these recurrent
inspections according to the Provisions for the Prevention of Accidents BGV D6 valid in Germany.
Recurrent yearly inspections of cranes can be effected by experts or by persons who have acquired special
knowledge in the crane sector. This inspection is essentially a visual inspection which serves to assess the
condition of the crane as a whole and of its components.
Moreover, according to the Provisions for the Prevention of Accidents BGV D6 (§ 26), an inspection by
an expert must be performed every 4 years.
Any deficiencies detected must be recorded in the crane's inspection booklet; the operating company is
obliged to eliminate these deficiencies. A subsequent inspection may be necessary.
The load handling equipment is subject to the Provisions for the Prevention of Accidents VBG 9a or to
the corresponding national testing instructions.
In the scope of the recurrent inspections, the automatic safe load indicator and all hydraulic and electrical
control and safety devices must also be checked by an expert.
The expert or the person who has acquired special knowledge in the crane sector is solely responsible for
the entire extent of the checks to be performed in the scope of the recurrent inspection.
The following text contains a few important instructions which are to be observed in the scope of the recur-
rent inspections.
However, we would like to point out that this text does not cover all items within the scope of inspection.
1 Inspection of supporting steel structures

All supporting steel structures, such as boom, superstructure rotary platform with the screws and bolts of the
ball bearing slewing ring, chassis frame, outrigger casings and outrigger beams must be checked at regular
intervals, depending on the operating conditions, at least, however, once per year. Weld seams, even those
which are subjected to less stress, must also be checked thoroughly.
Various stress cycle figures have been determined for the various high-tensile fine grain steels according to
DIN 15017 part 3. According to this standard, FAUN cranes have been designed for the load ensemble S1
light and a stress cycle figure of 25000 load cycles. They can be used to calculate the service life of the
crane in question, depending on the crane's operating conditions. This service life does not only depend on
the stress cycle figure, but also on the loads to which the crane was subjected during the period of operation.
The following drawings (refer to item 1.1) are examples for some load-supporting steel structures of the
crane and are to provide some guidelines for the inspector regarding the areas to be checked. The areas
marked with arrows are subject to high stress and must be checked in the scope of the inspections, or de-
pending on the operating conditions.
However, please note expressly that the drawings are not meant to be complete, but are only to be consid-
ered as guidelines.
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2001-06 1/6
E-1 Inspection of supporting steel structures
cont'd.: 1 Inspection of supporting steel structures
If damage (e.g. cracks, deformations) is detected during these inspections, an expert must be consulted.
After the damage has been recorded, the vehicle manufacturer must be consulted based on the remark un-
der C1-1, item 1.2 “Welding and straightening work”.
The way how to effect repair must be determined by the vehicle manufacturer in agreement with the expert.
If welding work must be effected on the mobile crane, the following precautions must be taken as a minimum
before work is commenced, in order to protect the electronic control units:
- Turn the battery switch in chassis and superstructure OFF;

- disconnect battery cable in chassis and superstructure from the negative terminal, then disconnect the
battery cable from the positive terminal and connect them;
Attention During electrical welding work, the ground terminal of the welding unit must be con-
nected directly to the part to be welded.
If this instruction is not observed, the current flow may cause damage to loose con-
nections, e.g. tooth faces, bearings, slide pieces, shafts, the electronic system, the
ASLI, etc.
DANGER Make sure that the welding instructions are observed.
If the crane has been subjected to inadmissible stress during service (e.g. to a high shock load caused by a
load "dropped" into the rope, etc.), the machine must be checked to determine that its supporting compo-
nents are in perfect working order.
DANGER Any damage caused to the supporting components of the crane entails an increased
risk of accidents.
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2/6 2001-06
Inspection of supporting steel structures E-1
1.1 Guidelines for areas to be checked

1.1.1 Chassis frame
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2001-06 3/6
1.1.2 Superstructure frame
0505_EN_FA043_E1_01_01_00
4/6 2001-06
Inspection of supporting steel structures E-1
1.1.3 Boom
0505_EN_FA043_E1_01_01_00
2001-06 5/6
1.1.4 Boom extension (jib)**)
**)
Optional equipment
0505_EN_FA043_E1_01_01_00
6/6 2001-06
Inspection of the hook blocks E-2
2 Inspection of the hook blocks
DANGER Crane work using worn or faulty hook blocks is prohibited. Otherwise, accidents in-
volving damage to property or personal injury would be inevitable.
Thus, hook blocks must be checked at regular intervals for proper working order and good condition.
These inspections must be performed by experts. It is essential to comply with the appropriate national regu-
lations and directives.
Please do not hesitate to contact your TADANO-FAUN after sales service in case of queries or problems.
He will be pleased to perform for you all the servicing and maintenance work required.
The hook blocks or the load hooks have to be checked regularly by persons who dispose of special knowl-
edge in this field, at intervals which depend on the operating conditions of the crane, however at least once
per year. These regular inspections are intended to prevent accidents which might be due to deficiencies.
The deficiencies detected in the course of this inspection have to be recorded, and eliminated; afterwards,
the crane must be subjected to subsequent verification to ensure that the deficiencies have been eliminated.
2.1 Inspection for widening of the hook mouth
The hook mouth has to be checked for deformation at

regular intervals, as required, depending on the operat-
ing conditions of the crane, at least however once per
year.
The widening of the hook mouth must not exceed 10
%, referred to the original dimension "y", or "y1" and
"y2".
The original dimensions are specified on the load hook
and in the crane documentation. The dimensions "y" Identification
are measured between two dotting marks.
Measured length „y“ or „y1“ and „y2“ in the case of hammer-
forged load hooks
DANGER If the determined widening of the hook exceeds 10%, the load hook must not be used
any longer.
NOTE If any deformation is detected (even less than 10%), the load hook must be checked
for superficial cracks using appropriate means.
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E-2 Inspection of the hook blocks
2.2 Inspection for wear
According to German regulations, the wear of single and double hooks must not exceed 5 % of the height h2.
DANGER If the determined wear of the hook exceeds 5%, the load hook must not be used any
longer.
2.3 Inspection for corrosion
Especially the thread of the load hook has to be checked for corrosion. The load hook nut must be removed
from the hook stem to expose the thread turns of the lood hook stem so that they can be judged.
DANGER The load hook must not be used any longer if traces of corrosion or wear are visible at
the thread.
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Inspection of lifting ropes E-3
3 Inspection of lifting ropes
DANGER Crane work using worn or faulty winch ropes is prohibited. Otherwise, accidents in-
volving damage to property or personal injury would be inevitable.
Thus, winch ropes must be checked at regular intervals for proper working order and good condition.
He will be pleased to perform for you all the servicing and maintenance work required.
The rope drives of mobile cranes are not designed for high endurance strength. Thus, wire breaks occur
during operation. The principles for monitoring rope drives used for working applications are recorded in the
following text.
The ropes must be checked regularly, taking account of the prevailing operating conditions of the crane. The
rope must be observed more attentively at shorter intervals especially in the time just after it has been
placed, after a lifting rope has ben replaced and after extraordinary stress situations, or if internal damage is
suspected which is not visible on the outside.
The reliability of metallic ropes used in working applications can be judged by the following criteria:
• Type and number of wire breaks,

• Position and time intervals at which the wires break,
• Reduction of the rope diameter during the operating time,
• Corrosion,
• Abrasion,
• Deformations of the rope,
• Influence of heat,
• Service life.
Rope fastening and rope suspension devices must also be checked for safe condition. It should be pointed
out especially that wire breaks tend to be difficult to detect on these components. Other parts of the rope
drive, such as the rope drum or the rope pulley, must move easily in their bearings.
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E-3 Inspection of lifting ropes
3.1 Lifting ropes: Long lay - Cross-lay
NOTE The type of the lifting rope supplied with the vehicle and its type of lay is recorded in
the documentation supplied with the vehicle.
3.1.1 Direction of lay and type of lay of

round ropes
The term "direction of lay" (direction of rope winding)

refers to the direction of the helical line of the outer
strands.
A distinction is made between right-laid ropes (symbol
Z) and left-laid ropes (symbol S).
CROSS-LAY:
The direction of turning of the wires in the strands is

opposite to the direction of turning of the strands in the
rope.
LONG LAY:
The wires in the strands and the strands in the rope

have the same turning direction.
rechtsgängig - right-laid
linksgängig - left-laid
Kreuzschlag - cross-lay
Gleichschlag - long lay
DIN-Bezeichnung -
DIN designation
3.1.2 Approved winch ropes
For approved winch ropes, refer to crane inspection booklet or crane testing documents.
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3.2 Replacement state of repair of metallic ropes due to:

3.2.1 Wire breaks
A metallic rope must be discarded at the latest when the number of visible wire breaks which is specified in
the following table appears in any place of the rope.
Long-lay ropes
Number of load-bearing wires Number of visible wire breaks when the rope
in is ready for discarding, for a length of
the outer strands
6xd 30 x d
76 - 100 2 4
101 - 120 2 5
121 - 140 3 6
Cross-lay ropes
Number of load-bearing wires Number of visible wire breaks when the

in rope is ready for discarding, for a length of
the outer strands
6xd 30 x d
76 - 100 4 8
101 - 120 5 10
121 - 140 6 11
DANGER The rope must be discarded when the specified number of wire breaks is reached;
otherwise, there is an increased risk of accidents.
NOTE After the first wire breaks have been detected, the test intervals must be shortened to
ensure timely detection of the replacement state of wear.
It may be useful to record the occurrence of wire breaks via time. In this case, an increasing number of wire
breaks in the course of of time helps the user determine the expected time when the rope should be dis-
carded.
3.2.2 Replacement state of wear of metallic ropes due to tangles of broken wires
If tangles of broke wire occur, the metallic rope must be discarded. In case of breakage of a strand, the me-
tallic rope must be discarded immediately.
3.2.3 Reduction of diameter
The metallic rope must be discarded if its diameter is reduced, due to structural changes, by 15 % or more
over an extended length, as compared to its nominal diameter.
3.2.4 Corrosion
The metallic rope must be discarded if its diameter is reduced, due to corrosion damage, by 10 % or more,
as compared to the nominal diameter, even if no wire breaks are detected. It is difficult to determine corro-
sion in wires which are not visible externally.
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3.2.5 Abrasion
The wire rope must be discarded if its diameter is reduced, due to abrasion, by 10 % or more, as compared
to the nominal diameter, even if no wire breaks are detected. Abrasion may reduce the rope's static breaking
load (due to reduction of the metallic rope cross-section), and the endurance strength (due to abrasion not-
ches).
3.2.6 Rope deformation
Deformations of the rope are visible changes in the metallic rope's wire structure. The following deformations
can be distinguished by their appearance:
• Corkscrew-shaped deformations: The rope must be discarded as soon as the

unevenness reaches 1/3 or more of the ropes diameter.
• Basket-shaped deformations occur when the outer wire layer is loosened, or

when the outer strands are longer than the inner strands. As the outer wire or
strand layers are shifted with reference to the outer layers, the excess length is
shifted to one area. The metallic rope must be discarded as soon as basket-
shaped deformations appear.
• Loop-shaped deformations. In this case, single wires or wire groups resem-

bling hairpins protrude from the rope structure on the opposite side of the rope
groove. If the rope structure is changed substantially, the rope must be dis-
carded.
• Loosening of single wires or strands: In this case, the outer wires or single
strands of the metallic rope, which is under load, can be shifted. Thus, they are
not bearing the portion of the traction force for which they are intended, which
means that the other wires or strands are overcharged. If wires are loosened
due to corrosion or wear, the metallic rope has to be discarded. If this deforma-
tion is due to other causes, the resulting number of wire breaks determines the
time when the rope must be discarded.
• Knots are "swellings" within the metallic rope which occur repeatedly over a
certain rope length. Knots cause additional movements in the rope. Metallic ro-
pes which have numerous knots must be discarded.
• Contractions are reductions in the rope's diameter over short rope lengths.
Metallic ropes which present substantial contractions must be discarded.
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3.2.6 Rope deformation (cont'd.)
• Flat spots are permanent deformations of the metallic rope which are due to
bruising. Wire breaks tend to occur at flat spots.
• Buckling is deformation which occurs when an eyelet-shaped rope loop is pul-

led straight, whereby the resulting deformation cannot be eliminated by the rope
turning around its axis. Metallic ropes presenting one or several buckles must
be discarded.
• Kinks are deformations which occur if external violent loads act on the metallic
rope. Metallic ropes with kinks must be discarded.
• "Curl-shaped" deformations occur if the stressed metallic rope is pulled over an edge. Metallic ropes
containing such deformations must be discarded.
3.2.7 Influence of heat
These metallic ropes have been exposed to enormous heat, and are distinguished by tarnishing appearing in
various colours on the external wires. These metallic ropes must be discarded.
3.2.8 Service life
Provided that operating conditions are identical and the same metallic rope is used, the persons in charge of
a crane can estimate approximately the time when a metallic rope is to be replaced in the scope of preven-
tive maintenance of the crane, to the extent that they dispose of sufficient knowledge and experience in the
operation of a rope drive.
All the criteria specified above (items 3.2.1 to 3.2.8.) are nevertheless decisive for determination of the re-
placement state of wear of a metallic rope.
DANGER A metallic rope must be replaced immediately if it contains one of the following defi-
ciencies; otherwise, there would be an increased risk of accidents.
If there are doubts as regards the future suitability of a specific metallic rope, it
should be discarded on principle, or a specialist, e.g. a staff member of the rope ma-
nufacturer, should check the rope thoroughly.
NOTE Should any particular deficiencies be detected on the metallic rope, the reason for
those deficiencies must be determined and eliminated. A new rope should not be pla-
ced until after this measure has been taken.
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3.3 Replacement of a metallic rope
DANGER When a new rope is placed, make sure that only a rope of the same strength, make
and with the same nominal diameter as the former one (when new) is mounted.
The use of a different rope type requires the prior written approval of the crane manu-
facturer.
Metallic ropes must be unloaded, transported and stored with suffi-

cient care. During unloading and transport, the rope must be pro-
tected against mechanical damage, which may be caused by the
tines of forklift trucks or load hooks.
Ropes stored for use at a future date should be stored in a clean, cool and dry place covered by a roof, and
without touching the ground, e.g. on pallets.
When a new lifting rope is mounted, it is essential to ensure that the

new rope is spooled up on the winch without being twisted and dam-
aged. A rope supplied as a ring or on a reel should be spooled up
preferably using a rotary table or a trestle.
When the rope is spooled from the reel to the drum, the bending
direction must not changed.
The rope windings must definitely not be pulled off the ring or the reel laterally, as this would twist
the rope.
NOTE When placing the new rope, do not drag it on the ground. The sand which may stick to
the rope lubricant may damage wires in the contact area between the rope pulley and
the rope.
When the new metallic rope is mounted by means of the used rope to be discarded, or by means of an auxil-
iary rope, the new rope must not be twisted. Moreover, the two ropes must be connected safely. This con-
nection between the two ropes can either be established by means of welded-on eyelets or via a rope hose.
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3.3 Replacement of a metallic rope (cont'd.)
Wrong Wrong Wrong
To ensure that the metallic rope is spooled up correctly, particularly if several layers are to be arranged on
the drum, it is very important that the new rope is spooled on the drum under a pre-load of approx. 1 % to 2
% of the minimum breaking force of the rope. If the lower layers are spooled up on the drum with excessive
play, the upper layers may be squeezed between the loose, lower rope windings when subject to load. This
may cause serious damage to the rope.
The pre-load should be produced by braking the reel flange

using a board,
or using a brake disc mounted to the reel, by means of brake

strings.
It is absolutely inadmissible to produce the required pre-

load by clamping the metallic rope between two blocks of
wood.
Wrong
After the new rope has been mounted, it should be initially "run-in" under low partial loads. This way, the
rope "settles", and adapts better to the bending direction or the bending radii of the rope drum and the pulley.
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3.4 Service and Maintenance
Metallic ropes require maintenance at regular intervals which depend on the operating conditions. The ser-
vice life of a metallic rope can be extended considerably if it is subject to regular care.
The metallic ropes must be re-greased at regular intervals which depend on the operating circumstances.
Ropes which are well greased reach an essentially higher number of reversed bending stress cycles, and
thus a substantially longer service life.
NOTE The lubricant intended for re-greasing should be selected so that it is compatible with
the original lubricant supplied by the rope manufacturer.
Metallic ropes which are exposed to substantial quantities of dirt must be cleaned at regular intervals. This
cleaning should be performed preferably using brushes.
In many cases, metallic ropes have to be discarded which are only damaged on a relatively short length
which is subject to severe stress, e.g. at the transition from the first to the second layer, even though the rest
of the rope is still in good condition. Thus, the service life of a rope can be extended if the corresponding
rope length is cut off*), so that the rope length which was previously exposed to severe stress is now in an
area subject to less stress.
*) However, in case of ropes equipped with steel wire rope clamp (execution with Super-Stop rope socket),
the rope clamp must be press-fitted anew according to the provisions of the rope manufacturer.
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3.5 Elimination of elongation spin
This spin caused by elongation becomes apparent as a hook block without load turns during operation with
several rope falls. This indicates that spin compensation is required due to the settling and lengthening of the
rope after an extended period of use, and after a new rope has been placed. Due to this elongation spin, the
outer strands of the metallic rope can become loose, and may even form "baskets" under certain circum-
stances.
To eliminate this elongation spin, the following steps should be taken:
1. Deposit the hook block on the ground; to this effect, make sure that a maximum rope length is available
for spin compensation between the hook block and the boom pulley head.
2. Determine the inward turning direction; as this may prove to be difficult, a check twist should be effected
to find out whether the tress is twisted inwards or outwards.
3. Release the rope from the fixed point on the hook block or on the boom head; this work is considerably
facilitated if the spin compensation is effected with an odd number of rope falls, or if an odd number of ro-
pe falls is reeved. With an odd number, the fixed point of the rope is always located at the hook block,
and thus is easily accessible.
4. To compensate the spin, turn the rope fall released from the fixed point accordingly; it is important to note
that the rope released from the fixed point must be turned against the direction of turning which has cau-
sed the dissolution of the rope tress during trial turning.
NOTE It is essential to ensure that this turn is applied to a rope section which is as long as
possible. Turning a short rope length using force is strictly prohibited, as this might
destroy the rope structure.
5. Fasten the rope fall at the fixed point using the rope clamp by means of pins and the retaining clip.
6. After the spin compensation has been accomplished, a few lifting cycles in no-load condition have to be
effected so that this compensation can spread via the rope pulleys over the entire length of the rope.
NOTE In case of a particularly strong elongation spin, this spin compensation may have to
be effected several times, until the rope is moving correctly again.
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Memo:
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10/10 2003-01
Working life of the rope winch gear assemblies E-4
4 Working life of the rope winch gear assemblies
DANGER Should the hoisting gears not operate correctly or even be faulty, crane work is pro-
hibited. Otherwise, accidents involving damage to property or personal injury would
be inevitable.
Thus, hoisting gears must be checked at regular intervals for proper working order and good condition.
Should there be no national regulations, we recommend - regarding the inspection intervals - to proceed as
described in the following example.
He will be pleased to perform for you all the servicing, maintenance and repair work required.
4.1 Theoretical service life of the winch
The winch was designed and dimensioned on the basis of certain operating conditions and of a rated total
operating time, which enable the calculation of a theoretical service life of the winch.
The winch installed in the crane is rated as follows:
Drive assembly group M3

Load ensemble L1
Load ensemble factor Km = 0.125
Theoretical service life D = 3200 h
NOTE The theoretical service life must not be equated with the actual (real) service life of the
winch.
The actual (real) service life is affected additionally by a number of external influences, e.g.:
a) Overload if the crane is used for purposes not included within its intended fields of application;
b) Insufficient maintenance, e.g. neglect of the specified oil-change intervals;
c) Operating errors, extreme decelerations, or loads "dropping" in the rope;
d) Maintenance faults, e.g. incorrect oil type or filling volume; contamination in the course of oil change;
e) Assembly errors in the course of maintenance and repair;
f) Leaks which are not eliminated;
g) Incorrectly set safety equipment, e.g. pressure limiting valves;
h) Concealed damage due to accidents;
i) Extreme environmental conditions, e.g. dust and dirt; aggressive atmosphere, high or low temperatures.
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E-4 Working life of the rope winch gear assemblies
4.2 Consumed portion of the theoretical service life
The crane operator has the duty to check the crane or to have it checked at least once per year.
In this context, the consumed portion of the theoretical service life also has to be determined. If the crane
operator is not able to do this work on his own, he has to commission an expert with this task. In Germany,
this inspection is performed by a crane expert, based on § 28 BGV D6. In other countries, this is done by the
"expert engineer" pursuant to ISO 9927-1. Any deviation provisions valid in those countries must be adhered
to.
To calculate the consumed portion of the theoretical service life, the real operating conditions (load ensem-
ble) and the service hours of the winch per inspection interval must be determined. The operator is responsi-
ble for recording this data in the crane documentation correctly.
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4.2.1 Determination of the operating conditions
On the basis of the actual known operating conditions, one of the following load ensembles must be selected
and entered in the crane documentation for the appropriate inspection interval.
The load ensemble of the crane is divided into the following groups.
Load Load
en- Definitions Portions of operating time en- Schematic diagram
semble, semble
class factor
light Drive assemblies 10 % of operating time with Km = Load %
Q1 or parts of drive max. load 0.125
L 1 assemblies which
(dead load + 1/1 payload)
are only excep-
tionally subject to 40 % of operating time with
maximum load, dead load + 1/3 payload
which however, 50 % of operating time with
are subject to very dead load only
light stress on a
routine basis.
Service life %
medium Drive assemblies 1/6 of operating time with Km = Load %
Q2 or parts of drive max. load 0.25
are rather fre-
quently subject to 1/6 % of operating time with
maximum load, dead load + 2/3 payload
which however, 1/6 % of operating time with
are subject to light dead load + 1/3 payload
stress on a routine 50 % of operating time with
basis. dead load only
Service life %
heavy Drive assemblies 50 % of operating time with Km =0.5 Load%
Q3 or parts of drive max. load
are frequently
50 % of operating time with
subject to maxi-
dead load only
mum load, which
however, are sub-
ject to medium
stress on a routine
basis.
Service life %
Load%
very Drive assemblies 90 % of operating time with Km =1
heavy or parts of drive max. load
Q4 assemblies which
L 4 are regularly sub-
10 % of operating time with
ject to maximum
dead load only
load and stress in
a similar range
Service life %
NOTE When mobile cranes are used for assembly work, the load ensemble factor
Km = 0.125 must be used normally for the load ensemble L1.
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4.2.2 Determination of the effective service hours Ti
The service hours which are to be determined as described in the following text, have to be entered into the
crane documentation for the winch, for the appropriate inspection interval. Depending on the crane model, it
may be necessary to determine the effective service hours according to one of the following four cases:
NOTE Normally, the reference value specified below in per cent for the determination of the
service hours of hoisting gears are only valid for the main hoist winches. The portions
of the total service hours of any auxiliary hoist winches **) may be essentially lower
and must consequently be estimated by the operator according to the prevailing op-
erating conditions.
4.2.3 Hourmeter provided on each winch
If the crane is equipped with an hourmeter on each winch, the actual number of service hours "Ti" is indi-
cated directly for the inspection interval in question.
4.2.4 Hour-meter provided for superstructure operation as a whole
The actual portion of the service hours of the winch, referred to the total number of service hours of the su-
perstructure, is to be estimated by the operator.
NOTE If a mobile crane is used for assembly work, a value of 20 % can normally be assumed
for the portion of service hours of the winch, referred to the service hours used for
superstructure operation as a whole.
4.2.5 One combined hour-meter provided for crane and driving operation
The actual portion of the service hours of the winch, referred to the total service hours of the machine is to
be estimated by the operator.
NOTE In the case of mobile cranes used for assembly work, a portion of 60 % can normally
be assumed for the service hours of the superstructure, referred to the machine's to-
tal service hours. If 20 % are assumed for the portion of the service hours of the
winch, referred to the service hours of the superstructure (as specified under item
4.2.4), a portion of 12 % results for the winch, referred to the machine's total service
hours.
4.2.6 No hour-meter provided - neither for the chassis nor for the crane
In this case, the operator has to estimate and to record the actual service hours of the winch according to the
operating conditions.
NOTE The indicated percentage values apply normally for the main winch. For the auxiliary
winch **), the portion of the entire accumulated service hours can be considerably
lower. It must be estimated by the operating company.
**) Optional equipment, possible for various vehicle types

0520_EN_FA043_E4_00_00_00
4/12 2003-01
4.3 Determination of the consumed portion of the theoretical service life
The following formula is used to compute the consumed portion "Si" of the theoretical service life "D" for an
inspection interval "i" (maximum 1 year):
Si = ( Kmi : Km ) x Ti
Km = Load ensemble factor used as a basis for design of the winch. This factor has been recorded in the
operating manual.
Kmi = Load ensemble factor in the inspection interval "i" according to section 4.2.1.
Ti = Effective service hours of the winch in the inspection interval "i" according to section 4.2.2.
After each inspection interval, this consumed portion "Si" of the theoretical service life is deducted from the
remaining theoretical service life "Di" (refer to example).
The operator has to ensure a general overhaul of the winch as soon as the remaining theoretical service life
is presumably no longer sufficient for the next inspection interval.
Once the theoretical service life "D" has been reached (refer to section 4.1), winch operation may only be
continued after a general overhaul.
DANGER A general overhaul must be performed at the latest on expiry of the theoretical service
life of the hoist winch, however in any case after 10 years.
The general overhaul is to be initiated by the crane operating company, and is to be effected by the hoist
winch manufacturer or by persons authorized by the hoist winch manufacturer; the overhaul must be re-
corded accordingly in the crane inspection booklet.
After the general overhaul has been performed, a new theoretical service life "D" is specified by the hoist
winch manufacturer or by persons authorized by him. This new theoretical service life "D" must be recorded
in the crane inspection booklet.
DANGER The subsequent general overhaul must be performed at the latest after the hoist
winch's theoretical service life has expired, or after 10 years.
If the theoretical service life has not yet been consumed after 10 years, winch operation can be continued
without general overhaul, if the crane expert confirms by signing in the crane inspection booklet on the occa-
sion of each expert inspection that the consumed portion of the service life has been determined correctly
and conveniently.
In this case, the winch must be subjected to a thorough test by the crane expert:
a) External visual inspection (deformations, damage, leakage etc.)

b) Inspection of the oil - specifically for metallic residues
c) Load tests at the maximum speed possible at maximum and minimum rope pull. At least one
rope layer must be spooled on the drum. In this load test, pay attention to abnormal sounds.
The crane expert must confirm this inspection in the crane inspection booklet and state whether winch op-
eration may be continued or not. The next inspection is to be effected prior to expiry of the 12th service year;
all the other inspections must be performed at yearly intervals.
0520_EN_FA043_E4_00_00_00
2003-01 5/12
4.3.1 Example showing the determination of the consumed portion of the theoretical
service life
The mobile crane has been equipped with a separate hourmeter in the superstructure. According to the
Operating Manual, the rope winch has the following rating:

Load ensemble L 1, Km = 0.125
The consumed portion "Si" of the theoretical service life of the winch is calculated using the various inspec-
tion intervals (once per year), as described below:
First inspection (after the first year of operation)
A separate hour-meter is provided on the superstructure. The crane has been used exclusively for assem-
bly work in the past 12 months. The load ensemble is:
L 1, i.e.: Km1 = 0.125.
The hour-meter of the superstructure indicates 800 h; the portion of service hours used for the winch is esti-
mated at 20 %,
i.e.: T1 = 160 h.
Thus, at the time of the first inspection, the consumed portion S1 of the theoretical service life amounts to:
S1 = ( Km1 : Km) x T1 = ( 0.125 : 0.125) x 160
S1 = 160 h
Consequently, the remaining theoretical service life amounts to:
D 1 = D - S1 = 3200 h - 160 h
D1 = 3040 h
These values must be recorded in the crane documentation (see Table).
0520_EN_FA043_E4_00_00_00
6/12 2003-01
4.3.1 Example showing the determination of the consumed portion of the theoretical service life
(cont'd.)
Second inspection (after the second year of operation)

The crane has been used mainly for unloading work in a port during the past 12 months. The load ensemble
is: L 3, i.e. Km2 = 0.5.
The hour-meter of the superstructure indicates 2000 h, i.e. the crane has been operated for 2000 h - 8000
h = 1200 h (these 800 h have already been accumulated during the first year).
The portion of service hours consumed by the winch is estimated at 40% of the superstructure's service
hours,
i.e.:T2 = 480 h
Thus, at the time of the second inspection, the consumed portion S2 of the theoretical service life amounts to:
S2 = ( Km2 : Km) x T2 = ( 0.5 : 0.125) x 480
S2 = 1920 h
D2 = D1 - S 2 = 3040 h - 1920 h
D2 = 1120 h
These values must also be recorded in the crane documentation (see Table).
Third inspection (after the third year of operation)

During the past 12 months, the crane has been used mainly for assembly work, and occasionally for unload-
ing work in a port. The load ensemble is: L 2, i.e. Km3 = 0.25.
The hour-meter of the superstructure indicates 3000 h, i.e. the crane has been operated for 3000 h - 800 h
- 1200 h = 1000 h during the third year of operation (2000 h have been accumulated in total during the first
and second years).
The portion of service hours consumed by the winch are estimated at 30 % of the service hours of the su-
perstructure,
i.e. T3 = 300 h
Thus, at the time of the third inspection, the consumed portion S3 of the theoretical service life amounts to:
S3 = ( Km3 : Km) x T3 = ( 0.25 : 0.125) x 300
S3 = 600 h
D 3 = D2 - S 3 = 1120 h - 600 h
D3 = 520 h
These values must also be recorded in the crane documentation (see Table).
0520_EN_FA043_E4_00_00_00
2003-01 7/12
(cont'd.)
Operation of the machine in its fourth year

If the crane is to be used in this year of intended operation like in the third year of operation (mainly assem-
bly work and occasional use for unloading work in a port with the load ensemble L2 and with an expected
similar number of service hours), the winch of this crane can be assumed to require a general overhaul
approximately at the end of the fourth year of operation, as its theoretical service life limit will be reached
or even have been exceeded at that time.
4.3.2 Example for the entries to be made in the table of the crane documentation
Serial No. Table for determination of the remaining theoretical service life of the hoisting gear Page No.
Hoisting gear no. 1

Identification no. according to nameplate: abc
Last general overhaul effected on: .........
Drive assembly group: M 3
Load ensemble: L 1
Load ensemble factor: Km = 0.125
Theoretical service life: 3200 h
Inspec- Date of Operat- Load Service Service Service Portion Service Consu- Re- Name Signa- Re-
tion no. initial ing en- hours hours hours of hoist- hours med main- of in- ture marks
op- condi- semble of the of su- of su- ing of hoist- por-tion ing spector
eration tions factor whole per- per- gear of ing of theo- theo-
/ in- since crane struc- struc- the ser- gear ret. ret. ser-
spec- the last ture ture vice since service vice life
tion in- since hours the last life D: Di=Di-
spec- the last of su- in- Si=Kmx Si
tion Km (h) in- per- spec- Ti
(load (h) spec- struc- tion (h)
en- tion ture (h)
semble) (h) (h) (h)
15.5.1991
0 - - - - - 0 3200
05.5.1992
1 L1 0.125 - 800 800 20 160 160 3040 XYZ
20.5.1993
2 L3 0.5 - 2000 1200 40 480 1920 1120 XXZ
01.6.1994
3 L2 0.25 - 3000 1000 30 300 600 520 YXX
10
Attention: A general overhaul must be performed at the latest on expiry of the theoretical service life of the hoist
winch, however in any case after 10 years.
General overhaul effected on: (Company): Name: Signature:
0520_EN_FA043_E4_00_00_00
8/12 2003-01
4.3.3 Example showing the determination of the consumed portion of the theoretical
service life in case of machine models with separate hourmeter for hoisting
winch**)
The mobile crane is equipped with a separate hourmeter for the hoisting winch. According to the Operating
Manual, the hoisting winch has the following rating:

Load ensemble L 1, Km = 0.125
The consumed portion "Si" of the theoretical service life of the hoisting winch is calculated using the various
inspection intervals (once per year), as described below:
1. inspection (after the first year of operation)
The hoisting winch is equipped with a separate hourmeter. The crane has been used exclusively for
assembly work during the past 12 months. The load ensemble is:
L 1, i.e:. Km1 = 0.125.
The hoisting winch hourmeter indicates 160 hours.
i.e:. T1 = 160 h.
Consequently, at the time of the first inspection, the consumed portion S1 of the theoretical service life
amounts to: S1 = ( Km1 : Km) x T1 = ( 0.125 : 0.125) x 160
S1 = 160 h
Thus, the remaining theoretical service life amounts to:
D 1 = D - S1 = 3200 h - 160 h
D1 = 3040 h
These values must be recorded in the crane inspection booklet (refer to Table).

0520_EN_FA043_E4_00_00_00
2003-01 9/12
(cont'd.)
2. inspection (after the 2nd year of operation)

The crane has been used mainly for unloading work in a port during the past 12 months. The load ensemble
is: L 3, i.e. Km2 = 0.5.
The hourmeter of the hoisting winch indicates 640 h, i.e. the crane has been operated for 640 h - 160 h =
480 h during the 2nd year of operation (these 160 h have already been accumulated during the first year).
i.e.:T2 = 480 h
Consequently, at the time of the second inspection, the consumed portion S2 of the theoretical service life
S2 = 1920 h
D2 = D1 - S 2 = 3040 h - 1920 h
D2 = 1120 h
These values must also be recorded in the crane inspection booklet (refer to Table).
3. inspection (after the 3rd year of operation)

During this year, the crane has been used mainly for assembly work, and occasionally for unloading work in
a port. The load ensemble is: L 2, d. h. Km3 = 0.25.
The hourmeter of the superstructure indicates 940 h, i.e. the crane has been operated for 940 h - 160 h -
400 h = 300 h during the 3rd year of operation (640 h have already been accumulated in total during the first
and second years).
i.e.: T3 = 300 h
Consequently, at the time of the third inspection, the consumed portion S3 of the theoretical service life
S3 = 600 h
D3 = D2 - S 3 = 1120 h - 600 h
D3 = 520 h
These values must also be recorded in the crane inspection booklet (refer to Table).
0520_EN_FA043_E4_00_00_00
10/12 2003-01
(cont'd.)
Operation of the machine in the following, 4th year

If the crane is to be used in this year of intended operation like in the third year of operation (mainly
assembly work and occasional use for unloading work in a port with the load ensemble L2 and with an
expected similar number of service hours), the winch of this crane can be assumed to require a general
overhaul approximately at the end of the fourth year of operation, as its theoretical service life limit will
be reached or even have been exceeded at that time.
4.3.4 Example for the entries to be made into the table of the crane inspection booklet
Serial No. Table for determination of the remaining theoretical service life of the hoisting gear Page No.
Hoisting gear no. 1

Identification no. according to nameplate: abc
Last general overhaul effected on: .........
Drive assembly group: M 3
Load ensemble: L 1
Load ensemble factor: Km = 0.125
Theoretical service life: 3200 h
Inspec- Date of Operat- Load Service Service Service Portion Service Consu- Re- Name Signa- Re-
tion no. initial ing en- hours hours hours of hoist- hours med main- of in- ture marks
op- condi- semble of the of su- of su- ing of hoist- por-tion ing spector
eration tions factor whole per- per- gear of ing of theo- theo-
/ in- since crane struc- struc- the ser- gear ret. ret. ser-
spec- the last ture ture vice since service vice life
tion in- since hours the last life D: Di=Di-
spec- the last of su- in- Si=Kmx Si
tion Km (h) in- per- spec- Ti
(load (h) spec- struc- tion (h)
en- tion ture (h)
semble) (h) (h) (h)
15.5.1991
0 - - - - - 0 3200
05.5.1992
1 L1 0.125 - 800 800 20 160 160 3040 XYZ
20.5.1993
2 L3 0.5 - 2000 1200 40 480 1920 1120 XXZ
01.6.1994
3 L2 0.25 - 3000 1000 30 300 600 520 YXX
10
Attention: A general overhaul must be performed at the latest on expiry of the theoretical service life of the hoist
winch, however in any case after 10 years.
General overhaul effected on: (Company): Name: Signature:
0520_EN_FA043_E4_00_00_00
2003-01 11/12
Memo:
0520_EN_FA043_E4_00_00_00
12/12 2003-01
Monitoring the slewing device E-5
5 Monitoring the slewing device

5.1 Inspection of the ring-gear securing pins
The securing pins of the ball-bearing slewing device may have to be retightened due to setting of the appro-
priate components. The tightening torques required to this effect are specified in the Operating Manual.
The first inspection of the securing pins is to be effected after approx. 100 service hours. The ring-gear pins
must be checked at regular intervals, depending on the actual operating conditions of the crane, at least,
however, every 500 service hours.
If the crane has been subjected to an inadmissible load during operation (e.g. a high shock load caused by a
load "dropping" in the rope, or similar stress), the pins of the ring-gear and the other supporting components
of the crane must be checked within the scope of an additional inspection.
0525_EN_FA043_E5_00_00_00
2003-01 1/2
E-5 Monitoring the slewing device
Memo:
0525_EN_FA043_E5_00_00_00
2/2 2003-01
Part F
Troubleshooting
0530_EN_ALLGE_F_00_00_00
Part F1
Troubleshooting
Chassis
0535_EN_ALLGE_F1_00_00_00
Troubleshooting in the chassis F1-0
Troubleshooting in the chassis
The following table is intended to help you locate the reason of, and - if necessary - repair any failures or
certain malfunctions of the machine. Of course, this table cannot cover all causes of malfunctions.
The hydraulic piping diagrams, brake system diagrams and electric circuit diagrams also help you locate and
eliminate malfunctions.
A troubleshooting guide is no substitute for a specialist. If the cause of the malfunction cannot be determined
or eliminated by means of the table, please contact the After-Sales Service of TADANO-FAUN GmbH.
0540_EN_FA043_F1_00_00_00
2003-01 1/2
F1-0 Troubleshooting in the chassis
Memo:
0540_EN_FA043_F1_00_00_00
2/2 2003-01
Engine F1-1
1 Engine
For malfunctions concerning specifically the engine and the appropriate remedial measures, please refer to
the operating manual of the engine manufacturer.
Malfunction Possible cause Remedy
Engine does not start. A gear is engaged (check also in Set gearbox selector lever to neutral
superstructure). "N".
No electrical connection between Battery main switch is not set to "ON".

battery and consumers.
Key-actuated switch is set to wrong Set key switch to position I (chassis).

position.
Engine operates Air cleaner clogged (possibly faulty Replace filter element, clean filter
irregularly or with an indicator lamp ignored). bowl; replace bulb of indicator lamp.
insufficient power
output.
Leakage in air intake lines. Check air intake system for leakage,
re-tighten hose clamps.
Injection system and turbocharger are Have these components checked in a

not in proper working order. specialist workshop.
0545_EN_FA043_F1_01_00_00
2003-01 1/2
F1-1 Engine
1 Engine (cont'd.)
Excessive radiator Radiator fins clogged. Clean fins by blowing out with
temperature although compressed air or a steam jet unit.
the engine is not
subject to load
(thermometer Coolant drain cocks open. Check cocks.
indicates more than
100°C and the engine
malfunction warning
lamp is lit)
Coolant level too low Leakage in coolant hose connections. Re-tighten hose clamps.
(warning lamp is lit).
Pressure relief valve on expansion Check pressure relief valve for proper
tank faulty. working order; replace it, if necessary.
Coolant hoses attacked by porosity. Replace.
Engine cannot be Electric connections loosened, or Slip-on cable lugs or replace switch.
stalled. switch defective.
0545_EN_FA043_F1_01_00_00
2/2 2003-01
Gearbox F1-2
2 Gearbox
For information and an error list, refer to the enclosed operating manuals (gearbox and Intarder) of the
gearbox manufacturer.
How to read out the error codes:
• The vehicle is parked.

• The engine is stopped.
• The gearshift lever is in "neutral" position.
• The parking brake is engaged.
• The battery main switch is turned ON.
• The ignition is ON.
- Actuate the service brake.
- Push jogging lever to the left.
The gearbox display (refer to item B1-4.6.4.2) indicates the error codes.
0550_EN_FA043_F1_02_00_00
2003-01 1/2
F1-2 Gearbox
Memo:
0550_EN_FA043_F1_02_00_00
2/2 2003-01
Transfer box F1-3
3 Transfer box
The change-over from Pneumatic control pressure insuffi- Brake-air pressure of compressed air
on-road to off-road cient. system (min. 6 bar).
gear is not possible.
Rocker tip switch or electrical connec- Replace rocker tip switch, check con-
tors faulty or loosened. nections.
Solenoid valve faulty. Replace valve.
Change-over valve in neutral position. Set change-over valve to on-road

gear.
The vehicle cannot be Change-over valve in neutral position. Set change-over valve to on-road
set into motion. gear.
Transfer box is over- Insufficient oil level. Inspection for leakage. Replenish oil.
heating.
Wrong oil type. Observe recommendations regarding
oil types.
0552_EN_FA043_F1_03_00_00
2003-01 1/2
F1-3 Transfer box
Memo:
0552_EN_FA043_F1_03_00_00
2/2 2003-01
Axle differential locks and drive assemblies F1-4
4 Axle differential locks and drive assemblies
Connection of diffe- Pneumatic control pressure Brake-air pressure of brake system

rential locks and 2nd insufficient. (min. 6 bar).
axle drive**) not
possible.
Rotary switch, rocker tip switch or Replace rotary switch or rocker

electrical connectors faulty or switch; check connectors.
loosened.
Drive assemblies Insufficient oil level. Check for leakages; replenish oil.
produce a roaring
sound. Wrong oil type. Observe recommendations regarding
oil types.
Balancing plates on propeller shafts Replace propeller shafts.

are missing.
Propeller shafts are worn. Replace propeller shafts.

0555_EN_FA043_F1_04_00_00
2003-01 1/2
F1-4 Axle differential locks and drive assemblies
Memo:
0555_EN_FA043_F1_04_00_00
2/2 2003-01
Hydraulic system in general F1-5
Pump produces Pump defective. Repair or replace pump.

excessive noise.
Intake line on tank blocked. Clean, and remove dirt from tank.
Hydraulic oil pump sucks in air. Stop pump immediately; check pump
for leakages and oil supply.
Hydraulic system Air entered into hydraulic system. Check oil level; bleed cylinder.
operates jerkily.
Pump not properly fastened. Tighten screws and bolts.
Leaks in suction pipe. Re-tighten screw couplings; replace

seals.
Oil in tank is foaming. Check hydraulic oil level.
Pump pressure. Check pressure at test connector.
Valve block or solenoid valves or Repair valve block or replace valves

pressure limiting valves on valve block on block.
defective.
Cylinders worn or damaged. Replace cylinder(s).
Hydraulic system Control pressure insufficient. Check pressure at test connector.

does not reach full
power output.
Pressure limiting valves or solenoid Remove valves; check them for dirt
valves on valve block clogged or accumulation; replace, if necessary.
defective.
Oil of incorrect viscosity grade. Fill in oil sort specified according to the
prevailing ambient temperature.
0560_EN_FA043_F1_05_00_00
2003-01 1/10
F1-5 Hydraulic system in general
5.1 Steering system - mechanical section
Excessive backlash of Connection of track rod loosened. Readjust and re-tighten.

steering wheel.
Backlash in steering gear. Check backlash in gearing; readjust, if

necessary.
Backlash in ball joints of track rod and Replace ball joints.

steering rod.
Adjustable steering wheel - steering Check rocker tip switches on steering

column loosened. wheel; actuate them.
Excessive wear of Incorrect wheel toe. Set wheel toe to ± 0.

tires; wheels are
fluttering.
Incorrect tire pressure. Check and, if necessary, readjust tire
inflating pressure.
Wheel bearings defective. Check and, if necessary, replace

bearings.
Lateral or vertical movement of rim or Check in specialist workshop; if

disc wheel. necessary,
*)Replace the rim.
Piston rod of steering cylinder or track *)Replace cylinder, or

rod deformed. *)Replace track rod.
Wheel nuts loosened. Check wheel nuts for tight fit and re-
tighten, if necessary.
Locking of steered Locking cylinder faulty, pin seized. Check cylinder for proper function;
rear axles not restore pin to proper working order.
possible in straight-
ahead position.
Brake-air pressure of brake system Min. brake-air pressure 6 bar.

insufficient.
*) Make sure that only genuine FAUN spare parts are used
0560_EN_FA043_F1_05_00_00
2/10 2003-01
5.2 Steering system - hydraulic / electrical section
Steering hard to Pump of steering hydraulics does not Check setpoint pressure by applying a
operate. supply enough oil; insufficient pressure gauge to the test connectors
pressure. M1 = steering circuit 1
M2 = steering circuit 2.
Piston packing ring on steering Replace cylinder.

cylinder damaged.
Piston rod of a steering cylinder Replace cylinder.

deformed.
Pump, circuit I or II, defective. Replace pump.
Valve block or multi-way valve in Repair, clean or replace the multi-way

block defective or clogged. valve.
Leakages in steering block. Check screw couplings and seals.
Rear axle steering Relay for rear axle steering faulty. Replace relay.
does not operate.
Rear axle steering Check set-point pressure with

hard to operate. pressure gauge on test connector.
Pilot lamp of a Flowmeter defective. Replace.

steering circuit goes
on.
Flow limiting valve defective. Replace.
Hose pipe leaking. Replace hoses.
Screw coupling in pipe system Check screw couplings for tight fit and
loosened; loss of oil. seals for perfect condition.
0560_EN_FA043_F1_05_00_00
2003-01 3/10
5.2 Steering system - hydraulic / electrical section (cont'd.)
Steering pump Pump defective. Repair or replace pump.

produces excessive
noise.
Pump sucks in air. Check for leakages and good
condition of screw couplings.
Leakages in suction pipe. Check screw couplings.
Steering of rear axles Rocker tip switch faulty, or electrical Check rocker tip switch, check electric
not possible. connections loosened. plug-and-socket connectors.
Solenoid valves for unlocking of rear Check valves; clean and replace, if
axle or electro-pneumatic valves in necessary.
valve block faulty or clogged.
Relay for unlocking of rear axle is Replace relay.

faulty.
Insufficient pump pressure (pump Check set-point pressure on test

faulty, leakage, filter in return pipe connector.
etc.)
Pilot lamp Flowmeter or flow limiting valve Replace.

"emergency pump" is defective.
lit although the two
steering circuits are in Emergency steering pump defective. Replace.
Steering of axles from Relay for change-over of steering Replace relay.

the superstructure not assembly is faulty.
possible
Rocker tip switch faulty. Replace rocker tip switch.
Fuse in superstructure faulty. Replace fuse.
Rear axle locking system faulty. Check compressed air supply, locking
cylinder for proper working order,
superstructure steering system.
0560_EN_FA043_F1_05_00_00
4/10 2003-01
5.3 Hydraulic system of suspension
Blocking of suspen- Rocker switch defective or electrical Replace rocker tip switch; check cable
sion is not possible; cable interrupted. connection.
pilot lamp is not lit.
Key switch set to wrong position. Set key switch to position 2 (operation
from superstructure).
Fuse defective. Replace fuse.
Blocking of axle Valve block or solenoid valves in Replace valve block or exchange
suspension is not valve block faulty (blocking valve on solenoid valves (if necessary, check
possible, although the each cylinder). electrical components).
pilot lamp is lit.
Suspension block faulty. Replace valve block.
Front axle transverse Fuse defective. Replace fuse.

oscillation does not
operate (in case of
working position
“boom over-rear”)
Electro-hydraulic ball cock defective Replace ball cock.
(front axle).
Lock pin in superstructure is not Check pin fastening assembly.

completely moved in, the proximity
switch has not operated.
Roller switch faulty (in superstructure). Replace switch.
Leveling valve defective (front axles). Replace valve.
Check solenoid valve on the blocking Replace solenoid valve.

valves of the front axles.
0560_EN_FA043_F1_05_00_00
2003-01 5/10
5.3 Hydraulic system of suspension (cont'd.)
Axle locking cylinder Valve block on cylinder leaking. Replace valves and seals.
sinks in.
Screw coupling leaking. Check screw couplings for tight fit.
Leveling valves leaking or defective. Replace valve.
Cylinder defective. Replace cylinder.
Hydraulic accumulator defective. Check preload pressure; replace

accumulator, if necessary.
DANGER The oil bearing end of

the accumulator must
be depressurized
before the pressure
check.
Check pressure via the test connector

at the valve block of each cylinder.
Air inclusions in the suspension Bleed suspension system by lowering

system. the vehicle several times while
actuating the leveling valve.
Hydraulic hoses attacked by porosity. Replace hoses.
Suspension too stiff. Insufficient pressure of nitrogen Check accumulator pressure.

accumulator in hydraulic accumulator. Adjust or replenish pre-load pressure
in a specialist workshop.
Leakages in the hydraulic Replace accumulator.

accumulator.
Solenoid valves in the valve block of Replace solenoid valves.

each cylinder defective.
0560_EN_FA043_F1_05_00_00
6/10 2003-01
5.4 Inclination adjustment and level control
Inclination adjustment Rocker tip switch defective. Replace tip switch.

or lowering the vehicle
is not possible.
Axle suspension not locked via rocker Actuate rocker switch

switch. (Indicator lamp must be lit).
Valve block or solenoid valve in block Check valve block; replace valve, if
defective. necessary.
No flow in return line. Check return flow at hydraulic oil tank

(also bleeding function).
Leveling not possible. Axle suspension still locked via rocker Unlock axle locking assembly via the
switch. rocker switch (indicator lamp must not
be lit).
Rocker tip switch defective. Replace rocker tip switch.
Leveling valve defective. Replace valve.
Valve block defective or pressure Replace valve block.

control valve in valve block defective.
Suspension cylinder leaking, or screw Check cylinder for leakages; check

coupling loosened. screw couplings; readjust, if
necessary.
Insufficient pump pressure. Check pressure at test connector.
0560_EN_FA043_F1_05_00_00
2003-01 7/10
Outriggers cannot be Key switch in wrong position. Set key switch in chassis to position 1.
extended / retracted.
Locking pins are still inserted. Remove pins from beams.
Preselector switch in control box of Set preselector switch into the

outrigger actuation system is not position desired for outrigger
actuated. extension or retraction.
Preselector or selector switch faulty or Replace switch; check electrical

electrical connections loosened. connections.
Fuse defective. Replace fuse.
Relay "change-over: beams / Replace relay.

cylinders" defective.
Solenoid valve "outrigger beams / Replace valve.

cylinders" defective.
Diode defective. Replace diode.
Pump defective. Replace pump.
Pressure limiting valve in valve block Replace valve.

defective or clogged.
0560_EN_FA043_F1_05_00_00
8/10 2003-01
5.5 Hydraulic system of outriggers (cont'd.)
Outrigger cylinder is Solenoid valve defective. Replace valve.

retracted without
being actuated, while
the machine is being
supported by
outriggers.
Shut-off valve on cylinder leaking or Clean and check valve, replace if

clogged. necessary.
Piston seal of cylinder defective. Replace sealing kit; replace cylinder, if

necessary.
Air penetrated in cylinder or line. Bleed cylinder.
Outrigger cylinder, Stop valve at cylinder leaky or Clean and check valve; replace, if
when retracted, clogged. necessary.
moves downwards
without being
actuated.
Line or hose leaky. Check and re-tighten screw couplings;

if necessary; replace hose.
Solenoid valve defective. Replace valve.
Outriggers can only Insufficient engine speed. Increase engine speed.

be extended /
retracted very slowly.
Return line to filter or filter clogged. Check and clean return line, if ne-
cessary; replace filter in return line.
Suction pipe to pump leaking. Check and re-tighten screw couplings,

if necessary.
Solenoid valve is seized. Replace valve.
Viscosity grade of hydraulic oil too Fill in the specified oil type according to
high. the prevailing ambient temperature.
0560_EN_FA043_F1_05_00_00
2003-01 9/10
Memo:
0560_EN_FA043_F1_05_00_00
10/10 2003-01
Brake system F1-6
6 Brake system
Specified brake-air Insufficient air compressor delivery *) Check for proper function.
pressure is not rate.
reached (warning
lamp is lit). Hand in
pressure gauge
indicates less than 5.5
bar.
Pressure governor does not stop or *) Functional inspection - check for
blows off permanently. proper setting of switch-off pressure.
Leakages in brake line. *) Replace.
Air tank drainage valve defective. Replace valve.
Deficiency in air accumulator circuit. *) Check.
Warning lamp is lit Pressure switch in BBA I or BBA II Replace switch.

although the pressure defective.
gauge indicates more
than 5.5 bar.
Brake cylinders (air accumulator Handbrake is not completely released.
section) are not completely vented.
Deficiency in air accumulator circuit, *) Check.

functionality of valves.
Insufficient braking Brake linings worn or dirty (oily). *) Renew brake linings.
effect despite correct
supply pressure.
Wear of spreading wedge system. *) Repair spreading wedge system;
replace wear parts.
Excessive air gap between lining and *) Adjust air gap.

drum.
High wear of linings; No air gap, or insufficient air gap *) Readjust air gap; renew linings if
brakes get hot. between brake lining and drum. necessary.
Spreading wedge system seized. *) Repair.
*) in a specialist workshop
0565_EN_FA043_F1_06_00_00
2003-01 1/2
F1-6 Brake system
cont: 6 Brake system
High wear of linings; Bleeding of brake valves or brake Clean.

brakes get hot. cylinders clogged.
Pedal plate valve adjusted incorrectly. Check and correct setting.
The ABV warning The ABV has been switched off via Switch on ABV.
lamp does not go out the rocker tip switch in the instrument
after the ignition has panel.
been switched on.
Sensors are not fitting correctly, cable Check and repair, if necessary;
connections faulty. replace damaged parts.
Electric cables damaged.
Electronic system faulty. Take the machine to a specialist

workshop.
0565_EN_FA043_F1_06_00_00
2/2 2003-01
Electrical equipment F1-7
Batteries are not Battery defective. Replace batteries.

charged at all or not
sufficiently.
Cables loosened or defective. Re-tighten or replace.
Battery main switch not correctly turned Check switch;

ON, or cable loosened. check cable.
Generator warning Cable is short-circuited to ground, or Insulate or fasten.

lamp is lit or flickers loosened.
while the engine is
running.
Governor defective Replace governor
Generator defective Check or replace
No current available No connection between negative Turn battery main switch ON (actuate
when ignition battery terminal and ground. rocker switch in the instrument panel).
is switched ON.
Ground strap loose. Secure strap safely.
Engine cannot be Ignition starter switch defective. Replace switch.

started.
Relay defective. Replace relay.
Battery defective or discharged. Replace / recharge battery; use a

battery having the same capacity.
Gearbox selector lever not in Set gearbox selector lever to "N".

"neutral".
Starter interlock relay defective when Replace relay.

gearbox selector lever is in "neutral".
0570_EN_FA043_F1_07_00_00
2003-01 1/2
F1-7 Electrical equipment
Memo:
0570_EN_FA043_F1_07_00_00
2/2 2003-01
Eddy current brake**) F1-8
8 Eddy current brake**)
Eddy current brake Hand switch or contact faulty. *)Replace switch.

does not react when
hand switch is
actuated, warning
lamp is not lit.
Fuse defective. Replace fuse in fuse box.
Relay or diodes in relay box defective. *) Check relay box; replace defective
components.
Fuse in relay box defective. Replace fuse.
Fuse in battery box defective. Replace fuse.
Bad braking effect in Insulation and condition of cabling; or *) Check; replace cabling, if
all gearsteps. ground connection loosened. necessary.
Excessive backlash "rotor / stator"; *) Have measured, checked and

excessive air gap, wear of silent repaired.
blocks.
Coils of stator defective. *) Check or replace.
Excessive current Hand switch is not in "0" position. Set hand switch into "0" position. Turn
consumption of battery main switch OFF if machine is
batteries while vehicle inoperative for an extended period of
or engine is not time (e.g. at night).
running; consequently,
eddy current brake gets
hot.

*) in a specialist workshop
0575_EN_FA043_F1_08_00_00
2003-01 1/2
F1-8 Eddy current brake**)
Memo:
0575_EN_FA043_F1_08_00_00
2/2 2003-01
Part F2
Troubleshooting
Superstructure
0580_EN_ALLGE_F2_00_00_00
Troubleshooting in the superstructure F2-0
Troubleshooting in the superstructure
The following table is intended to help you locate the reason of, and - if necessary - repair any failures or
certain malfunctions of the machine in a short time. Of course, this table cannot cover all causes of
malfunctions.
The hydraulic piping diagrams and the electric circuit diagrams also help you locate and eliminate
malfunctions.
A troubleshooting guide is no substitute for a specialist. If the cause of the malfunction cannot be determined
or eliminated by means of the table, please contact the After-Sales Service of TADANO-FAUN GmbH.
0585_EN_FA043_F2_00_00_00
2003-01 1/2
F2-0 Troubleshooting in the superstructure
Memo:
0585_EN_FA043_F2_00_00_00
2/2 2003-01
Engine F2-1
1 Engine
For malfunctions concerning specifically the engine, and the appropriate remedial measures, please refer to
the operating manual of the engine manufacturer.
Engine in superstructure No electrical connection between Battery main switch (rocker switch) is
does not start (for further battery and consumers. not turned ON. Actuate rocker switch in
possible causes, please instrument panel of superstructure.
refer to item electrical,
electrical equipment).
Switch in superstructure set to the Change position of switch.
wrong position.
Ignition starter switch defective or Replace switch

electric plug-and-socket connector Check plug-and-socket connectors.
loosened.
Engine operates Air cleaner clogged. Replace filter elements, clean filter bowl
irregularly or with an (observe servicing indicator).
insufficient power output.
Leakage in air intake lines. Check air intake system for leakage, re-
tighten hose clamps.
Function of the injection system. Have checked in a specialist workshop.
Excessive coolant tem- Radiator fins clogged. Clean fins or blow them out with
perature although the compressed air; if necessary, check
engine is not subject to Vee belts.
load (indicator lamp is
lit). Leakage in cooling system. Check system for leakage.
Coolant level too low Leakage in coolant hose connections. Re-tighten hose clamps.
(pilot lamp is lit).
Pressure relief valve on compensating Check pressure relief valve for proper
tank defective. working order; replace, if necessary.
Coolant hoses attacked by porosity. Replace hoses completely.
0590_EN_FA043_F2_01_00_00
2003-01 1/2
F2-1 Engine
Memo:
0590_EN_FA043_F2_01_00_00
2/2 2003-01
Hydraulic system does Air penetrated in the system. Bleed.

not reach its full power
output.
Insufficient pilot pressure (supply with Pressure limiting valve (DBV): Check
control oil). pressure setting, readjust, if necessary.
Check pressure at test connector.
Pump control signal is not emitted at all, Check pressure setting, readjust, if
or not completely. necessary.
Pressure limiting device not adjusted Check pressure, readjust, if necessary.

correctly.
Continued suction valve contaminated. Clean valve.
Hydraulic pump or pump controller Check pump, check setting of

defective. controller, or repair it.
Oil of incorrect viscosity grade. Fill in the oil specified according to the
prevailing ambient temperature.
Pumps produce Pumps suck in air Stop engine immediately; check suction
excessive noise pipes for leakage; check hydraulic oil
level
Pumps defective. Repair or replace the pumps.
Stop cock closed. Open stock cock.
Hydraulic system of Left-hand seat bracket is not folded Fold armrest down to enable the switch
superstructure does not down completely. functions.
operate.
Switch defective. Replace switch.
Pump defective. Replace the pump.
Mechanical connection to the pumps Check the screw couplings.

loosened.
LMB in shut-off condition. Select the proper LMB program.
Pilot valve missing. Check control system.
Excessive temperature of Oil cooler clogged. Clean the cooler.

the hydraulic oil.
(For further possible causes, please
refer to item Electrical equipment).
0595_EN_FA043_F2_02_00_00
2003-01 1/2
Memo:
0595_EN_FA043_F2_02_00_00
2/2 2003-01
Swing mechanism F2-3
3 Swing mechanism
Swing mechanism turns Insufficient control oil pressure. Check pressure at test connector.
but slowly.
Manual control valve defective. Replace valve.
Axial piston motor defective. Repair or replace.
Swing mechanism pump defective. Overhaul or replace.
Pump control valve defective. Replace valve.
Compensating nozzle missing. Replace nozzle.
Brake is not completely released. Slew superstructure while swing brake

is released; the superstructure must not
stop suddenly, but must gradually come
to a standstill.
Swing mechanism turns Manual control valve defective. Replace valve.

only in one direction.
Check valves in triple control block Replace valves.

defective.
Swing mechanism Multiple discs worn. Replace complete disc package.

cannot be braked
completely.
Pedal brake valve faulty. Replace valve.
No hydraulic oil in supply tank of swing Check for leakage, replenish oil and
brake. bleed brake system.
3/2 way valve faulty. Replace valve.
Master cylinder leaky. Replace cylinder.
Swing mechanism does Brake is not released. Check hydraulic pressure.

not operate in spite of
actuation of the manual
control valve. Manual control valve faulty. Replace.
0600_EN_FA043_F2_03_00_00
2003-01 1/2
F2-3 Swing mechanism
3 Swing mechanism (cont)
Pilot lamp "Swing Proximity sensor in the chassis Replace proximity sensor.
mechanism locked" is not defective.
lit in spite of actuation of
the superstructure lock.
Swing brake cannot be Insufficient hydraulic pressure. Check pressure at test connector.
disengaged.
0600_EN_FA043_F2_03_00_00
2/2 2003-01
Telescoping mechanism F2-4
4 Telescoping mechanism
Boom is extended and Boom sliding surfaces and slideway Grease according to lubricating
retracted by jerks. linings are not lubricated. scheme, readjust slideway linings;
replace, if necessary.
Air inclusions in the cylinder. Bleed cylinder.
Telescopes do neither Fuses in telescope control defective. Replace fuses.

extend nor retract.
Relay of telescope control defective. Replace relay.
Solenoid valve defective. Replace solenoid valve.

(see electrical circuit diagrams).
Fast speed not available Fast speed valve in valve block Replace valve.
when telescopes are defective.
extended.
Tip switch in manual control valve Replace tip switch.
defective.
0605_EN_FA043_F2_04_00_00
2003-01 1/2
F2-4 Telescoping mechanism
Memo:
0605_EN_FA043_F2_04_00_00
2/2 2003-01
Boom elevation F2-5
5 Boom elevation
Boom elevation cylinder Air inclusion in cylinder. Bleed cylinder.

sinks in.
Piston seal of cylinders leaky. Exchange seals completely.
Brake valve defective. Replace valve.
Upward and downward Control pressure insufficient. Readjust.

movement of boom
elevation too slow. Control piston in double control block Replace valve.
defective.
Brake valve defective. Replace brake valve.
Sinter filter in brake valve clogged. Replace filter.
Lowering via boom Brake valve defective. Replace valve.

elevation no longer
possible. Pressure limiting valve defective. Replace valve.
Sinter filter clogged. Replace filter.
Fast speed not available Fast speed valve in valve block Replace valve.
for lifting via the boom defective.
elevation.
defective.
0610_EN_FA043_F2_05_00_00
2003-01 1/2
F2-5 Boom elevation
Memo:
0610_EN_FA043_F2_05_00_00
2/2 2003-01
Hoisting gear F2-6
6 Hoisting gear
Load is lowered slowly or Hydraulic multiple-disc brake worn. Replace complete disc package.
jerkily while the manual
control lever is in central Damage to free wheeling. Replace free wheeling.
position.
Hoisting gear turns too Insufficient control oil pressure. Check pressure at test connector.
slowly.
Continued suction valve leaking. Replace valve.
Lowering movement of Sinter filter clogged. Replace filter.

hoisting gear is too slow.
Hoisting gear does not LMB in shut-off condition. Set LMB into operating condition
operate.
Hoist limit switch is in shut-off condition Lower bottom block or replace switch.
or defective.
Manual control valve defective. Replace valve.
Valve in simple control block defective. Replace valve.
Winch motor defective. Replace motor.
No fast speed. Fast speed valve in valve block Replace valve.

defective.

defective.
0615_EN_FA043_F2_06_00_00
2003-01 1/2
F2-6 Hoisting gear
Memo:
0615_EN_FA043_F2_06_00_00
2/2 2003-01
Counterweight F2-7
7 Counterweight
Weight units are lowered Leakage of ballast cylinder(s). Replace cylinder seals, replace
slowly without cylinder(s), if necessary.
corresponding actuation.
Air inclusion in cylinder(s). Bleed cylinder(s).
Load retaining valve defective. Replace valve.
Weight units cannot be Valve in triple control block defective. Replace valve.
locked or unlocked.
Crane control lever defective or Replace crane control lever; if
electrical cable loosened. necessary, check electrical connection.
Swing motor at cylinder defective. Replace swing motor.
Ballast cylinders are not completely Extend cylinders completely, the pilot
extended. lamp must be lit.
Ballast cylinders are not Nozzle in flow divider clogged. Clean nozzle.
evenly lowered.
Weight units cannot be Valve in triple control block defective. Replace valve.
lifted or lowered.
Crane control lever defective. Replace crane control lever; if
necessary, check electrical connection.
Ballast cylinders are Insufficient hydraulic pressure. Check pressure at test connector.
extended or retracted too
slowly. Insufficient pilot pressure. Check pressure at test connector.
0620_EN_FA043_F2_07_00_00
2003-01 1/2
F2-7 Counterweight
Memo:
0620_EN_FA043_F2_07_00_00
2/2 2003-01
Electrical equipment F2-8
No power supply. No connection between ground and Switch on battery main switch.
negative (-) battery terminal.
Grounding strip detached. Fasten the strip.
Engine in superstructure Fuse faulty. Replace the fuse.

cannot be started.
Starter defective. Overhaul or replace starter.
Ignition starter switch defective. Replace switch.
Engine in chassis cannot Wrong position of rocker switch. Turn on rocker switch in the superstruc-
be started from super- ture.
structure.
"Start engine in chassis" function faulty Check plug-and socket connector of the
or electric plug-and-socket connector tip switch.
loosened.
Fuse faulty. Replace the fuse.
Battery main switch in chassis not tur- Switch on.

ned "on".
Ignition starter switch in chassis in Turn ignition starter switch in chassis to

wrong position. position 1.
Engine in chassis cannot Rocker switch faulty. Replace switch.

be stopped from super-
structure.
Hydraulic oil temperature Temperature switch, radiator motor Replace switch.

too high (indicator lamp defective.
is lit).
Relay radiator control, defective. Replace relay (refer also to part C2)
"Relay arrangement").
Cooler engine or fuse defective. Replace engine or fuse (refer also to

part C2 "Fuse arrangement").
0625_EN_FA043_F2_08_00_00
2003-01 1/2
F2-8 Electrical equipment
Memo:
0625_EN_FA043_F2_08_00_00
2/2 2003-01
Part F3
Connection diagram
Chassis
0630_EN_ALLGE_F3_00_00_00
Connection diagram F3-1
1 Connection diagram
0635_EN_FA043_F3_01_00_00_AB_FZ02
2001-06 1/2
F3-1 Connection diagram
Memo:
Key for diagram:
German English
Abstütz. links Outriggers, left-hand
Abstütz. rechts Outriggers, right-hand
Anschlussplan ABV-Stecker Connection diagram, ABS connector
frei free
Massebolzen Ground pin
R-Signal R signal
Telma Telma
Verteilerdose hinten Distributor box, rear
Verteilerkasten Distribution box
Kupp (Kupplung) Clutch
0635_EN_FA043_F3_01_00_00_AB_FZ02
2/2 2001-06
Part G
Annex
0640_EN_ALLGE_G_00_00_00
Part G1
Annex
Chassis
0645_EN_ALLGE_G1_00_00_00
Operating instructions for
ZF gearbox
0650_EN_ALLGE_G1_01_00_00
0650_EN_ALLGE_G1_01_00_00
12 AS 2301 / 16 AS 2601
ZF Standard
1328 758 104

Subject to alterations in design
Copyright by ZF
This operating manual is protected by copyright. Reproduction

and dissemination in any form, either wholly or in part especially
as a reproduction, photomechanical or electronic copies or
storage in data processing equipment or data networks without
the approval of the legal owner is expressly prohibited and any
violation will be pursued vigorously in the civil and criminal
courts.
Printed in Germany
Edition: 2000 - 09
Foreword
Please read this operating manual carefully before driving

your vehicle.
When operating the shift system, please note the special
instructions provided in the vehicle manufacturer's
operating manual.
Your vehicle is fitted with a ZF-AS TRONIC automatic shift
system. The more you familiarize yourself with this system,
the more economically you can drive your vehicle. This
operating manual will provide you with all the information
you require to be able to make full use of the advanced
technical features of the ZF-AS TRONIC. To ensure operating
safety, please note the maintenance specifications. Specialists
employed by ZF After-Sales Service are always available to
help with maintenance work on the transmission and are there
to assist you should any other problems occur. The relevant
addresses can be obtained from ZF in Friedrichshafen.
We would like to wish you pleasant driving with your

ZF-AS TRONIC
ZF Friedrichshafen AG
Truck Transmissions Division
D-88038 Friedrichshafen
Telefon: (0 75 41) 77-0
Telefax: (0 75 41) 77-90 80 00
3
Important work safety notice
The following safety instructions appear in this manual:

! ENVIRONMENTAL HAZARD !
Lubricants and cleaning agents must not be allowed
NOTE to enter the ground, the water table or the sewage
Refers to special processes, techniques, data, etc. system.
© Request safety information for the products
concerned from your local environmental
CAUTION protection authority and follow any instructions
This is used when incorrect, unprofessional working herein at all times.
practices could damage the product. © Always collect used oil in a suitably large
container.
© Always dispose of used oil, clogged filters,
lubricants and cleaning agents in accordance with
! DANGER! ! environmental protection laws.
This is used when lack of care could lead to personal © Always observe manufacturer instructions when
injury and damage to property. dealing with lubricants and cleaning agents.
4
Table of contents
16 AS 2601 with ZF-Intarder (Photo) . . . . . . . . . 1-1 2.6 Changing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.6.1 Changing gear in automatic mode . . . . . . . . . . . . 2-5
1 Description of system . . . . . . . . . . . . . . . . . . . . . 1-2
2.6.2 Changing gear in manual mode . . . . . . . . . . . . . . 2-5
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.7 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
1.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.7.1 Changing direction of travel . . . . . . . . . . . . . . . . . 2-7
1.3 Range selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.8 Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
1.4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2.9 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
1.5 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2.10 Switching off engine/ parking vehicle . . . . . . . . . 2-9
1.6 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2.11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
1.7 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.12 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
1.8 ZF auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.13 Clutch protection . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.14 Overspeed protection . . . . . . . . . . . . . . . . . . . . . . 2-11
2.1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.14.1 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.2 Setting off, forwards travel . . . . . . . . . . . . . . . . . . 2-2 2.14.2 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.2.1 Correcting the starting gear . . . . . . . . . . . . . . . . . 2-2 2.15 Operation with a clutch-dependent PTO . . . . . . . 2-12
2.3 Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.15.1 In stationary mode . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4 Starting to roll on slopes . . . . . . . . . . . . . . . . . . . . 2-4 2.15.2 Stationary operation . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5 Changing between manual and 2.16 Roller test rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
5
Table of contents
2.17 Display for ZF-AS TRONIC . . . . . . . . . . . . . . . . 2-13 4 List of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2.18 System errors (error messages) . . . . . . . . . . . . . . 2-16 4.1 Key to error list . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2.19 Starting the vehicle at very low temperatures . . . 2-17 4.2 List of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
2.19.1 Operation of vehicle at sustained ambient-
temperatures of between 0 °C and -40 °C . . . . . 2-17
2.19.2 Parking the vehicle at low temperatures . . . . . . . 2-17
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Oil changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2 Draining oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.3 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Transmission ventilation . . . . . . . . . . . . . . . . . . . 3-4
3.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6 Visual inspection of wiring . . . . . . . . . . . . . . . . . 3-5
3.7 Pneumatic system maintenance . . . . . . . . . . . . . . 3-5
6
16 AS 2601 with Intarder
013165
1-1
Description of system
1 Description of system
1.1 General description
The ZF-AS TRONIC automatic transmission is adapted The transmission actuator and the clutch actuator are
to the engine by means of a standard dry clutch. Since the components most crucial to complete transmission
the clutch is also controlled by the ZF-AS TRONIC automation.
transmission system, the clutch pedal can be dispensed
with. The transmission actuator consists of the transmission
electronics, shift valves, shift cylinders and sensors.
The ZF-AS TRONIC consists of a basic transmission
and an integrated splitter and planetary group. The clutch actuator is electro-pneumatically controlled
and is responsible for the entire clutch actuation process.
The basic transmission is shifted using constant mesh
gears. The splitter and planetary group are synchronized.
A display in the dashboard shows the driver all the

system information required (e.g. gear stage, fault, etc.)
1-2
Description of the system
1.2 Overview 4
6
3
5
2
8 7
017
179
017179
Key 3 E module 5 Clutch actuator

1 Console range selector 4 Transmission actuator with 6 Transmission
integrated electronic
2 Display 7 Accelerator
transmission control unit
8 Brake pedal
1-3
1.3 Range selector
The range selector consists of a rotary switch and a tip The tip lever is used to select gears and change
lever (shift lever). operating mode.
Console range selector Whenever actuated, the tip lever always springs back
into its original position.
Upshifts and downshifts covering several stages can be

performed by toggling the tip lever several times.
+ Upshift through one stage

+ + Upshift through two stages
014 295 – Downshift through one stage
– – Downshift through two stages
The rotary switch has 3 settings:
D N R Mode changes:
«D» forwards travel Press tip lever to the left
«N» neutral (no gears selected to switch between manual mode and automatic
A/M
in transmission) mode and vice versa.
«R» reverse travel
013 176
When the rotary switch is in the « N » position, the tip

lever does not function.
1-4
Description of system
1.4 Display 1.5 Accelerator
Automatic mode When a gear is engaged, to move the vehicle, you simply
have to depress the accelerator. Do not alter the
Transmission in automatic accelerator pedal setting during the shift operation.
mode (4 bars and 2 arrows) The ZF-AS TRONIC takes full charge of clutch
operation.
013 585
During the gear change, the engine is controlled by the
ZF-AS TRONIC.
4th gear selected in transmission
1.6 Automatic mode

Manual mode
Rotary switch in « D » position. The shift system
automatically selects the most appropriate gear for
4th gear selected starting off.
in transmission The ZF-AS TRONIC shift system automatically
008 014 performs upshifts and downshifts during travel.
Change from automatic to manual mode is always
possible.
Downshift option from 8th
gear into 5th gear (one gear
per bar)
014 789
1-5
1.7 Manual mode
Rotary switch in « D » position. If the tip lever is

actuated, the ZF-AS TRONIC transmission switches into
manual mode.
Using the tip lever, the driver can also select a gear for
setting off other than that suggested.
The driver must avoid over-revving the engine.
The engine stall if the accelerator is depressed in too
high gear.
1.8 ZF auxiliary units
Depending on the vehicle version, the ZF-AS TRONIC

can be equipped with the following auxiliary units.
ZF-Intarder
ZF PTO (clutch-dependent)
ZF emergency steering pump
Please refer to the Operating Manual to find out how to

operate and maintain the auxiliary equipment.
1-6
Operation
2 Operation 2.1 Starting the engine
Some deviations from the operating processes are ð Engage parking brake. D N R
permitted depending on the manufacturer and vehicle
type. ð Rotary switch is pointing
Therefore, also consult the vehicle manufacturer's to « N »
operating manual. (transmission in neutral
setting). 013 176
! DANGER ! ð Switch on "ignition".

The driver must not leave the vehicle when the engine
is running and a gear is selected. Ä Self-check of
shift system
(« CH »display). 008 010
ð Start the engine.

Ä Self-check is complete.
« N » appears on the display,
transmission is in neutral
008 011
setting.
NOTE
Gear shifts are not possible when the engine is at a
standstill.
2-1
Operation
2.2 Setting off, forwards travel 2.2.1 Correcting the starting gear
ð Start the engine (see 2.1). D N R The driver may correct the starting gear selected by the
system.
ð Turn rotary switch from
« N » to « D ». How to make a correction:
013 178
Ä Automatic mode is activated. ð Press tip lever in the « – » or « + » direction.

Ä The display shows the starting gear selected.
Ä The display shows the

starting gear selected.
(The system selects the
starting gear itself, the clutch Console range selector
remains separated 014 788
(disengaged)
ð Depress accelerator and at the same time release the

parking brake.
! DANGER!
The vehicle may roll away even if the accelerator is 014 822
not depressed.
Ä Vehicle sets off (clutch closes automatically).
2-2
Operation
2.3 Maneuvering
D N R
Unlimited maneuvering time

For extremely slow-speed travel (e.g. connecting or
disconnecting a trailer or semi-trailer), a maneuvering In the event of clutch overload, the dis-
option is provided. D N R
play shows « CL ».
For maneuvering purposes, the system can call on the

first 2 forward gears and both reverse gears.
In other gears, the maneuvering option is not available.
The system recognizes maneuvering status from the
position of the accelerator pedal and the low roadspeed.
In maneuvering mode, the vehicle (accelerator) is more
responsive and clutch actuation is different from normal
status.
Whenever clutch overload occurs, the
display unit shows « CL ».
! DANGER ! D N R
Depending on the accelerator position and vehicle

roadspeed the system switches from maneuvering to ! DANGER !
startup mode. If the driver fails to respond to the display
The vehicle can accelerate. D N R « CL », the system switches from
RISK OF ACCIDENT! maneuvering.
The vehicle can accelerate at this point.
RISK OF ACCIDENT!
2-3
Operation
2.4 Starting to roll on slopes 2.5 Changing between manual and automatic mode
Precondition: the engine must be running. Always possible, even while the vehicle is in motion.
! DANGER! Changing from manual to automatic mode:

If the vehicle starts to roll and no gears are
selected - rotary switch pointing to « N » - the engine
A/M ð tip lever to the left.
brake is ineffective! Changing from automatic to manual mode:
Do not allow the vehicle to roll in the opposite
direction of travel to that of the gear selected.
ð tip lever to the left or push tip lever in the
« + » or « – » direction.
If the vehicle rolls forwards - with transmission in

neutral - once the brake is released and the driver shifts
from « N » to « D », then the system selects a gear
suitable for the roadspeed. The driveline is then fully
engaged.
D N R
014 290
013 178 014 788
2-4
Operation
2.6 Changing gear 2.6.2 Changing gear in manual mode

2.6.1 Changing gear in automatic mode
ð Push tip lever in « + » or « – » direction.
Ä All upshifts and downshifts are performed
automatically.
These depend on:

ä driving resistance
ä loading
ä accelerator-position
ä speed
ä engine speed
014 290
When a shift is performed manually, the shift system

automatically exits automatic mode.
If the driver moves the tip lever to the left, automatic
013586
mode is reactivated.
The gear indication appears as a digit in the display
during travel.
2-5
Operation
Jumping gears
! DANGER !
Jumping one gear: The driver may shift to "Neutral" during travel. If
ð Twice in rapid succession, push tip lever in the the driver does shift to "Neutral", the driveline is
direction required. interrupted.
The engine brake is then no longer effective.
Jumping two gears:

ð Three times in rapid succession, push tip lever in
the direction required.
NOTES
ä You can use the rotary switch to shift any gear
to neutral at any time. This shift process always takes
priority.
ä The position of the accelerator must not be changed

during the shift process because the engine is
automatically controlled.
ä A shift command is not carried out if this shift

would lead to the maximum engine speed being
exceeded.
2-6
Operation
2.7 Reversing 2.7.1 Changing direction of travel
! DANGER ! Changing from reverse « R » to forwards travel « D »

If the vehicle is rolling, shifts cannot be made into reverse! and vice versa.
Stop the vehicle immediately.
ð Turn rotary switch from « R » to « D ».
Selecting reversing gear:
ð The vehicle must be at a D N R D N R
standstill. D N R
ð Turn rotary switch to « R ».

Ä « R » appears in the display 013 177 013 177 013 178
(clutch remains separated/
disengaged).
ð Depress accelerator and at the
same time, release brake ! DANGER !
(clutch closes automatically). 010 765
A change in the direction of travel, performed by
moving the rotary switch from « R » to « D » and vice
Ä Vehicle moves backwards. versa « D » to « R », may only be undertaken when
the vehicle is at a standstill otherwise the
transmission will shift into neutral.
2-7
Operation
2.8 Engine brake 2.9 Stopping
! DANGER ! ä After releasing the accelerator pedal, retard the

vehicle using the service brake, until it comes to a
The engine braking action is interrupted during the gear
complete stop.
change process. The vehicle may accelerate when travelling
downhill. ä The clutch opens automatically before the vehicle
comes to a complete stop, preventing the engine from
stalling.
Manual driving mode
ä If ever the vehicle is stationary for extended periods,
The engine brake is deactivated by the system during
ZF advises you to select transmission neutral.
gear changes. After successful shifts, the engine brake is
automatically re-engaged.
Automatic driving mode ! DANGER !

When the engine brake is employed, the system changes ä If ever the vehicle is stationary with the engine run
down to deliver maximum braking torque. ning and the gear engaged, you only have to press
the accelerator pedal for the vehicle to set off unless
the parking brake is applied!
ä Before leaving the vehicle with the engine running,

the transmission must be in neutral and the
parking brake engaged.
ä The engine may stall if the parking brake is

actuated while the vehicle is in motion on slippery
road surfaces. If this happens, power steering
assistance is NO LONGER available!
2-8
Operation
2.10 Switching off engine/parking vehicle 2.11 Towing
ð Bring vehicle to a standstill. D N R Vehicle manufacturer instructions must be observed

ð Engage parking brake. when towing!
ð Move rotary switch to « N ».
CAUTION
ð Switch off engine via ignition key. 014 176
For towing purposes, always disconnect the propeller shaft
ð Place chocks under vehicle wheels (e.g. on gradients). flange from the rear axle before setting off. If it cannot be
disconnected, remove both stub shafts.
Avoid polluting the environment in the event of oil loss.
! DANGER !
The ZF AS TRONIC automatically selects Neutral 2.12 Tow-starting
whenever the engine is switched off. The vehicle may
roll away if brakes are not actuated. The engine cannot be tow-started.
2-9
Operation
2.13 Clutch protection ä To conserve the mechanical components of the clutch

release device, the transmission should be shifted to
« CL » appears in display if there is a risk of clutch neutral if the vehicle stops for long periods of time
overload resulting from several starting process (for more than approx. 1 to 2 min., for example, in
occurring in rapid succession or of crawling in too a traffic jams, at railway crossings etc.).This closes the
high starting gear. clutch and relieves the clutch release device.
NOTE Even though the clutch is automated, the driver still has
Select an operating mode in which the clutch will not be considerable influence on clutch service life.
overloaded, for example: To keep levels of wear on the clutch low, we would
ä accelerate vehicle (to close the clutch). recommend that when setting off, you always select the
ä stop the vehicle. lowest gear possible.
ä set off in a lower gear.
! DANGER !
If the driver ignores the warning signal, the clutch
will close when the accelerator is depressed.
The clutch thereby avoids further loading.
This may cause the engine to "stall" and, if on an
incline, it is possible that the vehicle will roll
backwards.
The clutch opens again when speed is reduced.
2-10
Operation
2.14 Overspeed protection 2.14.2 Automatic mode
To protect the entire driveline from excessive speeds,

the ZF-AS TRONIC only permits gear shifts which fall ! DANGER !
within the vehicle manufacturer's specified range of The vehicle may accelerate on downhill slopes.
engine speeds. The system will undertake upshifts to protect the
engine from damage in the overspeed range
(red range).
2.14.1 Manual mode
ä Ensure that the engine does not exceed the permitted

speed range.
ä If the vehicle accelerates on downhill slopes, there

is no automatic upshift into a higher gear.
CAUTION
The engine may be damaged if the vehicle is accelerated on
downhill gradients and the engine thereby enters the
overspeed range.
2-11
Operation
2.15 Operation with a clutch-dependent PTO 2.15.2 Stationary operation
2.15.1 In stationary mode When the PTO is in stationary mode, no gear can be
selected. The transmission remains in neutral position.
ä During non-stationary operation of the PTO, only
the following forward gears and reverse gear
« RL » can be selected:
2.16 Roller test rig
Direct drive gear ä setting off in gears 1, 3, 5 D N R
Overdrive gear ä setting off in gears 2, 4, 6 Having driven onto the roller test rig
(brake test rig), shift transmission into
ä Gear shifts only take place while the vehicle is "neutral". 014 176
stationary. There is no scope for making gear
changes while the vehicle is in motion. ä When the roller is activated, the system recognizes
the "driving vehicle" function. If the driver selects a
ð Engage the PTO and select a gear for setting off. gear, the clutch closes.
ä Reverse gear cannot be selected when the roller is
Ä The display then shows, e.g.: activated.
! DANGER !
The vehicle may drive off the roller even if the
accelerator is not depressed.
008 018
i.e.: PTO 1 is activated, setting off gear 3 is enga-

ged. Also refer to Chapter entitled "Displays".
2-12
Operation
2.17 Display for ZF-AS TRONIC

! DANGER !
The display provides information on the status of the If shifts are undertaken when pneumatic pressure
transmission. It usually shows the gear selected is too low, the transmission may remain in neutral to
(e.g.: 1 - 16 or « N », « R »). ensure that there is no direct drive and that the
engine brake is ineffective.
Additional display information:
u « CH » = system self-check. u « FP » = drive pedal (accelerator)

u Display appears when u Bring accelerator to idling position.
«ignition is ON ». u If the display does not go out, there is a
008 010 008 012
system error. The vehicle cannot be
driven!
u « AL » = Airless (Luftmangel).
u Alternates with the normal display. The u « CL » = clutch (clutch)
transmission compressed air system u Alternates with the normal display.
008 128
hasinsufficient pressure. Clutch is overloaded.
008 021
u Remedy: chapter 2.11 Clutch protection.
NOTE
Only set off once there is sufficient air pressure in the u « CW » = clutch wear (clutch wear)
system. If air pressure is too low when the vehicle stops, u Proceed to approved workshop to have
do not open the clutch otherwise the engine will "stall". clutch exchanged at next opportunity.
008 029
u Automatic mode is shown in the display

by means of 4 bars and 2 arrows. (8th
gear is selected in transmission)
013 586
2-13
Operation
u « EE » = Electronic Error u Manual mode

u Appears if display communicationis u 4th gear selected in transmission.
impaired by the transmission electro-
008 122
nics. 008 014
u Manual mode
u « s PN » = PTO* 1, transmission in u Downshift option from 8th gear into
« Neutrtal » 5th gear (one gear per bar).
008 024
u PTO is activated. The transmission may 014 789
for example be in neutral position.

s Arrow facing upwards = PTO 1 is
activated.
u « st P3 » = PTO* 1 + 2, transmission
008 102 in 3rd gear
u PTOs 1 and 2 are activated. The trans-
mission is in its 3rd setting off gear.
s Arrow facing upwards = PTO 1 is
activated.
t Arrow pointing downwards = PTO 2
is activated.
*PTO = Power Take Off
2-14
Operation
u « Spanner » = system error

u Appears if the operating mode is only
available with restrictions.
008 026 u Visit a specialist workshop as soon as
possible.
NOTE
When certain system error occurs, automatic mode is
deactivated and the transmission system remains in manual
mode.
u « STOP » + « spanner »
= serious system error
u Stop the vehicle. Vehicle may no longer
008 027
be driven and must be taken to works-
hop.
! DANGER !
If possible, do not stop the vehicle when it is in a
danger zone.
ä Also refer to chapter 2.18.
2-15
Operation
2.18 System error (error messages) Console range selector
u If a « spanner symbol » appears in the display, a

system error has occurred. Operation may only be
possible with restrictions. If « STOP » and the
« spanner symbol » appear in display, a serious
system error has occurred. Stop the vehicle. Vehicle
may no longer be driven (refer to chapter 2.17 and 4).
u Error messages and the reactions resulting from

these errors can be deleted with the vehicle at a 014 289
standstill and the «ignition OFF», wait until the

display goes out. If the display does not go out once
the ignition has been turned Off, use the battery Depending on the version, a 2 or 3-digit error number
isolator to switch off the system. Switch the ignition appears on the display. This corresponds to the error
back on. If the error message is still in place, the currently in place.
vehicle will have to be taken to a service point.
Please specify the error number(s) when the service If 4 bars are displayed in addition to the number,
point is contacted. this means: error no. + 100 (only applies to two-digit
displays).
Calling up error numbers:
ð Switch on ignition
ð Turn rotary switch to « N »
ð Hold tip lever in « + » position
013 588 013 587
e.g.: error no. 74 error no. 174

2-16
Operation
Calling up inactive error numbers from the error u At outside temperatures of below -30 °C,
memory: warm air must be used to heat transmission up
to a temperature above -30 °C before the
ð switch on ignition. engine is started.
ð turn rotary switch to « N » and at the same time
depress foot brake.
ð hold tip lever in « + » position.
The errors stored are shown on the display one after
another.
2.19.1 Using the vehicle when the outside temperature is
between 0 °C and -40 °C
2.19 Starting the vehicle at very low temperatures
If the outside temperature is continually very low,
The transmission is filled in accordance with ZF List of specifications for starting the vehicle must be
Lubricants TE-ML 02. It can therefore be used in outsi- requested from the engineering department at ZF.
de temperatures of down to -30 °C.
The following should be noted:
2.19.2 Parking the vehicle at very low temperatures
The vehicle manufacturer's specifications should always
be observed. The vehicle may be parked for a long time or the
transmission may be stored at outside temperatures of
down to -40 °C.
u At outside temperatures of below -20 °C,
the transmission will require a warming up
phase once the engine is started. The engine
must be operated for at least 10 minutes with
the vehicle at a standstill until the
transmission oil has warmed up.
2-17
Maintenance
3 Maintenance 3.1.2 Oil quantities
Regular maintenance work increases the operational To ensure correct oil quantities when changing oil,
safety of the transmission. always conduct the oil filling process as specified (refer
Visual check for oil leaks conducted during the to chapter 3.2.2).
scheduled vehicle service check.
When driving with transmissions fitted with ZF Intarder,
Transmission Oil changes Initial fill at
the ZF Intarder operating manual 6085 758 002 should
OEM or after
be observed.
repair work
12 AS 2301 11 / 12* litres 11 / 21* litres
3.1 Transmission oil
16 AS 2601 12 / 13* litres 12 / 23* litres
* with intarder
3.1.1 Oil grade
According to ZF List of Lubricants TE-ML 02. The ZF 3.2 Oil changes

List of Lubricants is available from all ZF subsidiaries
or via Internet http://www.zf.com/zf-n NOTE
Vehicle should be on horizontal ground when oil is
changed.
3.2.1 Oil change intervals
To safeguard reliable operation of the transmission,

compliance with the oil change intervals specified in ZF
List of Lubricants TE-ML 02 is mandatory!
3-1
Maintenance
3.2.2 Draining oil
Always change oil after long journeys provided that the

transmission oil is still at operating temperature and is
still thin.
! DANGER !
Risk of burning upon contact with parts and with the
transmission oil.
ð Remove oil drain plugs from transmission (Figs. 1.1

and 1.2, items 1 and 2) and collect transmission
oil in a suitable container. Dispose of in an
environmentally-friendly manner.
ð Clean oil drain plug with magnetic plug and replace
seal.
ð Tighten oil drain plugs to the specified torque.
3-2
Maintenance
Key to Figs. 1.1 and 1.2

1 Oil drain plug
tightening torque TA = 60 Nm
2 Oil drain plug
tightening torque TA = 60 Nm
3 Oil fill and overflow measurement point
There is a notice on this screw indicating the oil gra-
des and oil change intervals.
010 768 2 3 1 tightening torque TA = 60 Nm
Fig. 1.1 Version: solo transmission
3.2.3 Oil filling
ð Top up with oil through the oil filling point.

(Figs. 1.1 and 1.2, item 3).
Ä The oil level is correct once the top of the oil has
reached the bottom of the filling point or once oil has
already started to escape from the filling point.
014 783
2 3 1
Fig. 1.2 Version: transmission with Intarder
3-3
Maintenance
3.3 Checking oil level 3.4 Transmission ventilation
The transmission oil heats up during travel. This causes

! DANGER ! excess pressure which is continually reduced by a
The transmission will be damaged if it does not breather valve.
contain enough oil. Ensure that the breather valve is always functioning
RISK OF ACCIDENT! correctly. The breather (item 5) must be clean and must
not have a plastic cover.
Regularly check the oil level in the transmission: 5 7

Ä Check the oil level when the vehicle is on horizontal
ground.
Ä Do not check oil level straight after a journey
(incorrect measurement). Only check once the trans-
mission oil has cooled down (<40 °C).
ð Remove oil fill screw (item 3).
6
ð If the oil level has fallen below the oil filling point, it
will have to be topped up (section 3.2.2).
NOTE 3
Each time you check the oil, also watch out for any Fig. 2
013165
leakages on the transmission.
3 Oil fill screw 7 Initial fill or oil top ups
5 Transm. breather after repairs, only in
6 Type plate Intarder version
3-4
Maintenance
3.5 Type plate 3.6 Visual inspection of wiring
The type plate contains the most important data. It can ð Check wiring for damage.
be found on the left-hand side of the transmission when
viewed from the output.
ð Ensure that connectors are seated correctly, connec-
tors must be fitted with tension relief.
The following should always be specified when making
inquiries or repairs:
u parts list no. of transmission 3.7 Pneumatic system maintenance
u transmission type
u serial no. of transmission ð The maintenance instructions of the vehicle
manufacturer must be observed.
ð The compressed air reservoir must be drained every
week (every day in winter).
16 AS 2601+ IT
1328 040 xxx 200 010 NOTE

XXXXX When the compressed air reservoir is drained, the
compressed air cleaner and water separator must also be
XXXX X
drained unless these operate automatically.
XXXX
23 02
Fig. 3 Type plate (example)
3-5
List of errors
4 List of errors
4.1 Key to error list
GV setting: odd or even gear numbers
GP setting:
In 12th gear
Low ratio (gears 1 - 6) or
High ratio (gears 7 - 12) range-change group
With 16 ratios
Low ratio (gears 1 - 8) or
High ratio (gears 9 - 16) range-change group
PTO: Power Take Off
RESET: Switch off ignition while vehicle is stationary

and wait until display goes out. Then switch on
the ignition. If there is an error in the system,
visit a workshop without delay.
4-1
Standard error list (status 2000-09-08)
Section 1: Implications
02,03,04,05,06,07,08,09,22,34, In motion: gear shifts are inhibited.
35,36,37,38,39,40,41,54,61,62, Stationary: automatic shift to neutral and gear change
66,67,68,69,70,71,72,73,77,78, inhibited.
82,83,84,85,90,101,105,117,132136 No longer possible to continue driving.
,140,144,169,170,177,179, System not available.
180,181,188,189,190,191,193.
Section 2 If two or more errors occur from Section 2, the system
responds in the same manner as in Section 1.
10,42 Motion: gear shift action inhibited including neutral.
Setting-off gear: only if lowest gear is selected in the
high-range GP.
Ignition ON: system not available.
17,18,19, 20,21,49,50,51, 52,53, 97, This may have the following implications! Motion:
98, 99,107,120,121,122,123, 124, Reduced comfort when setting off, maneuvering, shifting,
164,165 extended shift time and engagement time for PTO.
Stationary: average setting-off gear.
No maneuvering mode.
81 Motion: gear shift action inhibited.
Stationary: selection of setting-off gears is possible.
Setting off is possible.
110 Motion: gear shift action inhibited, including shift
attempts to Neutral.
Stationary: Setting off is possible.
118 Motion: gear shift action inhibited.
Stationary: engine stalls if clutch fails to open.
119 Motion: Clutch closes rapidly. Gear shift
inhibited.
Stationary: automatic neutral shift.
System not available.
Section 3: Errors which, even if they occur frequently, do not have
to lead to impaired availability of the system.
11 Warning buzzer permanently active.
12,44 Activation of reversing light not possible.
13,14,45,46,59,60,63,64 PTO 1 or 2 not available. No other system limitations.
23 Continuous activation of warning lamp.
25,89 Display EE. No system response.
26,27,28,30,31,32,33,91,92,93, The following effects can occur!
94,96,113,171,173,182,183,184,192 Motion: reduced comfort when setting off, maneuvering,
,197,199 shifting gear, increased shift time.
Stationary: mean setting-off gear.
No maneuvering mode.
43,75 Warning buzzer cannot be activated.
55,87 Warning lamp cannot be activated.
76 Reversing light is permanently switched on.
86 Display cannot be switched off.
Speed range selector does not switch off.
No restrictions on system availability.
95,100,104,111,112,125,127, As an isolated error, no impact on system or on certain
128,167,174,195,196,198 calculations, e.g. clutch wear assessment is not possible.
102,163 Motion: gear shift action inhibited, including shift
attempts to neutral.
Stationary: setting off is possible.
108,175 The following errors can occur!
Motion: gear selection inhibited.
Stationary: system not available, setting off is possible
126 System function not impaired.
Any possible pressure loss is not displayed.
Longer learning period.
129,130,131 Motion: gear shift action inhibited, shift from neutral is
possible.
Stationary: setting-off gears are possible.
133,134,135 Motion: restricted number of gears.
Stationary: Restricted gear choice for setting off, no
reverse gear.
137,138,139,145,146,147 Motion: GP shift is inhibited. Only gears in shifted GP
range can be selected. Reduced shift comfort, extended
shift time.
Stationary: setting-off gears are possible
141,142,143,148,149,152 Motion: automatic gear correction (last GV setting) or
neutral shift.
Stationary: setting off in last GV setting or via Speed
range selector.
150 System not available. Subsequent GV shift attempts are
possible.
151 Motion: automatic gear correction or neutral shift.
Stationary: setting-off gear only selectable using speed
range selector.
153,155,156 Motion and stationary: automatic neutral selection.
Subsequent shifts using speed range selector.
154 Motion: clutch closes. Next shift attempt using speed
range selector.
Stationary: set off in lowest gear, high-range GP.
158,159,160 Automatic gear correction.
166 Motion: shifts possible while vehicle is in motion.
Stationary: system not available.
168 Motion: no restriction on system.
Stationary: after reset, setting off can be possible.
Chart of lubricants for ZF
gearbox
0660_EN_ALLGE_G1_03_00_00
0660_EN_ALLGE_G1_03_00_00
Commercial Vehicle and
Special Driveline Technology
Manual and automatic transmissions x

for trucks and buses List of lubricants TE-ML 02
Product groups (1) Lubricant classes for service fills (2)

Transmissions without Transmissions with
_ ZF-Intarder ZF-Intarder
Transmission types see page 3!
VAN ZF-Ecofluid M (02E) x
02D / 02F (3) / 02G x
Ecolite / AS Tronic lite alternative (4): ---
truck 1 + bus 1 02A / 02B / 02L
x ZF-Ecofluid M (02E) x
truck 2 + bus 2 02Gx ---
alternative (4):
02A / 02B / 02C / 02D
Hydraulic actuators 02K ---
truck 3 + bus 3
_ _
Ecomid / Ecomid with NMV ZF-Ecofluid M (02E) ZF-Ecofluid M (02E)
truck + bus 02A / 02B / 02C / 02D / 02H / 02L 02C / 02D / 02H / 02L
Ecosplit / Ecosplit with NMV
truck 1
truck 2 ZF-Ecofluid M (02E) ZF-Ecofluid M (02E)
alternative (6): alternative (6):
02A / 02B / 02D / 02H / 02L 02D / 02H / 02L
NewEcolite / AS Tronic lite x x
truck + bus ZF-Ecofluid M (02E) ---
02D / 02Lx
New Ecomid alternative (4): ZF-Ecofluid M (02E)
truck 02A / 02B 02D / 02L
NewEcosplit / NewEcosplit with NMV ZF-Ecofluid M (02E) ZF-Ecofluid M (02E)

truck 1 02A / 02B / 02C / 02D / 02H / 02L 02C / 02D / 02H / 02L
truck 2 ZF-Ecofluid M (02E) ZF-Ecofluid M (02E)
alternative (6): alternative (6):
02A / 02B / 02D / 02H / 02L 02D / 02H / 02L
Classic Line ZF-Ecofluid M (02E) x
truck + bus 02A / 02B / 02C / 02D / 02H / 02L ---
Transmatic 02C (5) ---
_
Warning: Note continuation of table and footnotes on page 2!
The list of lubricants TE-ML 02, Edition 01.04.2006 replaces all ZF Friedrichshafen AG
previous editions. The current list can be requested from any ZF D-88038 Friedrichshafen
after-sales service center or accessed on the Internet under phone: + 49 7541 77 3505x
www.zf.com. fax: + 49 7541 77 7319
x
Page 1 of 17 1205 754 102o / 04.2006
Continued ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.04.2006
Product groups (1) Lubricant classes for service fills (2)

x Transmissions without Transmissions with
Transmission types see page 3! ZF-Intarder ZF-Intarder
AS Tronic mid ZF-Ecofluid M (02E) ---
truck + crane vehicle 02A / 02B / 02D (6)
AS Tronic 1 ZF-Ecofluid M (02E)x ZF-Ecofluid M (02E)x
truck 02A / 02B / 02C / 02H 02C / 02H
AS Tronic 2 x ZF-Ecofluid M (02E)x
truck, bus + crane vehicle ZF-Ecofluid M (02E)x 02D (6) / 02H / 02L
02A/ 02D (6) / 02H / 02L
TC Tronic x
Transmission AS Tronic 2 ---
Torque converter lock-up clutches TC 2 02C (5) / ATF in ---
accordance with TE-ML 14
x
(1) Approved lubricant classes for models not listed here:
- Torque converter lock-up clutches (WSK) with separate oil circuit: 02C, ATF in accordance with TE-ML 14x
- Constant-mesh and synchronised transmissions for commercial vehicles: 02A / 02B / 02C / 02H /x
ZF-Ecofluid M (02E)
(2) Refer to the following pages for approved commercial products, oil change intervals and low temperature
limits.
(3) Product groups VAN, Ecolite - truck 1 + bus 1: TE-ML 02 applies only after the transmission has reached a total
of 2,500 km. This also applies to repairs.
(4) Product groups VAN, Ecolite: In moderate climate zones, shift quality is impaired if oils of the lubricant classes
02A / 02B / 02C / 02D / 02H / 02L are used.
(5) Lubricants marked (*) on the following pages must not be used.
(6) Lubricant classes can only be used after a total transmission mileage of 540 000 km / 3 years (long-haul / coach
operation) or 360 000 km / 3 years (local / distribution / service route operation, heavy-duty operation).
x
Comments:
1. Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 010 and
1328 765 001 must be followed.
2. A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at
greasing points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).
3. Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore
not permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such
additives.
Page 2 of 17 1205 754 102o / 04.2006

Transmission classification List of lubricants TE-ML 02

in accordance to product groups
x
Product groups Transmission types (only basic transmission named)
(type in bold/italic are available with ZF Intarder)
VAN 5S200, 5S270, 5S510, 5S640, 6S300, 6S320, 6S350, 6S380, 6S420,
6S650, 6S720
Ecolite / AS Tronic lite S5-18, S5-24, S5-42, S5-420, S5-680, S6-36, S6-36/2
truck 1 + bus 1
truck 2 6S850, 6AS850
bus 2 6S890, 6S700BO
truck 3 + bus 3 S6-85, 6S1000BO, 6S1200, 6S1600, 6S1900, 6S1700
Ecomid / Ecomid with NMV 9S75, 9S109, 16S109
truck
bus 8S180, 8S2100
Ecosplit / Ecosplit with NMV 8S151, 16S151, 8S181, 16S181, 16S221, 16S251
truck 1
truck 2 16S231
NewEcolite / AS Tronic lite 6S700TO, 6AS700TO, 6S700TD, 6AS700TD, 6S800TO, 6AS800TO,
truck + bus 6S800TD, 6AS800TD, 6S1000TO, 6AS1000TO; 6S710BO,
6AS710BO, 6S710BD, 6AS710BD, 6S810BO, 6AS810BO, 6S810BD,
6AS810BD, 6S1010BO, 6AS1010BO
NewEcomid 9S1110, 9S1310
truck
NewEcosplit / NewEcosplit with NMV 8S1620, 16S1620, 8S1820, 16S1820, 8S1920, 16S1920, 16S2020,
truck 1 8S2220, 16S2220, 16S2520, 16S2720
truck 2 16S2320
Classic Line 8S1350, 16S1650, 16S1950
truck
bus S6-1550, 6S1380
Transmatic (Ecosplit with WSK / 16S151, 16S221, 16S251, 16S1623, 16S1823, 16S2223, 16S2523,
NewEcosplit with WSK) 16S2720
AS Tronic mid 12AS1010, 12AS1210, 12AS1220, 12AS1420, 12AS1620
truck
crane vehicle 12AS1620SO
AS Tronic 1 12AS1800, 16AS2200
truck
AS Tronic 2 12AS1630, 12AS1930, 12AS2130, 16AS2230, 12AS2300, 12AS2330,
truck 12AS2340, 12AS2530, 12AS2540, 16AS2600, 16AS2630, 12AS2740,
12AS2940
bus 10AS2300, 12AS2000, 12AS2300, 10AS2310, 12AS2700
crane vehicle 12AS2300, 16AS2600
TC Tronic 12TC2740, TC2
x
Page 3 of 17 1205 754 102o / 04.2006

_
Warning: Refer to the table on page 1 for the lubricant classes authorized for the individual
product groups.
_
Oil change intervals List of lubricants TE-ML 02

x
x x 02B, 02C, x x x
Lubricant class 02A 02F, 02G, 02Hx 02D, 02L ZF-Ecofluid M 02K
ATF (02E)
Application oil change interval (8)
VAN transmissions 60.000 km 120.000 km 240.000 km No oil change ---
needed
Short-distance transport x x x
(trucks), scheduled routes 60.000 km 120.000 kmx 240.000 kmx With dry room _
(buses), tough operating 1 year 1 year 2 years breather (7): ---
conditions x
360.000 km
3 years
Long-distance transport x x x
(trucks) 90.000 kmx 160.000 kmx 300.000 km With dry room _
Long-distance coach 1 year 1 year 2 years breather (7): ---
journeys (buses) x
540.000 km
3 years
Hydraulic actuators --- --- --- --- No oil change
needed
(7) These intervals only apply to a hose breather in a dry room. If there is no hose breather in the dry room, the oil
change intervals specified for lubricant classes 02D / 02L apply.
(8) Oil change required, depending on what occurs first.
x
Low temperatures limits

x
Lubricant classes Oil type / SAE viscosity grade Use at oil sump
temperatures
ZF-Ecofluid M (02E) / 75W / 75W-80 / 75W-85 / 75W-90 / ATF above -40°C
02B / 02D / 02F / 02G / 02K / 02L / ATF
02A / 02B / 02H 80W / 80W-85 / 80W-90 above -25°C
x 40 above 0 °C
02C
30 above -15°C
20W (Transmatic, TC Tronic only) below -15°C
x
Page 4 of 17 1205 754 102o / 04.2006

Lubricant class 02A

Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 (not applicable for Intarder)
x
Note:
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are
used.
x
Manufacturer (02A) Trade name (02A)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W-90
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL GETRIEBEÖL 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W-90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA GEAR OIL MZ 80
BAYWA AG, MÜNCHEN/D BAYWA MEHRZWECKGETRIEBEÖL SAE 80
BEHRAN OIL CO., TEHRAN/IR BEHRAN SAMAND MB 80W-90
BELGIN MADENI YAGLAR, GEBZE KOCAELI/TR BELGEAR EP MB 80
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W-100
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W-68
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL MEHRZWECKGETRIEBEÖL SAE 80W
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W/90
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MP GEAR OIL 80W GL 4
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EP 80W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EP80W
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL UNITRON 80W
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES F SAE 80
CHEVRON BRASIL LTDA., RIO DE JANEIRO/BRAZIL UNIVERSAL EP SAE 80W
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W-90
COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE JANEIRO/BR IPIRGEROL EP 80W
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR A ( 80W )
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MULTIPURPOSE GEAR OIL SAE 80W90
EKOPROM, UFA/RUS EKOIL ECO-TRANS SAE 80W
EKOPROM, UFA/RUS EKOIL ECO-TRANS SAE 80W-85
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA HY 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA HY DB 80W
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL GP-D 80W
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE GX-A 80W
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR MP SAE 80W
GINOUVES GEORGES SA, LA FARLEDE/F YORK 791 SAE 80W85
HAFA, PARIS/F HAFA MPB SAE 80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W-90
IGOL FRANCE SA, AMIENS/F TRANS EPA SAE80W-85W
KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-MEHRZWECK-GETRIEBEOEL SAE 80W-90
KRAFFT S.L., ANDOAIN/E HIDROIL SAE 80W90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 35 SAE 80 W
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 35 SAE 80W-90
LIQUI MOLY GMBH, ULM/D LIQUI MOLY GETRIEBEÖL GL 4 SAE 80W
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL DB 80W
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL HD 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE 80W
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL 80W
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR MB 80W
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE GEAR EP 80W-90
NEW PROCESS AG, TÜBACH/CH EP GEAROIL SAE 80W
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 4 80W
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL SAE 80W
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL SAE 80W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL MP SAE 80W-85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W/90
Page 5 of 17
PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W90

PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W
PRISTA OIL AD, ROUSSE/BG PRISTA EP 80W
PT PERTAMINA (PERSERO), JAKARTA/RI RORED EP-A SAE80W-90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL 10 ZF
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL SUPER GL-4 80W
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL SUPER GL-4 80W-90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL MZ-GETRIEBEÖL 80 GL 4
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL MZ-GETRIEBEÖL 80W-90 GL4
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CS EP M SAE 80W
S.A.E.L., MADRID/E GULF GEAR LUBRICANT 80W-85
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL SPIRAX G 80W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MA 80W
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEÖL 80
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN MEHRZWECK-GETRIEBEÖL 80W-90
TOTAL ISU OIL CO. LTD., SEOUL/ROK TOTAL EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EP 80W
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC N 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC N 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W-90
UNIL S.A., SAUMUR CEDEX/F UNIL OPAL GEAR EP SAE 80W85W
VALVOLINE EUROPE, DORDRECHT/NL HIGH PERFORMANCE GEAR OIL GL-4 80W
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR SAE 80W
YACCO, ST PIERRE LES ELBEUF/F BVX M 100 80W85
Page 6 of 17
Lubricant class 02B

Gear oil of viscosity grades: SAE 80W / 80W-85 / 80W-90 / 75W-80 / 75W-85 / 75W-90x
(not applicable for Intarder)
_
Note:
used.x
x
Manufacturer (02B) Trade name (02B)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP ROTRA TRUCK GEAR S, SAE 75W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP PLUS 80W-90
ARMORINE S.A., LANESTER CEDEX/F BM 80
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 75W-90 EP
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MÜNCHEN/D BAYWA SUPER 8090 MC
BEHRAN OIL CO., TEHRAN/IR BEHRAN SAMAND OEM 1 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR DL 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR SHX-M SAE 75W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL GETRIEBEÖL FE SAE 80W-90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNISYNT TX
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MULTI GEAR OIL FE 80W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR ULTRA
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE PLUS 75W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MULTIDRIVE 80W90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP FE+LD 75W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR S 75W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX TRANSLUBE LD SAE 80W
CHEVRONTEXACO, SYDNEY/AUS CALTEX TRANSLUBE LD SAE 80W-90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA LSX 75W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA TRUCK GEAR 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL TDL 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE 1 SHC 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE S 80W-90
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER EP GEAR OIL 80W/90 GL-4
FUCHS PETROLUB AG, MANNHEIM/D TITAN SUPERGEAR MC 80W-90
GENOL GMBH & CO., WIEN/A GENOL GEAR-SYN 80W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 896
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR TDL 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF SYNGEAR 75W-90
HAFA, PARIS/F EUROGEAR SAE 75W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA P ECO 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA PXD ECO 75W-90
IGOL FRANCE SA, AMIENS/F GEAR M 80W90
IGOL FRANCE SA, AMIENS/F SYNTHEGEAR SAE75W90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 GEAR OIL XG SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 TRANS XGS SAE 75W-90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEÖL TDL SAE 80W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL TDL 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN FE/MILLERS TRX SYNTH 75W/90
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 80W
MODRICA OIL REFINERY, MODRICA/BIH TRANSLUBE GL-4 SAE 80W
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL KZ 80W-90
MORRIS LUBRICANTS, SHREWSBURY/GB LODEXOL SS 80W
MORRIS LUBRICANTS, SHREWSBURY/GB SERVOL EP 80W/90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR SYNT TDL 75W-90
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE HYPOIDI TDL S 75W-90
NEW PROCESS AG, TÜBACH/CH GEAROIL SYNTH
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 5 80W-90
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST SYNTH GETRIEBEÖL SAE 75W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL XD-4 SAE 80W-85
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR S SAE 75W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR SAE 80W-90
Page 7 of 17
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR CBS SAE 75W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL 75W90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL EXTRA GL-4 80W-90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL EXTRA GL-5 80W-90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SLG SPEC. LKW GETR.ÖL 80W90
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CARTAGO FE LD 75W90
S.A.E.L., MADRID/E GULF SYTHETIC GEAR LUBRICANT 75W-90
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU EP GEAR LUBE 80W/90 (GL-4)
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX GX 80W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX GX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MX 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID SML 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN RSG 80
STATOIL LUBRICANTS, STOCKHOLM/S GEARWAY G4 80W
STRUB + CO AG, REIDEN/CH STRUB MULTIGEAR SGO 80W-90
STRUB + CO AG, REIDEN/CH VULCOGEAR SYNT SGX 75W-90
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPS 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR UNIVERSAL FE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC FDL 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION RS FE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION SYN FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF SYNTHESE FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF UNIVERSAL FE 80W-90
VALVOLINE EUROPE, DORDRECHT/NL SYNPOWER GEAR OIL TDL 75W-90
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE STX GEAR OIL GL-5 80W-90
YACCO, ST PIERRE LES ELBEUF/F BVX 1000
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL GEAR OIL STO SAE 80W-90
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID X
Page 8 of 17
Lubricant class 02C

Monograde engine oil of viscosity grades: SAE 30 / 40
(mineral oil-based, applicable for Intarder)x
x
Note:
1. In moderate climate zones, shift quality is impaired if viscosity grade SAE 40 is used.
2. Product group Transmatic/TC Tronic: At ambient temperatures below -15°C, engine oil of
viscosity grade SAE 20W (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL specifications
or ACEA categories A/B/E) must be used. If possible, any one of the below-mentioned
commercial products in the viscosity class SAE 20W is to be used.
3. Product group Transmatic/TC Tronic: The lubricants marked thus (*) may not be used.
x
Manufacturer (02C) Trade name (02C)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL TURBO DIESEL MD 305 SAE 30
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL TURBO DIESEL MD 405 SAE 40 (*)
ARAL AG, BOCHUM/D ARAL BASIC TURBORAL 30
ARAL AG, BOCHUM/D ARAL BASIC TURBORAL 40 (*)
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SPECIAL HDC SAE 30
BEHRAN OIL CO., TEHRAN/IR BEHRAN TURBO DIESEL SAE 40 (*)
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASOL 30
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASOL 40 (*)
BP INTERNATIONAL, PANGBOURNE, READING/GB BP VANELLUS C3 MONO SAE 30
BP INTERNATIONAL, PANGBOURNE, READING/GB BP VANELLUS C3 MONO SAE 40 (*)
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX EXTRA 30
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX MULTI DF 30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL ASSURON T PLUS SAE 30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL ASSURONT PLUS SAE 40 (*)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL CRF 30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL CRF 40 (*)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TROPICAL TURBO 40 ZF (*)
CHEVRON BRASIL LTDA., RIO DE JANEIRO/BRAZIL URSA LA 3 SAE 40 (*)
CHEVRON BRASIL LTDA., RIO DE JANEIRO/BRAZIL URSA TRANS FF SAE 40 (*)
CHEVRONTEXACO, GHENT/B URSA SUPER LA 30
CHEVRONTEXACO, GHENT/B URSA SUPER LA 40 (*)
FUCHS LUBRICANTS (UK) PLC, HANLEY/GB TITAN TXE 30
FUCHS PETROLUB AG, MANNHEIM/D TITAN UNIVERSAL HD 30
GENOL GMBH & CO., WIEN/A GENOL MULTI-TURBO 30
HINO MOTORS LTD, HINO-SHI TOKYO/J BLUE RIBBON BIG SUPER 30 SAE#30
HUILES BERLIET S.A., SAINT PRIEST/F RTO PREXIMA 40 (*)
IGOL FRANCE SA, AMIENS/F TRANS TURBO 4 SAE30
INA MAZIVA RIJEKA, RIJEKA/HR INA GORGONELA S 30
INA MAZIVA RIJEKA, RIJEKA/HR INA SAGARTIA 30
INA MAZIVA RIJEKA, RIJEKA/HR INA SUPER 3 30
INA MAZIVA RIJEKA, RIJEKA/HR INA SUPER 5 30
KRAFFT S.L., ANDOAIN/E MONOGRADO SUPER S-3 SAE 40 (*)
LIQUI MOLY GMBH, ULM/D LIQUI MOLY TOURING HIGH TECH HD 40 (*)
LIQUI MOLY GMBH, ULM/D TOURING HIGH TECH MOTOROIL SAE 30
LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA MONOLEC GFS ENGINE OIL SAE 30
MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK OMEGA 643 SAE 40 (*)
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MOTORENOEL HD-C3 SG SAE 30
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MOTORENOEL HD-C3 SG SAE 40 (*)
NEW PROCESS AG, TÜBACH/CH MONO DIESEL SAE 30
OMV REFINING & MARKETING GMBH, WIEN/A OMV TRUCK SAE 30
OMV REFINING & MARKETING GMBH, WIEN/A OMV TRUCK SAE 40 (*)
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY DRACO 3001 SAE 30
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY DRACO 3001 SAE 40 (*)
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO PKO HD 4 SAE 30
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO PKO HD 4 SAE 40 (*)
PANOLIN AG, MADETSWIL/CH PANOLIN EXTRA DIESEL 30
PANOLIN AG, MADETSWIL/CH PANOLIN EXTRA DIESEL 40 (*)
PROFI-TECH GMBH, GINGEN/D PROFI-CAR EXTRA C SAE 40 (*)
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SUPER TRUCK SAE 30
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SUPER TRUCK SAE 40 (*)
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL GADINIA 30
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL GADINIA 40 (*)
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL RIMULA X 30
STATOIL LUBRICANTS, STOCKHOLM/S STATOIL DIESELWAY 30
Page 9 of 17
STATOIL LUBRICANTS, STOCKHOLM/S STATOIL DIESELWAY 40 (*)

STRUB + CO AG, REIDEN/CH TURBO HD SAE 30
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL POWER D SAE 30
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR TRAXOLIA Z 40 (*)
TOTAL LUBRIFIANTS S.A., PARIS/F ELF PERFORMANCE SUPER D 30
TOTAL LUBRIFIANTS S.A., PARIS/F ELF PERFORMANCE SUPER D 40 (*)
YACCO, ST PIERRE LES ELBEUF/F YACCO TRANSPRO MAS3 SAE 30
Page 10 of 17
Lubricant class 02D

Gear oil of viscosity grades: SAE 75W-80
(semi-synthetic, synthetic, applicable for Intarder)x
x
Manufacturer (02D) Trade name (02D)
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL GETRIEBEÖL VSL-4 75W-80
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL SNS SAE 75W-80
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX PRISMA TF 75W/80
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES FE+LD 75W-80
CHEVRONTEXACO, GHENT/B MULTIGEAR MTF 75W-80W
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MT/LD GEAR OIL 75W80
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILTRANS SHC 30
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE XHP 75W-80
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA TRUCK GEAR FE (SAE 75W80)
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA TRUCK GEARLITE SAE 75W80
FUCHS PETROLUB AG, MANNHEIM/D TITAN CYTRAC LD 75W-80
GINOUVES GEORGES SA, LA FARLEDE/F YORK 894 75W-80
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENNOCO FLEET TRANSMISSION LUBE ED SAE 75W-80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA ECO 75W-80
IGOL FRANCE SA, AMIENS/F TRANS GEAR ZF 75W80
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 60 SAE 75W-80
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL HD 75W-80
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL MOTYLGEAR 75W-80
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND CRYPTO GEAR
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL LDI SAE 75W-80
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GOLDENGEAR LD SAE 75W/80
PANOLIN AG, MADETSWIL/CH PANOLIN TRANSGEAR 75W/80W
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL ULTRA 75W80
RALOY LUBRICANTES S.A. DE C.V., TIANGUISTENCO/MEX NEW EXPERIENCE SYNTHETIC OIL 341
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CARTAGO CAJAS FE LD 75W-80
S.A.E.L., MADRID/E GULF INTARDER GEAR OIL 75W-80
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL TRANSMISSION OIL ZFLD 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR LD 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC TI 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION TI 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF LD 75W-80
UNIL S.A., SAUMUR CEDEX/F GERION LD 75W80
YACCO, ST PIERRE LES ELBEUF/F BVX Z-500 75W-80
Page 11 of 17
Lubricant class 02E

Gear oil of viscosity grades: SAE 75W-80
(synthetic, applicable for Intarder)x
x
Manufacturer (02E) Trade name (02E)
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SYNTRANS MAX 75W-80
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID M
Page 12 of 17
Lubricant class 02F

ATF
x
Manufacturer (02F) Trade name (02F)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL ATF D II D
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL ATF D III
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP DEXRON III
AMERICAN AGIP COMPANY, CABOT/USA AGIP HD SYNTHETIC BLEND ATF
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 98
BEHRAN OIL CO., TEHRAN/IR BEHRAN AUTOMATIC II
BELGIN MADENI YAGLAR, GEBZE KOCAELI/TR LUBEX ATF-II
BELGIN MADENI YAGLAR, GEBZE KOCAELI/TR LUBEX ATF-III M
CEPSA LUBRICANTS S.A., MADRID/E CEPSA ATF 2000 (SAE 10W)
CHEVRON BRASIL LTDA., RIO DE JANEIRO/BRAZIL TEXAMATIC 7045E
CHEVRONTEXACO, GHENT/B TEXTRAN PSM
CHEVRONTEXACO, SYDNEY/AUS CALTEX ATF-HDM
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR ATF DMM
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN ATF III
FL BRASIL, CONTAGEM/BR TUTELA GI/A PLUS
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA TRANS XHD
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA HYDRODEX 3
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA CAR GI/E
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA GI/A
FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 4000
GRUPA LOTOS SA, GDANSK/PL LOTOS ATF IID
IGOL FRANCE SA, AMIENS/F ATF 430
KLORA AS, GEBZE/KOCAELI / TR KLORA ATF II K
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 14
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 15
LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA 1150 TRANS-ALL EHP AUTOMATIC TRANSMISSION FLUID
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA ATF DX IID
MORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC SUPER ATF
OMV REFINING & MARKETING GMBH, WIEN/A OMV ATF III
PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON III
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN HEAVY DUTY SYNTHETIC BLEND ATF
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN MERCON V ATF H-36007
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN SYNTHETIC BLEND ATF
PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PO ATF-2
PRISTA OIL AD, ROUSSE/BG PRISTA ATF
PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL VECO MATIC IID
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL ATF II D
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL ATF III
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL DEXRON F III
REDOIL ITALIA SPA, SAN VITALIANO (NA)/I CHALLOILS ATF III
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL ATF III
SYNECO SPA, SAN GIULIANO MILANESE/I ATF PLUS
TOROS MADENI YAGLAR NAKLIYAT, SELCUKLU - KONYA/TR TOROS OIL ATF II
TOROS MADENI YAGLAR NAKLIYAT, SELCUKLU - KONYA/TR TOROS OIL ATF III
TOTAL LUBRIFIANTS S.A., PARIS/F FINAMATIC HP
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL FLUIDE AT 42
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL ATF DEXRON III (F-30521)
WARREN OIL CO., DUNN, NORTH CAROLINA/USA UNIVERSAL SYNTHETIC BLEND AUTOMATIC TRANSMISSION F
YACCO, ST PIERRE LES ELBEUF/F YACCO ATF III
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL FLUID III F
Page 13 of 17
Lubricant class 02G

Gear oilx
Viscosity grade: SAE 75W (mineral oil-based, not applicable for Intarder)x
x
Manufacturer (02G) Trade name (02G)
CHEVRONTEXACO, GHENT/B MULTIGEAR MTF LT
FUCHS PETROLUB AG, MANNHEIM/D TITAN EG 75 ZF
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR ZF
Page 14 of 17
Lubricant class 02H

Gear oil of viscosity grades: SAE 75W-80 / 75W-85 / 75W-90 / 80W / 80W-90 / 85W-90 / 30x
(mineral oil-based, applicable for Intarder)x
x
Note:
used.
x
Manufacturer (02H) Trade name (02H)
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA TRUCK ZC 90 SAE80W-90
Page 15 of 17
Lubricant class 02K

Hydraulic fluid
x
Manufacturer (02K) Trade name (02K)
DEUTSCHE PENTOSIN WERKE GMBH, WEDEL/D PENTOSIN CHF 11S HYDRAULIC FLUID (70W-75)
Page 16 of 17
Lubricant class 02L

Gear oil of viscosity grades: SAE 75W-80 / 75W-85x
(semi-synthetic, synthetic, applicable for Intarder)x
x
Manufacturer (02L) Trade name (02L)
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX 30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SYNTRANS
COGNIS DEUTSCHLAND GMBH, MONHEIM/D EMGARD 2924
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL SYNMESH
Page 17 of 17
system
0670_EN_ALLGE_G1_04_00_00
0670_EN_ALLGE_G1_04_00_00
Overview of lubricating points

Chassis
0675_EN_FA043_SCHMIERSTELLEN_BERSICHT
2003-01 1/2
Achsschenkel unten Lower stub axle

Achsschenkel oben Upper stub axle
Lenkhebel Drop arm
18 Schmierstellen 18 points of lubrication
Hochdruckschlauch High-pressure hose
Polyamidrohr Polyamide pipe
Schmierzeit: 3 min Lubrication time: 3 min
Pausenzeit: 3h Pause time: 3h
EP-1, 24V, 1.9 kg mit PE 120, und integr. EP-1, 24V, 1.9 kg with PE 120, and integr.
Steuerung S-EP4, komplett fettgefüllt controller S-EP4, completely filled with grease
2/2 2003-01
Central Lubricating System G1-4
Method of operation of the central grease lubrication system
Beschreibung_EN_G1.doc
2003-01 1/12
G1-4 Central Lubricating System
2/12 2003-01
2003-01 3/12
4/12 2003-01
2003-01 5/12
6/12 2003-01
2003-01 7/12
8/12 2003-01
2003-01 9/12
10/12 2003-01
2003-01 11/12
Memo:
12/12 2003-01
Part G2
Annes
Superstructure
0690_EN_ALLGE_G2_00_00_00
Operating
Load Moment Limiter
0695_EN_ALLGE_G2_01_00_00
0695_EN_ALLGE_G2_01_00_00
IK 350 / 1365
Operator’s Console Contents
for ATF 80-4 General information
Important notes
System description
Programming
Checks before start-up
Service and maintenance
Troubleshooting
Appendix
Operator’s Manual
Issue 4/2004 Rev. A
This document has the order no.

xxxxxx - 50 350 19 1365 e (ATF 80-4)
Operator’s Manual IK 350 / 1365 (FAUN ATF 80-4)
TABLE OF CONTENTS
1. General information 3
2. Important notes 4
3. System description 5
3.1 System functions 6
3.2 Control console 6
3.3 Indicators and control elements 7
3.4 Data display (normal operation) 15
3.5 Data display (illustration for counterweight assembly) 16
3.6 Data display (telescoping and bolting display) 17
4. Programming 18
4.1 Programming the required mode 19
4.2 Setting the rope fall arrangement 20
4.3 Speed preselection for master controller 21
4.4 Contrast setting, data display 22
4.5 Adjust zero point of pressure transducers 23
4.6 Limitations of geometry 25
4.6.1 Limitation of the slewing angle 26
4.6.2 Limitation of the boom head height 28
4.6.3 Limitation of the boom angle 29
4.6.4 Limitation of radius 31
5. Checks before start-up 33

5.1 Operation 35
6. Service and maintenance 36

6.1 Service menu 36
7. Troubleshooting 39
7.1 General information 39
7.2 System messages 39
7.3 Error messages (E ##) 40
7.4 Error messages (S ####) 48
Important information
for crane operators and crane operating companies 50
© 2004 PAT GmbH ∙ D-76275 Ettlingen ∙ Hertzstr. 32 - 34 ∙ ++49 (0) 7243 709-0 ∙ FAX ++49 (0) 7243 709-222 ∙ Email: pat.ettlingen@pat-group.de 2
50 350 19 1365e_Rev A (ATF 80-4).doc / 8.04.2004 / Rev. A / rk.
General Information / Important Notes
1. GENERAL INFORMATION
The task of the PAT DS 350 Automatic Safe Load Indicator (ASLI) is to provide the crane operator
with important information required to operate the crane within the operating ranges described by the
manufacturer. With the help of various sensors, the ASLI monitors various crane functions and
continuously provides the crane operator with the performance data of the crane. These data change
continuously with the movement of the crane.
Whenever the crane approaches its load rating limits, the ASLI warns the crane operator by means of
an acoustic and a visual signal. As soon as the crane reaches an unacceptable operating condition,
all crane movements that might increase the load on the crane are also disabled.
The contents of this Manual is subject to alterations. PAT can accept no warranty for this material, including any related
warranty with respect to marketability and suitability for particular purposes. PAT can accept no warranty for errors in the
content of this Manual, nor for direct or indirect damage caused in connection with the provision and the use of this Manual.
This manual is protected by copyright. All rights reserved. This Manual may not be copied, either in full or in part, reproduced
or translated into another language without the prior written authorization by PAT.
General Information / Important Notes
2. IMPORTANT NOTES
The ASLI is an operating aid to warn the crane operator of an imminent overload or proximity of the
hook block to the boom head, in order to avoid possible damage to property or personal injury.
The system cannot be, and is not intended to be, a substitute for good judgement or experience on
the part of the crane operator, or for the application of recognised, safe working methods when using
cranes.
ATTENTION
The crane operator is not released from his obligation to operate the crane safely. He must
ensure that he fully understands and follows the notes and instructions displayed.
Before beginning work with the crane, the crane operator must carefully read and
understand the entire Manual to ensure that he is aware of the operation and limitations of
the ASLI.
Proper functioning depends on due daily inspection and compliance with the operating
instructions listed in this Manual. Please read section 5 of this Manual.
The ASLI can only offer the crane operator help if it is correctly adjusted, and the correct
load chart and the correct operating code have been selected for the particular rig
arrangement. To avoid damage to property and serious or even fatal injuries to persons, it
is essential to ensure that the ASLI is correctly adjusted before beginning crane work.
This system can be equipped with an external key-operated switch which is located on the
side of the housing of the central unit. This key-actuated switch bridges (overrides) the
control lever's shut-off function by the ASLI. This switch may only be actuated in
emergencies by authorized personnel. Non-compliance with these instructions may lead to
damage to property and serious or even fatal injuries to persons.
System description
3. SYSTEM DESCRIPTION
The PAT DS 350 Automatic Safe Load indicator system consists of a modular micro-processor
central unit, a display and control console as well as various sensors for recording the measured
values.
The system works according to the principle of variance comparison. The actual value which is
obtained by pressure measurement, is compared with the set values stored in the central data
memory, and evaluated by the microprocessor. When the limit values are reached, an overload
warning signal is triggered on the display and control console. At the same time, any crane
movements that could increase the load are disabled.
The crane-related data specified by the manufacture, such as load charts, boom weights, centres of
gravity and dimensions, are stored in memory chips in the central data memory. These data form the
reference values for calculating the operating states.
In some cases, the system function is controlled by automatic components such as boom length and
angle transmitters, and in other cases by manual devices, such as keys on the display and control
console.
The boom angle and the boom length are detected by a length-angle transmitter mounted on the
boom. The crane load is measured using pressure sensors mounted on the piston and rod sides of
the boom elevation cylinder.
System description
3.1 System functions
After the system is switched ON, it starts with an automatic test run of the ASLI system, the displays
and control elements as well as of the acoustic alarm.
During the test run, the start screen is displayed:
• The set-up menu is automatically displayed after the test run has been finished.
• First, the system expects entry of the mode code which corresponds to the instantaneous crane
configuration.
• The next step is entry of the rope fall arrangement (rope reeving).
• The entries are displayed in the form of symbols on the following confirmation screen.
• After confirmation, the entries are taken over by the system. Only now is the system ready to
operate.
In case of malfunction, an appropriate error code "E##" or "S##" appears on the data display (1).
(In this context, refer also to chapter 3.4 and chapter 7.)
3.2 Control console
The console has two functions:

• Inputs into the ASLI system by the crane operator (operation modes, numbers of rope falls)
• Indication of important data and information
The control console is located in the crane cabin in the crane operator's field of vision. To improve
identification of the displays and control elements, these are backlit during operation. The console
comprises various control elements as well as a multifunctional LCD; these are described in detail in
chapters 3.3 and 3.4.
Operation
3.3 Indicators and control elements
Fig. 1 shows the indicator and control elements of the DS 350 /1365 console. The numbers in the
figure correspond to the numbers in the following functional description for each element.
Fig. 1
1 Data display 10 "increase contrast" tip switch
2 Auslastungsanzeige (Bargraf) 11 "decrease contrast" tip switch
3 Function keys F1...F5 12 "Alarm off" tip switch
4 "ASLI override" warning lamp 13 "Information" tip switch
5 Warnlampe "Überbrückung HES" 14 Numerical keypad
6 "A2B override" warning lamp 15 "Operation mode" tip switch
7 Pre-warning lamp (load moment) 16 "Geometrical limits" tip switch
8 Overload lamp (load moment) 17 "Tara" tip switch
9 Contrast sensor 18 special functions tip switch
Operation
(1) Data display
The data display (1) is a backlit graphic LC display which shows, depending on the operating state,
the required information, such as load values, geometric and crane data, symbols etc. During night
work, the indication appears inverted to prevent dazzling the crane operator.
Examples for possible indications:
Set-up menu (operation mode) Normal operation display Telescopng and bolting display
Speed preselection menu Contrast setting display Service menu

for master controller
A detailed description of the symbols and indicators is given in chapters 3.4, 3.5, 3.6 and 6 of this
manual.
Operation
(2) Utilization bar graph
This utilization bar graph display (2) indicates how much of the
loader‘s rated capacity is being used. (utilization)
As the rated capacity of the loader changes as it is moved through
its various motions, the utilization display will constantly change as
well.
The bar graph is marked with different colors:
• green: and safe section (0%...90% of rated cap.)
• yellow: prewarning section (90%...100% of rated cap.)
• red: overload section (>100% of safe working load)
(3) Function keys F1...F5
These keys can be used to select certain functions from among

menu symbols with selection options. The symbols above the keys
identify the function in question.
The meaning of the various symbols is shown in chapters 3.4 to
3.6 and in chapter 6.
(4) "ASLI override" warning lamp
This red warning lamp goes on if the ASLI shut-off feature has
been bridged manually.
(only, if signal input is wired to pin 2-3 of plug X2 of plug location A 102)
(5) "Hoist limit switch (HES) override" warning lamp
This red warning lamp goes on if the hoist limit switch shut-off
feature has been bridged manually.
(only, if signal input is wired to pin 5-6 of plug X2 of plug location A 102)
Operation
(6) "Hoist limit" warning lamp
This red warning lamp goes on if the contacts of the hoist limit
switch open, i.e. a hoist limit state has occurred. The acoustical
alarm sounds, while crane movements increasing the load
moment are stopped.
NOTE
A hoist limit state occurs if the hook block touches the

boom head. In this case, there is a risk of the winch rope
breaking and the load falling. The cause of the hoist limit
state may be that the load has been drawn against the
boom head or that the boom has been extended or lowered
without the corresponding length of winch rope having
been unwound.
(7) "Pre-warning load moment" warning lamp
This yellow pre-warning lamp goes on if the load of the crane

amounts to more than 90 % of the rated lifting capacity in question,
thus indicating an imminent overload situation.
ATTENTION
This means that the crane operator is only allowed to

continue crane work with extreme caution!
(8) "Overload" warning lamp
This red overload warning lamp informs the crane operator that an
overload condition has occurred.
It goes on when the load imposed on the crane has reached 100
% of the maximum lifting capacity which is admissible for the
current operating state. The acoustical alarm will sound. At the
same time, the crane movements increasing the load moment are
stopped.
Operation
(9) Sensor "display contrast"
Dependent to the surrounding light conditions this sensor controls

the brightness of the LC display and the buttons.
(10-11) "Contrast setting" tip switchs
With this buttons the display contrast can be adjusted according to

the environmental light conditions. By pressing both buttons simul-
taneousely the preset contrast is set. The contrast setting also can
set via the contrast setting menu (chapter 4.3)
(12) "Horn off" key
Operation of this push-button serves to briefly suppress the

acoustical alarm. The alarm sounds again after approx. 10
seconds, if the reason for which the alarm has been triggered is
still present.
(13) "Info" key
This key selects system

information as follows
press key once >for the Tele-

scoping and Bolting menu (chp.
3.6)
press key twice >for the Service menu (chp.6.1)
SEL
followed by will also call up the Service menu
Operation
(14) Numerical keypad
These numerical keys are used for the following entries:

- Entry of the mode code (refer to chapter 4.1)
- Entry of the number of rope falls used (refer to chapter 4.2)
The keys and have no function !
(15) "Select" key (SEL)
The key "SEL" is used to call up the set-up menu for setting the
mode codes, the number of rope falls and the speed preselection
of the master controllers. Upon actuation, the hoist limit switch
warning lamp (7) and the overload warning lamp (8) go on, and the
ASLI shut-off feature is activated.
The correct setting of the ASLI for the rig arrangement in

question is extremely important for correct functioning of
the system and the crane. Thus, mode codes and the
number of rope falls may only be set by crane operators
who are absolutely familiar with load charts, utilization and
operation of the system.
The procedure for entering the mode code, the number of rope falls and the speed preselection for
the master controllers is described in chapter 4.
Operation
(16) "Limits" key (LIM)
Key used to program limitations of geometry.

(refer to chapter 4.6)
(17) "Tare" key (TARE)
The "TARE" key (17) serves to issue the net load to the actual
load indicator "ACT" (refer to chapter 3.4). The net load is the
actual load less load lifting equipment and hook block. The "TARE"
key must be pushed before hoisting operation is commenced.
After the key has been actuated, it lights up and the actual load
indication is set to zero (tared). After the load has been lifted, the
net load (payload) appears in the actual load indicator.
As soon as the working radius is changed (due to changes of the
angle or radius), the indicator displays again the actual load, and
the taring function is finished.
NOTE
The actual load comprises the hook block, the winch rope
and all load handling devices. The net load is the load
currently fixed to the hook, without load handling device.
Incorrect indications may be due to ambient influences,
e.g. the wind acting on a boom or the load.
(18) "Control" key (CTRL)
The "CTRL" (18) key serves to select the special functions. The
following special functions can be selected:
• Display contrast setting (see chapter 4.4).
• Zero point adjustment of pressure transducer
(refer to chp. 4.5)
- if key -was selected beforehand
Operation
Acoustical alarm (without illustration)
The acoustical alarm sounds in the following cases:

System test, overload condition, approaching a hoist limit state (if
hoist limit switch function is detected by ASLI), malfunction of ASLI
system, and in case of operating errors detected by the system.
The acoustical alarm can be suppressed briefly via the key (12)
"Alarm switch".
Operation
3.4 Data display (normal operation)
Operation
3.5 Data display (illustration for counterweight assembly)
Operation
3.6 Data display (telescoping and bolting display)
This menu is displayed after selecting key once.
Programming
4. PROGRAMMING
After switching ON the system, the operating parameters must first be entered according to the actual
rig arrangement of the crane. Here, it is essential that the crane operator's entries are made correctly!
This procedure consists of two parts:

• Programming the ASLI according to the crane's rig arrangement, using the correct operating code
for the selected load chart (refer to chapter 4.1).
• Input of the rope fall arrangement (rope reeving) according to the actual number of rope falls used
(refer to chapter 4.2).
Wrong input into the ASLI of the operating code and the number of rope falls used can
result in material damage and/or in serious, even fatal injury to persons.
The correct input of the operating code and the number of rope falls is essential for proper
functioning of the system and the crane.
Consequently, these entries may only be performed by crane operators who are absolutely
familiar with load charts and the application and control of the ASLI.
• The speed preselection for the master controllers can be performed in another menu. (refer to
chapter 4.3)
Programming
4.1 Programming the required mode
The programming mode (Set-up) is requested by actuation of the key
During the programming procedure, the system interrupts crane movements temporarily. Moreover, the warning
lamps (6) and (12) go on.
Request menu "Input of mode number"
Request menu "Input of number of rope falls"
Request menu "master controller speed

preselection"
Terminate set-up menu
- Enter the various digits via the keys 0...9.

- To confirm/take them over into the system, actuate the OK key.
- After input of the mode number, the menu is closed and the system
returns to the mode confirmation screen.
Set cursor to the left by one digit.
Set cursor to the right by one digit.
Confirm mode number.
Programming
4.2 Setting the rope fall arrangement
Request menu "master controller speed

preselection"
- Enter the various digits via the keys 0...9.

(possible number of rope falls: 00...15)
- To confirm/take them over into the system, actuate the OK key.
- After input of the number of rope falls, the menu is closed and the
system returns to the mode confirmation screen.
Set cursor to the left by one digit.
Set cursor to the right by one digit.
Confirm number of rope falls used.
Programming
4.3 Speed preselection for master controller
Request menu "speed preselection for

master controller"
Activate bar to the right of the one being edited.
Increment value by 1 %.
Decrement value by 1 %.
Confirm input.
The keys + and - feature a quick setting option. By keeping the keys pressed, the
quick setting is activated after a delay of 1 s. The default values are 100 % in
each case. If the value is changed, the following symbol appears on the operat-
ing menu screen: .
Speed preselection for telescope

Meaning of the symbols:
Speed preselection for winch
Speed preselection for auxiliary winch
Speed preselection for boom elevation
Speed preselection for slewing gear
Marking the current bar
Programming
4.4 Contrast setting, data display
This function can be used to adjust the display contrast optimally according to the light conditions.
The setting remains stored and thus need not be performed every time the system is started up.
Actuate "CTRL" key.
A pattern enabling optimum contrast tuning appears on the display.

If necessary, set contrast via the function keys as follows:
more contrast
less contrast
Actuate the key to save the settings and to terminate the function.
Programming
4.5 Zero point adjustment of pressure transducer
The ASLI system features a function which allows for the manual / automatic adjustment of the pres-
sure transducers at the lifting cylinder. The function is protected by a service code inquiry in order to
prevent unauthorized access.
The following conditions must be complied with, before it can be activated:

• Lay down the boom completely
• Ensure the hydraulic system is depressurized
Activation of function: select key followed by key .
Service code inquiry
Decrease value by 1
Increase value by 1
Select next digit
Confirm entry
This message will be displayed, if an erroneous

Service code has been entered. Enter the code
once more, or abort the zero point adjustment by
way of the ESC key.
Abort function
Re-enter code
Programming
Execution of zero point adjustment of pressure transducers
The menu for the zero point adjustment of the

cylinder side pressure transducer will be displayed
after entering the correct service code.
Abort function
Zero point more negative
Zero point more positive
Save zero point(cylinder side)
Adjust the zero point automatically by simultaneous

selection of the - and the + key, or manually by
selecting either the - or the + key. Check the analog
scale for the actual zero point display.
After saving the cylinder side zero point, the menu

for the rod side pressure transducer is displayed.
The procedure is the same as described above.
The service menu is terminated and the normal

working display is presented after saving the rod
side zero point.
Programming
4.6 Limitations of geometry
• The ASLI system comprises programmed limit entries for the operating range of the crane.
Programming is facilitated by interactive step-by-step guidance.
• The functions can be used individually or combined.
• If a programmed limit is exceeded, this triggers an acoustical and visual alarm.
If necessary, other symbols appear on the data display (1).
Slewing angle limitation symbol

• Continuous display:
Slewing angle limitation activated
• Flashing display:
Slewing angle limits exceeded
(> refer to chapter 4.6.1)
Height limitation symbol:

Height limitation activated
Height limits exceeded
Boom angle limitation symbol

Boom angle limitation activated
Angle limits exceeded
Radius limitation symbol:

Radius limitation activated
Radius limitation exceeded
Programming
4.6.1 Limitation of the slewing angle
Programmable function for limitation of the left and/or right slewing angle.
• Entry of function:
Actuate selection key for entry of LIMIT.
Select the function "slewing angle limitation" by selection of the symbol

shown on the left.
• Entering / deleting the left slewing angle:
Selection of side for slewing angle:
Select left side
Entry: Delete:
Move boom into its left limitation
Delete left limit by actuation of
position.
the DELETE key.
Program slewing angle

position as left limit by actuation
of SET.
Exit the function by

actuating OK.
Programming
• Entering / deleting the right slewing angle:
Selection of side for slewing angle:
Select right side:
Entry: Delete:
Move boom into its right limitation
Delete right limit by actuation
position.
of the DELETE key.
Program slewing angle

position as right limit by actuation
of SET.
The symbols and angle limits of

the programmed slewing angle
limitation are displayed.
Symbols without angle limits are

displayed.
Exit the function by actuating OK.
Programming
4.6.2 Limitation of the boom head height
Programmed function for limitation of the head height.
• Setting / deleting the height limit:
Select the function "limitation of boom head height" by selection of the

symbol shown on the left.
Actuate the key
Entry: Delete:
Extend pulley head until the
Delete head height limitation
desired upper limit is reached.
by actuating DELETE.
Program the height

reached as boom head height
limit by actuating SET.
The symbol and value of the

programmed boom head height
limitation are displayed.
Symbol without values is displayed.

actuating OK.
Programming
4.6.3 Limitation of the boom angle
Programmable function for limitation of the upper and/or lower boom angle.
Select the function "boom angle limitation" by selection of the symbol

shown on the left.
• Setting / deleting the upper angle limit:

Select angle height:
Selection of the upper angle limit.
Entry: Delete:
Elevate boom until the required
Delete upper angle limit by
limit value is reached.
actuating DELETE.
Actuate SET to enter the

boom angle reached as upper
limit.
The symbol and the value of the

upper angle limit are displayed.
The symbol is displayed without the
value of the upper angle limit.

actuating OK.
Programming
• Setting / deleting the lower angle limit:
Select angle height:
Select the lower angle limit.
Setting: Delete:
Lower boom until the required
Delete lower angle limit by
limit value is reached.
actuating DELETE.
Actuate SET to enter the

boom angle reached as lower
limit.

lower angle limit are displayed.
value of the lower angle limit.

actuating OK.
Programming
4.6.4 Limitation of radius
Programmable function to limit the smallest and/or the biggest boom radius.
Select the function "radius limitation" by selection of the symbol shown

on the left.
• Setting / deleting the smallest boom radius:

Select type of radius size:
Select this symbol for the smallest radius
Entry: Delete:
Move the boom until the smallest
Actuate DELETE to delete the
radius required is reached.
smallest radius.
Enter the boom radius

reached as smallest radius by
actuating SET.

smallest radius are displayed.

value of the smallest radius.

actuating OK.
Programming
• Setting / deleting the biggest boom radius:
Select type of radius size:
Select this symbol for the biggest radius
Entry: Delete:
Move the boom until the biggest
Actuate DELETE to delete the
radius required is reached.
biggest radius.
Enter the boom radius

reached as biggest radius by
actuating SET.

biggest radius are displayed.

value of the biggest radius .

actuating OK.
5. CHECKS BEFORE START-UP
Before crane work is commenced, the following electrical connections must be checked to ensure that
the ASLI system is correctly wired for the current crane rig arrangement.
❍ Cranes with main hoisting gear only

If the crane is working with the main boom, i.e. without boom extension or fly jib, no additional
connections are required. However, it is important to ensure that the hoist limit switch weight is
correctly mounted on the main boom winch rope. With an even number of rope falls, the hoist limit
switch weight is mounted at the "dead end" of the winch rope. With an odd number of rope falls, the
hoist limit switch weight is mounted at the rope fall with the lowest working speed.
If the crane is working with a main boom extension or fly jib, the connecting cable must be installed
between the distributor plugbox on the fly jib and the distributor plugbox on the main boom. The
weight of the hoist limit switch of the main boom must be removed and then mounted on the hoist limit
switch of the boom extension or of the fly jib.
If the hoist limit switch weight is not repositioned, the hoist limit switch system cannot work
properly. During work with the boom extension / fly jib, no weights should be mounted on
the hoist limit switch of the main boom.
❍ Cranes with main and auxiliary hoisting gear

If the main boom extension or fly jib is not used, the override plug must be inserted into the distributor
plugbox on the main boom and the hoist limit switch weight must be mounted on the main boom.
If the crane is working with a main boom extension or a fly jib, the connecting cable must be installed
between the distributor plugbox on the boom extension or the fly jib and the distributor plugbox on the
main boom. Moreover, weights must be mounted to the hoist limit switch of the main boom and the
boom extension or the fly jib.
If the boom extension or the fly jib is in working position, and if the main boom is not equipped with a
winch rope, then the weight of the hoist limit switch must be removed from the main boom in order to
eliminate any risk to persons or damage to the equipment.
After the electrical cable connections have been checked for the rig arrangement in question, the
following inspections must also be carried out:
1. Check all cable connections to the system components for damage.
2. Check the hoist limit switches and hoist limit switch weights for ease of movement.
3. Check the spring-loaded cable drum for ease of running, drum pre-tension and correct cable
winding.
4. Check the mechanical and the electrical installation of the load cells on the fly jib (if fitted).
The checks described below must be carried out carefully in order to prevent damage to the
crane and injury to persons. The correct function of the ASLI system depends on
successful completion of these checks before work is started. If the crane operator cannot
see the hook block while approaching the pulley head, he must instruct an assistant
(slinger) to help him. The crane operator must be ready to stop the crane immediately if the
ASLI system does not work correctly, that is, if the red warning lamps do not light up, the
acoustic alarm does not sound and crane movements, such as hoisting, telescopic
extension and lowering cannot be disabled.
Check the hoist limit switch warning lamp (6) and the acoustic alarm as follows:
1. Manually lift the weight attached to the hoist limit switch. As soon as the weight is lifted, the
acoustic alarm should sound and the Hoist limit switch warning lamp (6) should light up.
2. Use the main hoisting gear to pull the hook block slowly against the hoist limit switch weight. As
soon as the hook block starts lifting the weight, the acoustic alarm should be actuated, the hoist
limit switch warning lamp (6) should light up and the main hoisting gear should be switched off.
Lower the hook block slightly in order to terminate this state.
3. Lower the main boom slowly using the boom elevation in order to bring about a possible hoist limit
state. As soon as the hook block starts lifting the weight, the acoustic alarm should sound, the
hoist limit switch warning lamp (6) should light up and the boom elevation should be switched off.
Lower the hook block slightly in order to terminate this state.
4. Slowly extend the telescopic boom in order to bring about a possible hoist limit state. As soon as
the hook block starts lifting the weight, the acoustic alarm should sound, the hoist limit switch
warning lamp (6) should light up and the telescoping function should be switched off. Lower the
hook block slightly in order to terminate this state.
If the warning lamp and the acoustic alarm do not function as described, and if the crane
movements are not disabled, the system is not working properly. The fault must be
eliminated before work is started.
5. If the crane is fitted with a main boom extension or a fly jib, the test must be repeated for the hoist
limit switch of the boom extension / fly jib.
6. Check whether the displayed main boom length corresponds to the actual length.
7. Check whether the displayed angle of the main boom corresponds to the actual angle.
8. Check whether the displayed working radius of the crane corresponds to the actual working radius.
9. Check the load display by lifting a known weight. The accuracy of the load display must be within
the given tolerance.
5.1 Operation
After being set correctly, the ASLI is ready to operate. The crane operator must therefore be familiar
with all the control elements of the ASLI and enter the correct commands before the crane can start
work. All settings must be tested by lifting a known weight and comparing this with the information
displayed by the ASLI.
The figures in the load chart contain the weight of the hook block, the load securing ropes and other
load lifting devices. This combined weight must be deducted from the figures in the load chart in order
to determine the net load to be lifted.
If any of the displays shows a discrepancy between the values displayed and the actual
values, please contact your local PAT Service Centre for repair of your system or to have
calibration of the ASLI tested.
Any modification of the crane structure or changes to the crane require subsequent testing
of the ASLI's calibration.
6. SERVICE AND MAINTENANCE
Maintenance of the Automatic Safe Load Indicator comprises the inspection of the following:
1. Wiring connecting the various parts of the system. If a cable is damaged, it must be replaced
immediately.
2. The insulation of the length transmitter rope or the hoist limit switch cable and of the cable guides.
If the insulation is worn, or the cables guides damaged, these parts should be replaced.
3. Inspection of the hoist limit switch for ease of movement.
4. Inspection of the cable drum for sufficient pre-tension.
5. Inspection of the pressure sensors on the boom elevation cylinders and connection hoses for oil
leaks.
Staff who have not been specially trained may only eliminate the faults listed in the error
table, but must not replace any defective mechanical parts or cables.
6.1 Service menu
The system comprises a menu structure which makes information about the various system
components available.
• To get to the service menu, actuate the keys and then
or: push key .twice !
• Now the signals of all the available input and output cards can be retrieved by selection via the
directional keys and .
• To finish the service menu, actuate the key .
Below, please find examples for indication of the various card types:
Digital inputs Digital outputs Digital inputs Digitalg inputs Analog inputs
(DI) (DO) (DI) (DI) (AI)
Card(s): A105 Card(s): A106/A107 Card(s): A108 Card(s): A109 Card(s): A111/ (A112)
Analog outputs
(AO)
Card(s): A113
Value = Initial value

F= Enable bit
R= Directional bit
Troubleshooting
7. TROUBLESHOOTING
7.1 General information
In the event of a malfunction or operator error detected by the system, a code "E xx" (ASLI error) or
"S xxxx" (control error) appears on the data display (1), thus specifying the reason for the malfunction.
The error codes listed in the error table explain the various errors that can occur in the ASLI system.
Faults in the ASLI system caused by exceeding the predefined ranges or through operator error
caused by the crane operator can normally be remedied by the crane operator himself. Faults in the
microprocessor system may only be remedied by factory-trained after-sales service staff. In this
case, please contact the PAT after-sales service.
7.2 System messages
Code letters O: Overload

P: Prewarning
H: Hoist limit switch actuated
Troubleshooting
7.3 Error messages (E ##)
Error code Error Cause Remedy

O Overload Shut-off due to overload Reduce load moment.
P Prewarning
H Hoist limit switch The hoist limit switch has reac- Lower hook block.
ted
E01 Radius range not Due to excessive boom raising Lower boom via the boom ele-
reached or angle via the boom elevation, the vation to a radius or angle spe-
range exceeded. radius was less than the mini- cified in the load chart.
mum radius specified in the
relevant load chart, or the ma-
ximum angle was exceeded.
E02 Radius range Due to excessive boom lowe- Raise boom via the boom ele-
exceeded or angle ring via the boom elevation, the vation to a radius or angle spe-
range not reached. radius was greater than the cified in the load chart.
maximum radius specified in
the relevant load chart, or the
minimum angle was not rea-
ched.
E04 Mode not The selected mode is not avai- Enter correct mode via the keys
acknowledged, or not lable. as assigned to the mode in
available. question.
The selected mode is not sto- Check programming in TLK

red in the data EPROM, or is EPROM.
disabled.
Troubleshooting

E05 Invalid length range. Boom was telescoped too Telescope boom to the correct
much or too little, e.g. if work is length.
only admissible up to a certain
max. boom length, or in case of
lifting capacity charts for fly jib,
when the main boom must be
telescoped to a certain length.
Length transmitter setting has

changed, e.g.: Rope came off Retract boom. Check pretensi-
the length transmitter reel. on of rope drum (rope must be
tensioned). Open length trans-
mitter and turn length pot coun-
ter-clockwise to its stop careful-
ly using a screwdriver.
Defective coupling between

length transmitter pot and drive. Replace coupling complete with
drive gear and set length pot.
+5V supply for the analog sec-
tion of the analog module failed. Check +5V voltage. If voltage
is not available or breaks down
in the presence of a load of
approx. 50 Ohm, replace ASLI
basic module.
Cable connecting central unit to
length transmitter faulty or sag- Check cables and connectors; if
ging. necessary, replace.
Length potentiometer faulty. Replace length pot.

E07 Incorrect feedback Overload relay faulty or inter- Replace ASLI module.
from overload relay to face module faulty.
interface module.
ASLI module faulty
Relay should have
picked up, however
nd
the 2 contact is
signalled as OFF, or
nd
2 contact is
signalled as ON while
relay should have
dropped out.
Troubleshooting

E21 Upper limit for Bus error Check bus cable and connec-
measuring channel tor.
"tel. boom length"
(length 1) exceeded. Length transmitter not connec- Connect transmitter correctly.
ted correctly.
Replace bus coupler.
Bus coupler faulty
Replace length transmitter.
Length transmitter faulty
E22 Upper limit in Bus error Check bus cable and connec-
"pressure low"
exceeded. Pressure sensor not connected Connect transmitter correctly.
correctly.
Bus coupler faulty
Replace pressure sensor.
Pressure sensor faulty
E23 Upper limit in as E22 as E22
measuring channel
"pressure high"
exceeded.
"control pressure" not
reached. Pressure sensor not connected Connect transmitter correctly.
correctly.
Bus coupler faulty
Replace pressure sensor.
Pressure sensor faulty
"main boom angle"
exceeded. Angle transmitter not connected Connect transmitter correctly.
correctly.
Bus coupler faulty
Replace angle transmitter.
Angle transmitter faulty
"wind speed" not
reached. Anemometer not connected Connect transmitter correctly.
correctly.
Bus coupler faulty
Replace anemometer.
Anemometer faulty
Troubleshooting

E27 Upper limit in as E21 as E21
measuring channel
"length, telescope I
(+II)" not reached (if
available)
E31 Error in system The system program PROM is Replace system program
program faulty. PROM (PROM no. 0).
E37 Error in logic program The system program PROM is Replace system program
sequence faulty. PROM (PROM no. 0).
Computer module 80C537 faul- Replace computer module

ty. 80C537.
ASLI module faulty Replace ASLI module.

E38 System program and The ASLI's system program is Replace system program
data EPROM not not compatible with the data PROM or data EPROM (PROM
compatible. EPROM programming. no. 1).
E39 System program and The ASLI's system program is Replace system program
TLK EPROM not not compatible with the TLK PROM or TLK EPROM (PROM
compatible. EPROM programming. no. 2).
E41 Error in internal Computer module 80C537 faul- Replace computer module
read/write memory ty. 80C537.
(RAM) of the
computer module CPU module faulty. Replace CPU module.
80C537.
Processor module faulty. Replace processor module with
CPU module.
E42 Error in the external Read/write memory (CMOS Replace processor module with
read/write memory, RAM) or processor module CPU module.
part I (RAM) faulty.
E43 Error in the external as E42 as E42
read/write memory,
part II (RAM)
E47 Monitored read / write The CRC check character of Restart ASLI.
memory faulty. the monitored read/write memo-
ry is not correct.
The CRC check of the
monitored read/ write The buffer battery is discharged Replace buffer battery on the
memory gives an (< 2V at 1kOhm). ASLI basic module.
incorrect result.
Processor module faulty. Replace processor module.
Troubleshooting

E48 Cyclic RAM test: Error Computer module 80C537 faul- Replace computer module
in internal read/write ty. 80C537.
memory (RAM) of the
computer module CPU module faulty. Replace CPU module.
80C537.
Processor module faulty. Replace processor module with
CPU module.
E51 Error in crane data Crane data EEPROM without Load crane data EEPROM with
EPROM or EEPROM. valid data. valid data.
Memory module incorrectly Bridge memory module accor-

bridged. ding to memory type.
Crane data EPROM faulty. Replace crane data EPROM.
E52 Error in lifting capacity Memory module incorrectly Bridge memory module accor-
chart PROM. bridged. ding to memory type.
Lifting capacity chart EPROM Replace lifting capacity chart

faulty. EPROM.
E53 Error in crane data Memory module incorrectly Bridge memory module accor-
EEPROM. bridged. ding to memory type.
(Bank 2...4)
Crane data EEPROM (bank Replace crane data EEPROM.
2...4) faulty.
E56 Error in crane data Memory module incorrectly Bridge memory module accor-
EEPROM. bridged. ding to memory type.
Crane data EEPROM faulty. Replace crane data EEPROM.
E57 Error in serial crane Serial crane data EEPROM Write data into serial crane data
data EEPROM. without valid data. EEPROM (test program or onli-
ne function), then re-start ASLI.
Replace memory module.

Memory module faulty.
E61 Error in crane data Selected crane data EPROM Check crane data EPROM.
EPROM. bank without valid data, or not
compatible with TLK EPROM.
Memory module incorrectly

bridged. Bridge memory module accor-
ding to memory type.
E66 Error in telescope Telescope 1 signalled as "lok- Check locking system.
locking system. ked" and as "unlocked".
Troubleshooting

E67 Error in counterweight Proximity sensor signalled as Check position of proximity
proximity sensors. "up" and "down". sensor.
Proximity sensors on right and
left have non-identical states. Check counterweight position.
E82 Error on locking the The 1st telescope is unlocked Lock telescope 1.
st
1 telescope. although telescope 2 is not
retracted.
Sensors "telescope retracted" Check sensors.

or "telescope locked" faulty.
E83 Telescoping error The 3rd and/or the 4th telesco- Retract telescopes 3 and 4.
pes are not retracted, although
the 2nd telescope is retracted.
E84 Incorrect rig The selected rig arrangement is Select different rig arrange-
arrangement. not contained in the data ment.
EPROM. Check programming in data
EPROM.
E85 Error in radius The calculated radius is too Check programming in data
determination. small (negative deflection). EPROM.
E86 Incorrect percentage Telescope has a percentage of Read percentage data from
for at least 1 < -2% or > 106 %. console. If telescope was ex-
telescope. tended too far: retract and pin-
fasten telescope.
Length measurement of teles- Check length measurement of

cope I (+II) faulty. telescope I (see E27).
Measurement of overall length Check length measurement

faulty. (see E21).
E87 Error in length Monitored read / write memory Retract all telescopes and, if
measurement. faulty. necessary, lock telescope 1.
The telescope Length measurement of teles- Check length measurement of

combination cope I (+II) faulty (if available). telescope I (+II) (see E27).
determined does not
correspond to the Measurement of overall length Check length measurement
length measurement. faulty. (see E21).
Sensors "telescope retracted" Check sensors.

or "telescope locked" faulty.
Troubleshooting

E91 No data transmission 24 V supply of console interrup- Check 24 V on terminal X1 of
from the console to ted. the console electronics.
the central unit.
Breakage or short to ground on Check the connection between
the line connecting the console the console electronics and the
electronics to the central unit. central unit.
If short to ground is detected,
this means probably that the
emitter module in the console
electronics is damaged. Thus,
the console electronics should
be replaced.
Replace console electronics or

Emitter/receiver module faulty. PDC basic module.
E92 Error in data Intermittent electrical contact on Check the connection between
transmission from the the line connecting the console the console electronics and the
console to the central electronics to the central unit. central unit.
unit.
Emitter/receiver module faulty. Replace console electronics or
ASLI basic module.
E93 Error in data as E92 as E92
transmission from the
central unit to the
console.
E94 No data transmission Breakage or short to ground on Check line to console (in case
from the central unit the line connecting the central of short to ground, replace also
to the console. unit to the console. the console electronics.)
Replace PDC module.

PDC module faulty.
Replace console electronics or
Emitter/receiver module faulty. PDC module.
Electromagnetic interference Eliminate source of interference

(e.g. on switching contactors or by cancelling diodes or vari-
valves). stors.
E95 Error in console The console EPROM is faulty. Replace console EPROM.
EPROM.
E97 Semaphore in dual ASLI module faulty Replace ASLI module.
port RAM cannot be
read.
After repeated Dual port RAM faulty. Replace dual port RAM.
reading attempts, the
same contents do not
result twice. Backplane faulty. Replace backplane.
Troubleshooting

E98 Semaphore in dual port as E97 as E97
RAM cannot be written.
After repeated writing
attempts, the same
contents do not result
twice.
Note:
Should an error message be displayed which is not included in the above list, please contact your local PAT
After-Sales Service.
Troubleshooting
7.4 Error Codes, Control S####
S 00nn Error code, control system in general
S 0001 List of inputs not available

S 0002 Definition error in list of inputs
S 0003 No space available for table of inputs
S 0004 Variable from list of inputs not available in PDB
S 0009 Undefined error in list of inputs
S 0011 List of outputs not available

S 0012 Definition error in list of outputs
S 0013 No space available for table of outputs
S 0014 Variable from list of outputs not available in PDB
S 0019 Undefined error in list of inputs
S 0020 No control program available

S 0021 No free memory space for modules (cold start)
S 0022 Checksum error on cold start
S 0023 No data modules in EEPROM
S 0030 Check sum error during operation, control system stopped
S 0096 Error in control cycle, control system stopped

S 0097 WatchProfibus: Polling re-started
S 0098 CRC error in EPROM
S 0099 Fatal error, control system stopped
Troubleshooting
S 01nn Input invalid
S 011E Precontrol lever, left-hand, y direction faulty

S 011F Precontrol lever, left-hand, y direction: Directional contact hang-up
S 0120 Precontrol lever, left-hand, x direction faulty
S 0121 Precontrol lever, left-hand, x direction: Directional contact hang-up
S 0122 Precontrol lever, right-hand, y direction faulty
S 0123 Precontrol lever, right-hand, y direction: Directional contact hang-up
S 0124 Precontrol lever, right-hand, x direction faulty
S 0125 Precontrol lever, right-hand, x direction: Directional contact hang-up
S 015A Slewing angle transmitter faulty
S 02nn* Read data module: Module not available
S 03nn* Read data module: Length of module incorrect
S 04nn* Read data module: Checksum incorrect
S 05nn* Write data module: Module not available
S 06nn* Write data module: Length of module incorrect
S 07nn* Write data module: Error on writing the EEPROM
S 09nn Error code precontrol allocation
S 0901 Error, double allocation of pre-control lever
S 0902 No allocation for telescope, auxiliary winch
S 0904 No allocation for slewing gear
S 0908 No allocation for boom elevation
S 0910 No allocation for winch
nn contains the number of the last invalid input in the control system's input list
*nn contains the number of the module (hexadecimal)
Annex: Important notes for crane operators and crane operating companies
INSTRUCTIONS 1 Shut-off values for boom cranes with variable load ratings
depending on variable working radius
The crane shut-off values are determined by us based on the load charts and design drawings specified by the
crane manufacturer.
These theoretical shut-off values must be checked by means of tests on the crane with weighed test loads for all
modes and at least with the following rig arrangements, depending on the crane design.
• Cranes with fixed boom length in operation:
Smallest, medium and largest radius for shortest, medium and longest boom length, as well as shortest,
medium and longest fly jibs for these boom lengths.
• Cranes with boom length variable in operation:

Smallest, medium and largest radius for each length increment as well as for all fly jibs.
INSTRUCTIONS 2 Important notes for the crane operator
The ASLI is an operating aid to warn the crane operator of an imminent overload or of the hook block
approaching the boom head, in order to avoid possible damage to property or personal injury.
This system cannot be, and is not intended to be, a substitute for good judgement or experience on the part of
the crane operator, or for the application of recognised, safe working methods when using cranes. The crane
operator is not released from his obligation to operate the crane safely. He must ensure that he fully
understands and follows the notes and instructions displayed. Before beginning work with the crane, the crane
operator must carefully read and understand the entire Manual to ensure that he is aware of the operation of the
ASLI and the crane. Proper functioning depends on due daily inspection of the system and compliance with the
operating instructions listed in this Manual.
The system can only offer the crane operator help if the ASLI is correctly adjusted, and the correct load chart
and the correct operating code have been entered for the particular rig arrangement. To avoid damage to
property and serious or even fatal injuries to persons, it is essential to ensure that the ASLI is correctly adjusted
before beginning crane work.
This system can be equipped with a key-operated switch which is located in the
microprocessor central unit. This key-operated switch overrides the ASLI's shut-off feature.
The switch may only be actuated in emergencies by authorized personnel. Non-compliance
with these instructions may lead to damage to property and serious or even fatal injuries to
persons.
INSTRUCTIONS 3 Important notes for the crane operating company

In the Federal Republic of Germany, the design of overload safety devices for cranes is subject to the directives
of VDI standard 3570 (VDI = Verein Deutscher Ingenieure - Association of German Engineers). The significance
and the limitations of overload safety devices are also pointed out in this directive.
"In the operation of cranes, overload safety devices are intended to prevent accidents and risks to persons,
property, the load and the crane as far as possible as a result of overloading. The crane operating company and
the crane operator must remember that an overload safety device cannot detect all hazards in good time, and
that a malfunction is possible through influences that are not apparent. For this reason, you cannot be released
from your obligation to exercise due care and from your responsibility for complying with the operating
regulations and the load limits of the crane. Overload safety devices must not be used for standard operation.
They should only react in emergencies. The load rating of the hoisting equipment must not be reduced by an
overload safety device."
VDMA Instruction Sheet for Overload Safety Devices (Automatic Safe Load Indicators)
for Boom Cranes
According to § 24 of the UVV (provisions for the prevention of accidents) "Boom cranes", the boom crane delivered to you is
equipped with an overload safety device (automatic safe load indicator) which switches off the crane's hoisting gear and the
boom retracting mechanism when the admissible load moment is exceeded. In order to enable discharging after the
overload safety device has reacted, it must still be possible to perform a contrary movement. This means, for example, that it
must still be possible to lower the load after the hoisting gear has been switched OFF.
An overload safety device (automatic safe load indicator) is installed to prevent crane use for lifting of loads which endanger
its stability. Thus, the overload safety device (automatic safe load indicator) is an emergency switch which, in case of crane
overloads, shuts off all movements which might increase the load moment, and thus prevents possible damage or accidents.
In order to enable the overload safety device to fulfil its functions as a safety unit, please pay attention to the following
instructions:
1. Overload safety devices (automatic safe load indicators) must not be used for switching off the hoisting gear or the boom
retracting mechanism during normal operation. The crane operator has to make sure in all cases before such work that
the lifting capacity is not exceeded by the load to be lifted. Loads which exceed the lifting capacity of the crane must not
be lifted in spite of the fact that the overload safety device is installed. This device must not be used for weighing
purposes, and the crane must not be charged with loads exceeding the individually highest admissible load.
2. Tearing off fixed loads is only admissible if the crane manufacturer has agreed to it, and only with cranes which are
specially equipped for this purpose. During such operations, the overload safety device (automatic safe load indicator)
must not be used as load measuring equipment for normal operation.
3. The overload safety device installed in the crane must be serviced at regular intervals and checked for safe operation
before crane work. According to § 35 of the UVV (Provisions for the Prevention of Accidents) "Boom cranes", crane
maintenance work also comprises regular inspections of the overload safety device.
4. In general, the overload safety device is not automatically adjusted to the different modes of operation of the crane.
Therefore the crane operator is obliged to adjust the overload safety device to a different range of lifting capacities or
load moments, when the mode of operation of the crane is altered. To this effect, the operating instructions of the
manufacturer of the installed overload safety device must be complied with. Safe operation of the machine and crane
work free of accidents depend to a large extent on careful compliance with these instructions. An incorrectly set overload
safety device, e.g. a device which is set to a high load moment while the outriggers are retracted, is considerably more
dangerous than a crane without an overload safety device, as it conveys a feeling of safety to the driver, which is in fact
not justified, and which may cause serious accidents.
5. The overload safety device (automatic safe load indicator) installed must be adjusted by the crane driver to the different
ranges of lifting capacities or load moments, when the crane is adjusted to different modes of operation, such as:
a) when the outriggers are extended or retracted (switching over to the high or low load moment)
b) when the boom length is changed by:
- manual extending and retracting (telescoping)
- mounting or dismounting intermediate elements;
c) when the crane is swung or slewed into the range of the higher or lower stability moment (switching over to the high
or low load moment)
d) when changing over to a different lifting capacity range by fitting multiple rope falls to the hoisting gear or the boom
retracting mechanism.
6. Please note positively that the overload safety device cannot become effective, i.e. the drive assembly cannot be
switched off quickly enough when the crane is operated incorrectly. In this case, accidents cannot be precluded
completely in spite of the overload safety device being installed. This applies particularly to the following cases:
- the hook or the load lifting equipment is fixed underneath the load;
- excessive time-lag forces are effective;
- loads are dropped into the rope;
- the load is pulled diagonally;
- moving the crane in an area with significant ground slope;
- subsiding subsoil;
- wind load.
7. If an equipment for switching off or overriding the overload safety device (automatic safe load indicator) is installed, it
may only be used if particular precautions have been taken, and in the presence of the crane supervisors, e.g. during
crane inspections and during the operations intended by the crane manufacturer.
Careful compliance with the provisions comprised in this instruction sheet and in the operating manual
of the crane manufacturer is a prerequisite to safe operation of the overload safety device (overload
disconnect unit).
Should you have any doubts, please consult the manufacturer's Operating Manual. If it does not provide
sufficient information, it will be necessary to contact the company in question.
Unauthorized tampering with the overload safety device's mechanical components will rule out all
warranty claims.
Issued by: VDMA Fachgemeinschaft für Hebezeuge und Fördermittel

im Verein Deutscher Maschinenbau-Anstalten e.V.
Düsseldorf-Oberkassel
INSTRUCTIONS 4 Notes on Electromagnetic Compatibility (EMC) in electronic

systems taking account of the effect of electromagnetic fields
Electromagnetic fields are having an increasing effect on electronic systems and may lead to malfunctions; to
avoid these, we have listed preventive measures in the following, according to the latest state of technology:
1. The preventive measures proceed primarily from the basic idea that the electronic circuits should be
shielded from irradiated high frequencies by a closed, low-resistance protective skin against high-frequency
interference.
− All components are equipped with metallic outer housings with earthing option;
− only cables with a braided screen are used. The screen must generously cover all connectors and must
be of high conductivity;
− coupling of the crane earth and the electronics earth in one single point of the system only.
2. The general precautions listed under Section 1 cannot assure complete protection against electromagnetic
fields in all cases, however, since the size and type of effect depend on local conditions.
Examples of such influencing factors are:

− particularly unfavourable arrangement of the aerials in relation to the system,
− very high transmission power,
− consistent compliance with measures of Section 1 not possible due to local conditions,
− long cables,
− coupling of interference into the supply leads.
In unfavourable conditions, one has no choice but to take experimental measures on site, in addition to the
preventive measures, while taking account of the principles mentioned in Section 1, for example:
• fitting filters or short-circuiting the interference frequencies using capacitors;

• establishing or separating earth connections;
• using a guarded shield system.
INSTRUCTIONS 5 Notes on industrial safety when repairing display and control

consoles
Caution: Liquid crystal displays contain liquid chemical substances in the display.
Particular caution and care are therefore necessary:
• when operating equipment containing liquid crystal displays

• during storage and transport (risk of breakage !)
• when disposing of unusable or excess liquid crystal displays
Possible sources of danger are chemical effects in the event of skin contact with broken
liquid crystal displays. In the event of contact, wash the affected skin areas thoroughly with
soap. Be particularly careful with open wounds !
INSTRUCTIONS 6 Installation instructions for display and control consoles without

closed metallic housing
To avoid radio interference, high-frequency devices and equipment coming under general approval
requirements published by the Federal Minister for Post and Telecommunications in his Official Gazette No.
163/1984 as Decree No. 1045/1984 and No. 1046/1984 must comply with the limit values and conditions laid
down there.
For display and control consoles without closed metallic housing (dashboard installation version), the conductor
screen must therefore be mounted on the dashboard directly in front of the console by means of a bare cable
clip.
Version Review
VERSION REVIEW
Version Date Modifications Name

Vers. A 8.04.2004 Issue according to german manual Rev. A (9.12.2003) Konopka
for FAUN FA-020 / ATF 80-4
System software: LEF1
Console software: KFAE V 1.1
system
0705_EN_ALLGE_G2_02_00_00
0705_EN_ALLGE_G2_02_00_00

Superstructure
2003-01 1/2
Ausleger Boom
Drehkranz Ringgear
Hochdruckschlauch High-pressure hose
Hubwinde 1 Hoist winch 1
Hubwinde 2 Hoist winch 2
Kabine Cabin
Polyamidrohr Polyamide pipe
12 Schmierstellen 12 points of lubrication
Wippzylinder Boom elevation cylinder
2/2 2003-01
2003-01 1/12
2/12 2003-01
2003-01 3/12
4/12 2003-01
2003-01 5/12
6/12 2003-01
2003-01 7/12
8/12 2003-01
2003-01 9/12
10/12 2003-01
2003-01 11/12
Memo:
12/12 2003-01
Documents regarding
heating, ventilation and the
**)
air conditioning system -
superstructure cabin
**)
Optional equipment
0725_EN_ALLGE_G2_03_00_00
0725_EN_ALLGE_G2_03_00_00
WÖLFLE GmbH Operating Instructions
1. Application
The Wölfle heater unit 910154 has been developed specifically for heating the
superstructure cabins of TADANO FAUN automobile cranes.
Moreover, the unit is used for defrosting the vehicle's window panes.
2. Technical Details
Design : Air heater unit with water heat exchanger
Thermal output : (so far, no measured data)
Rated voltage : 24 V
Service voltage : 20....28V
Service overpressure : 1 bar
Blower fan : - 1060 m3/h (blowing free)

: - 3-stage
: - Long Life Motor
1
Heater unit
The heater unit is installed below the seat bracket.
Towards foot Recirculating air

compartment
Fan
Heat exchanger
Fresh/ recirculating air flap

Towards
windscreen
Towards rear window

Filter
Water
valve
Towards head Fresh air induction
room
Control element
The control element is located to the right of the foot compartment. >
3-stage fan switch Actuation of fresh /recirculating air flap

Actuation of water valve
The water valve and the flap are actuated via Bowden cables.
2
Schematic view of air vent distribution:
Windscreen
Foot compartment
Head room
Rear window
Operation of the heater unit
Switching ON
To switch the heater unit ON, turn the temperature controller clockwise. At the same time, turn the fan
switch ON to propel the heated air into the cabin.
Operation
The heater unit can be supplied at choice with fresh air or recirculating air by actuation of the fresh /
recirculating air selector switch.
The temperature controller in conjunction with the 3-stage fan switch enables individual variation of the
inside cabin temperature.
For maximum heating effect:
- turn temperature switch to the right to its stop;
- set fan to stage 3;
- set flap to "recirculating air";
- close the door and the windows;
- open all air vents.
Defrosting of window panes as above, however:

- only open the air vents concerned (example: for windscreen only the windscreen air vents)
Switching OFF
The heater unit is switched OFF by turning the temperature controller and the fan switch to "0".
Ventilation operation
3
For simple ventilation operation, the temperature controller remains set to "0"; the fan switch is set to the desired
position at stage 1, 2 or 3. Open the required air vents.
Other components
The heater unit has been equipped as standard with a filter, category F7. In case of a considerable reduction of the
capacity during fresh air operation, the filter must be replaced.
Malfunctions
Malfunction Error location /

elimination
Reduced air throughput Replace filter
Fan inoperative Check fuse F823
Check fan switch
Check fan *
* This kind of work may only be performed by specialists.
4
Air conditioning system
Application
The Wölfle air conditioning system 965212 is a useful extension of our basic heater unit
910154 and is used to condition the superstructure cabin of TADANO FAUN automobile
cranes. Thus, please read first of all the enclosed operating instructions for the Wölfle heater
unit 910154.
Technical Details
Air conditioning system cpl.
Manufacturer Wölfle GmbH
Model R134a/ Air
Rated voltage 24 V
Refrigerant R134a (filling capacity 1600 g)
Refrigerating oil PAG
Air conditioning expansion kit

Rated voltage --
Cooling capacity (in connection with heater 4.5 kW ( ± 10%)
unit 910154)
Condenser unit (964081)

Rated voltage 24 V
Max. air throughput 2100 m³/h
Thermal output approx. 13 kW
Fan stages 1
Max. power consumption 11 A
Weight approx. 9.7 kg
Compressor (359213)
Model Seltec TM - 15HD
Rated voltage 24 V
Max. speed 6000 rpm
Delivery 147 cm³
Sense of rotation right-hand or left-hand
Refrigerant R134a
Oil ZXL100PG (PAG oil)
- Filling capacity 150 cm³
Weight 7 kg
Max. electr. power consumption 48 W
Filter drier (427009)

Capacity 0.7 l
Filtering effect up to particle size > 6 μm
Water absorption of dry-type filter cartridge 16 g
Refrigerant R134a
Weight 1 kg
These data are partially given without being established by measurements and thus should only be considered
as approximate values!
1
Refrigerating cycle
Low
pressure, Evaporator
gaseous Expansion valve
Temperature
High
Thermostat pressure,
liquid
Compressor
High
pressure, Filter drier
gaseous
Pressure Inspection
switch glass
Condenser
High pressure,
liquid
The components of the refrigerating cycle are located as follows:
Evaporator : Retrofit evaporator on the heater housing

Expansion valve : on the evaporator
Temperature sensor : on the heater housing, in the air flow towards the evaporator
Thermostat : in the electric case next to the MB engine control unit
Compressor : on the engine or, in case of a hydraulic drive, in the hydraulic drive unit
Filter drier : on the condenser unit
Pressure switch : on the filter drier
Inspection glass : on the filter drier
Condenser unit : on the ballast
2
Operation of the air conditioning system
Switching ON
For operation of your Wölfle air conditioning system, an additional knob for adjustment of the
thermostat with ON/OFF switch for air conditioner operation is located in the control element.
LED indicator "air condition ON" ON/OFF switch for air conditioning unit with temperature
selector function
Operation
The air conditioning only operates if the fan switch is set at least to stage 1.
The LED indicator "air condition ON" is lit. The condenser fan is running.
For maximum cooling effect:
- turn thermostatic switch to the right to its stop;
- turn the temperature switch to the left to its stop ("OFF" position);
- set fan to stage 3;
- set flap to "circulating air"
- close the door and the windows;
- open all air vents.
An individual conditioning comfort range can be adjusted for each crane operator via the air vents
which can be varied independently of one another, the thermostat control and the fan control.
You can also operate your air conditioning system in the cold season. Switched on together with
your heating, it keeps the air in the driver's cab dry and stops the window panes misting up. To do
so, it is sufficient to set the air condition's thermostatic switch to low capacity.
3
Switching OFF
To switch off operation of the air conditioning system, turn the thermostatic control to the left to its
final stop in position "OFF".
Maintenance
The air conditioning system must be switched on briefly at least once per month. This operation is
required to ensure lubrication of the compressor.
The following maintenance work must be performed at the beginning, in the middle and at the end
of a cooling period:
- Check Vee belt tension and fastening of the compressor
- Check refrigerant filling
. To this effect, the refrigerant must pass the inspection glass of the liquid
tank free of bubbles when the engine is running and the air
conditioning system is operating at maximum capacity.
- Cleaning the condenser:
. The discs of the condenser must be cleaned gently without using high
pressure, as they would otherwise get bent.
The system should be checked in your workshop every year at the beginning of a refrigerating
period.
4
Error diagnosis
To this effect, refer also to "Electric circuit diagram, air conditioning system in superstructure
99707770980, page 32“
This list only mentions the most frequent fault hazards. Only specialist staff should be allowed to work on the
air conditioner !!!
Malfunction Cause Fault detection Remedy

System's cooling effect Insufficient air Check filter Replace filter
insufficient throughput in the
cabin
Leakage in air guide Eliminate leakage
system
Temperature sensor Replace sensor
faulty (evaporator iced)
Condenser soiled Visual inspection Clean condenser,
(do not bend discs)
Vee belt loosened Hissing sounds Check Vee belt tension
Condenser fan is not Visual inspection Check fuse (F843)
running
Check electrical
connections
if necessary, replace
fan
Compressor damage Abnormal sounds Replace compressor
Increased compressor Replace compressor
temp.
Lubricant has soiled Clean
belt pulley
Insufficient Bubbles in the
refrigerant inspection glass during
air conditioner
operation
Filter drier soiled Vessel is sensibly Replace component
cooler than supply line
Expansion valve Excessive high and low Replace component
faulty pressure
Pressure compensation Replace component
System does not operate Fuse faulty F823 / F843 Replace component
5
Relay faulty Replace component

Thermostat faulty Replace component
Pressure switch Replace component
faulty
Thermostatic switch Replace component
faulty
No refrigerant Repair leakage and fill
system again

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Operating, Service and

Vehicle identification no: WFN4 RTY N9 62043…

Manufacturer After-Sales Service:

We have gone to great lengths to provide the conditions for a long

1. Paint takes some time to develop its maximum resistance. Thus,

2. When using the crane on construction sites, when loading it with

3. Damage may also be caused by stone impact during travel. This

4. The paintwork is also vulnerable to weather conditions and thaw-

Customer satisfaction is our aim!

1 How to use this Operating Manual

2 Technical data, operation, maintenance, troubleshooting

3 Handling of this Operating Manual

4 Mounting locations of the vehicle identification number and of the nameplate

Part A) Technical Details

1 General technical details (chassis)

2 Technical details of components (chassis))

2.3 Transfer box

Part A) Technical Details

3 Technical details of components (superstructure)

4 Illustration of the vehicle

Part B.0) Safety Instructions

1 Requirements and conditions for vehicles used in public road traffic

2 Instructions for the crane operator

Part B) Operating Instructions

1 General instructions concerning operation of the vehicle

4 How to put the machine into operation

5 Gearshift and driving operation

**) Optional equipment

Part B) Operating Instructions

6 Outrigger the vehicle

7 Emergency control features

9 Steps for access to the superstructure

Part B) Operating Instructions

10 Attachments, optional equipment and accessories

11 Instrument panel - chassis

Part B) Operating Instructions

4 How to put the machine into operation

5 Gearshift, driving and outrigger operation from the superstructure

Part B) Operating Instructions

6 Crane movements in no-load condition

7 Crane operation with a load fixed to the boom

**) Optional equipment

Part B) Operating Instructions

11 Attachments, optional equipment and accessories

Part C) Service and Maintenance

Part C) Service and Maintenance

8 Eddy-current brake **)

**) Optional equipment

Part C) Service and Maintenance

13 Wheels and tires

Part C) Service and Maintenance

16 Miscellaneous; other points of lubrication, servicing and maintenance

24 Summary of oil types and filling capacities

25 Summary of lubricating grease types (recommended grease types)

26 Chart of approved consumables and lubricants

27 Inspection scheme (before start-up, daily)

28 Inspection and Cleaning Scheme

29 Oil/coolant level inspection and change scheme

**) Optional equipment

Part C) Service and Maintenance

**) Optional equipment

Part C) Service and Maintenance

5 Hoisting gear and auxiliary hoisting gear**) (2nd winch)