Om Atf60g-3 2064139 Uw en

Operation Manual
ATF 60G-3
Carrier
Serial-number
2064139
2021-10_EN
All rights reserved, particularly the right of reproduction and distribution.
Copyright 2021
TADANO Ltd.
The reproduction, editing, copying and distribution of this manual, including excerpts, are only permitted
with the express written approval of TADANO.
Any type of reproduction, distribution or storage on data carriers in any form not authorized by TADANO
represents a violation of the applicable copyright laws and will be prosecuted.
We reserve the right to carry out technical changes, which serve to improve our mobile cranes, or which
increase the safety standard - even without separate prior notice.
Manufacturer After-Sales Service

TADANO FAUN GmbH TADANO FAUN GmbH
Faunberg 2 Faunberg 2
91207 Lauf a. d. Pegnitz, Germany 91207 Lauf a. d. Pegnitz, Germany
Phone: +49 9123 185 0 Phone: +49 9123 185 5100
Fax: +49 9123 7 53 20 Fax: +49 9123 185 155
E-mail: info@tadanofaun.de E-mail: service@tadanofaun.de
www.tadanofaun.de www.tadanofaun.de
Table of contents
Table of contents
1 Preface 11
1.1 Using the operating manual 11
1.2 Vehicle identification number, name plate 13
1.3 In case of Damage 14
1.4 Warranty 14
2 General safety instructions 15

2.1 Basic Safety Information 15
2.1.1 Use of the Mobile Crane 15
2.1.2 Personnel Requirements 16
2.1.3 Planning Use 19
2.1.4 Ramming or pulling out posts or sheet piles 24
2.1.5 Outrigger 25
2.1.6 Service and Maintenance 27
2.1.7 Welding and alignment work 29
2.1.8 Painting work 30
2.1.9 Risk of fire and explosion 31
2.1.10 Different lengths of the hydraulic cylinders 31
2.1.11 Dismounting and disposal 32
2.2 Basic information concerning safety in the carrier 33
2.2.1 Warning and instruction signs 33
2.2.2 Before driving 39
2.2.3 Initial Operation and Running-in 40
2.2.4 Driving mode 40
2.2.5 Notes and Regulations on the Installed Pressure Tanks 43
2.2.6 Stopping the Mobile Crane 44
2.2.7 Towing 45
3 Safety devices 47
3.1 Safety equipment of the mobile crane 47
3.2 Engine emergency stop 48
3.3 Wheel chocks 50
3.4 Emergency hammer 52
4 Components and operating elements 55

4.1 Carrier - location of components 55
4.2 Carrier cab – interior fittings 56
4.3 Carrier cab – operating elements on instrument panel 57
4.4 Steering column switches 68
4.5 Carrier cab - shifting and driving 70
WFN3RUWW2K2064139
4.6 Carrier cab - gear selector lever 71

4.7 Carrier cab - Rear steering operating elements 72
4.8 Ignition key 72
4.9 Working speed 73
4.9.1 Safety instructions 73
4.9.2 Overview 74
ATF 60G-3 3
2019-03_EN
Table of contents
4.9.3 Switching working speed on/off 74

4.10 Ladders 74
4.11 Storage box-Timber storage 75
4.12 Double ladder 75
4.13 Crank handle 78
4.14 Roller sun visor 79
4.15 Rear area monitoring 79
4.16 Asymmetrical outrigger base 79
5 Operation of on-board computer 84

5.1 Description of function 84
5.2 Overview of the operating elements 84
5.3 Layout of the main display 88
5.3.1 Overview 88
5.3.2 Status information 89
5.3.3 Navigation area 90
5.3.4 Status displays 92
5.3.5 Indicator and warning lamps 95
5.3.6 Navigation in a menu 97
5.4 "Axle drive, differential locks, rear steering" menu 99
5.5 "Outrigger information" menu 101
5.6 "Suspension" menu 102
5.6.1 Tyre pressure monitoring system *) 104
5.7 "Engine information" menu 105
5.8 “Camera view” menu 107
5.9 “Other menus” menu 108
5.10 "Error messages" menu 110
5.11 "Software and hardware information" menu 111
5.12 "User settings" menu 112
5.12.1 Overview 112
5.12.2 “Front camera start menu” setting 113
5.12.3 “Automatic menu change” setting 114
5.12.4 “Navigation control button assignment” setting 116
5.12.5 “Brightness” setting 118
5.13 Menu "Service" 119
5.13.1 "Engine fault" menu 120
5.13.2 "Tyre pressure" menu 121
5.14 Messages, pilot and warning lamps 123
5.14.1 Messages 123
6 Transport 133
WFN3RUWW2K2064139
6.1 Ladders 133

6.2 Loading the mobile crane 135
7 Putting into operation 139

7.1 Carrier cab 139
7.1.1 Unlocking and locking doors from inside / outside 139
4 ATF 60G-3
2019-03_EN
Table of contents
7.1.2 Adjusting seats 144

7.1.3 Adjusting the steering wheel 149
7.1.4 Fastening/unfastening the seat belt 149
7.1.5 Adjusting the external mirror 150
7.1.6 Heating, ventilation, air conditioning system *) 152
7.1.7 Opening/closing the carrier cab side window 155
7.1.8 Interior lighting 157
7.2 Checking the lighting 158
7.2.2 Checking exterior lighting 158
7.2.3 Checking interior pilot lamps and indicators 159
7.2.4 Checking lighting, pilot lamps and indicators individually 160
8 Outrigger 163
8.1 Installation location of control panel 163
8.2 Safety instructions 163
8.3 Control panel 165
8.3.1 Structure of control panel 165
8.3.2 Buttons of the control panel 166
8.3.3 "Start menu" button 168
8.3.4 Menu "Main menu" 170
8.3.5 Menu "Retracting/extending outrigger beams" 172
8.3.6 Menu "Retracting/extending outrigger floats" 178
8.3.7 "Suspension cylinders" menu 184
8.4 Supporting the mobile crane 190
8.4.1 Preparations in carrier cab 190
8.4.2 Extending outrigger beams to the required outrigger base 191
8.4.3 Shifting outrigger floats in working position 193
8.4.4 Supporting the outrigger plates from below 194
8.4.5 Extending outrigger float 195
8.5 Retracting the outrigger 197
8.5.1 Preparations in carrier cab 197
8.5.2 Retracting the outrigger floats 198
8.5.3 Shifting of outrigger floats in transport position 198
8.5.4 Retracting outrigger beam 199
9 Driving mode 201

9.1 General principles 201
9.2 Before driving 201
9.2.1 Set down the hook block in the holder 201
9.2.2 Attaching the hook block for road travel 202
9.2.3 Checking resources and tyres 204
9.2.4 Requirements for driving mode 206
9.3 Starting/stopping engine 209
WFN3RUWW2K2064139
9.3.1 Starting the engine 209

9.3.2 Switching off the engine 213
9.4 Shifting and driving 213
9.4.1 Starting and stopping 213
9.4.2 Activating rear steering 217
9.4.3 Engaging and disengaging axle drive and differential locks 220
9.4.4 Brakes 223
9.4.5 Cruise control 230
ATF 60G-3 5
2019-03_EN
Table of contents
9.4.6 Tilt adjustment / driving level 233

9.4.7 Driving with trailer 236
9.4.8 Parking the mobile crane 239
10 Driving mode in winter 241

10.1 General safety instructions 241
10.2 Engine 241
10.2.1 Fuel 241
10.2.2 Engine oil 242
10.2.3 Coolant and anti-freeze 242
10.2.4 AdBlue in winter operation 242
10.3 Windshield washing system 242
10.4 Hydraulic system 243
10.4.1 Heating instructions for hydraulic oils 243
10.4.2 Switching to another oil 243
10.5 Gearbox 243
10.6 Anti-skid chains 244
10.7 Superstructure auxiliary heater 244
11 Special equipment 247

11.1 Underride protection 247
11.2 Spare wheel 248
12 Troubleshooting 251
12.1 General hints 251
12.2 Differential locks, axles and drive 251
12.3 Chassis hydraulic system - general 252
12.3.1 Suspension hydraulics 252
12.3.2 Inclination adjustment and leveling 253
12.3.3 Outrigger hydraulic system 253
12.4 Steering 253
12.4.1 Steering - mechanical part 253
12.4.2 Steering - hydraulic/electrical part 254
12.5 Braking system 254
12.6 Electrical system 255
12.7 Centralized lubrication system 255
12.8 Auxiliary heater 255
13 Self-help 257
13.1 Charging batteries 257
13.1.2 Charging batteries with charger 258
WFN3RUWW2K2064139
13.1.3 Charging batteries through the charging socket *) 259

13.2 Starting/stopping the engine with the start/stop pushbutton 261
13.3 Starting the engine with help from external current 263
13.3.1 Starting the engine with help from jump leads 263
13.3.2 Starting the engine with help from jump start socket *) 266
13.4 Bleeding the fuel system 267
6 ATF 60G-3
2019-03_EN
Table of contents
13.5 Filling the tyres 269

13.6 Measures in case of an overheated engine 271
14 Emergency operation 273

14.2 Retracting/extending outriggers in case of failure of operating elements 274
14.3 Centring rear wheels in case of failure of the rear steering 277
14.4 Switching on cooling system ventilator manually 280
15 Service and maintenance 283

15.1 Description of maintenance chart 283
15.3 Daily maintenance tasks 285
15.4 Recurring maintenance tasks 286
15.5 Filling up the heating's fuel tank 292
15.6 Filling up fuel or AdBlue 293
15.7 Checking the fasteners 298
15.7.1 Checking folding plugs and spring clips 298
15.8 Checking carrier for leaks 300
15.8.1 Introduction 300
15.8.2 Checking assemblies for leaks and condition 301
15.8.3 Checking hydraulic system for leaks 301
15.9 Engine and assemblies 302
15.9.1 Engine 302
15.9.2 Engine cooling system 309
15.9.3 Air cleaner 315
15.9.4 Fuel system 317
15.9.5 Exhaust system 323
15.10 Drive train 323
15.10.2 Transfer case 323
15.10.3 Drive shafts 326
15.11 Axles and brakes 327
15.11.1 Axle drives 327
15.11.2 Wheel drives 330
15.11.3 Visual inspection and switching function test 332
15.11.4 Braking system 332
15.11.5 Checking compressed air system 335
15.11.6 Cleaning drain valves 337
15.11.7 Engine brake and exhaust flaps 339
15.11.8 Inspect the protective caps, bushings and seals 339
15.11.9 Inspecting the diaphragm cylinder 339
WFN3RUWW2K2064139
15.11.10 Checking the ABS system 339

15.11.11 Steering 339
15.11.12 Checking the screws on axles, steering levers, push rods for tightness 339
15.11.13 Eddy-current brake *) 340
15.12 Hydraulic system 342
15.12.2 Checking the hydraulic oil level 343
ATF 60G-3 7
2019-03_EN
Table of contents
15.12.3 Checking hydraulic hoses 345

15.12.4 Replacing hydraulic hoses 346
15.12.5 Checking the hydraulic accumulator preloading pressure 346
15.13.1 Fuses 346
15.13.2 Relay 350
15.13.3 Bulbs and lamps 354
15.14 Breathers 356
15.14.1 Introduction 356
15.14.3 Requirements 357
15.14.4 Installation location 357
15.14.5 Checking bleeder valve of axle drives 358
15.14.6 Checking braking system bleeder valves 358
15.14.7 Checking fuel tank bleeder valve 359
15.14.8 Checking transfer case breathers 361
15.15 Wheels and tyres 361
15.15.1 Service life of wheel rims 361
15.15.2 Checking wheels and tyres 362
15.15.3 Checking the wheel nuts 362
15.15.4 Retightening wheel nuts (axle load up to 13 t) 363
15.15.5 Retightening wheel nuts (axle load over 13 t) 364
15.15.6 Checking and adapting tyre pressure 365
15.15.7 Interchanging wheels in case of tire wear 367
15.15.8 Changing wheel module for air pressure display *) 367
15.15.9 Checking wheel tracking 368
15.15.10 Checking the toe-in 368
15.16 Outrigger system 369
15.16.3 Overview 370
15.16.4 Checking and maintaining outrigger 370
15.16.5 Check and adjust the wear plates of the outrigger 370
15.16.6 Check and adjust the outrigger cylinder guide 370
15.16.7 Checking hoses and cables 370
15.17 Carrier cab 371
15.17.1 General information 371
15.17.2 Doors and flaps of carrier cab 371
15.17.3 Oil/lubricate joints, hinges and all moving parts 374
15.17.4 Windshield washer system 375
15.17.5 Air conditioning system *) 378
15.17.6 Heating 378
15.17.7 Rear area monitoring *) 379
15.17.8 Changing battery of ignition key 379
15.18 Trailer hitch *) 381
WFN3RUWW2K2064139
15.18.1 Maintaining trailer hitch 381

15.18.2 Inspecting the compressed air coupling heads 382
15.19 Oiling and lubricating 383
15.19.1 Oiling and lubricating 383
15.19.2 Lubricating joints, pins, hinges and all moving parts 383
15.19.3 Lubricating the steering knuckles 383
8 ATF 60G-3
2019-03_EN
Table of contents

15.20.2 Overview of lubrication points 385
15.20.3 Checking fill level of reservoir 386
15.20.4 Inspect the lines and screw couplings for leaks and damage 386
15.21 Sliding coupling 387
15.21.1 Checking the sliding coupling for damage 387
15.22 Suspension 388
15.22.1 Checking the bellows 388
16 Crane testing instructions 391

16.1 Periodic tests of cranes 391
16.2 Checking the load-bearing steel structures 391
17 Removal from operation 393

17.1 Maintenance tasks in the event of temporarily decommissioned mobile crane 393
17.1.1 Preparing mobile crane for temporary decommissioning 393
17.1.2 Monthly maintenance tasks on temporarily decommissioned mobile crane 393
17.1.3 Putting mobile crane into operation after temporary decommissioning 394
18 Technical data 395

18.1 Filling levels 395
18.2 Dimensions and weight 397
18.3 Engine 403
18.4 Gearbox 403
18.5 Brakes 403
18.6 Wheels and tyres 404
18.7 Outrigger 404
18.9 Lubricants 404
19 Annex 405
19.1 Gearbox 405
19.3 Heating, ventilation, air-conditioning of chassis cab 498
Glossary 533
WFN3RUWW2K2064139
ATF 60G-3 9
2019-03_EN
Table of contents
WFN3RUWW2K2064139
10 ATF 60G-3
2019-03_EN
1 Preface
1 Preface
1.1 Using the operating manual
Introduction
This operating manual should make it possible for the user to operate the mobile crane safely
and use its functions. It provides important information that is a prerequisite for safe operation.
Carrier (chassis) and superstructure have been separately explained.
Safety instructions
DANGER
Risk of accident due to incorrect use.
Incorrect use or maintenance of the mobile crane can lead to accidents.
This could cause fatal injuries to persons.
1. Operation and maintenance of the mobile crane may be carried out
only by qualified and trained experts.
2. Observe the notes in the operating manual during all activities.
Using the operating manual

The operating manual is primarily intended for the operator and the maintenance expert. The
operator and the maintenance personnel must be able to access it at all times. The operating
manual should thus be kept near the workplace of the operator, i.e. in the carrier or superstruc-
ture cab. The operating manual is a part of the mobile crane.
If you receive additional information from our after-sales service, make a note of it and keep it
with the operating manual.
Read the operating manual carefully before the commissioning of the mobile crane. Be well ac-
quainted with the content as well as the instruction signs and their meanings. You must also be
acquainted with the structure, function and the actuation direction of all operating elements be-
fore operating the mobile crane.
Scope of delivery
The documents of the mobile crane consist of the following parts:
▪ Operating manual of the superstructure.
▪ Operating manual of the carrier.
▪ Schemata, wiring diagrams.
▪ Operating manual of the engine.
WFN3RUWW2K2064139
▪ Further operating manuals depending on the installed special equipments or options.

▪ Electronic data carrier with operating manuals, diagrams, load rating charts, and, if neces-
sary, the operating manual of the engine.
ATF 60G-3 11
2019-03_EN
1 Preface
Structure
The operating manual describes the delivered design as well as the special equipment, if any.
The Table of Contents helps you find the desired information. In addition, the header on every
page also contains the title of the relevant chapter.
The crane components, as well as the checking, switching and control devices within the cabs,
are mentioned on many pages of the operating manual. Overviews of the key crane compon-
ents for the crane operator (and references to further chapters with detailed information) are loc-
ated in the chapter Components. Overviews of the instrument panels, crane control levers / foot
pedals, as well as the software operating consoles are located in the chapters Components,
Operating elements, and AML crane control.
The images in the operating manual may deviate from the actual design. The functional inform-
ation is not affected by this.
Please follow the specifications in the additional pamphlets of the vehicle documentation.
This operating manual has been translated to the best of the knowledge and capacity of the
translator. Only the German version is definitive for the functional correctness.
The TADANO After-sales Service is at your disposal for answering any questions that you may
have. Please contact the Customer Service Department if you have any questions even after
reading through the operating manual. Put get all questions clarified before operating the mobile
crane.
The operating manual is not a work instruction for carrying out greater commissioning work. The
TADANO After-sales Service will explain this to you.
If the mobile crane is sold, give the operating manual to the new owner!
Definition of the direction specifications

Driving forwards means: Driving with the carrier cab facing forward.
Driving backwards means: Driving with the tail-lights of the carrier facing forward.
Forward, backward, right, left on the mobile crane means that the carrier cab and the boom
head point in the same direction. The front is then always the direction of the carrier cab.
Forward, backward, right, left in the carrier cab refers only to the carrier cab. The carrier cab is
then always forward.
Forward, backward, right, left in the superstructure cab refers only to the superstructure. For-
ward is then always the direction of the boom head.
Option
Options, special equipment and country-specific versions are marked with *).
Symbols and safety instructions

The following safety instructions are used in this operating manual.
DANGER
WFN3RUWW2K2064139
Type and source of danger

DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
12 ATF 60G-3
2019-03_EN
1 Preface
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could res-
ult in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
Tips and recommended actions
Provides information if adherence to specific instructions is important for

economical use of the mobile crane or in case of additional information
and tips about the use of the mobile crane.
1.2 Vehicle identification number, name plate
2
WFN3xxxxxxxxx
1 Name plate 2 Chassis number
The following labels should be present on the mobile crane:

WFN3RUWW2K2064139
▪ Name plate, in the carrier cab, on the right-hand side, next to the passenger seat.
▪ Chassis number, on the right-hand side of the vehicle, behind the control panel.
ATF 60G-3 13
2019-03_EN
1 Preface
1.3 In case of Damage
Introduction
In case of damage, contact the nearest TADANO workshop or TADANO dealer.
Specify the following:
▪ Chassis number or serial number
▪ Type and scope of damage.
1.4 Warranty
Introduction
Observe the stipulated guarantee provisions.
The type and manner of use of the mobile crane must be completely in accordance with the
specifications in the operating manual.
The mobile crane may be modified only after a written approval of the manufacturer.
In case of non-adherence, the warranty of the mobile crane becomes invalid. We assume no li-
ability for damage resulting from non-adherence to the operating manual and the instructions
contained therein, or due to improper use of the mobile crane. The operating manual does not
specify our sales and delivery conditions.
Safety instructions
NOTICE
Loss of guarantee
If parts installed in the company are removed, changed or replaced with
non-original parts, the crane authorization as well as the manufacturer's
guarantee expires.
1. Do not dismantle original parts!
2. Do not modify original parts!
3. Use only original parts from TADANO.
WFN3RUWW2K2064139
14 ATF 60G-3
2019-03_EN
2 General safety instructions
2.1 Basic Safety Information
2.1.1 Use of the Mobile Crane
Introduction
This mobile crane has been built in accordance with the latest technology and approved safety
regulations. Nevertheless, danger to life and limb and damage to property may occur during its
use. It is therefore necessary to pay attention to the manual to reduce these risks.
It is only permitted to operate the mobile crane when it is technically in sound condition and in
accordance with its regulations. Problems or faults which affect the safety of the mobile crane
must be rectified immediately. Please contact TADANO After-sales Service if you have any
questions.
All specifications and descriptions in the manual assume that the mobile crane is being oper-
ated and used as described in the chapter Proper use.
Safety instructions
DANGER
Improper use of the mobile crane!
Improper use causes danger to life and limb.
1. Read and understand the manual.
2. Only trained, qualified personnel may operate the mobile crane.
Proper Use
Introduction
Proper use of the mobile crane consists exclusively of the lifting and lowering of unfixed loads.
To do this, the weight and center of gravity of the load must be known. The weight of the load
may not exceed the lifting capacity of the mobile crane.
A bottom block or hook tackle, in either case approved by TADANO, must be reeved to the
hoisting rope. The bottom block must be centered over the center of gravity of the load before
lifting. It may only be operated in the permissible setup conditions.
The mobile crane may only be moved if this is permitted according to the available moving and
lifting capacity charts. The setup conditions and specifications given in the operating instructions
must be adhered to.
WFN3RUWW2K2064139
With its standard equipment, the mobile crane may only be operated at a temperature range
from -25 °C to +40 °C ambient temperature.
Any other use is classified as improper.
The manufacturer bears no liability for damage resulting from improper use of the mobile crane.
The responsibility for this is exclusively that of the director of operations and the crane operator.
ATF 60G-3 15
2019-03_EN
Improper Use
Introduction
Incorrect use includes:
▪ using equipment parts not approved for the mobile crane,
▪ using load rating charts which do not correspond to the actual setup condition,
▪ working in slewing ranges and jib lengths which are not permitted according to the load rat-
ing charts,
▪ working with setup conditions which are not permitted according to the load rating charts,
▪ by-passing safety devices e.g. anti-two-block device,
▪ increasing the jib length of the lifted load after an automatic safe load indicator shut-off,
▪ pushing, pressing or lifting loads with the outrigger beams, the outrigger floats, or the level-
ling,
▪ sliding, pushing or lifting loads with the luffing or the slewing gear,
▪ using the mobile crane to break off fixed objects,
▪ using the mobile crane for handling operations,
▪ loading or unloading the mobile crane suddenly (use with chutes, containers or claws),
▪ using the mobile crane for work in which the swinging load alters in weight, e.g. filling a con-
crete container, containers or chutes,
▪ using the mobile crane to transport flammable or other hazardous materials,
▪ using the mobile crane to catch falling objects or parts,
▪ using the mobile crane for bungee jumping,
▪ driving the mobile crane in an unsuitable condition,
▪ driving on public roads when the equipment is not in a permitted state (dimensions, axle
loads),
The mobile crane may not be used for:
▪ rigging loads whose centers of gravity and weights are unknown and which are then re-
leased, e.g. by dismounting, separating,
▪ working without the necessary additional equipment, e.g. two hook block operation,
▪ transporting loads on the carrier,
▪ carrying persons outside the carrier cab,
▪ carrying persons in the superstructure cab while driving,
▪ carrying persons on the load or the load lifting device,
▪ carrying persons in workman's baskets without written authorization from the responsible au-
thorities. National regulations of the area of use must also be observed.
2.1.2 Personnel Requirements

WFN3RUWW2K2064139
Introduction
General and type-specific driver and after-sales service training courses are carried out at
TADANO Ltd..
Persons who are still undergoing training may only work on the mobile crane under the supervi-
sion of qualified members of staff.
16 ATF 60G-3
2019-03_EN
Safety instructions
WARNING
Risk of accidents due to untrained handling of the mobile crane.
Improper operation or maintenance of the mobile crane can lead to acci-
dents.
This could cause serious or fatal injuries.
1. Have the operation, maintenance, and repair only carried out by quali-
fied professionals that a are trained on the mobile crane.
2. Read and understand the operating manual.
WARNING
Risk of accidents due to inappropriate work clothes.
Loose clothing can get caught in rotating parts. Body parts may get
crushed or torn. Loose clothing can get caught on to protruding vehicle
parts. This could cause serious or fatal injuries.
1. Wear tight-fitting clothes.
2. Tie up long hair and protect them with a hair net.
3. Use personal protective gear.
WARNING
Risk of accidents due to influence of alcohol, drugs and medicines.
The maintenance personnel and the operating personnel must not be un-
der the influence of alcohol, drugs, or any medication, and must not be
overtired. In such a case, the risks cannot longer be assessed clearly.
This may result in accidents. This could cause serious or fatal injuries.
1. Operation or maintenance activities must only be carried out by
healthy individuals.
WARNING
Risk of falling due to unsafe or defective ladders.
When climbing and stepping on ladders, take utmost care especially in
case of humid weather. There is risk of slipping and risk of falling. This
could cause serious or fatal injuries.
1. Keep ladders clean at all times.
2. Wear sturdy, non-slip footwear.
3. Always hold the ladder beams or handles while climbing up or down.
WFN3RUWW2K2064139
4. Replace faulty ladders immediately.

5. Ensure that the ladders are safe.
ATF 60G-3 17
2019-03_EN
Crane Operators
Introduction
Only trained and authorized personnel may work with the mobile crane.
The crane operator must be able to recognize hazards to themselves and others, and to prevent
them adopting suitable measures.
The crane operator must fulfil the following requirements:
▪ He must hold the permission to drive and operate the mobile crane required in the country of
use.
▪ He must hold comprehensive knowledge of handling mobile cranes as well as the qualifica-
tions prescribed in the country of use.
▪ He must possess the intellectual and physical requirements to be able to independently op-
erate a mobile crane.
▪ He must be trained in the intended use of the mobile crane.
▪ He must hold the knowledge and understanding of the operating manual for the mobile
crane.
▪ He must hold the knowledge and understanding of the relevant accident prevention regula-
tions.
▪ He must hold knowledge of the emergency equipment of the mobile crane and be able to ap-
ply it.
Only those persons who have been briefed and are aware of the valid accident prevention regu-
lations may engage in the rigging of loads and signaling to the crane operator.
Maintenance personnel
Introduction
Maintenance activities on the mobile crane must only be carried out by qualified, trained profes-
sionals, which hold the appropriate training and experience in the fields of electrical, electronic,
hydraulic , and pneumatic systems.
The maintenance personnel must possess the intellectual and physical requirements for the
WFN3RUWW2K2064139
activities.
Skilled Repair Technicians
Introduction
Only qualified and trained, expert personnel may carry out repairs on the mobile crane. These
are, for example, trained specialists from the fields of mechatronics or the automotive trade.
18 ATF 60G-3
2019-03_EN
Only personnel from a specialist brakes workshop or with equivalent qualifications may carry out
work on the brakes and compressed air system.
National regulations which differ from the above regulations should be observed.
Personal Protective Equipment
Introduction
Observe the accident prevention regulations of the country of use.
Safety instructions
WARNING
Risk of falling of unsecured personnel.
If the personnel is not adequately secured during mounting and mainten-
ance activities, this may lead to accidents. This may result in fatal or seri-
ous injury.
1. Secure personnel against falling during mounting and maintenance
activities on the mobile crane with suitable aids, e.g. auxiliary crane,
lifting platform, scaffolding or ladders.
2. Use the provided handrail and ladders.
3. Wear personal protective gear.
4. Use safety harnesses if required.
2.1.3 Planning Use
Introduction
The national legislation and regulations applicable at the place of use must be observed.
Smooth operation requires careful planning of use.
The operator must have all the required specifications and documents before going to the in-
stallation location.
WFN3RUWW2K2064139
ATF 60G-3 19
2019-03_EN
Safety instructions
WARNING
Missing information on use!
A lack of information may make the planned work at the site of use unfeas-
ible and may force the crane operator to improvise.
1. Work with the crane may only be carried out when all documents/spe-
cifications are complete and correct.
When going to the installation location

▪ an exact route plan,
▪ a plan to the place of use for the vehicle with regard to its length, width and height as well as
its total weight, taking into accounting bridge loads, access heights and the width of streets,
▪ if necessary request police escort and obtain approval from the authorities,
▪ the necessary driving and special approvals,
▪ observe the paragraphs of the Road Traffic Licensing Regulations and the Highway Code
(observe the regulations valid in the area of use),
▪ permissible axle loads and total weight for the journey.
When carrying out the planned work

▪ a precise schedule,
▪ the type of planned crane use,
▪ weight and size of the load to be lifted,
▪ required jib length and lifting height,
▪ load bearing capacity of the ground at the site of the mobile crane (channels, water and gas
pipes, underground channels or cavities);
▪ space and possible limitations at the site of the mobile crane,
▪ overhead electric lines and their voltage,
▪ more personnel for instructing or for loading/equipping work,
▪ communication procedure, contact addresses, emergency addresses,
▪ any authorization from the authorities.
Required crane equipment

Because of the existing specifications, the necessary crane equipment must be assembled to
carry out the planned use:
▪ hook tackle or hook blocks,
WFN3RUWW2K2064139
▪ jibs,
▪ counterweights,
▪ slinging ropes, chain suspension, cross beams and similar aids,
▪ support base plates,
▪ additional transport vehicle.
20 ATF 60G-3
2019-03_EN
Choice of Site
Introduction
A basic prerequisite for working safely with a mobile crane is that it is used on ground which can
bear sufficient load.
Safety instructions
WARNING
Weak ground!
Wear ground implies risk of tipping and thus risk of accidents.
1. Only position and operate the mobile crane on ground which can bear
sufficient load.
2. Thus, place outrigger plates underneath.
Choice of Site
When selecting the site, it should be ensured that
▪ the available ground conditions can withstand the resulting strain,
▪ the outriggers can be extended in accordance with the value specified in the load rating
chart,
▪ the work can be carried out with as small a jib length as possible,
▪ there are no obstacles in the slewing range of the superstructure.
Permissible Ground Pressure
Introduction
When the mobile crane is supported, the outrigger cylinders transmit the forces to the ground.
The maximum force can reach almost the weight of the mobile crane including the load. These
forces are sent directly into the ground via the surfaces of the outrigger floats. If these surfaces
are insufficient, the ground must be appropriately supported.
The maximum reaction forces which can occur with 360° slewing of the load are specified in the
reaction force tables.
Safety instructions
WARNING
Tipping of the mobile crane due to unstable support!
WFN3RUWW2K2064139
In case of an unstable support, there is a risk of tipping and thus a risk of

accidents.
1. Only use stable materials to support the crane, such as adequate
wooden planks.
2. The support must be situated centrally underneath the outrigger floats
so that the distribution of pressure is equal.
ATF 60G-3 21
2019-03_EN
Calculating the support area

The minimum support area required may be calculated from the reaction force of the mobile
crane (refer to reaction force chart) divided by the permissible load bearing capability of the
ground.
supporting force
required support area = permissible load bearing capability of ground
On no account may the support area be smaller than the required area calculated.
If the load bearing capability of the ground is unknown, its strength must be determined with ap-
propriate tests, for example with a penetrometer.
Permissible ground pressure (extract from DIN 1054)

Type of ground daN/cm2
Backfilled ground, not artificially compressed: 0-1
Natural, obviously untouched ground:
Mud, peat, moor earth 0
Fine to medium sand 1.5
Coarse sand to gravel 2.0
Cohesive soils:
mushy 0
soft 0.4
firm 1.0
semi-solid 2.0
hard 4.0
Rock with minimal jointing in good, unweathered condition and favourable strati-
fication:
in closed sequence of strata 15
in bulky and columnar formation 30
Artificially compressed ground:
Asphalt 5 - 15
Concrete B I 50 - 250
Concrete B II 350 - 550
Slopes and depressions
Introduction
When choosing the site to position the mobile crane, it must be ensured that the mobile crane
does not stand too close to ditches, slopes or trenches.
A safe distance between the outriggers and the edge of the trench must be maintained, accord-
WFN3RUWW2K2064139
ing to the type of ground.

The safe distance is measured from the edge of the trench.
Subsurface Safe distance
Firm, natural, non-grainy soil (∝ ≥ 45°) 1 times depth of depression (A = 1 x T)
Grainy, soft or backfilled soil (∝ ≤ 30°) 2 times depth of depression (A = 2 x T)
22 ATF 60G-3
2019-03_EN
Safety instructions
WARNING
Vehicle tips over!
The edge of the slope or trench could cave in under the resulting stress
and cause the mobile crane to turn over.
1. A safe distance must be maintained between the mobile crane and the
edge of the trench.
2. Support slope or trench.
Overview
T Depth of depression A Safe distance α Gradient

WFN3RUWW2K2064139
ATF 60G-3 23
2019-03_EN
Counterweight
Safety instructions
WARNING
Danger to life from falling counterweights.
In case of technical defects, counterweights may come loose and fall. Per-
sons staying underneath the counterweights may get seriously or fatally in-
jured.
1. Do not stay underneath counterweights.
2. Make sure that no persons are staying underneath the counterweights.
2.1.4 Ramming or pulling out posts or sheet piles
Introduction
When ramming or pulling out posts or sheet piles with the mobile crane, vibrations can be trans-
ferred to the load-bearing steel structure of the mobile crane. These vibrations can lead to pre-
mature fatigue of the material and, thus, to cracks in the load-bearing steel structure.
Vibratory equipments that, due to their design, do not transfer any vibrations to the mobile crane
can be attached directly to the mobile crane. Otherwise, an additional device shall be attached
as damping element.
The national legislation and regulations applicable at the place of use shall be complied with.
Measures
Vibratory ramming or pulling out of posts and sheet piles with the mobile crane is permissible on
the following conditions:
▪ The automatic safe load indicator may not be overridden.
▪ The ramming equipment shall only be attached to the mobile crane via the wire rope and the
hook block. Any contact of the ramming equipment to other parts of the mobile crane is not
permissible.
▪ The posts and sheet piles to be driven in shall be adequately secured against tipping over.
▪ The ramming equipment may not start vibrating before the entire weight load of the post or of
the sheet pile is on the ground.
▪ While pulling the ramming equipment away from the driven-in post or sheet pile, the hook
block shall be positioned vertically above the attachment point.
▪ While pulling out, it must be avoided that the post or the sheet pile come out of the ground
with a jerk.
▪ As soon as the post or the sheet pile come out of the ground, the vibration of the ramming
WFN3RUWW2K2064139
equipment shall be stopped to prevent vibrations from being transferred to the mobile crane.
▪ After finishing any ramming tasks, the load-bearing parts of the mobile crane shall be
checked for cracks and loose parts.
Before the mobile crane is used again for normal lifting tasks, a thorough inspection of the
mobile crane shall be performed, refer to chapter Crane testing instructions in the operating
manual.
24 ATF 60G-3
2019-03_EN
▪ The frequency and scope of the checks for wear and signs of fatigue shall be adapted cor-
respondingly.
▪ The instructions and restrictions of the ramming equipment's manufacturer shall be complied
with.
2.1.5 Outrigger
Introduction
All outrigger beams must be extended on the outrigger base in accordance with the selected
load rating chart.
All outrigger floats must hold. All wheels shall have a distance of at least 5 cm to the ground.
The mobile crane must be levelled after extending the outrigger beams and the outrigger floats.
Safety instructions
DANGER
Danger of the mobile crane tipping due to abrupt unloading!
If the wire rope tears or the load falls while it is being lifted, the mobile
crane is unloaded abruptly. In this case, if the non-load side outriggers are
not extended, the sudden unloading of the crane can cause it to overturn
backwards.
1. All outrigger beams that are on the load side and non-load side always
support according to the outrigger extensions in the load rating charts.
2. Insert all locking pins completely into the outrigger beams.
WARNING
Risk of accidents when extending the outriggers.
If the operator cannot see the outrigger area, people who are present in
this area may get injured.
1. Evacuate people from the outrigger area of outriggers.
2. Only extend and retract outriggers if the operator or another person
can see the outrigger area for the duration of the outrigger process.
Aligning the Mobile Crane
Introduction
It is of great importance for safe operation that, as well as the correct and stable support of all
WFN3RUWW2K2064139
outrigger floats, the mobile crane is also evenly aligned.
ATF 60G-3 25
2019-03_EN
Safety instructions
DANGER
Tilted position causes danger that the mobile crane will tip over!
If the boom is slewed towards the slope on a mobile crane which is not
evenly aligned, there is an increase in the jib length which can cause the
mobile crane to tip over.
1. Align the mobile crane horizontally.
WFN3RUWW2K2064139
26 ATF 60G-3
2019-03_EN
Overview
Example:
Boom length: 60 m
Inclination: 5°
Jib length (a) increases by approx. 5 m.
WFN3RUWW2K2064139
2.1.6 Service and Maintenance
Introduction
The maintenance personnel must be able to recognize hazards to themselves and others, and
to prevent them adopting suitable measures. Refer also to chapter "Service and maintenance".
Causes of damage from maintenance errors:
ATF 60G-3 27
2019-03_EN
▪ lack of oil, grease, coolant or de-icing fluid in the various units,

▪ use of impermissible lubricants,
▪ water in the compressed air system,
▪ filter in the air dryer not changed on time,
▪ damage to the plastic tubing of compressed air and central lubrication system from drilling or
welding, e.g. plastic tubing not covered or removed,
▪ sudden loss of pressure in the tyres due to tyre damage which has not been rectified,
▪ tightening torques of the nuts or screws not observed, e.g. when changing wheel or other in-
stallation work,
▪ units not functional e.g. brakes or steering, because of inadequate maintenance,
▪ faults on the brake and compressed air system, e.g. worn hoses,
▪ insufficient visual inspections carried out on steel construction, welded parts and parts sub-
ject to heavy loads,
▪ faults on the hydraulic system, e.g. worn hoses,
▪ worn ropes which need to be replaced and could break suddenly,
▪ faulty or insufficiently functional safety devices, e.g. automatic safe load indicator or anti-two-
block device/limit switch of the hoisting winch.
Safety instructions
WARNING
Risk of accident due to impermissible commissioning.
If the vehicle is operated during maintenance and inspection, there are
risks of accidents and damage to the vehicle.
1. Do not operate the mobile crane during maintenance and inspection
work.
2. Secure the danger zone and do not allow unauthorized persons.
3. Indicate the maintenance work on the mobile crane using appropriate
warning tags, e.g. on doors, on the steering wheel, on the control
lever.
WARNING
Danger of accidents from incorrect maintenance.
A significant proportion of cases of damage on/with mobile cranes is
caused by the lack of and/or incorrect maintenance of the mobile crane.
1. Maintenance work may only be carried out by trained personnel in ac-
cordance with the maintenance plan.
WFN3RUWW2K2064139
28 ATF 60G-3
2019-03_EN
CAUTION
Improper disposal or lubricants, consumables and cleaning agents
can cause environmental damage.
Lubricants, consumables and cleaning agents must be treated as hazard-
ous waste. Lubricants, consumables and cleaning agents must not enter
the ground, water, sewage system or ground water.
1. Do not allow lubricants, consumables and cleaning agents to run off
uncontrolled.
2. Dispose of lubricants, consumables and cleaning agents properly. Fol-
low the national regulations.
2.1.7 Welding and alignment work
Measures in the event of damage on the steel structure
Introduction
Consult a crane expert if damage (e.g. cracks, distortions) are detected on the mobile crane.
Consult the crane manufacturer after investigating the fault.
The repair method should then be decided on in consultation between the crane manufacturer
and the expert.
Safety instructions
WARNING
Improperly carried out welding or alignment work!
If welding, heat treatments or alignment work is carried out improperly,
loss of material properties must be expected.
Measures to protect electronic parts during welding
Introduction
If it is necessary to carry out welding on the mobile crane, the following steps must be carried
out before beginning work to protect the electronic control units:
▪ Switch off battery main switch (on the superstructure as well, if present),
▪ Remove the battery cable at the negative pole, then remove the battery cable at the positive
pole and connect them with each other (on the superstructure as well, if present),
▪ Pull out plugs of electronic parts.
WFN3RUWW2K2064139
ATF 60G-3 29
2019-03_EN
Safety instructions
NOTICE
High current during welding!
The flow of current can cause damage to loose connections during weld-
ing, e.g. tooth flanks, bearings, spline ends, shafts, the electronics, the
automatic safe load indicator, etc.
1. When electrowelding, the ground terminal of the welding machine must
be connected directly to the part to be welded.
2. Welding regulations must be observed.
2.1.8 Painting work
Introduction
The following components must be covered prior to painting work and uncovered again after
painting:
▪ Breather and ventilation valves.
▪ Contact surfaces between rims and wheel hubs.
▪ Contact surfaces between wheel nuts and rims.
▪ Running areas and sliding surfaces of piston rods.
▪ Sliding surfaces and fits.
▪ Hoses.
▪ Glass panes.
▪ Hinges.
▪ Moving parts.
▪ Guide rollers.
▪ Lighting devices.
WFN3RUWW2K2064139
30 ATF 60G-3
2019-03_EN
2.1.9 Risk of fire and explosion
Safety instructions
DANGER
Risk of fire and explosion!
Non-compliance with the following items may lead to burns or life-threaten-
ing injuries.
➢ The mobile crane must not be used in areas with a risk of explosion.
➢ It is prohibited to smoke and use open flames when working with fuels
or operating materials while performing maintenance tasks on the bat-
teries.
➢ Fire or open flames are forbidden on the mobile crane.
➢ The mobile crane must be refueled only when the engine is switched
off and in outdoor or well ventilated areas.
1. Follow the accident prevention regulations.
2. Wipe off spilled fuel or oil immediately using suitable tools (e.g. oil
binders).
3. Replace insulation or sound insulation mats which have become con-
taminated with fuel, oil or grease with new, clean insulation mats. Con-
taminated insulation mats near hot surfaces present a serious fire risk.
4. Do not use flammable solvents.
5. Keep flammable objects such as dry leaves or paper waste away from
the engine.
6. Only carry out maintenance on units which have cooled down, other-
wise there is a danger of burns.
7. During grinding and welding, ensure that dangerous objects and ma-
terials are located at a safe distance.
2.1.10 Different lengths of the hydraulic cylinders
Introduction
The hydraulic oil heats up while the crane is being used.
Temperature variations alter the oil volume in the hydraulic cylinders, e.g. luffing cylinders or
outrigger cylinders. This can lead to differences in length of the cylinders and has a particular
impact after long periods of operation. The difference in length can be determined using the dia-
gram below.
WFN3RUWW2K2064139
Example:
An hydraulic cylinder with 6.5 m stroke alters its length by approx. 24 cm with a 50 °C difference
in the hydraulic oil temperature.
ATF 60G-3 31
2019-03_EN
Safety instructions
WARNING
Extending/retracting of hydraulic cylinders due to temperature differ-
ences!
Temperature variations alter the oil volume of the hydraulic oil. This can
lead to variations in the length of the hydraulic cylinders.
The mobile crane can therefore become unstable.
This may result in accidents. This could cause serious or fatal injuries to
persons.
1. Check the condition of the hydraulic cylinders if temperatures fluctuate
or after long periods of operation.
Overview
t= Temperature difference
s= Length difference
s= Total stroke
2.1.11 Dismounting and disposal
Introduction
Dispose of operating materials, lubricants and auxiliary materials in an environment-friendly
manner.
Separate the components of the mobile crane as per their reuse value and feed them into the
recycling loop.
WFN3RUWW2K2064139
▪ Scrap the remaining metallic components.

▪ Give plastic parts for recycling.
▪ Sort the remaining components as per their material composition and dispose them appropri-
ately.
Follow the legal regulations applicable in the country of application for proper and environment-
friendly disposal.
32 ATF 60G-3
2019-03_EN
2.2 Basic information concerning safety in the carrier
2.2.1 Warning and instruction signs
Overview
WFN3RUWW2K2064139
ATF 60G-3 33
2019-03_EN
WFN3RUWW2K2064139
34 ATF 60G-3
2019-03_EN
Warning and instruction signs
1 2 3
A
D
B
C E
Check wheel nuts.
Initially after 50 km, then after
Multiple warning sign: Release spring-loaded accu-
100 km and again after a fur-
ther 200 km. A = Do not remain in the car- mulator cylinder.
rier cab during crane opera-
tion.
B = Do not remain under or on
the mobile crane while it is be-
ing lowered.
C = Only lower the mobile
crane when engine is running.
D = Caution when engaging
the differential locks.
E = Observe the operating
manual.
4 9 19
The braking system is supplied

Name plate. with plastic tubing. Caution
when drilling, welding and
grinding. No contact with
acids. Temperature-resistant
from -40 °C to +100 °C.
Parking brake.
WFN3RUWW2K2064139
ATF 60G-3 35
2019-03_EN
35 37 43
Tyre pressure.
No access to unauthorised
persons.
Engage parking brake before

leaving the carrier cab.
44 46 47
2.4 m width of outrigger exten- 6.4 m width of outrigger exten-

sion. sion.
Outrigger width identification.

48 49 52
4.4 m width of outrigger exten- 5.4 m width of outrigger exten-

sion. sion.
WFN3RUWW2K2064139
Fastening eye.
36 ATF 60G-3
2019-03_EN
53 54 71
Protect against direct splash Fastening strap.

water.
85 88 89
24 V socket. 12 V socket.
Maximum load 100 kg.

90
Engine instruction sign
Additional warning and instruction signs for Great Britain

WFN3RUWW2K2064139
Overview
ATF 60G-3 37
2019-03_EN
Warning and instruction signs

300 *) 400 *) 401 *)
Maximum vehicle height STGO category B. STGO category C.

403 *)
WFN3RUWW2K2064139
STGO.
38 ATF 60G-3
2019-03_EN
Additional warning and instruction signs for Italy
500 *)
Maximum driving speed
Ensure legibility of the warning and instruction signs

All warning and instruction signs put up on the mobile crane describe important safety precau-
tions. Note that the warning and instruction signs must always be clean and completely legible.
Reorder and fit damaged or missing signs via TADANO customer service or TADANO dealers.
2.2.2 Before driving
WARNING
Risk of accident!
The mobile crane must be in a sound technical condition during its entire
period of use. Improper components can fail and cause accidents.
➢ If defects or irregularities are identified, the travel should not be star-

ted.
1. Always check the mobile crane before beginning to drive and rectify
any faults identified.
The condition of the mobile crane should be checked before the travel, see part B "Before
travel".
It must be checked that:
▪ all covers are present and closed,
▪ all safety devices are present, correctly installed and in good condition,
▪ wheels and tires do not display any visual defects,
▪ the anemometer is not installed,
▪ the bottom block/hook tackle is attached properly,
▪ Windows, mirrors, lamps and lights are clean and a good view in all directions is ensured,
▪ there are no persons or objects under or near the mobile crane,
▪ The seat and the steering wheel should be adjusted such that the pedals are correctly actu-
ated and the steering wheel can be easily operated,
▪ the driver and the passenger have put on the seat belt,
WFN3RUWW2K2064139
▪ there are no loose objects in the leg space on the driver side that can slide under the accel-
erators during the travel.
Before starting the engine:
▪ check the control and operating elements as described in part B "Commissioning" and
▪ sound the horn to warn persons who are in the vicinity of the vehicle.
Pay attention to all control elements and lights after starting the engine.
ATF 60G-3 39
2019-03_EN
2.2.3 Initial Operation and Running-in

The mobile crane can be fully used and loaded from the start. However, it is recommended to
pay close attention to checking and display instruments during the first operating hours.
Running in the Brake Lining

New brake linings need to be worn in, i.e. activated so that they achieve the full braking effect.
WARNING
Overheating of the wheel brakes!
Violent braking at high speeds or repeated continuous braking can lead to
loss of brake power or increased braking distance.
1. Avoid repeated violent braking at high speeds.
2. Do not brake for long periods of time.
3. Use interval braking to activate the linings.
2.2.4 Driving mode
Requirements for Driving Operation
WARNING
Slewing or sheering crane parts!
If the mobile crane is not in the proper transport condition, there is a risk of
accident due to swiveling or protruding mobile crane parts.
1. Establish the transport condition. Follow the following points.
When driving on public roads, observe the following:

▪ The superstructure must be turned in the direction of travel, mechanically secured so that it
cannot turn and the slewing brake must be engaged.
▪ The telescopic boom must be driven in the position specified in the vehicle approval and
mechanically secured there so that it cannot move out of place.
▪ Any special equipment present (e.g. boom extension, hook blocks) must be fixed securely to
the appropriate places in accordance with the specifications in the operating instructions. If
this leads to the permissible axle loads being exceeded, they must be removed and trans-
ported separately, e.g. counterweights.
▪ The outriggers must be completely retracted and the support beams mechanically secured.
▪ The support plates must be inserted and mechanically secured in the transport position, or
removed and transported separately if this is stated in the vehicle documents.
▪ The axle suspension system may not be blocked when driving on the road. The suspension
WFN3RUWW2K2064139
system must be brought to the level for the traveling configuration "On-road travel", in ac-
cordance with the operating instructions.
▪ The "On-road travel" steering program must be activated.
▪ The differential locks must be deactivated.
▪ No one may stay in the crane cab.
▪ Work lights, if present, must be turned off.
40 ATF 60G-3
2019-03_EN
The vehicle certificate specifies which setup conditions maintain the permissible axle loads and
total weight. These setup conditions may not be altered by the addition or removal of parts.
Additional loads can lead to the axle load being exceeded.
The specifications in the operating instructions for driving on public roads must be adhered to.
At least 2-4 chocks (depending on vehicle type), at least two warning triangles and 2 portable
warning lights must be carried.
Notes to driving mode

Much damage to mobile cranes is caused by user error.
A decisive factor in the avoidance of accidents is therefore the thorough training of the crane
operator in the operation and use of the mobile crane.
The crane operator must be able to recognize risks to themselves and others and to implement
suitable measures to avoid these risks.
Regulate for the safe travel mode:
1. Adapt the manner of driving and speed to the travel and road conditions.
2. Keep a sufficient distance from the preceding vehicles and apply brakes early.
3. Avoid sudden acceleration, braking or fast steering movements.
4. Use a signal person when working at invisible places such as curves or narrow passages
as well as at blind sight corners.
5. Pay attention to access heights and widths such as bridges, overpasses, tunnels, roofs,
electrical free lines, etc. Vehicle dimensions must be known to the crane operator
6. Avoid excessive use of the service brake. The brakes can overheat and fail. Downshift the
gear in time and use the engine brake when driving over steep stretches for a long time.
7. If the engine stops during traveling, immediately stop the mobile crane at a safe place. A
pressure drop in the operating system leads to a brake failure.
WARNING
Breakdowns when driving!
Broken down vehicles are threats to the traffic coming from behind, espe-
cially at night and at unclear places.
1. Switch on the hazard warning system and stop the mobile crane at a
safe place.
2. Secure the mobile crane against inadvertent rolling.
3. If required, put up a warning triangle and a warning light to warn the
traffic coming from behind.
WFN3RUWW2K2064139
Causes of damage in driving operation

▪ engine and/or gears overwound when skidding,
▪ differential locks not switched off when driving on the road,
▪ parking brake not engaged when parked, no additional chocks used when parked on slopes,
▪ loose objects left lying on the mobile crane,
▪ collisions with bridges, roofs due to low access height,
ATF 60G-3 41
2019-03_EN
▪ exceeding the permissible axle loads/the total weight (observe regulations valid in place of
use),
▪ driving at excessive speed.
WARNING
Increased Braking Distance!
Driving with impermissible axle loads, impermissible total weight, or in-
creased speed leads to an increase in the braking distance. The entire
braking system thus no longer corresponds to legal regulations.
1. Permissible axle loads and total weight may not be exceeded.
Tyres capacities as a function of the travel speed
Description
On the subject of axle loads, there is a difference between technically permissible axle loads
and legally prescribed axle loads of the licensing country. In the countries of the European
Union, axle loads of over 12 t are not permitted on public roads, in accordance with EU regula-
tions.
General
Pay attention to the following when driving with axle loads in excess of 12 t:
▪ The braking distance can be increased significantly.
▪ Increased wear, particularly on the brake linings.
▪ Wheel nuts must be checked to make sure that they are tight and tightened in accordance
with the maintenance plan.
The wheel rims used have a limited service life, in accordance with their technical specifications.
Since the wheel rims represent an important safety component in the mobile crane, they
must be regularly checked and documented.
A service life of the wheel rim of the mobile crane of approx. 80,000 – 100,000 km can be as-
sumed with normal use.
Large, spasmodic stresses or driving with excessive axle loads, more than the constructional
guidelines, can lead to a reduction in the specified service life.
The wheel rims should therefore be inspected regularly, depending on the conditions of use of
the vehicle, and checks for cracks carried out on the critical areas e.g. welding seam between
disc and rim. Any cracks which may be present may not be repaired by welding.
Relation between the permissible axle loads and the maximum speed
NOTICE
WFN3RUWW2K2064139
Tyre failure due to overload.

The 445/95 R 25 177F tyres from Dunlop or Yokohama can be over-
loaded. This may lead to tyre failures.
1. When using 445/95 R 25 177F tyres from Dunlop or Yokohama, do not
cover greater distances than 75 km in one hour.
42 ATF 60G-3
2019-03_EN
The vehicle operator may only use wheel rims which are approved by the
mobile crane manufacturer.
Tyre size Max. speed [km/

h]
385/95 385/95 445/95 445/95 525/80 525/80
R25 R25 R25 R25 R25 R25
170F 170E 174F 177E 176F 179E
Max. permissible axle load [t]
11.6 — 13.0 — 13.8 11.8 85
12.0 9.9 13.4 12.0 14.2 12.7 80
12.6 12.0 14.1 14.5 14.9 15.5 70
13.2 13.3 14.7 15.0 15.6 17.4 60
13.4 14.0 15.0 15.5 15.9 18.3 50
2.2.5 Notes and Regulations on the Installed Pressure Tanks

The installed pressure tanks comply with EEC (EU) directive 87/404/EEC and are exclusively
approved for compressed air braking systems.
Checking the pressure tanks!

National regulations should be observed.
The pressure tanks are subject to tests in accordance with the maintenance regulations of state
legislation.
Check and drain the pressure tanks periodically of any accumulated water., refer to Testing
function of air dryer [} page 332].
WFN3RUWW2K2064139
ATF 60G-3 43
2019-03_EN
2.2.6 Stopping the Mobile Crane
Safety instructions
DANGER
The mobile crane can roll away out of control.
So that the wheel chocks have sufficient hold, the mobile crane may only
be parked on a surface with a sufficient load-bearing capacity.
Fatal accidents can result if the following points are not obeyed.
➢ The uphill or downhill gradient must not exceed 18 %, without trailer.
➢ The uphill or downhill gradient must not exceed 12 % if the mobile

crane is parked with a trailer.
1. Engage the parking brake.
2. Secure the mobile crane with wheel chocks.
DANGER
The mobile crane can roll away out of control!
If the mobile crane's wheels are not secured with wheel chocks directly on
the side facing downhill, the mobile crane can roll away out of control and
kill people.
1. Place wheel chocks tightly under the wheels on the side facing down-
hill so that the mobile crane remains in its parked position.
2. Select a firm parking surface so that the wheel chocks cannot sink into
the ground.
Requirements
The following requirements must be fulfilled:
▪ The mobile crane must be on a stable surface.
▪ The parking brake is engaged.
▪ In the case of mobile cranes with trailers, the retention force of the entire combination is
checked and ensured via the test position of the hand brake valve.
In addition to the parking brake being applied, the mobile crane must also be secured with the
specified number of wheel chocks when:
▪ The mobile crane is parked on an uphill or downhill gradient
▪ The mobile crane is parked unsupervised
▪ The mobile crane is defective, particularly in the case of parking brake system defects.
WFN3RUWW2K2064139
Securing the mobile crane against unauthorized use

1. Switch off engine.
2. Remove the ignition key and put it in a safe place.
3. Switch off the battery main switch.
4. Make sure that there is nobody in the carrier cab or the superstructure cab.
44 ATF 60G-3
2019-03_EN
5. Lock carrier cab and superstructure cab.
2.2.7 Towing
It is only permitted to tow the mobile crane when it can no longer be moved out of a dangerous
area with its own power. Additional measures must be taken to tow the vehicle for longer dis-
tances.
DANGER
Risk of accidents due to brakes that are not working.
The supply pressure in the braking system must be at least 8 bar during
towing for the brakes to function sufficiently.
The engine must be running to build up sufficient brake pressure.
1. If the engine does not run, load mobile crane.
The towing vehicle must be adequately dimensioned and equipped with an appropriate towing
hitch.
WFN3RUWW2K2064139
ATF 60G-3 45
2019-03_EN
WFN3RUWW2K2064139
46 ATF 60G-3
2019-03_EN
3 Safety devices
3 Safety devices
3.1 Safety equipment of the mobile crane
Safety instructions
WARNING
Non-functioning safety devices!
Non-functioning safety devices may cause accidents.
1. Check the safety devices described below for their flawless functioning
before starting work.
Safety equipment of the mobile crane

The mobile crane is equipped with the following safety devices:
▪ Engine emergency stop [} page 48].
▪ Wheel chocks [} page 50].
▪ Emergency hammer [} page 52].
WFN3RUWW2K2064139
ATF 60G-3 47
2019-03_EN
3 Safety devices
3.2 Engine emergency stop
Installation location in the superstructure cab
Overview
1 Emergency stop switch
Explanation
The Emergency stop switch is installed in the superstructure cab.
WFN3RUWW2K2064139
48 ATF 60G-3
2019-03_EN
3 Safety devices
Installation location on the superstructure *)
Overview
Explanation
The Emergency stop switch *) is located on the right-hand side of the superstructure panelling.
Function
Overview
Stopping the engine

1. Press Emergency stop *) switch.
WFN3RUWW2K2064139
Starting the engine

1. Press the Emergency stop switch *) again.
ð The switch springs back to its initial position.
2. Start engine, refer to Starting the engine [} page 209].
ATF 60G-3 49
2019-03_EN
3 Safety devices
3.3 Wheel chocks
Introduction
The mobile crane is equipped with (folding) wheel chocks in line with the legal requirements.
For transport, fold up the wheel chocks and stow them securely.
Fold out the wheel chocks to prevent the mobile crane from rolling away.
Safety instructions
CAUTION
Risk of crushing when unfolding the wheel chock.
The folding chock automatically unfolds into its working position when
pressing the lock. While doing this, there is a risk of crushing the fingers.
1. Do not reach into the marked area.
Overview
1 Folding chock ! Area of danger of crushing
WFN3RUWW2K2064139
50 ATF 60G-3
2019-03_EN
3 Safety devices
Folding out the wheel chocks
Overview
A B
A Transport position 1 Lock

B Working position 2 Wheel chock
Procedure
1. Open the folding chock pressing the lock.
ð The wheel chock automatically unfolds into its working position.
ð The wheel chock has been unfolded.
WFN3RUWW2K2064139
ATF 60G-3 51
2019-03_EN
3 Safety devices
Positioning the wheel chock at the wheel
Overview
2 Wheel chock 3 Wheel
Procedure
1. Place the unfolded wheel chock tightly on the lower side of the wheel (facing the valley) (as
shown).
ð The mobile crane has been secured with wheel chocks against rolling away.
3.4 Emergency hammer
Introduction
If the mobile crane cannot be left in the event of an emergency, a window can be broken with
the emergency hammer. In case of emergency, a blocked safety belt can be cut with the belt
cutter.
WFN3RUWW2K2064139
For safety reasons, the windshield is made of laminated glass and cannot be penetrated with
the emergency hammer.
52 ATF 60G-3
2019-03_EN
3 Safety devices
Installation location
Overview
1 Hammer head 2 Belt cutter
Procedure
1. Cut safety belt with the belt cutter.
2. Strike the window firmly with the tip of the hammer head until the window breaks.
WFN3RUWW2K2064139
3. Push or knock the broken window out.

ð The mobile crane can be left.
ATF 60G-3 53
2019-03_EN
3 Safety devices
WFN3RUWW2K2064139
54 ATF 60G-3
2019-03_EN
4 Components and operating elements
4.1 Carrier - location of components
Overview
1 Swivelling ladder 6 Swivelling ladder

2 Swivelling ladder 7 Swivelling ladder
3 Tool box *) 8 Front outrigger
4 Rear outrigger 9 Access step to carrier cab
5 Ladder, permanently attached 10 Carrier cab
WFN3RUWW2K2064139
ATF 60G-3 55
2019-03_EN
4.2 Carrier cab – interior fittings
1 Steering wheel adjustment 11 Safety belt

2 Interior ventilation 12 24 V socket
3 Side window ventilation 13 12 V socket
4 Instrument panel 14 Ashtray/cup holder
5 Control unit for heating, ventilation and air- 15 Refrigerator box *)
conditioning system
6 Radio/CD 16 Storage box
WFN3RUWW2K2064139
7 Storage tray 17 First aid kit *)

8 Fuses, relays, diagnostic connector 18 Auxiliary heater*) control unit
9 Roller sun visor 19 Navigation *)
10 Fire extinguisher 20 Modular tachograph
56 ATF 60G-3
2019-03_EN
4.3 Carrier cab – operating elements on instrument panel
Overview
1 Instrument panel 1 3 Instrument panel 3

2 Instrument panel 2
WFN3RUWW2K2064139
ATF 60G-3 57
2019-03_EN
Instrument panel 1
1 2 3
2 4
5 6 7 8
9 10
11
1 Mirror heater switch 7 Rotary beacon switch

2 Super-tone horn/signal horn *) switch 8 Rear rotary beacon *) switch
3 Reversing signal *) switch 9 Carrier operation/superstructure operation
switch
4 Carrier cab ambience interior lighting 10 Parking light / low beam light switch
switch
5 Fog light *) switch 11 Battery main switch key switch
6 Rear fog light pushbutton
Switches and pushbuttons

"Mirror heater" switch
Press upper part = switch off mirror heater.
Press lower part = switch on mirror heater.
All the mirrors except the front mirror can be heated.
"Super-tone horn/signal horn" switch *)

Press upper part = select signal horn.
Press lower part = select super-tone horn.
"Reversing signal" switch *)

Press upper part = switch off warning device.
WFN3RUWW2K2064139
Press lower part = switch on warning device.

NOTICE! Only switch off warning device if it is possible to view the area behind the
vehicle.
58 ATF 60G-3
2019-03_EN
"Carrier cab ambience interior lighting" switch

Press upper part = Deactivate carrier cab ambience interior lighting lamp.
Press lower part = Activate carrier cab ambience interior lighting lamp.
"Fog light" switch *)

Press upper part = switch off fog light.
Press lower part = switch on fog lamps (when low beam light is switched on).
"Rear fog light" pushbutton

Press upper part = switch off rear fog light.
Press lower part = switch on rear fog light.
"Rotary beacon" switch *)

Press upper part = switch off rotary beacon.
Press lower part = switch on rotary beacon.
"Rear rotary beacon" switch *)

Press upper part = switch off rear rotary beacon.
Press lower part = switch on rear rotary beacon.
"Parking light / low beam light" switch

Rotation 0 = switch off light.
Rotation 1 = parking light.
Rotation 2 = low beam light.
"Battery main switch" switch

Press upper part = disconnect connection to battery.
Press lower part = establish connection to battery.
Switch with lockout: Press down to release the locking handle.

"Carrier operation/superstructure operation" key switch
Rotation 1 = carrier operation.
Rotation 2 = superstructure operation.
WFN3RUWW2K2064139
ATF 60G-3 59
2019-03_EN
Instrument panel 2
12 13 18 16 14 15 17 19 20 21
22 28
23 29
30
24 25 26 27
12 Service brake circuit I air pressure gauge 22 Service brake warning lamp
13 Service brake circuit II air pressure gauge 23 Parking brake warning lamp
14 Direction indicator pilot lamp 24 Engine fault warning buzzer
15 Trailer direction indicator *) pilot lamp 25 Speedometer with trip meter
16 Serious engine fault warning lamp 26 Gearbox fault warning buzzer
17 Minor engine fault warning lamp 27 Speed indicator
18 Fill level and quality monitoring of AdBlue® 28 Gearbox fault warning lamp
warning lamp
19 Operating restriction active warning lamp 29 Carrier central warning warning lamp
20 Engine temperature gauge 30 Steering or service brake fault, braking sys-
tem pressure drop warning *), slewing gear
lock-out for dolly *) warning buzzer
21 Fuel gauge
WFN3RUWW2K2064139
60 ATF 60G-3
2019-03_EN
Indicator and warning lamps

Safety notice
DANGER
Risk of accidents or damages on the vehicle if red warning lamp
lights up.
If one ore more warning lamps light up on the instrument panel, there is a
risk of accidents or damages on de mobile crane.
1. Stop the mobile crane as quickly as possible taking account of the
traffic situation, and park it in a safe place. Switch off the engine.
2. Determine the cause of the fault and rectify it immediately.
3. Do not operate de mobile crane again before the damage has not
been eliminated.
"Direction indicator" pilot lamp

Flashes = direction indicator is activated.
Flashes faster = defective flashing light.
"Trailer direction indicator" pilot lamp *)

Flashes = direction indicator is activated.
Flashes faster = defective flashing light.
"Gearbox fault" warning lamp

Is lit = gearbox fault.
"Serious engine fault" warning lamp

Is lit = serious engine fault.
"Minor engine fault" warning lamp

Is lit = minor engine fault.
"Fill level and quality monitoring of AdBlue®" warning lamp

Is lit = AdBlue filling level is low.
Flashes = start of operating restriction.
There can be an operating restriction when the warning lamp lights up.
For further information, refer to Aftertreatment of exhaust gases (SCR system).
"Operating restriction active" warning lamp
Flashes = start of operating restriction.
WFN3RUWW2K2064139
Flashes = serious operating restriction.
There can be an operating restriction when the warning lamp lights up.
For further information, refer to Aftertreatment of exhaust gases (SCR system).
ATF 60G-3 61
2019-03_EN
"Service brake" warning lamp

Is lit while driving = brake pressure is too low.
"Parking brake" warning lamp

Is lit = parking brake is engaged.
"Carrier central warning" warning lamp

Is lit = fault in the electronic system.
Checking devices
Air pressure gauge
The supply pressure of brake circuit I or II is displayed.
"Engine" temperature gauge

Engine coolant temperature is displayed.
Fuel gauge
Fill level of the fuel tank is displayed.
Speedometer with trip meter

The current driving speed is displayed.
The trip distance is displayed.
Speed indicator
The engine speed is displayed.
WFN3RUWW2K2064139
62 ATF 60G-3
2019-03_EN
Warning buzzers
Safety notice
DANGER
Risk of accidents or damages on the vehicle if buzzer sounds.
When the warning buzzer in the instrument panel sounds, there is a risk of
accidents or damages on the mobile crane.
1. Stop the mobile crane as quickly as possible taking account of the
traffic situation, and park it in a safe place. Switch off the engine.
2. Determine the cause of the fault and rectify it immediately.
3. Do not operate de mobile crane again before the damage has not
been eliminated.
"Engine fault" warning buzzer

Sounds = fault in the engine.
"Gearbox fault" warning buzzer

Sounds = fault in the gearbox.
"Steering or service brake fault, braking system pressure drop warning *), slewing gear
lock-out for dolly *)" warning buzzer
Sounds = steering or service brake fault, braking system pressure drop warning*)/ slewing gear
lock-out for dolly *).
WFN3RUWW2K2064139
ATF 60G-3 63
2019-03_EN
Instrument panel 3
34 35 36 37 38 39
40 41 42 43 44 45
58 59
46 47 48 49 50 51
60 62 63 64
52 53 54 55 56 57
61 65
WFN3RUWW2K2064139
34 Working floodlights on external mirrors *) 50 —

switch
35 — 51 —
36 — 52 Cancel operating restriction pushbutton
37 Driving level pushbutton 53 —
38 Front left-hand suspension cylinder push- 54 —
button
64 ATF 60G-3
2019-03_EN
39 Front right-hand suspension cylinder push- 55 Working speed / cruise control switch
button
40 Working floodlight on the outrigger switch 56 —
41 Change vehicle height pushbutton 57 Off-road mode ABS *) pushbutton
42 — 58 —
43 Axle suspension locking switch 59 Heating/ventilation/air conditioning system
control unit
44 Rear left-hand suspension cylinder push- 60 Starting/stopping engine pushbutton
button
45 Rear right-hand suspension cylinder push- 61 Ignition lock
button
46 Rear working floodlight *) switch 62 —
47 — 63 —
48 — 64 Hazard warning lights switch
49 Axle drive/differential locks pushbutton 65 Gearbox display
Switches and pushbuttons

"Working floodlights on external mirrors" switch *)
Press upper part = switch off working floodlights on the external mirrors.
Press lower part = switch on working floodlights on the external mirrors.
"Driving level" pushbutton

Press and hold upper part = bring mobile crane into driving level.
"Front left-hand suspension cylinder" pushbutton

Press and hold upper part = extend suspension cylinder.
Press and hold lower part = retract suspension cylinder.
"Front right-hand suspension cylinder" pushbutton

"Working floodlight on the outrigger" switch

Press upper part = switch off working floodlights on the outrigger.
Press lower part = switch on working floodlights on the outrigger.
WFN3RUWW2K2064139

"Change vehicle height" pushbutton
Press and hold upper part = lift all suspension cylinders.
Press and hold lower part = lower all suspension cylinders.
ATF 60G-3 65
2019-03_EN
"Axle suspension locking" switch

Press upper part = switch off axle suspension locking.
Press lower part = switch on axle suspension locking.

"Rear left-hand suspension cylinder" pushbutton
"Rear right-hand suspension cylinder" pushbutton

"Rear working floodlight" switch *)

Press upper part = switch off rear working floodlight.
Press lower part = switch on rear working floodlight.

"Axle drive/differential locks" pushbutton
Press lower part = switch on inter-wheel differential locks.
Press upper part = switch off differential locks.
"Cancel operating restriction" pushbutton

Press = operating restriction is cancelled.
NOTICE! The operating restriction can be cancelled a maximum of three times for
30 minutes.
"Working speed / cruise control" switch

Press upper part = switch off working speed and cruise control.
Press lower part = switch on working speed and cruise control.
"Off-road mode ABS" pushbutton

Press upper part = switch off ABS off-road mode.
Press lower part = switch on ABS off-road mode.
With the ABS off-road mode, you can reduce the braking distance off-road and on dirt roads.
WFN3RUWW2K2064139
"Starting/stopping engine" pushbutton

Press pushbutton = start engine.
Press pushbutton = switch off engine.
66 ATF 60G-3
2019-03_EN
"Hazard warning lights" switch

Press upper part = switch off hazard warning lights.
Press lower part = switch on hazard warning lights.
Checking devices
Gearbox display
The current gearbox status is displayed.
Miscellaneous
Ignition lock
Insert the ignition key: Ignition is switched on. The immobilizer is deactivated.
Remove the ignition key: Ignition is switched off. The immobilizer is activated.
Heating/ventilation/air conditioning system control unit

Regulates the following:
▪ Blower.
▪ Heating.
▪ Air switchover.
▪ Air regulation.
▪ Air conditioning system.
WFN3RUWW2K2064139
ATF 60G-3 67
2019-03_EN
4.4 Steering column switches
1 Left steering column switch 2 Right steering column switch
NOTICE! Switch positions of the steering column switch that are not described in the fol-
lowing are without any function.
Left steering column switch

Windshield wipers / windshield washers
Shift ring in position 0 = switch off windshield wipers.
Shift ring in position INT = intermittent operation.
Shift ring in position I = wipe slowly.
Shift ring in position II = wipe quickly.
Moving shift ring = switch on windshield washers.
High beam light / headlight flasher

Press steering column switch away from driver = switch on high beam light
WFN3RUWW2K2064139
(locking position).
Pull steering column switch towards driver = switch on headlight flasher.
68 ATF 60G-3
2019-03_EN
NOTICE! The low beam light must be switched on for high beam light operation.
Direction indicator
Push steering column switch up = switch on turn signal indicator on right
side of vehicle.
Push steering column switch down = switch on turn signal indicator on left
side of vehicle.
Signal horn
Push pushbutton on steering column switch = switch on signal horn.
Right steering column switch

Engine brake/Bremsomat
Position 0 = switch off engine brake / Bremsomat.
Position 1 = switch on engine brake and Bremsomat.
Position 2 = no function.
Engine brake / Bremsomat / eddy-current brake *)

Position 0 = switch off engine brake / Bremsomat / eddy-current brake.
Position 1 = switch on engine brake / Bremsomat.
Position 2 = switch on 25 % eddy-current brake and engine brake.
Cruise control
Position 1 = switch on cruise control.
WFN3RUWW2K2064139
ATF 60G-3 69
2019-03_EN
NOTICE! The Working speed / cruise control switch must be switched on for cruise con-
trol operation.
4.5 Carrier cab - shifting and driving
1 Safety belt 9 Side bordering light

2 Accelerator pedal 10 Rotary beacon
3 Brake pedal 11 Gear selector lever
4 Direction indicator 12 Operating elements Rear steering
5 Left steering column switch 13 Mirror adjustment
6 Steering wheel 14 Parking brake
7 Right steering column switch 15 On-board computer monitor
8 Speedometer 16 Navigation control
WFN3RUWW2K2064139
70 ATF 60G-3
2019-03_EN
4.6 Carrier cab - gear selector lever
Overview
1 Gear selector lever DM Forward maneuvering

2 Gear pre-selection switch D Forward driving
A Shift up gears N Neutral position
First spring position = shift up one gear
Stop spring position = shift up two gears
B Shift down gears R Reverse driving
First spring position = shift down one gear
Stop spring position = shift down two gears
M/A Toggle between manual/automatic driving RM Reverse maneuvering
modes
S —
WFN3RUWW2K2064139
ATF 60G-3 71
2019-03_EN
4.7 Carrier cab - Rear steering operating elements
1 Unlock rear steering switch 2 Manual rear steering to the right/left push-
button
4.8 Ignition key
Overview
WFN3RUWW2K2064139
1 Unfold/fold ignition key button 4 Lock carrier cab door pushbutton

2 Key 5 Unlock carrier cab door pushbutton
3 Ignition key 6 —
72 ATF 60G-3
2019-03_EN
Procedure – Unfolding
1. Press and hold the Unfold/fold ignition key button.
ð The key unfolds.
Procedure – Folding
1. Press and hold the Unfold/fold ignition key button.
2. Fold in the key.
ð The ignition key is folded.
Procedure – Unlocking
1. Press the Unlock carrier cab door pushbutton on the ignition key.
ð The door is unlocked.
Procedure – Locking
1. Press the Lock carrier cab door pushbutton on the ignition key.
ð The door is locked.
4.9 Working speed
4.9.1 Safety instructions
WARNING
Risk of accidents when driving with working speed.
If the engine runs at an increased and fixed speed when driving, the driv-
ing behaviour of the mobile crane can only be controlled to a certain ex-
tent. This may lead to accidents.
1. Before driving, reduce working speed to idling speed.
WFN3RUWW2K2064139
ATF 60G-3 73
2019-03_EN
4.9.2 Overview
1 Working speed / cruise control switch
NOTICE! Before changing the engine speed from the outrigger casings, the Working
speed mode must be activated.
4.9.3 Switching working speed on/off
Activating Working speed mode

1. Press Working speed / cruise control switch.
The maximum working speed is approx. 1800 rpm.
Deactivating Working speed mode

1. Press Working speed / cruise control switch.
4.10 Ladders
Overview
WFN3RUWW2K2064139
1 Swivelling ladders 2 Ladder, permanently attached
74 ATF 60G-3
2019-03_EN
4.11 Storage box-Timber storage
Overview
1 Storage box 2 Timber storage
4.12 Double ladder

A stepladder is provided with the mobile crane for carrying out mounting and maintenance activ-
ities on the jib. The ladder is provided under the carrier cab. If a storage box is mounted on the
carrier cab, the stepladder is located on the rear panel of the carrier.
DANGER
Risk of falling!
Improperly attached ladders and their improper use may pose the risk of
falling.
1. Place the ladder only on the plane and non-slippery surface having ad-
equate load-bearing capacity.
2. Check the stability.
WFN3RUWW2K2064139
3. Follow the accident prevention regulations when using ladders and ac-
cess steps.
ATF 60G-3 75
2019-03_EN
Overview
1 Angle bracket 5 Turnbuckle eye

2 Turnbuckle 6 Locating cramp
3 Lock tab 7 Padlock
4 Spring latch
Removing the stepladder:

1. Remove the padlock.
2. Turn the lock tab upwards by 180°.
3. Press the spring latch up.
4. Release the turnbuckle eye and lower the bracket.
5. Open the second turnbuckle.
6. Remove the stepladder.
Stowing and securing the stepladder
WARNING
WFN3RUWW2K2064139
Risk of accident!
If ladders come off when driving, they may result in serious accidents.
1. Check the ladders for secure fastening and firmness.
76 ATF 60G-3
2019-03_EN
1 Angle bracket 6 Locating cramp

2 Turnbuckle 7 Retaining plate
3 Lock tab 8 Top rung
4 Spring latch 9 Padlock
5 Turnbuckle eye
Stowing the stepladder:

1. Fold up the stepladder.
2. Mount the retaining plate on the top rung of the stepladder.
NOTICE! The retaining plate must face onwards.
3. Push the ladder into the rear part of the angle brackets.
NOTICE! The bars on the movable part of the brackets must rest against one of the
ladder's rungs in order to secure the ladder against shifting to the side.
4. Attach the turnbuckle eye at the top in the locating cramp.
5. Press the spring latch down
6. Turn the lock tab downwards by 180°.
7. Close and secure the second turnbuckle.
WFN3RUWW2K2064139
8. Attach the provided padlock into one of the two lock tabs and lock it.
ATF 60G-3 77
2019-03_EN
Fixing the ladders
1. Fold out the ladders completely and rest at a suitable position.

Remove and stow away the ladders in the logical reverse order.
4.13 Crank handle
1 Crank handle
Crank handle holders

WFN3RUWW2K2064139
1 Crank handle holders (3 ea.)
78 ATF 60G-3
2019-03_EN
4.14 Roller sun visor
Overview
1 Roller sun visor 2 Link
4.15 Rear area monitoring
Rear area monitoring

When engaging the reverse gear, the image of the rear view camera is displayed on the mon-
itor.
For further information, refer to “Camera view” menu [} page 107].
4.16 Asymmetrical outrigger base
Starting position
Introduction
Sometimes, it is not possible to fully extend all outrigger beams due to lack of space. The outrig-
ger beams extended to various lengths result in an asymmetrical outrigger base.
WFN3RUWW2K2064139
ATF 60G-3 79
2019-03_EN
Overview
Explanation
In the example, all outrigger beams of the mobile crane are extended differently using the per-
missible outrigger bases.
The automatic safe load indicator detects the position of the outrigger beams and enables the
load rating chart depending on the slewing angle of the superstructure.
In the case of an asymmetrical outrigger base, different load rating charts will apply along the
rotary movement of the superstructure.
When the mobile crane reaches the limit of the load rating chart while rotating with load in a de-
termined rigging status, the automatic safe load indicator switches over to another load rating
chart. Depending on the current load, the rotary movement of the superstructure might be
stopped.
WFN3RUWW2K2064139
80 ATF 60G-3
2019-03_EN
Movement range within load rating charts
Introduction
The following example shows the principle. Differences in number and type of the outrigger
bases are possible in the case of different crane types.
Overview
A Symmetrical, maximum possible outrigger 1 Direction of travel

base
B Symmetrical, half the outrigger base 2 Load rating chart corresponding to the out-
rigger base
WFN3RUWW2K2064139
C Asymmetrical outrigger base 3 Load rating chart depending on outrigger

base and slewing angle of the superstruc-
ture
4 Possible outrigger bases
5 Active outrigger bases
ATF 60G-3 81
2019-03_EN
Explanation
These examples shall be used to describe the function of the asymmetrical outrigger base.
Each type of crane has its own outrigger bases. This means that there are numerous possible
load rating charts.
The grey area represents the applicable range of the respective load rating chart, the thick bor-
dering the outer limit. At a cornerstone of the bordering, the crane control switches over to an-
other load rating chart.
Behaviour of the automatic safe load indicator
Introduction
In the following example, the switchover behaviour of the automatic safe load indicator when us-
ing an asymmetrical outrigger base is described generically. A certain load and a certain rigging
status are assumed. Only the rotary movement is considered.
On the basis of the active outrigger bases, the automatic safe load indicator determines the load
rating chart depending on the slewing angle of the superstructure.
Overview
1 Switchover point to lower load rating chart 2 Switchover point to higher load rating chart
Explanation
While rotating clockwise, the mobile crane reaches a switchover point at position 1. The auto-
matic safe load indicator switches over to another load rating chart with lower load. If the current
load exceeds the load of the lower load rating chart, the rotary movement of the superstructure
WFN3RUWW2K2064139
stops.
If necessary, the superstructure can be rotated beyond position 1 by adopting the following
measures:
▪ Raise the telescopic boom.
▪ Retract the telescopic boom.
▪ Put down the load.
82 ATF 60G-3
2019-03_EN
Continuing the clockwise rotation, the mobile crane reaches a further switchover point at posi-
tion 2. The automatic safe load indicator switches over to another load rating chart with higher
load. In this case, the rotary movement can continue unhindered; the telescopic boom can e.g.
be lowered.
WFN3RUWW2K2064139
ATF 60G-3 83
2019-03_EN
5 Operation of on-board computer
5.1 Description of function
Introduction
The mobile crane's carrier is equipped with a on-board computer.
The on-board computer consists of a monitor and operating elements.
Various monitoring and control functions are performed by the on-board computer.
NOTICE! The following numerical values are examples and are intended for illustrative
purposes only. The may vary from the original condition.
5.2 Overview of the operating elements
Overview
WFN3RUWW2K2064139
1 Main display 2 Navigation control
84 ATF 60G-3
2019-03_EN
Main display
Overview
11 12
13
1
2
3
10 9 8 7 6 5 4
1 Up button 8 Outrigger information button
2 Confirm selection or Service menu button. 9 Axle drive, differential locks, rear steering
button
3 Down button 10 One menu level back button
4 Menu selection button 11 Communication OK (green) indicator
5 Camera view button 12 Communication disturbed (red) indicator
6 Engine information button 13 Brightness sensor
7 Suspension button
Explanation
In the start menu, press the Service menu button and hold for 5 seconds to go to the Service
menu. For further information, refer to Menu "Service" [} page 119].
WFN3RUWW2K2064139
ATF 60G-3 85
2019-03_EN
Alternative operation of the main display
Overview
1
2
1 Button in the main display 2 Button in the frame
Explanation
The menus can be selected with both the buttons in the frame and the buttons in the main dis-
play.
WFN3RUWW2K2064139
86 ATF 60G-3
2019-03_EN
Navigation control
Introduction
Alternatively, the main display can be controlled via the Navigation Control.
Overview
1 2 3
4 5
1 Function key 1 – Menu change 4 Function key 4 – Tilt display upwards

2 Function key 2 – Acoustic alarm off 5 Function key 5 – Tilt display downwards
3 Function key 3 – Telescope 6 Pushbutton/rotary knob/tilt button
Explanation
The Navigation Control has five buttons and one pushbutton/rotary knob/tilt button.
The pushbutton/rotary knob/tilt button can be moved as follows:
▪ Tilting: changing between navigation area and submenu.
▪ Rotating: selection of buttons.
▪ Pressing: confirmation of selection.
WFN3RUWW2K2064139
ATF 60G-3 87
2019-03_EN
5.3 Layout of the main display
5.3.1 Overview
1 Status information 4 Display area of the front camera

2 Menu area 5 Status displays
3 Navigation area
The layout of the main display is as follows:

▪ Status information, see Status information [} page 89].
▪ Menu area.
▪ Navigation area, see Navigation area [} page 90].
▪ Display area of the front camera.
▪ Status displays, refer to Status displays [} page 92].
WFN3RUWW2K2064139
88 ATF 60G-3
2019-03_EN
5.3.2 Status information
Overview
1 2 34 9 5 6
2/17 W0 0032 7h 00103
E F
AdBlue AVG
7 8
1 Error count indicator 6 Menu number indicator

2 Error type indicator 7 Fuel and AdBlue fill levels indicator
3 Classification indicator 8 Fuel consumption indicator
4 Error number indicator 9 Carrier engine hour meter indicator
5 Warning lamps indicator
Indicators
"Message" indicator
17/17 W0 0032 The Message indicator shows messages.
Pressing the indicator will display a list with errors in the Crane information area.
"Pilot and warning lamps" display

The Pilot and warning lamps display shows the occurrence of errors.
WFN3RUWW2K2064139
For further information, refer to Indicator and warning lamps [} page 95].
“Menu number” indicator

00103 The Menu number indicator shows the number of the active menu.
By pressing the indicator and entering the menu number you can go to other menus.
ATF 60G-3 89
2019-03_EN
"Fuel consumption” indicator
AVG
The Fuel consumption indicator shows the fuel consumption in l since the last reset to
zero. For further information, see "Engine information" menu [} page 105].
“Fuel and AdBlue fill levels” indicator
AdBlue
E F The Fuel and AdBlue fill levels indicator shows the fill level of the fuel tank and of the Ad-
Blue tank in %.
The upper indicator shows the fill level of the fuel tank, the lower the fill level of the AdBlue
tank.
E = empty.
F = full.
"Carrier engine hour meter" indicator

_._ h The Carrier engine operating hours indicator shows the operating hours.
5.3.3 Navigation area
Overview
00000
B
WFN3RUWW2K2064139
1 2 3 4 5 6 7
1 One menu level back button 5 Engine information menu button
2 Axle drive, differential locks, rear steering 6 Camera view menu button
menu button
3 Outrigger information menu button 7 Other menus button
4 Suspension menu button
90 ATF 60G-3
2019-03_EN
Buttons
"One menu level back" button
Press button = go to the menu one level above.
"Axle drive, differential locks, rear steering menu" button

Press button = go to the Axle drive, differential locks, rear steering menu.
For further information, refer to "Axle drive, differential locks, rear steering" menu
[} page 99].
"Outrigger information menu" button

Press button = go to the Outrigger information menu.
For further information, refer to "Outrigger information" menu [} page 101].
"Suspension menu" button

Press button = go to Suspension menu.
For further information, refer to "Suspension" menu [} page 102].
"Engine information menu" button

i Press button = go to the Engine information menu.
For further information, refer to "Engine information" menu [} page 105].
"Camera view menu" button

Press button = go to the Camera view menu.
For further information, refer to “Camera view” menu [} page 107].
Note: Pressing the Camera view button again changes the displays of the cameras.
"Other menus" button

Press button = go to the Other menus menu.
For further information, refer to “Other menus” menu [} page 108].
B
WFN3RUWW2K2064139
ATF 60G-3 91
2019-03_EN
5.3.4 Status displays
Overview
1
1 Indicator and warning lamps
Indicator and warning lamps

The following pilot and warning lamps are shown in the order of occurrence.
"Cruise control" pilot lamp
Is lit green = cruise control is switched on and active.
"Boom raised" pilot lamp

Is lit = telescopic boom is not in boom rest.
"Axle oscillation" pilot lamp

WFN3RUWW2K2064139
Is lit = axle oscillation is switched on.
"Upshift lock" pilot lamp
4+
Is lit = upshift lock is switched on.
Note: Gearbox shifts up only to the third gear.
92 ATF 60G-3
2019-03_EN
"Axle suspension locking" pilot lamp

Is lit yellow = axle suspension locking terminated successfully.
Is lit blue = axle suspension is not entirely locked.
"Superstructure operation" pilot lamp

Is lit = superstructure operation function is active.
"Levelling" pilot lamp

Is lit yellow = levelling terminated successfully.
LEVEL
"High beam light" pilot lamp

Is lit = high beam light is activated.
"Centralized lubrication system" warning lamp

Is lit = fault in centralized lubrication system.
"ABS trailer" *) warning lamp

Is lit = failure of the ABS trailer components.
However, the functional safety of the pneumatic braking system is fully maintained.
"Mobile crane ABS" warning lamp

Flashes = ABS off-road mode is active.
"Starting/stopping engine" warning lamp

Is lit = key is not recognized. Immobilizer is active. Engine cannot be started.
"Rear fog light" pilot lamp

Is lit = rear fog light is activated.
“Windshield washer system fill level” warning lamp

Is lit = fill level of windshield washer system is too low.
"Inter-axle lock blocked" pilot lamp

Is lit = All inter-axle locks are blocked.
"Inter-wheel differential locks blocked" pilot lamp

WFN3RUWW2K2064139
Is lit = all inter-wheel differential locks are blocked.
"All differential locks blocked" pilot lamp

Is lit = all inter-axle and inter-wheel differential locks are blocked.
ATF 60G-3 93
2019-03_EN
"Superstructure locked" pilot lamp

Is lit = superstructure is locked.
"Superstructure locked" pilot lamp

Is lit = superstructure is locked.
"Eddy-current brake" pilot lamp

Is lit = eddy-current brake is activated.
"Fog lights" pilot lamp

Is lit = fog lights are switched on.
"AdBlue tank heating" *) pilot lamp

Is lit = heating of the AdBlue tank is switched on.
"Rear steering unlocked" pilot lamp

Is lit yellow = construction-site mode active.
Is lit red = error.
WFN3RUWW2K2064139
94 ATF 60G-3
2019-03_EN
5.3.5 Indicator and warning lamps

1
2/17 W0 0032 7h 00103
E F
AdBlue AVG
1 Pilot and warning lamps display
The following error symbols are shown in the order of occurrence.

"Sensor error" warning lamp
Is lit = an error has occurred.
"CAN error" warning lamp

Is lit = general communication error (CAN bus) has occurred.
"Engine oil level" warning lamp

Is lit yellow = engine oil level is low.
Is lit red = engine oil level is too low. Low level threshold is reached.
"Engine oil pressure" warning lamp

WFN3RUWW2K2064139
Is lit = engine oil pressure is too low.
"Emergency steering pump" warning lamp

Is lit when switching the ignition on = function check.
Is lit permanently = an error has occurred.
ATF 60G-3 95
2019-03_EN
“Coolant and coolant level” warning lamp

Is lit = an error has occurred.
"Parking brake" warning lamp

Is lit = parking brake is engaged.
"Air cleaner" warning lamp

Is lit = air cleaner is contaminated.
"Brake lining wear" warning lamp

Is lit = brake linings are worn out.
"Hydraulic oil filter" warning lamp

Is lit = hydraulic oil filter is contaminated.
"Hydraulic oil level" warning lamp

Is lit = hydraulic oil level is too low.
"Hydraulic oil temperature" warning lamp

Is lit = hydraulic oil temperature is too high.
“Immobilizer error” warning lamp

Is lit = an error is present in the immobilizer.
"Fuel tank fill level" warning lamp

Is lit = fuel tank level is too low. Low level threshold is reached.
"Air pressure gauge" warning lamp

Flashes red = supply pressure of brake circuit 1 and/or 2 has dropped below 6.5 bar.
Is lit red = supply pressure of brake circuit 1 and/or 2 has dropped below 5.5 bar.
"Tyre pressure monitoring system" warning lamp *)

Is lit = tyre pressure too low.
"Rear steering unlocked" pilot lamp

WFN3RUWW2K2064139
Is lit yellow = construction-site mode active.

Is lit red = error.
96 ATF 60G-3
2019-03_EN
5.3.6 Navigation in a menu
Overview
1 Status information 4 Display area of the front camera

2 Menu area 5 Status displays
3 Navigation area
The layout of the main display is as follows:

▪ Status information, see Status information [} page 89].
▪ Menu area.
▪ Navigation area, see Navigation area [} page 90].
▪ Display area of the front camera.
▪ Status displays, refer to Status displays [} page 92].
The menu area’s layout is as follows:

WFN3RUWW2K2064139
▪ "Axle drive, differential locks, rear steering" menu [} page 99].

▪ "Outrigger information" menu [} page 101].
▪ "Suspension" menu [} page 102].
▪ "Engine information" menu [} page 105].
▪ “Camera view” menu [} page 107].
▪ “Other menus” menu [} page 108].
ATF 60G-3 97
2019-03_EN
▪ "Error messages" menu [} page 110].

▪ "Software and hardware information" menu [} page 111].
▪ "User settings" menu [} page 112].
Buttons
The following buttons are of general importance and appear in the individual menus, as the situ-
ation requires.
"One page up" button
Press button = menu moves one page up.
"One page down" button

Press button = menu moves one page down.
"Confirm" button
Press button = confirm and save selection.
Note: All changes must be saved with the Confirm button.
WFN3RUWW2K2064139
98 ATF 60G-3
2019-03_EN
5.4 "Axle drive, differential locks, rear steering" menu
Introduction
You will automatically go the menu when pressing the following pushbutton on the instrument
panel:
▪ Axle drive/differential locks pushbutton.
An automatic change to this menu can be activated and deactivated in the Automatic menu
change menu. For further information, refer to “Automatic menu change” setting [} page 114].
Overview
1 2 3
00101
00s
-20º
6 5 4
1 Remaining period of inter-wheel differential 4 Steering angle indicator
locks indicator
2 Inter-axle differential locks pilot lamp 5 Differential locks indicator
WFN3RUWW2K2064139
3 Inter-wheel differential locks pilot lamp 6 Axle drive indicator
NOTICE! The pilot lamps or warning lamps are shown in the order of occurrence.
ATF 60G-3 99
2019-03_EN
Indicators and lamps

"Remaining period of inter-wheel differential locks" indicator
The Remaining period of inter-wheel differential locks indicator shows the remaining period
00s of activated inter-wheel differential locks.
"Inter-axle differential locks" pilot lamp

The Inter-axle differential locks pilot lamp shows the activated inter-axle differential locks.
"Inter-wheel differential locks" pilot lamp

The Inter-wheel differential locks pilot lamp shows the activated inter-wheel differential
locks.
"Differential locks" indicator

The Differential locks indicator shows the activated or deactivated differential locks.
Cross = engaged.
Empty circle = switched off.
"Axle drive" indicator

The Axle drive indicator shows the driven or not driven axle drive.
Filled circle = driven.
Non-filled circle = not driven.
"Steering angle" indicator

10° The Steering angle indicator shows the steering angle.
WFN3RUWW2K2064139
100 ATF 60G-3

2019-03_EN
5.5 "Outrigger information" menu
Overview
1 2 3 4 5 6 7 8
10º 0º -12º 00102

-20º
2.75 8 20 0.00
m t t m
0.1 º
F Re
-0.1 º
m 16 117 m
2.72 t t 0.00
12 11 10 9
1 Mobile crane longitudinal and lateral inclin- 7 Outrigger pressure, rear right indicator
ation indicator
2 CAN error warning lamp 8 Outrigger base, rear right indicator
3 Sensor error warning lamp 9 Outrigger base, rear left indicator
4 Outrigger base, front right indicator 10 Outrigger pressure, rear left indicator
5 Outrigger pressure, front right indicator 11 Outrigger pressure, front left indicator
6 Circular spirit level 12 Outrigger base, front left indicator
WFN3RUWW2K2064139
ATF 60G-3 101

2019-03_EN
5.6 "Suspension" menu
Introduction
You will automatically go the Suspension menu when pressing the following switch or pushbut-
ton on the instrument panel:
▪ Axle suspension locking switch.
▪ Rear left-hand suspension cylinder pushbutton.
▪ Rear right-hand suspension cylinder pushbutton
▪ Front left-hand suspension cylinder pushbutton.
▪ Front right-hand suspension cylinder pushbutton.
▪ Change vehicle height pushbutton.
WFN3RUWW2K2064139
102 ATF 60G-3

2019-03_EN
Overview
1 2 3 4 5 6
00103
LEVEL
8 7
1 Axle suspension locking pilot lamp 5 —

2 — 6 —
3 Axle oscillation pilot lamp 7 Axle suspension locking indicator
Yellow and empty = locked
Green and filled = not locked
4 Mobile crane levelled pilot lamp 8 Axle oscillation indicator
Yellow = axles oscillating
Green = axles not oscillating
WFN3RUWW2K2064139
ATF 60G-3 103

2019-03_EN
5.6.1 Tyre pressure monitoring system *)
Overview
1 2 3
1 Tyre fill colour Green 3 Tyres without fill colour

2 Tyre fill colour Red
Checking the tyre pressure

1. Press the Suspension menu button.
ð The fill colour of the wheels displays the pressure of the respective tyre.
▪ Fill colour Green: tyre pressure is in order.
▪ Fill colour Yellow: minor pressure error; reduce the speed and adjust the tyre pressure as
soon as possible.
▪ Fill colour Red: serious pressure error; stop the mobile crane immediately at a secure
place, check the tyre, and correct the error.
▪ Without fill colour: transmission disturbed or empty battery in the tyre module. Refer to
Changing wheel module for air pressure display *) [} page 367]. WFN3RUWW2K2064139
104 ATF 60G-3

2019-03_EN
5.7 "Engine information" menu
Overview
00104
1
11
32 %
_ ºC
10
-.- %
-.- l 2
9 -.- kmh -.- v 3
8 _ 4
-.- %
_._ h
7 _._ h _._ l
5
32 % 6
1 Hydraulic oil temperature indicator 7 Carrier engine hour meter indicator

2 Engine oil refill quantity indicator 8 Engine speed indicator
3 Battery voltage indicator 9 Set driving speed (cruise control) indicator
4 Accelerator pedal position indicator 10 Engine oil level indicator
5 Drive time and fuel consumption day 11 Hydraulic oil level indicator
counter indicator
6 Reset drive time and fuel consumption day
counter indicator to zero button
Indicators
"Hydraulic oil temperature" indicator
_ ºC The Hydraulic oil temperature indicator shows the temperature of the hydraulic oil.
"Engine oil refill quantity" indicator

WFN3RUWW2K2064139
-.- l The Engine oil refill quantity indicator shows the refill quantity for engine oil.
A positive display means overfilled. A negative display means overfilled.
"Battery voltage" indicator

-.- v The Battery voltage indicator shows the voltage of the battery.
ATF 60G-3 105

2019-03_EN
"Accelerator pedal position" indicator

-.- % The Accelerator pedal position indicator shows the position of the accelerator pedal.
"Drive time and fuel consumption day counter" indicator

_._
_._
h
l The Drive time and fuel consumption day counter indicator shows the drive time and the
fuel consumption.
"Carrier engine hour meter" indicator

_._ h The Carrier engine operating hours indicator shows the operating hours.
"Engine speed" indicator

The Engine speed indicator shows the speed of the engine.
n/min
"Set driving speed (cruise control)" indicator

-.- kmh The Set driving speed (cruise control) indicator shows the driving speed set in the cruise
control. If the cruise control is active, the speed currently driven is displayed.
"Engine oil level" indicator
-.- %
The Engine oil level indicator shows the engine's oil level approx. 1 minute after engine is
switched off.
"Hydraulic oil level" indicator

32 % The Hydraulic oil level indicator shows the oil level of the hydraulic oil tank.
Button
"Reset drive time and fuel consumption day counter indicator to zero" button
Press button = the Drive time and fuel consumption indicators are reset to zero.
WFN3RUWW2K2064139
106 ATF 60G-3

2019-03_EN
5.8 “Camera view” menu
Introduction
The camera image from the rear view camera is displayed in the menu area when reverse gear
is engaged. The camera image of the front camera moves to the left and downward into the dis-
play area of the front camera.
Pressing the Camera view button changes the displays of the cameras.
Overview
00105
1 2 3
1 Camera image from the front camera 3 Camera view menu button
2 Camera image from the reversing camera
Note: The camera image of the front camera is displayed up to a speed of 10 km/h.
WFN3RUWW2K2064139
ATF 60G-3 107

2019-03_EN
5.9 “Other menus” menu
Overview
1 2 3
00106
1 Error messages menu 3 Software and hardware information menu

2 User settings menu
Buttons
"Error messages menu" button
Press button = go to the Error messages menu.
For further information, refer to "Error messages" menu [} page 110].
"User settings menu" button

WFN3RUWW2K2064139
Press button = go to the User settings menu.

For further information, refer to "User settings" menu [} page 112].
108 ATF 60G-3

2019-03_EN
"Software and hardware information menu" button

Press button = go to Software and hardware information menu.
For further information, refer to "Software and hardware information" menu [} page 111].
WFN3RUWW2K2064139
ATF 60G-3 109

2019-03_EN
5.10 "Error messages" menu
Overview
00261
1 2 3
1 Error message list indicator 3 One page down button

2 One page up button
Indicators and buttons

"Error message list" indicator
The error message list shows an error with a symbol, an error code and a brief description.
The errors are sorted according to priority. The most important errors are at the top.
"One page up" button

Press button = menu moves one page up.
WFN3RUWW2K2064139
"One page down" button

Press button = menu moves one page down.
110 ATF 60G-3

2019-03_EN
5.11 "Software and hardware information" menu
Overview
1 2
00263
Software Version
...
Hardware-Information - Display
...
4 3
1 Software version indicator 3 One page down button

2 Hardware information indicator 4 One page up button
WFN3RUWW2K2064139
ATF 60G-3 111

2019-03_EN
5.12 "User settings" menu
5.12.1 Overview
00262
User Settings
Start to front camera ON OFF 1
Automatic Mask Change

Differentials ON OFF
2
Rear View Camera ON OFF
Suspension ON OFF
Shortcuts
Button 1 Page 101 - Differentials
Button 2 None 3
Button 3 None
Button 4 None
AUTO
5 4
1 Front camera start menu setting 4 Confirm button
2 Automatic menu change setting 5 Brightness setting
3 Navigation control button assignment set-
ting
Settings and buttons

“Front camera start menu” setting
Start to front camera ON OFF
Change the automatic display of the camera image of the front camera.
For further information, refer to “Front camera start menu” setting [} page 113].
“Automatic menu change” setting

Differentials
Rear View Camera
Suspension
ON
ON
ON
OFF
OFF
OFF
Change automatic menu change.
For further information, see “Automatic menu change” setting [} page 114].
WFN3RUWW2K2064139
“Navigation control button assignment” setting

Shortcuts
Button 2 None
Button 3 None
Button 4 None
Change button assignment of the navigation control.
For further information, see “Navigation control button assignment” setting [} page 116].
112 ATF 60G-3

2019-03_EN
Menu "Brightness"
Changing the brightness of the display.
AUTO
For further information, see “Brightness” setting [} page 118].
"Confirm" button
Press button = confirm and save selection.
Note: All changes must be saved with the Confirm button.
5.12.2 “Front camera start menu” setting
Overview
Start to front camera ON OFF
1 2
1 Front camera start menu indicator 2 Front camera start menu button

"Front camera start menu" button
Press button = activate or deactivate front camera start menu.
"Front camera start menu" indicator

ON OFF
The Front camera start menu indicator changes between ON and OFF.
In the case of the ON position, the camera image of the front camera will be displayed in
the menu area when starting the on-board computer.
WFN3RUWW2K2064139
ATF 60G-3 113

2019-03_EN
5.12.3 “Automatic menu change” setting
Introduction
You can switch the automatic menu change on and off in case of the following menus:
▪ "Axle drive, differential locks, rear steering" menu [} page 99].
▪ “Camera view” menu [} page 107].
▪ "Suspension" menu [} page 102].
Overview

Differentials ON OFF
Rear View Camera ON OFF
Suspension ON OFF
1 2 3 4 5 6
1 Axle drive, differential locks, rear steering 4 Axle drive, differential locks, rear steering
indicator button
2 Camera view indicator 5 Camera view button
3 Suspension indicator 6 Suspension button
Buttons
"Axle drive, differential locks, rear steering" button
Press button = activate or deactivate the automatic Axle drive, differential locks, rear steer-
ing menu change.
"Camera view" button

Press button = activate or deactivate automatic Camera view menu change.
"Suspension" button
Press button = activate or deactivate automatic Suspension menu change.
Indicators
"Axle drive, differential locks, rear steering" indicator
ON OFF
The indicator changes between ON and OFF.
In the case of the ON position, when pressing the Axle drive/differential locks pushbutton,
the menu will automatically change to the Axle drive, differential locks, rear steering menu,
refer to "Axle drive, differential locks, rear steering" menu [} page 99].
WFN3RUWW2K2064139
"Camera view" indicator

ON OFF
In the case of the ON position, the camera image of the rear view camera will be displayed
in the menu area when reverse gear is engaged.
114 ATF 60G-3

2019-03_EN
"Suspension" indicator
ON OFF
In the case of ON position, the menu automatically changes to the Suspension menu when
pressing the following pushbuttons, refer to "Suspension" menu [} page 102]:
▪ Axle suspension locking.
▪ Front left-hand suspension cylinder.
▪ Front right-hand suspension cylinder.
▪ Rear left-hand suspension cylinder.
▪ Rear right-hand suspension cylinder.
▪ Axle oscillation.
Operation example
1. Press the Change automatic menu change button next to the desired function.
ð The setting in the Automatic menu change display area changes.
2. Save the selection with the Confirm button.
ð The change of the automatic menu change is stored.
WFN3RUWW2K2064139
ATF 60G-3 115

2019-03_EN
5.12.4 “Navigation control button assignment” setting
Introduction
Different menus can be assigned to the function keys 1 to 4 of the navigation control.
Pressing the function key selects the preassigned menu.
Overview
Navigation control
1 2 3
4
1 Function key 1 (Button 1) 3 Function key 3 (Button 3)
2 Function key 2 (Button 2) 3 Function key 4 (Button 4)
Navigation control button assignment
Shortcuts
Button 2 None
Button 3 None
Button 4 None
A B 1 C
A Function keys display area 1 Reassign function key button
B Function keys assignment display area
C Function keys reassignment button area
Button
WFN3RUWW2K2064139
"Reassign function key" button

Press button = change assignment of the adjacent function key.
Operation example
1. Press the Reassign function key button until the desired menu appears in the Function key
assignment display area.
116 ATF 60G-3

2019-03_EN
2. Save the selection with the Confirm button.

ð The function key assignment is changed.
WFN3RUWW2K2064139
ATF 60G-3 117

2019-03_EN
5.12.5 “Brightness” setting
Overview
AUTO

"Minus" button
Press button = reduce value.
"Brightness Display AUTO" indicator

Press button = automatic brightness setting of the main display.
A sensor will automatically set the brightness of the main display according to the bright-
AUTO
ness of the surroundings.
"Plus" button
Press button = increase value.
WFN3RUWW2K2064139
118 ATF 60G-3

2019-03_EN
5.13 Menu "Service"
Overview
00109
Service Menu
Enter Service Key :
OCD
Update
I/0
4 3 2 1
1 Engine fault menu button 3 —

2 Tyre pressure menu button 4 —
Buttons
"Engine fault menu" button
Press button = go to the Engine fault menu.
For further information, refer to "Engine fault" menu [} page 120].
WFN3RUWW2K2064139
"Tyre pressure menu" button

Press button = go to the Tyre pressure menu.
For further information, refer to "Tyre pressure" menu [} page 121].
ATF 60G-3 119

2019-03_EN
5.13.1 "Engine fault" menu
Overview
00293
Active Controller: CPC4 - Engine1

SPN FMI OC SPN FMI OC
6 5 4 3 2
1 Active control unit indicator 4 Error rate indicator

2 Change control unit button 5 Error type indicator
3 Change control unit button 6 Error category indicator
Indicators
"Active control unit" indicator
Active Con- The Active control unit indicator shows the active control unit.
troller
"Error rate" indicator

WFN3RUWW2K2064139
OC The Error rate indicator shows the frequency of the error since switching on the ignition.
"Error type" indicator

FMI The Error type indicator shows the error type.
"Error category" indicator

SPN The Error category indicator shows the error category.
120 ATF 60G-3

2019-03_EN
Buttons
"Change control unit" buttons
Press buttons = the menu scrolls to the previous or the next control unit.
5.13.2 "Tyre pressure" menu
Overview
00267
Pressure: _._ _._

Temperature: _._ _._
Pressure: _._ _._

Pressure: _._ _._

Pressure:
Temperature:
Pressure:
Temperature:
2 1
1 Display Symbol 2 Tyre parameters indicator

WFN3RUWW2K2064139
Indicators
"Tyre parameters" indicator
Pressure: The Tyre parameters indicator shows the tyre pressure and the tyre temperature.
Temperat-
ure:
ATF 60G-3 121

2019-03_EN
"Display symbols"
The display symbols show information and error messages on the respective tyre.
Lights up green = tyre pressure is in order.
Lights up yellow = minor pressure fault.
Lights up red = serious pressure fault.
Lights up red = Communication error.
Display Symbol
Overview
1
Pressure: 2
Temperature:
3
Pressure:
Temperature: 4
5
Pressure:
Temperature: 6
1 Left-hand Axle 1 tyre parameters indicator 4 Right-hand Axle 2 tyre parameters indic-
ator
2 Right-hand Axle 1 tyre parameters indic- 5 Left-hand Axle 3 tyre parameters indicator
ator
ator
WFN3RUWW2K2064139
122 ATF 60G-3

2019-03_EN
Tyre parameters
Overview
1
Pressure: _._ _._
_._ _._ 2
Temperature:
3
Pressure: _._ _._
Temperature: _._ _._ 4
5
Pressure: _._ _._
Temperature: _._ _._ 6
ator
2 Right-hand Axle 1 tyre parameters indic- 5 Left-hand Axle 3 tyre parameters indicator
ator
ator
5.14 Messages, pilot and warning lamps
5.14.1 Messages
Errors of components
Desig- Component name Description, Function
nation
WFN3RUWW2K2064139
00 0000 B613 Outrigger system SP sensor piston chamber FR: SC

00 0001 B613 Outrigger system SP sensor piston chamber FR: CB
00 0002 B609 Outrigger system SP sensor piston chamber FL: SC
00 0003 B609 Outrigger system SP sensor piston chamber FL: CB
00 0004 B611 Outrigger system SP sensor piston chamber RL: SC
00 0005 B611 Outrigger system SP sensor piston chamber RL: CB
ATF 60G-3 123

2019-03_EN

nation
00 0006 B615 Outrigger system SP sensor piston chamber RR: SC
00 0007 B615 Outrigger system SP sensor piston chamber RR: CB
00 0008 B614 Outrigger system SP sensor annulus FR: SC
00 0009 B614 Outrigger system SP sensor annulus FR: CB
00 0010 B610 Outrigger system SP sensor annulus FL: SC
00 0011 B610 Outrigger system SP sensor annulus FL: CB
00 0012 B612 Outrigger system SP sensor annulus RL: SC
00 0013 B612 Outrigger system SP sensor annulus RL: CB
00 0014 B616 Outrigger system SP sensor annulus RR: SC
00 0015 B616 Outrigger system SP sensor annulus RR: CB
00 0016 K120 Outrigger system Bordering light outrigger: CB
00 0017 K120 Outrigger system Bordering light outrigger: SC
01 0000 B016 Brake Sensor brake circuit 1: CB
01 0001 B016 Brake Sensor brake circuit 1: SC
01 0002 B019 Brake Sensor brake circuit 2: CB
01 0003 B019 Brake Sensor brake circuit 2: SC
01 0004 A015 Hydraulics Fill level sensor hydraulic oil: CB
01 0005 A015 Hydraulics Fill level sensor hydraulic oil: SC
01 0006 A015 Hydraulics Temperature sensor hydraulic oil: CB
01 0007 A015 Hydraulics Temperature sensor hydraulic oil: SC
01 0008 J1939 Communication CAN bus: conn. to engine bus J1939
lost
01 0009 B016 Brake Brake circuit 1: Pressure < 5.5 bar
01 0011 A020 Dolly Stop immediately! Dolly incorrect
01 0012 A502 Steering Steering: rear steering reports error
01 0013 S039 Steering Steering: steer pump active eng run-
ning
01 0014 S040 Steering Steer: emerg steer pump 1 act veh
stat
01 0015 S522 Steering Steer: emerg steer pump 2 act veh
stat
01 0016 S039 Steering Steering: steer pump inact eng run-
ning
01 0017 A020 PTO Error PTO conn. lift. plat. op.: code 1
WFN3RUWW2K2064139
01 0024 A020 Platform Error PTO conn. lift. plat. op.: code 8
124 ATF 60G-3

2019-03_EN

nation
01 0031 A020 Suspension Lift axle: axle not lifted
01 0032 A020 Suspension Lift axle: error lowering axle
01 0033 A020 Suspension Lift axle: error lifting axle
01 0034 A020 Suspension Lift axle: error in program sequence
02 0000 Y031 Hydraulics Hydraulic valve: cable break
02 0001 Y031 Hydraulics Hydraulic valve: Short-circuit
02 0002 Y033 Hydraulics Hydraulic valve: cable break
02 0003 Y033 Hydraulics Hydraulic valve: Short-circuit
02 0004 B515 Instrument panel Warning buzzer: cable break
02 0005 B515 Instrument panel Warning buzzer: Short-circuit
02 0006 E010 Lighting Daytime running light: cable break
02 0007 E010 Lighting Daytime running light: short-circuit
02 0008 K008 Lighting Rear fog light: cable break
02 0009 K008 Lighting Rear fog light: short-circuit
02 0010 K061 Instrument panel Warn. lamp central warning: cable
break
02 0011 K061 Instrument panel Warn. lamp central warning: SC
02 0012 K001 Electrical system Relay ignition: cable break
02 0013 K001 Electrical system Relay ignition: short-circuit
02 0014 K006 Lighting Relay fog lamp: cable break
02 0015 K006 Lighting Relay fog lamp: short-circuit
02 0016 K009 Lighting Relay hazard warning lights: CB
02 0017 K009 Lighting Relay hazard warning lights: SC
02 0018 K012 Electrical system Relay signal horn: cable break
02 0019 K012 Electrical system Relay signal horn: short-circuit
02 0020 K013 Instrument panel Relay battery main switch: CB
02 0021 K013 Instrument panel Relay battery main switch: SC
02 0022 K035/ Electrical system Relay self-retaining: CB
K036
02 0023 K035/ Electrical system Relay self-retaining: SC
K036
02 0024 K044 Cruise control Relay speed/cruise control minus: CB
02 0025 K044 Cruise control Relay speed/cruise control minus: SC
02 0026 K045 Cruise control Relay speed/cruise control plus: CB
02 0027 K045 Cruise control Relay speed/cruise control plus: SC
02 0028 K066 Lighting Relay working floodlights left: CB
02 0029 K066 Lighting Relay working floodlights left: SC
WFN3RUWW2K2064139
02 0030 K067 Lighting Relay working floodlights right: CB

02 0031 K067 Lighting Relay working floodlights right: SC
02 0032 K101 Brake Relay ABS off-road mode: CB
02 0033 K101 Brake Relay ABS off-road mode: SC
02 0036 S016 Instrument panel Supply switch transfer case: CB
02 0037 S016 Instrument panel Supply switch transfer case: SC
ATF 60G-3 125

2019-03_EN

nation
02 0038 Y007 Drive Request inter-wheel diff. locks: CB
02 0039 Y007 Drive Request inter-wheel diff. locks: SC
02 0040 Y0XX Drive Request inter-axle diff. locks: CB
02 0041 Y0XX Drive Request inter-axle diff. locks: SC
02 0042 Y111 AMOT AMOT-Control shut-off valve: CB
02 0043 Y111 AMOT AMOT-Control shut-off valve: SC
02 0046 B011 Fuel Fill level sensor fuel: CB
02 0047 B011 Fuel Fill level sensor fuel: SC
02 0048 S439 Suspension Length measurement suspension FR:
CB
02 0049 S439 Suspension Length measurement suspension FR:
SC
02 0050 S440 Suspension Length measurement suspension RR:
CB
02 0051 S440 Suspension Length measurement suspension RR:
SC
02 0052 S438 Suspension Length measurement suspension RL:
CB
02 0053 S438 Suspension Length measurement suspension RL:
SC
02 0054 A020 Communication CAN bus: conn. to cent. cont. sys. lost
02 0055 A040 Communication CAN bus: connect. to main display
lost
02 0056 D613 Communication CAN bus: connect. to IO node lost
02 0062 D0XX Communication CAN bus: connect. to IO node lost
02 0063 D611 Communication CAN bus: comm lost outrig ctrl pan
right
02 0064 D610 Communication CAN bus: comm lost outrig ctrl pan
left
02 0065 A965 Communication CAN bus: connect. superstructure lost
02 0066 A049 Immobilizer Immobilizer: communication error
02 0067 A049 Immobilizer Immobilizer: antenna error
02 0068 A049 Immobilizer Immobilizer: invalid data received
02 0069 A049 Immobilizer Immobilizer: invalid key received
WFN3RUWW2K2064139

02 0072 K004 Drive Generator: inactive, engine running
02 0073 K004 Drive Generator: active, engine not running
02 0074 S001 Drive Check wiring of start/stop pushbutton
02 0075 A007 Communication CAN bus comm lost to Navigation-
Control
02 0076 A020 Platform CAN bus comm lost to lifting platform
126 ATF 60G-3

2019-03_EN

nation
03 0000 Y038 Brake Valve axle 3 unbraked: CB
03 0001 Y038 Brake Valve axle 3 unbraked: SC
03 0002 Y139 Emergency control Valve emerg. supply superstructure:
CB
03 0003 Y139 Emergency control Valve emerg. supply superstructure:
SC
03 0004 Y401 Suspension Lower mobile crane FL: CB
03 0005 Y401 Suspension Lower mobile crane FL: SC
03 0006 Y402 Suspension Raise mobile crane FL: CB
03 0007 Y402 Suspension Raise mobile crane FL: SC
03 0008 Y403 Suspension Lower mobile crane RL: CB
03 0009 Y403 Suspension Lower the mobile crane RL: SC
03 0010 Y404 Suspension Raise mobile crane RL: CB
03 0011 Y404 Suspension Raise mobile crane RL: SC
03 0012 Y405 Suspension Lower mobile crane FR: CB
03 0013 Y405 Suspension Lower mobile crane FR: SC
03 0014 Y406 Suspension Raise mobile crane FR: CB
03 0015 Y406 Suspension Raise mobile crane FR: SC
03 0016 Y407 Suspension Lower mobile crane RR: CB
03 0017 Y407 Suspension Lower the mobile crane RR: SC
03 0018 Y408 Suspension Raise mobile crane RR: CB
03 0019 Y408 Suspension Raise mobile crane RR: SC
03 0020 Y411 Suspension Axle suspension locking: CB
03 0021 Y411 Suspension Axle suspension locking: SC
03 0022 Y412 Suspension Axle oscillation: Cable break
03 0023 Y412 Suspension Axle oscillation: Short-circuit
03 0024 Y415 Suspension Valve axle balance axle 3: CB
03 0025 Y415 Suspension Valve axle balance axle 3: SC
03 0026 Y438 Suspension Raise axles: cable break
03 0027 Y438 Suspension Raise axles: short-circuit
03 0028 Y440 Suspension Hold axles: cable break
03 0029 Y440 Suspension Hold axles: short-circuit
03 0030 Y45X Suspension Valve axle 3 depressurised: CB
03 0031 Y45X Suspension Valve axle 3 depressurised: SC
03 0032 Y602 Outrigger system Extend outrigger beam RR: CB
03 0033 Y602 Outrigger system Extend outrigger beam RR: SC
03 0034 Y603 Outrigger system Retract outrigger beam RR: CB
03 0035 Y603 Outrigger system Retract outrigger beam RR: SC
03 0036 Y604 Outrigger system Extend outrigger float RR: CB
WFN3RUWW2K2064139
03 0037 Y604 Outrigger system Extend outrigger float RR: SC

03 0038 Y605 Outrigger system Retract outrigger float RR: CB
03 0039 Y605 Outrigger system Retract outrigger float RR: SC
03 0040 Y606 Outrigger system Extend outrigger beam RL: CB
03 0041 Y606 Outrigger system Extend outrigger beam RL: SC
03 0042 Y607 Outrigger system Retract outrigger beam RL: CB
ATF 60G-3 127

2019-03_EN

nation
03 0043 Y607 Outrigger system Retract outrigger beam RL: SC
03 0044 Y608 Outrigger system Extend outrigger float RL: CB
03 0045 Y608 Outrigger system Extend outrigger float RL: SC
03 0046 Y609 Outrigger system Retract outrigger float RL: CB
03 0047 Y609 Outrigger system Retract outrigger float RL: SC
03 0048 Y610 Outrigger system Extend outrigger float FL: CB
03 0049 Y610 Outrigger system Extend outrigger float FL: SC
03 0050 Y611 Outrigger system Retract outrigger float FL: CB
03 0051 Y611 Outrigger system Retract outrigger float FL: SC
03 0052 Y612 Outrigger system Extend outrigger beam FL: CB
03 0053 Y612 Outrigger system Extend outrigger beam FL: SC
03 0054 Y613 Outrigger system Retract outrigger beam FL: CB
03 0055 Y613 Outrigger system Retract outrigger beam FL: SC
03 0056 Y614 Outrigger system Extend outrigger float FR: CB
03 0057 Y614 Outrigger system Extend outrigger float FR: SC
03 0058 Y615 Outrigger system Retract outrigger float FR: CB
03 0059 Y615 Outrigger system Retract outrigger float FR: SC
03 0060 Y616 Outrigger system Extend outrigger beam FR: CB
03 0061 Y616 Outrigger system Extend outrigger beam FR: SC
03 0062 Y617 Outrigger system Retract outrigger beam FR: CB
03 0063 Y617 Outrigger system Retract outrigger beam FR: SC
03 0064 Y463 Platform Activation hydraulic generator: CB
03 0065 Y463 Platform Activation hydraulic generator: SC
03 0066 Y618 Hydraulics Toggling ventilation/consumers: CB
03 0067 Y618 Hydraulics Toggling ventilation/consumers: SC
04 0000 Y618 Hydraulics Toggling fan/consumers: CB
04 0001 Y618 Hydraulics Toggling fan/consumers: SC
04 0002 Y619 Hydraulics Pressure limiting setting level 1: CB
04 0003 Y619 Hydraulics Pressure limiting setting level 1: SC
04 0004 Y620 Hydraulics Pressure limiting setting level 2: CB
04 0005 Y620 Hydraulics Pressure limiting setting level 2: SC
04 0006 B606 Outrigger system CAN bus: conn. to length sensor FR
lost
04 0007 B608 Outrigger system CAN bus: conn. to length sensor RR
lost
04 0008 B607 Outrigger system CAN bus: conn. to length sensor RL
lost
04 0009 B605 Outrigger system CAN bus: conn. to length sensor FL
lost
WFN3RUWW2K2064139
04 0010 D016 Outrigger system CAN bus: connect. to tilt sensor lost
04 0019 A020 Platform Electrical emergency pump: CB
04 0020 A020 Platform Electrical emergency pump: SC
128 ATF 60G-3

2019-03_EN
Errors related to safety condition

nation
10 0000 A015 Hydraulics Hydraulics: oil level too low
10 0001 A015 Hydraulics Hydraulics: oil temperature too high
10 0002 X121 Brake Brake lining wear
10 0003 S038 Engine Air cleaner is contaminated
10 0004 A020 Dolly Dolly: pre-warn. pres. sle. brake drop.
10 0005 A107 Tyre pressure Tyre pressure on axle 1 left: too low
10 0006 A107 Tyre pressure Tyre pressure on axle 1 left: too high
10 0017 A107 Tyre pressure Tyre pressure on axle 1 right: too low
10 0018 A107 Tyre pressure Tyre pressure on axle 1 right: too high
10 0029 Y0XX Drive Diff: inter-axle diff req but inactive
10 0030 Y0XX Drive Diff: inter-axle diff not req but active
10 0031 Y007 Drive Diff: inter-wheel diff req but inactive
10 0032 Y007 Drive Diff: inter-wheel dif not req but active
10 0033 B011 Fuel Fill level fuel tank low
10 0034 A101 Brake ABS system is inactive
10 0035 X101 Brake Trailer ABS system is inactive
10 0036 S413 Suspension Axle susp locking FR: not req but act-
WFN3RUWW2K2064139
ive
10 0037 S415 Suspension Axle susp locking RR: not req but act-
ive
10 0038 S414 Suspension Axle susp locking RL: not req but act-
ive
10 0039 S412 Suspension Axle susp locking FL: not req but act-
ive
ATF 60G-3 129

2019-03_EN

nation
10 0040 S413 Suspension Axle susp locking FR: req but not act-
ive
10 0041 S415 Suspension Axle susp locking RR: req but not act-
ive
10 0042 S414 Suspension Axle susp locking RL: req but not act-
ive
10 0043 S412 Suspension Axle susp locking FL: req but not act-
ive
10 0044 M005 Electrical system Fill level windshield washer system
low
10 0045 B011 Heating Fill level fuel low
11 0000 A107 Tyre pressure Tyre pres. axle 1 left: critic. too low
11 0001 A107 Tyre pressure Tyre pres. axle 1 left: critic. too high
11 0012 A107 Tyre pressure Tyre pres. axle 1 right: critic. too low
11 0013 A107 Tyre pressure Tyre pres. axle 1 right: crit. too high
11 0024 A020 Drive Diff.: speed for deactivation exceeded
11 0025 S139 Superstructure Emerg. operation superstructure act-
ive
12 0000 S058 Hydraulics Hydraulics: oil filter soiled
12 0001 S529 Steering Steering: oil filter soiled
WFN3RUWW2K2064139
12 0002 A030 Instrument panel Tachograph shows errors
130 ATF 60G-3

2019-03_EN
Warnings
nation
30 0000 A031 Aftertreatment of exhaust gases AdBlue®: fill level warning
30 0001 A031 Aftertreatment of exhaust gases AdBlue®: fill level low
30 0002 A031 Aftertreatment of exhaust gases AdBlue®: operating restriction
30 0003 A031 Aftertreatment of exhaust gases AdBlue®: operating restriction
30 0004 A031 Aftertreatment of exhaust gases AdBlue®: error exhaust gas aftertreat.
30 0005 A031 Aftertreatment of exhaust gases AdBlue®: error exhaust gas aftertreat.
30 0006 A010 Engine Both drop arm inputs active
30 0007 A010 Engine Cruise contr. active, although deactiv.
30 0008 A031 Aftertreatment of exhaust gases Particle filter soiled, start regen.
30 0009 A031 Aftertreatment of exhaust gases Partic. filter: regener. neces. or act.
30 0010 S030 Superstructure Inc. speed in superstr. oper. not poss.
31 0000 A301 Drive Converter: oil temperature too high
31 0001 A010 Engine Stop immediately! Engine fault
31 0002 A010 Engine Stop immediately! Engine fault
31 0003 A010 Engine Coolant level too low
31 0004 A010 Engine Coolant temperature too high
31 0005 A010 Engine Oil pressure too low
31 0006 A010 Engine Oil level too low
31 0007 A031 Aftertreatment of exhaust gases Particle filter full - start regen. now
32 0000 A010 Engine Check engine error
32 0001 A010 Engine Check engine error
32 0002 A010 Engine Oil level low
32 0003 Y320 PTO Valve PTO OFF: CB
32 0004 Y320 PTO Valve PTO OFF: SC
32 0005 Y319 PTO Valve PTO ON: CB
32 0006 Y319 PTO Valve PTO ON: SC
32 0007 Y321 PTO Valve transfer case neutral: CB
32 0008 Y321 PTO Valve transfer case neutral: SC
32 0009 Y014 PTO Valve transfer case road: CB
32 0010 Y014 PTO Valve transfer case road: SC
WFN3RUWW2K2064139
ATF 60G-3 131

2019-03_EN
Information
nation
21 0000 A020 Steering Logic errors: both direct. valv. activ.
21 0001 A020 Steering Log. errors: dir. switch act. both dir.
21 0002 A020 Steering Interlock inactive
21 0003 A020 Steering Upshift lock unlocked axle inactive
22 0000 A020 Steering Total volt. angle sensor implausible
22 0001 A020 Steering Axle not in interlock position
22 0002 A020 Steering Unwanted steering movement
22 0003 A020 Steering Upshift lock during locking inactive
WFN3RUWW2K2064139
132 ATF 60G-3

2019-03_EN
6 Transport
6 Transport
6.1 Ladders
Safety instructions
WARNING
Risk of falling due to unsafe or defective ladders.
When climbing and stepping on ladders, take utmost care especially in
case of humid weather. There is risk of slipping and risk of falling. This
could cause serious or fatal injuries.
1. Keep ladders clean at all times.
2. Wear sturdy, non-slip footwear.
3. Always hold the ladder beams or handles while climbing up or down.
4. Replace faulty ladders immediately.
5. Ensure that the ladders are safe.
WARNING
Risk of accidents when driving with swivelled out ladders.
Swivelling ladders protrude at the sides of the mobile crane. This could
cause serious or fatal injuries.
1. Before driving, swivel in the ladders.
Overview
1 Swivelling ladders 2 Ladder, permanently attached

WFN3RUWW2K2064139
ATF 60G-3 133

2019-03_EN
6 Transport
Overview of ladder swivelling
A Transport position 1 Ladder

B Climbing position 2 Clamp
Swivelling ladder out

▪ Wheels must be in straight position.
1. Extract the ladder from clamp by pulling upwards.
2. Swivel the ladder into climbing position.
Swivelling ladder in
1 Lever
Swivelling ladder in
WFN3RUWW2K2064139
1. Unlock ladder. Push lever upwards.

2. Swivel the ladder into transport position.
3. Press the ladder into de clamp.
ð The ladder is secured in transport position.
134 ATF 60G-3

2019-03_EN
6 Transport
6.2 Loading the mobile crane
Safety instructions
DANGER
Risk of accident due to improper securing.
If improperly secured, the mobile crane can move and possible break
away. This can cause serious accidents.
1. Secure the mobile crane to prevent it from rolling away.
2. Completely retract the mobile crane's hydraulic suspension.
3. Secure the mobile crane at all the specified attachment points.
Introduction
The lifting loads indicated below relate to a crane configuration with an axle load of 12 t.
Other axle loads result in other lifting loads.
Overview of lifting points
1 19.5 t 2 16.5 t
WFN3RUWW2K2064139
ATF 60G-3 135

2019-03_EN
6 Transport
Overview of attachment points
On the left
On the right / front
WFN3RUWW2K2064139
136 ATF 60G-3

2019-03_EN
6 Transport
Rear
Loading onto trailer by means of a pushing vehicle
Requirements
▪ The hydraulic steering must be functional.
▪ Use a towbar that is dimensioned for this work.
▪ An signalling person is present.
▪ The people involved must have visual contact with each other.
▪ The pushing vehicle must have a towing hitch.
Procedure
1. Connect the mobile crane and the pushing vehicle to the towing hitches using the towbar.
2. Manoeuvre the mobile crane onto the trailer with the aid of the pushing vehicle.
5. Lash down the mobile crane.
6. Detach the towbar from the mobile crane.
WFN3RUWW2K2064139
ð Mobile crane has been loaded onto trailer.
On a ship or railway
Procedure
1. Extend the outrigger as far as necessary and secure it.
ATF 60G-3 137

2019-03_EN
6 Transport
2. Lift the mobile crane onto the outriggers.

3. Lower the mobile crane onto the transport area.
6. Lash down the mobile crane.
ð Mobile crane has been loaded.
WFN3RUWW2K2064139
138 ATF 60G-3

2019-03_EN
7 Putting into operation
7.1 Carrier cab
7.1.1 Unlocking and locking doors from inside / outside
Safety instructions
WARNING
Risk of accidents due to carrier cab door that opens.
A carrier cab door, which is not closed correctly, can open when driving.
Persons may fall out off the carrier cab.
A carrier cab door that opens inadvertently when driving may lead to acci-
dents.
1. Close de carrier cab doors before driving.
2. Fasten the seat belts.
CAUTION
Risk of injury when closing the carrier cab door.
If the carrier cab doors are held by the frame while closing from outside,
the fingers can get caught and crushed.
1. Always hold the carrier cab door by the handle when closing from the
outside.
WFN3RUWW2K2064139
ATF 60G-3 139

2019-03_EN
Unlocking and locking doors with the key
1 Key 2 Door lock
1. Put the key in the door lock and turn it to the left (anti-clockwise).
1. Put the key in the door lock and turn it to the right (clockwise).
WFN3RUWW2K2064139
140 ATF 60G-3

2019-03_EN
Unlocking and locking doors with remote operation
1 Door lock 4 Unlock carrier cab door pushbutton

2 Ignition key 5 —
3 Lock carrier cab door pushbutton
1. Press the Unlock carrier cab door pushbutton on the ignition key.
1. Press the Lock carrier cab door pushbutton on the ignition key.
WFN3RUWW2K2064139
ATF 60G-3 141

2019-03_EN
Opening and closing doors from outside
1 Button 2 Handle
Procedure – Opening
1. Pull the handle.
ð Door is open.
Procedure – Closing
1. Hold the door by the handle and push it to lock it.
ð The door is closed.
WFN3RUWW2K2064139
142 ATF 60G-3

2019-03_EN
Opening and closing doors from inside
1 Door opener 2 Handle
Procedure – Opening
➢ If the door is to be opened, it must be unlocked.
1. Pull on the door opener. Open the door.
ð Door is open.
Procedure – Closing
1. Hold the door by the handle and pull it into the lock to lock it.
ð The door is closed.
WFN3RUWW2K2064139
ATF 60G-3 143

2019-03_EN
Locking doors from inside
1 Door lock
Procedure – Looking
1. Press the door lock.
Procedure – Unlooking
1. Pull the door lock or the door opener.
7.1.2 Adjusting seats
Safety instructions
CAUTION
Risk of injury due to objects in the adjusting range of the seat.
Objects in the range of the seat controls can cause injuries when adjusting
the seat.
1. Eliminate objects in the adjusting range of the seat.
WFN3RUWW2K2064139
144 ATF 60G-3

2019-03_EN
WARNING
Risk of accidents when adjusting the seat while driving.
If the seat is adjusted while driving, this may lead to driving errors. This
may lead to accidents.
1. Before driving, adjust the seat such that the pedals can be actuated
correctly, and the steering wheel can be operated securely.
2. Before driving, check if the seat is fixed securely.
3. Do not adjust the seat while driving.
Driver seat
Overview
1 Backrest lever 8 Longitudinal adjustment lever

2 Side contour switch 9 Inclination of seat surface lever
3 Lumbar support, top switch 10 Comfort seat rail release strap
4 Lumbar support, bottom switch 11 Fast lowering switch
5 Seat height lever 12 Seat depth lever
6 Vertical shock absorption lever 13 Armrest actuator wheel
7 Seat heater switch
WFN3RUWW2K2064139
Procedure – Adjusting backrest

1. Pull the Backrest lever up and hold it.
2. Move the backrest forwards or backwards.
ATF 60G-3 145

2019-03_EN
3. Release the Backrest lever and lock the backrest in place. The interlock shall engage aud-
ibly.
ð The backrest has been adjusted.
Procedure – Adjusting side contour

1. Press + or - on Side contour switch.
ð The right and left side contour changes.
Procedure – Adjusting lumbar support

1. Press Lumbar support, top or bottom switches towards + or -.
ð The top or bottom lumbar support changes.
Procedure – Adjusting seat height

1. Pull seat forcefully upwards.
ð The seat engages in higher seat position.
2. Pull seat upwards exceeding the highest locking position.
ð The seat moves downwards and engages in the lowest seat position.
ð The seat height has been adjusted
Procedure – Adjusting vertical shock absorption

1. Push Vertical shock absorption lever in direction soft or in direction hard and engage (four
stages).
Highest position = soft absorption.
Lowest position = hard absorption.
ð The vertical shock absorption is adjusted.
Procedure– Switching seat heater on/off

1. Press the Seat heater switch to position I or II.
ð The seat heater is switched on in position I or II.
2. Press the switch to the 0 position.
ð The seat heater is switched off.
Procedure– Adjusting seat in longitudinal direction

1. Pull the longitudinal adjustment lever up and hold it.
2. Put the seat in the desired position.
3. Release the longitudinal adjustment lever and lock the seat in place. The interlock shall en-
gage audibly.
WFN3RUWW2K2064139
ð The longitudinal adjustment is set.
Procedure– Adjusting the inclination of the seat area

1. Pull the Inclination of the seat area lever up and hold it.
2. Put the seat area in the desired position.
146 ATF 60G-3

2019-03_EN
3. Release the Inclination of the seat area lever. The interlock shall engage audibly.
ð The seat area is set.
Procedure – Adjusting comfort seat rail release

1. Pull the comfort seat rail release.
ð The seat rail is released.
2. Let go of the comfort seat rail release.
ð The seat rail is locked.
Procedure– Switching fast lowering on/off

1. Press the Fast lowering switch.
ð The seat lowers into the lowest position.
1. Press the Fast lowering switch again.
ð The seat returns to its initial position.
Procedure – Adjusting seat depth

1. Pull the seat depth lever up and hold it.
2. Put the seat area in the desired position.
3. Release the seat depth lever. The interlock shall engage audibly.
ð The seat depth is set.
Procedure – Adjusting armrest

1. Turn the armrest actuator wheel clockwise or anti-clockwise.
ð The armrest angle is adjusted.
WFN3RUWW2K2064139
ATF 60G-3 147

2019-03_EN
Passenger's seat
Optionally, a driver's seat can also be installed as passenger seat. For the
description, refer to Driver seat [} page 145].
Overview
1 Longitudinal adjustment lever 2 Backrest lever
Procedure– Adjusting seat in longitudinal direction

1. Pull the longitudinal adjustment lever up and hold it.
2. Put the seat in the desired position.
3. Release the longitudinal adjustment lever and lock the seat in place. The interlock shall en-
gage audibly.
ð The longitudinal adjustment is set.
Procedure – Adjusting backrest

1. Pull the Backrest lever up and hold it.
2. Move the backrest forwards or backwards.
3. Release the Backrest lever and lock the backrest in place. The interlock shall engage aud-
ibly.
WFN3RUWW2K2064139
ð The backrest has been adjusted.
148 ATF 60G-3

2019-03_EN
7.1.3 Adjusting the steering wheel
Overview
1 Steering wheel adjustment pushbutton
Procedure
➢ Mobile crane is standing still and parking brake is engaged.
1. Press the steering wheel adjustment pushbutton.
2. Adjust the inclination and height, hold the steering wheel in the desired position.
3. The locking takes place automatically after a few seconds.
ð The steering wheel is adjusted.
7.1.4 Fastening/unfastening the seat belt
Safety instructions
WARNING
Danger to life if the seat belt is not fastened.
The passengers can be severely injured or killed in case of accident if the
seat belt is not fastened.
1. Fasten seat belt when driving.
WFN3RUWW2K2064139
ATF 60G-3 149

2019-03_EN
Overview
1 Safety belt 3 Buckle

2 Tongue 4 Button
Fastening the seat belt

1. Pulling forward slightly, pull the seat belt out of the bracket.
2. Engage the tongue in the buckle.
ð The seat belt is fastened.
Unfastening the seat belt

1. Push the buckle button.
2. Return the seat belt into the bracket.
ð The seat belt is unfastened.
7.1.5 Adjusting the external mirror
Safety instructions
WARNING
WFN3RUWW2K2064139
Risk of accidents due to incorrectly adjusted mirrors.

Incorrectly adjusted mirrors may lead to inadequate visibility. This may
lead to accidents.
1. Adjust the external mirrors such that adequate visibility is ensured.
150 ATF 60G-3

2019-03_EN
Adjusting mirror supports
1 Driver side mirror α xx°

2 Passenger side mirror β 90°
1. Adjust mirror supports according to specified values.
Adjusting the external mirror

Requirements
▪ Battery main switch switch is switched on.
▪ The ignition is switched on.
Electrical adjustment of external mirrors
WFN3RUWW2K2064139
A Select left mirror 1 Mirror adjustment rotary knob

B Select right mirror
ATF 60G-3 151

2019-03_EN
1. Turn the Mirror adjustment rotary knob to the right or to the left.
ð The right or left mirror is selected.
2. Push the Mirror adjustment rotary knob forward, backward, to the left or to the right.
ð The mirror moves in the desired direction.
ð The mirror is adjusted.
7.1.6 Heating, ventilation, air conditioning system *)
Overview
1 2 3
4
5
1 Blower rotary knob 4 Circulating air switch

2 Temperature control rotary knob 5 Air conditioning system switch
3 Air distribution rotary knob
Requirements
Blower
Positions of the rotary knob

▪ Blower off (top).
▪ First stage: Low power.
▪ Second stage: Medium power.
▪ Third stage: High power (right).
Procedure – Switching the blower on

WFN3RUWW2K2064139
1. Switch the blower on; to do this, turn Blower rotary knob to the right.
Control air flow as required.
ð The blower has been switched on.
152 ATF 60G-3

2019-03_EN
Procedure – Switching the blower off

1. Switch the blower off; to do this, turn Blower rotary knob to the left.
ð The blower has been switched off.
Temperature control
Positions of the rotary knob

▪ Left = Cold.
▪ Right = Warm.
Procedure – Setting temperature

1. Adjust temperature control as required.
ð The temperature has been set.
Air distribution
Overview – Positions of the "Air distribution" rotary knob
Air into interior Air into interior and to windows Air to windows
Changing air distribution

1. Turn the Air distribution rotary knob into the desired position.
Circulating air
Introduction
The supply of outside air can be interrupted. The air circulates in the cab's closed circuit.
Positions of the Circulating air switch:
▪ Left = supply of outside air.
▪ Right = circulating air operation, closed circuit.
Procedure – Switching on circulating air operation

1. Push Circulating air switch to the right into position 1.
ð The circulating air operation has been switched on.
WFN3RUWW2K2064139
Procedure – Switching off circulating air operation

1. Push Circulating air switch to the left, into position 0.
ð The circulating air operation has been switched off.
ATF 60G-3 153

2019-03_EN
Air conditioning system *)

Safety instructions
Run the air conditioning system for approx. 10 minutes each month during
cold and dry periods in winter and if it is not being used frequently.
The air conditioning system is not operational if the outside temperature is
particularly low.
Requirements
▪ Carrier cab is closed.
▪ Engine is running.
Switching air conditioning system *) on
Positions of the Air conditioning system switch:
▪ Left = off.
▪ Right = on.
1. Push Air conditioning system switch to the right into position 1.
ð The air conditioning system is activated.
Controlling temperature
1. Set the temperature as required with the Temperature control rotary knob.
2. Set the air distribution as required with the Air distribution rotary knob.
3. Set the blower as required with the Blower rotary knob.
Switching off the air conditioning system *)
1. Push Air conditioning system switch to the left into position 0.
ð The air conditioning system is turned off.
WFN3RUWW2K2064139
154 ATF 60G-3

2019-03_EN
7.1.7 Opening/closing the carrier cab side window
Safety instructions
WARNING
Danger of crushing when closing the side window.
When closing the side window, body parts that are in between the side
window and the door frame may get crushed.
1. When closing the side window do not reach into the space between
the side window and the door frame.
WARNING
Risk of accidents due to moisture in the carrier cab.
If moisture penetrates into the carrier cab, components may be damaged.
The resulting failures may lead to accidents. This may lead to personal in-
juries and material damage.
1. Close side windows and doors when leaving the carrier cab.
Opening/closing the side window on the driver's side
Overview
WFN3RUWW2K2064139
1 Side window, driver's side pushbutton
Procedure — Opening side window

1. Press back and hold the Side window, driver's side pushbutton.
ATF 60G-3 155

2019-03_EN
Procedure — Closing side window

1. Press forward and hold the Side window, driver's side pushbutton.
Opening/closing the side window on the passenger side
Overview
1 Side window, passenger side pushbutton
Procedure — Opening side window

1. Press back and hold the Side window, passenger side pushbutton.
Procedure — Closing side window

1. Press forward and hold the Side window, passenger side pushbutton.
WFN3RUWW2K2064139
156 ATF 60G-3

2019-03_EN
7.1.8 Interior lighting
1 Switch position Interior lighting on 3 Switch position Interior lighting when door
is open
2 Switch position Interior lighting off
WFN3RUWW2K2064139
ATF 60G-3 157

2019-03_EN
7.2 Checking the lighting
CAUTION
Risk of accidents due to defective lighting.
Soiled, missing or not functioning lighting may affect the operational safety
of the mobile crane. This may lead to accidents.
1. Check the lighting before driving, and clean if necessary.
2. Have the defective lighting repaired or exchanged by professionals.
7.2.2 Checking exterior lighting
Overview
WFN3RUWW2K2064139
1 Rotary beacon 12 Clearance lamp

2 Clearance lamp 13 Clearance lamp
3 Side marker lamp 14 Flashing light
4 Reverse light 15 —
5 Rear fog light 16 Direction indicator flashing light
158 ATF 60G-3

2019-03_EN
6 Rear light 17 Daytime running light and position light

7 License plate light 18 Fog light
8 Reflector 19 Low beam light and high beam light
9 Brake light 20 Clearance lamp
10 Direction indicator flashing light 21 Roof lights (Canada) *)
11 Clearance lamp
Requirements
Checking the lighting

1. Check all lighting devices for soiling or damages. If necessary, clean or exchange.
2. For checking the lighting, refer to Checking lighting, pilot lamps and indicators individually
[} page 160].
7.2.3 Checking interior pilot lamps and indicators
Safety instructions
CAUTION
Risk of accidents due to defective operating elements.
Warning and lighting devices can no longer be operated. This may lead to
accidents.
1. Before driving, have defective operating elements repaired or ex-
changed by professionals.
WFN3RUWW2K2064139
ATF 60G-3 159

2019-03_EN
Overview
1
2 3
12
4
11
10
8
9 7
6 5
1 Direction indicator pilot lamp 7 Left steering column switch

2 Blower switch 8 Parking light / low beam light switch
3 Temperature control switch 9 Battery main switch switch
4 Hazard warning lights switch 10 Rotary beacon switch
5 Rear fog light indicator 11 Fog light switch
6 High beam light indicator 12 Rear fog light pushbutton
Checking switches and pilot lamps

1. For checking the switches and pilot lamps, refer to Checking lighting, pilot lamps and indic-
ators individually [} page 160].
7.2.4 Checking lighting, pilot lamps and indicators individually

WFN3RUWW2K2064139
Requirement
Tests when ignition is switched off

Switch on the following functions consecutively and check functionality. If necessary, have a
second person present.
160 ATF 60G-3

2019-03_EN
1. Check hazard warning system.

2. Check parking light.
3. Check rotary beacons.
4. Check the headlight flasher.
Tests when ignition is switched on

Switch on the following functions consecutively and check functionality. If necessary, have a
second person present.
1. Check Parking light / low beam light switch.
2. Check High beam light switch. The High beam light indicator is lit.
3. Check Direction of travel switch. Direction indicator pilot lamp is flashing.
4. Check Fog light switch.
5. Check Rear fog light pushbutton. The Rear fog light indicator is lit.
6. Check Signal horn pushbutton.
7. Check windshield wiper and wash system switch.
8. Check Blower switch.
9. Check Temperature control switch.
WFN3RUWW2K2064139
ATF 60G-3 161

2019-03_EN
WFN3RUWW2K2064139
162 ATF 60G-3

2019-03_EN
8 Outrigger
8 Outrigger
8.1 Installation location of control panel
1 Control panel
8.2 Safety instructions
DANGER
Danger of the mobile crane tipping due to abrupt unloading!
If the wire rope tears or the load falls while it is being lifted, the mobile
crane is unloaded abruptly. In this case, if the non-load side outriggers are
not extended, the sudden unloading of the crane can cause it to overturn
backwards.
1. All outrigger beams that are on the load side and non-load side always
support according to the outrigger extensions in the load rating charts.
2. Insert all locking pins completely into the outrigger beams.
WFN3RUWW2K2064139
ATF 60G-3 163

2019-03_EN
8 Outrigger
WARNING
Risk of accidents when extending or retracting the outrigger beams.
If the operator cannot see the outrigger area, persons or objects that are
present in this area may get caught. This may lead to personal injuries and
material damage.
1. Evacuate people from the outrigger area.
2. Ensure that the extension area is free of objects.
3. Only extend or retract outriggers if the operator or another person is
able to see the outrigger area.
WARNING
Risk of accidents if the wheels have contact with the ground during
crane operation.
Wheels and axles are part of the counterweight mass. If they have contact
with the ground during crane operation, the mobile crane may become un-
stable and overturn. This may lead to personal injuries and material dam-
age.
1. Extend the outrigger float until the wheels are no longer in contact with
the ground.
2. Do not support the wheels.
WARNING
Risk of accidents if the outriggers are not locked during crane opera-
tion.
If the outrigger beams are not locked during crane operation, they may ex-
tend or retract uncontrollably. This can cause an accident. This may lead
to personal injuries and material damage.
1. Lock all the outriggers before crane operation.
NOTICE
Damages on mobile crane if outrigger beams are not unlocked.
If the outrigger beams are not unlocked before extending or retracting, this
may lead to damages on the frame of the mobile crane.
1. Unlock outrigger beams before extending or retracting.
NOTICE
WFN3RUWW2K2064139
Damages on the outriggers if the outrigger floats are not retracted.

If the outrigger floats are not retracted before retracting or extending the
outrigger beams, this may lead to damages on the outriggers.
1. Retract the outrigger floats before retracting or extending the outrigger
beams.
164 ATF 60G-3

2019-03_EN
8 Outrigger
8.3 Control panel
8.3.1 Structure of control panel
Overview
2 3
2
1 Buttons with fixed assignment 3 Display
2 Buttons with variable assignment 4 Emergency stop switch
Buttons with fixed assignment

For button assignments refer to Buttons of the control panel [} page 166].
Buttons with variable assignment

In the individual menus, the buttons are assigned to different functions.
These are described in the respective menus.
The following menus may be represented on the display:

Menu "Main menu" [} page 170].
Menu "Retracting/extending outrigger beams" [} page 172].
WFN3RUWW2K2064139
Menu "Retracting/extending outrigger floats" [} page 178].

"Suspension cylinders" menu [} page 184].
ATF 60G-3 165

2019-03_EN
8 Outrigger
8.3.2 Buttons of the control panel
Introduction
The control panels on both sides of the mobile crane are identical. The graphics in the display
differ in order to show the mobile crane's direction.
Overview
2
1
4
2
1 Buttons for engine functions 4 Movements buttons
2 Buttons with variable assignment 5 Navigation button
3 Service button 6 Contrast button
"Start engine" button

Press button = start engine.
"Switch off engine" button

Press button = switch off engine.
WFN3RUWW2K2064139
"Reduce engine speed" button

Press button = reduce engine speed.
NOTICE! The engine speed is reduced in stages.
"Increase engine speed" button

Press button = increase engine speed.
NOTICE! The engine speed is increased in stages.
166 ATF 60G-3

2019-03_EN
8 Outrigger
Buttons with variable assignment

"Movements" buttons
"Navigation" button
Press button in Start menu = go to main menu.
Press button in a sub-menu = return to main menu.
Press button in main menu = go to Start menu.
"Contrast" button
Press and hold button = change contrast.
WFN3RUWW2K2064139
ATF 60G-3 167

2019-03_EN
8 Outrigger
8.3.3 "Start menu" button
Overview of buttons
1 Navigation button
Buttons
"Navigation" button
Press button = go to main menu.
WFN3RUWW2K2064139
168 ATF 60G-3

2019-03_EN
8 Outrigger
Overview of indicators
3 2 1
1 Navigation indicator 3 Superstructure operation indicator
2 Fault warning lamp
Indicators
"Navigation" indicator
Indicator is lit = change to main menu is possible.
"Fault" warning lamp

Warning lamp is lit = fault in the electronics.
Supporting is not possible.
Error code can be read on the display of the on-board computer in the carrier cab.
"Superstructure operation" indicator

Indicator flashes = superstructure operation. It is not possible to work in the control panel. Ob-
serve the Carrier operation/superstructure operation key switch.
WFN3RUWW2K2064139
ATF 60G-3 169

2019-03_EN
8 Outrigger
8.3.4 Menu "Main menu"
Overview of buttons
A B C
Step 2 / 3
RPM 1200
F G
A Retracting/extending outrigger beams E —
menu button
B Retracting/extending outrigger floats menu F Signal horn button
button
C Suspension cylinder menu button G Working floodlights on outriggers button
D —
Buttons
"Retracting/extending outrigger beams menu" button
Press button = go to Retracting/extending outrigger beams menu.
"Retracting/extending outrigger floats menu" button

Press button = go to Retracting/extending outrigger floats menu.
"Suspension cylinder menu" button

Press button = go to Suspension cylinder menu.
WFN3RUWW2K2064139
"Signal horn" button

Press and hold button = signal horn sounds for as long as the button is pressed.
170 ATF 60G-3

2019-03_EN
8 Outrigger
"Working floodlights on outriggers" button

Press button = switch working floodlights on the outriggers on/off.
Overview of indicators
1 2 3 4
Step 2 / 3
RPM 1200
7
1 Retracting/extending outrigger beams 5 —
menu indicator
2 Retracting/extending outrigger floats menu 6 —
indicator
3 Engine speed indicator 7 Signal horn indicator
4 Suspension cylinder menu indicator
Indicators
"Engine speed" indicator
Step 2 / 3
RPM 1200 Indicator is lit = the selected engine speed is displayed.
NOTICE! The button above the "Engine speed" indicator has no assigned function.
"Signal horn" indicator

Indicator is lit inversely = signal horn sounds.
WFN3RUWW2K2064139
ATF 60G-3 171

2019-03_EN
8 Outrigger
8.3.5 Menu "Retracting/extending outrigger beams"
Buttons – left-hand control panel
Overview
Step 0 / 3
RPM 400 H
1.4 m 1.4 m
+1,4° D
! 0,0°
E
1.4 m 1.4 m
A B C
A Preselect outrigger beam, front left button D Retract outrigger beam button
B Pre-select both outrigger beams, left button E Extend outrigger beam button
C Preselect outrigger beam, rear left button H Button lock override button
"Preselect outrigger beam, front left" button

Press button = preselect left-hand front outrigger beam.
Press button again = deselect left-hand front outrigger beam.
"Pre-select both outrigger beams, left" button

2 Press button = preselect left-hand front and rear outrigger beams.
Press button again = deselect left-hand front and rear outrigger beams.
"Preselect outrigger beam, rear left" button

Press button = preselect left-hand rear outrigger beam.
Press button again = deselect left-hand rear outrigger beam.
WFN3RUWW2K2064139
"Retract outrigger beam" button

Press and hold button = retract preselected outrigger beam.
172 ATF 60G-3

2019-03_EN
8 Outrigger
"Extend outrigger beam" button

Press and hold button = extend preselected outrigger beam.
"Button lock override" button

Press and hold button = override locked buttons.
To do this, simultaneously press and hold the Retracting/extending buttons.
Indicators – left-hand control panel
Overview
1.4 m 1.4 m
13
12 +1,4° 1
11 ! 2
10 0,0°
9 3
1.4 m 1.4 m 4
2
8 7 6 5
1 Retracting outrigger beam indicator 8 Outrigger base, front left *) indicator
2 Extending outrigger beam indicator 9 Superstructure not locked indicator
3 Outrigger beam, rear left indicator 10 Mobile crane lateral inclination indicator
4 Outrigger base, rear left *) indicator 11 Button lock indicator
5 Preselect outrigger beam, rear left indicator 12 Mobile crane longitudinal inclination indic-
ator
6 Outrigger beam, front left indicator 13 Boom not in boom rest indicator
7 Preselect outrigger beam, front left indic-
ator
WFN3RUWW2K2064139
"Outrigger base" *) indicator

1.4 m The current outrigger base of the individual outrigger beams is displayed.
ATF 60G-3 173

2019-03_EN
8 Outrigger
"Outrigger beam" indicators

Indicators are lit = outrigger beam is extending.
Indicators are lit = outrigger beam is retracting.
"Preselect outrigger beam, front left" indicator

Indicator is lit inversely = front left outrigger beam is preselected.
"Preselect outrigger beams, front and rear left" indicator

Indicators are lit inversely = both left outrigger beams are preselected.
"Preselect outrigger beam, rear left" indicator

Indicator is lit inversely = rear left outrigger beam is preselected.
"Mobile crane longitudinal inclination" indicator

+1,4° The Mobile crane longitudinal inclination indicator shows the current longitudinal inclination of the
mobile crane. The numerical display shows the exact deviation in °.
"Mobile crane lateral inclination" indicator

0,0° The Mobile crane lateral inclination indicator shows the current lateral inclination of the mobile
crane. The numerical display shows the exact deviation in °.
"Superstructure not locked" indicator

Indicator is lit = superstructure is not locked, all buttons are locked.
"Button lock" indicator

Indicator is lit = button lock is active.
!
"Boom not in boom rest" indicator
Indicator is lit = the boom is not located in the boom rest, all buttons are locked.
WFN3RUWW2K2064139
174 ATF 60G-3

2019-03_EN
8 Outrigger
Buttons – right-hand control panel
Overview
Step 0 / 3
RPM 400 H
1.4 m 1.4 m
+1,4°
D
!
0,0°
E
1.4 m 1.4 m
A B C
A Preselect outrigger beam, rear right button D Retract outrigger beam button
B Preselect both outrigger beams, right but- E Extend outrigger beam button
ton
C Preselect outrigger beam, front right button H Button lock override button
"Preselect outrigger beam, rear right" button

Press button = preselect right-hand rear outrigger beam.
Press button again = deselect right-hand rear outrigger beam.
"Preselect both outrigger beams, right" button

2 Press button = preselect right-hand front and rear outrigger beams.
Press button again = deselect right-hand front and rear outrigger beams.
"Preselect outrigger beam, front right" button

Press button = preselect right-hand front outrigger beam.
Press button again = deselect right-hand front outrigger beam.
"Retract outrigger beam" button

WFN3RUWW2K2064139
Press and hold button = retract preselected outrigger beam.
"Extend outrigger beam" button

Press and hold button = extend preselected outrigger beam.
ATF 60G-3 175

2019-03_EN
8 Outrigger

Indicators – right-hand control panel
Overview
13
Step 0 / 3
RPM 400
12 1.4 m 1.4 m
+1,4°
1
11 ! 2
0,0° 3
10
1.4 m 1.4 m
9 4
2
8 7 6 5
1 Retracting outrigger beam indicator 8 Outrigger base, rear right *) indicator
2 Mobile crane lateral inclination indicator 9 Outrigger beam, rear right indicator
3 Extending outrigger beam indicator 10 Superstructure not locked indicator
4 Outrigger base, front right *) indicator 11 Button lock indicator
5 Preselect outrigger beam, front right indic- 12 Boom not in boom rest indicator
ator
6 Outrigger beam, front right indicator 13 Mobile crane longitudinal inclination indic-
ator
7 Preselect outrigger beam, rear right indic-
ator
"Outrigger beam" indicators

Indicators are lit = outrigger beam is extending.
WFN3RUWW2K2064139
Indicators are lit = outrigger beam is retracting.
176 ATF 60G-3

2019-03_EN
8 Outrigger
"Outrigger base" *) indicator

1.4 m The current outrigger base of the individual outrigger beams is displayed.
"Preselect outrigger beam, rear right" indicator

Indicator is lit inversely = rear right outrigger beam is preselected.
"Preselect outrigger beams, rear right and front right" indicator

Indicators are lit = both right outrigger beams are preselected.
"Preselect outrigger beam, front right" indicator

Indicator is lit inversely = front right outrigger beam is preselected.




!
WFN3RUWW2K2064139
ATF 60G-3 177

2019-03_EN
8 Outrigger
8.3.6 Menu "Retracting/extending outrigger floats"
Overview of left control panel buttons
A B C
Step 0 / 3
4 RPM 400 I
15t 15t
+1,4° D
!
0°
E
15t 15t
F G H
A Preselect outrigger float, front right button F Preselect outrigger float, front left button
B Preselect all outrigger floats button G Preselect levelling button
C Preselect outrigger float, rear right button H Preselect outrigger float, rear left button
D Retracting outrigger float button I Button lock override button
E Extending outrigger float button,
Level mobile crane button
Buttons
"Preselect outrigger float, front" button
Press button = preselect outrigger float.
Press button again = deselect outrigger float.
"Preselect all outrigger floats" button

4 Press button = preselect all outrigger floats.
Press button again = deselect all outrigger floats.
"Preselect outrigger float, rear" button

WFN3RUWW2K2064139

"Retract outrigger float" button

Press and hold button = retract preselected outrigger float.
178 ATF 60G-3

2019-03_EN
8 Outrigger
"Extend outrigger float" button, "Level mobile crane" button

Press and hold button = extend preselected outrigger float or level mobile crane.
"Preselect levelling" button

Press button = preselect levelling.

Overview of left control panel indicators

2 34 5 6
Step 0 / 3
4 RPM 400
15 t 15 t 7
24
23 +1,4°
8
22 ! 9
21 0° 10
20 11
19 15 t 15 t 12
18 17 16 15 14 13
1 — 13 Preselect outrigger float, rear left indicator
2 Outrigger pressure, front right indicator *) 14 Outrigger pressure, rear left indicator *)
3 Outrigger float, front right indicator 15 Preselect levelling indicator
4 Preselect outrigger float, front right indic- 16 Levelling OK indicator
ator
5 Outrigger pressure, rear right indicator *) 17 Preselect outrigger float, front left indicator
6 Preselect outrigger float, rear right indicator 18 Outrigger pressure, front left indicator *)
7 Outrigger float, rear right indicator 19 Outrigger float, front left indicator
WFN3RUWW2K2064139
8 Retracting outrigger float indicator 20 Mobile crane lateral inclination indicator

9 Circular spirit level indicator 21 Superstructure not locked indicator
10 Extending outrigger float indicator 22 Button lock indicator
11 Mobile crane levelling indicator 23 Boom not in boom rest indicator
12 Outrigger float, rear left indicator 24 Mobile crane longitudinal inclination indic-
ator
ATF 60G-3 179

2019-03_EN
8 Outrigger
Indicators
"Outrigger pressure" *) indicator
15 t The current outrigger pressure of the individual outrigger floats is displayed.
"Preselect outrigger float, front" indicator

Indicator is lit inversely = outrigger float is preselected.
"Preselect all outrigger floats" indicator

Indicators are lit inversely = all outrigger floats are preselected.
"Outrigger float" indicators

Indicators are lit = outrigger float is extending.
Indicators are lit = outrigger float is retracting.
Indicator "Circular spirit level"

The circular spirit level shows the current inclination of the mobile crane.
The marking must be in the centre during crane operation.
"Levelling OK" indicator

Indicator is lit = mobile crane is levelled.
"Preselect levelling" indicator

Indicator is lit = levelling is preselected.


"Mobile crane levelling" indicator

Indicator is lit = the mobile crane is being levelled.
WFN3RUWW2K2064139

180 ATF 60G-3

2019-03_EN
8 Outrigger


!
Overview of right control panel buttons
A B C
Step 0 / 3
4 RPM 400 I
15 t 15 t
D
+1,4°
!
0°
E
15 t 15 t
F G H
A Preselect outrigger float, rear left button F Preselect outrigger float, rear right button
B Preselect all outrigger floats button G Preselect levelling button
C Preselect outrigger float, front left button H Preselect outrigger float, front right button
D Retracting outrigger float button I Button lock override button
E Extending outrigger float button,
Level mobile crane button
Buttons
"Preselect outrigger float, rear" button
WFN3RUWW2K2064139
"Preselect all outrigger floats" button

4 Press button = preselect all outrigger floats.
Press button again = deselect all outrigger floats.
ATF 60G-3 181

2019-03_EN
8 Outrigger
"Preselect outrigger float, front" button

"Retract outrigger float" button

Press and hold button = retract preselected outrigger float.
"Extend outrigger float" button, "Level mobile crane" button

Press and hold button = extend preselected outrigger float or level mobile crane.
"Preselect levelling" button

Press button = preselect levelling.

Overview of right control panel indicators
1 23 4 5 6
Step 0 / 3
4 RPM 400
15 t 15 t
24 8
23 +1,4° 9
22 ! 10
21 0° 12 11
15 t 15 t 13
20 19 18 17 16 15 14
WFN3RUWW2K2064139
1 Outrigger float, rear left indicator 13 Mobile crane levelling indicator

2 Preselect outrigger float, rear left indicator 14 Outrigger pressure, front right *) indicator
3 Outrigger pressure, rear left *) indicator 15 Outrigger float, front right indicator
4 Preselect outrigger float, front left indicator 16 Preselect outrigger float, front right indic-
ator
5 Outrigger float, front left indicator 17 Preselect levelling indicator
6 Outrigger pressure, front left *) indicator 18 Outrigger pressure, rear right *) indicator
182 ATF 60G-3

2019-03_EN
8 Outrigger
7 — 19 Preselect outrigger float, rear right indicator

8 Retracting outrigger float indicator 20 Outrigger float, rear right indicator
9 Mobile crane longitudinal inclination indic- 21 Superstructure not locked indicator
ator
10 Levelling OK indicator 22 Button lock indicator
11 Extending outrigger float indicator 23 Circular spirit level indicator
12 Mobile crane lateral inclination indicator 24 Boom not in boom rest indicator
Indicators
"Outrigger float" indicators
Indicators are lit = outrigger float is extending.
Indicators are lit = outrigger float is retracting.
"Preselect outrigger float, rear" indicator

Indicator is lit = outrigger float is preselected.
"Preselect all outrigger floats" indicator

Indicator is lit = all outrigger floats are preselected.
"Preselect outrigger float, front" indicator

Indicator is lit = outrigger float is preselected.
"Outrigger pressure" *) indicator
15 t The current outrigger pressure of the individual outrigger floats is displayed.


"Levelling OK" indicator

Indicator is lit = mobile crane is levelled.
WFN3RUWW2K2064139

Indicator is lit = the mobile crane is being levelled.
"Preselect levelling" indicator

Indicator is lit = levelling is preselected.
ATF 60G-3 183

2019-03_EN
8 Outrigger
Indicator "Circular spirit level"

The circular spirit level shows the current inclination of the mobile crane.
The marking must be in the centre during crane operation.



!
8.3.7 "Suspension cylinders" menu
Buttons – left-hand control panel
Overview
A B C
Step 0 / 3
RPM 400
E
WFN3RUWW2K2064139
F G H
A Preselect suspension cylinder, front right E Extending suspension cylinder button
button
B Preselect all suspension cylinders button F Preselect suspension cylinder, front left
button
C Preselect suspension cylinder, rear right G Level mobile crane button
button
184 ATF 60G-3

2019-03_EN
8 Outrigger
D Retracting suspension cylinder button H Preselect suspension cylinder, rear left but-
ton
"Preselect suspension cylinder" button

Press button = preselect suspension cylinder.
"Preselect all suspension cylinders" button

Press button = preselect all suspension cylinders.
"Retract suspension cylinders" button

Press and hold button = retract preselected suspension cylinders.
"Extend suspension cylinders" button

Press and hold button = extend preselected suspension cylinders.
"Level mobile crane" button

Press and hold button = level mobile crane.
When the indicator changes, the mobile crane is levelled.
Indicators – left-hand control panel
Overview
1 2
Step 0 / 3
RPM 400
11 3
4
5
12 6
WFN3RUWW2K2064139
7 8 9 10
1 Preselect suspension cylinder, front right 7 Preselect suspension cylinder, front left in-
indicator dicator
ATF 60G-3 185

2019-03_EN
8 Outrigger
2 Preselect suspension cylinder, rear right in- 8 Mobile crane levelling indicator
dicator
3 Suspension cylinder, rear right indicator 9 Preselect suspension cylinder, rear left in-
dicator
4 Retracting suspension cylinder indicator 10 Mobile crane levelling indicator
5 Extending suspension cylinder indicator 11 Suspension cylinder, front right indicator
6 Suspension cylinder, rear left indicator 12 Suspension cylinder, front left indicator
"Preselect suspension cylinder" indicator

Indicator is lit inversely = suspension cylinder is preselected.
"Suspension cylinder" indicators

Indicator is lit = suspension cylinder is extending.
Indicator is lit = suspension cylinder is retracting.

Indicator is not lit = mobile crane is not levelled.
Indicator is lit inversely = mobile crane is levelled.
WFN3RUWW2K2064139
186 ATF 60G-3

2019-03_EN
8 Outrigger
Buttons – right-hand control panel
Overview
A B C
Step 0 / 3
RPM 400
F G H
A Preselect suspension cylinder, rear left but- E Extending suspension cylinder button
ton
B Preselect all suspension cylinders button F Preselect suspension cylinder, rear right
button
C Preselect suspension cylinder, front left G Level mobile crane button
button
D Retracting suspension cylinder button H Preselect suspension cylinder, front right
button
"Preselect suspension cylinder" button

Press button = preselect suspension cylinder.
"Preselect all suspension cylinders" button

Press button = preselect all suspension cylinders.
"Retract suspension cylinders" button

Press and hold button = retract preselected suspension cylinders.
WFN3RUWW2K2064139
"Extend suspension cylinders" button

Press and hold button = extend preselected suspension cylinders.
ATF 60G-3 187

2019-03_EN
8 Outrigger
"Level mobile crane" button

Press and hold button = level mobile crane.
When the indicator changes, the mobile crane is levelled.
Indicators – right-hand control panel
Overview
1 2
Step 0 / 3
RPM 400
11 3
4
5
13 6
7 8 9 10
1 Preselect suspension cylinder, rear left in- 7 Preselect suspension cylinder, rear right in-
dicator dicator
2 Preselect suspension cylinder, front left in- 8 Mobile crane levelling indicator
dicator
3 Suspension cylinder, front left indicator 9 Preselect suspension cylinder, front right
indicator
4 Retracting suspension cylinder indicator 10 Mobile crane levelling indicator
5 Extending suspension cylinder indicator 11 Suspension cylinder, rear left indicator
6 Suspension cylinder, front right indicator 12 Suspension cylinder, rear right indicator
"Preselect suspension cylinder" indicator

Indicator is lit inversely = suspension cylinder is preselected.
WFN3RUWW2K2064139
"Suspension cylinder" indicators

Indicator is lit = suspension cylinder is extending.
Indicator is lit = suspension cylinder is retracting.
188 ATF 60G-3

2019-03_EN
8 Outrigger

Indicator is not lit = mobile crane is not levelled.
Indicator is lit inversely = mobile crane is levelled.
WFN3RUWW2K2064139
ATF 60G-3 189

2019-03_EN
8 Outrigger
8.4 Supporting the mobile crane
8.4.1 Preparations in carrier cab
Overview
3 6
4
5
2
1
1 Battery main switch switch 4 Ignition lock

2 Carrier operation/superstructure operation 5 Working speed / cruise control switch
key switch
3 Axle suspension locking switch 6 Starting/stopping engine pushbutton
Requirements
▪ The mobile crane is parked on the installation location.
▪ Parking brake is engaged.
WFN3RUWW2K2064139
▪ Gear pre-selection switch is adjusted in N position.
Procedure
1. Start the engine.
2. Switch on Working speed / cruise control switch.
3. Switch on Axle suspension locking switch.
190 ATF 60G-3

2019-03_EN
8 Outrigger
4. Turn Carrier operation/superstructure operation key switch to switch position 1.

ð The carrier has been prepared for outrigging process.
8.4.2 Extending outrigger beams to the required outrigger base

The following section describes the principle of extending the outriggers to the required outrig-
ger base.
Outrigger beams can only be extended and retracted on the respective operator side.
Outrigger floats can be extended or retracted on both sides.
Requirements
Lock positions and unlocking positions
A B
A Outrigger beam locked 1 Lock pin

B Outrigger beam unlocked
WFN3RUWW2K2064139
ATF 60G-3 191

2019-03_EN
8 Outrigger
Move to lock positions on the outrigger beams
1 2.4 m (both outrigger beams retracted) 3 5.4 m

2 4.4 m 4 6.4 m
Explanation
The first outrigger base corresponds to the road travel status. The outrigger does not need to be
extended.
Extending outrigger beams to other outrigger bases

1. Unlock both outrigger beams.
2. On the control panel, select the Retracting/extending outrigger beams menu.
3. Press the Outrigger beam pre-selection button.
4. Press and hold Extend outrigger beam(s) button until the required lock position has been
reached on both outrigger beams.
5. Lock both outrigger beams at the required position.
ð Outrigger beams have been extended to the required outrigger base and locked.
WFN3RUWW2K2064139
192 ATF 60G-3

2019-03_EN
8 Outrigger
8.4.3 Shifting outrigger floats in working position
Safety instructions
WARNING
Risk of accidents due to unsecured or damaged outrigger floats.
Unsecured or damaged outrigger floats may separate from the mobile
crane during crane operation. The mobile crane could turn over. This may
lead to personal injuries and material damage.
Damaged outrigger plates may break under load. As a result, the mobile
crane may become unstable and overturn. This may lead to personal injur-
ies and material damage.
1. Before crane operation, adjust and secure all outrigger floats in work-
ing position.
2. Check all outrigger floats for damages on the guide frames and hold-
ers.
3. Exchange damaged outrigger floats.
4. Remove foreign objects from the bearing surfaces.
Overview
A Transport position 1 Holder

B Working position 2 Hole for transport position
3 Locking pin
4 Hole for working position
WFN3RUWW2K2064139
5 Guide frame
Shifting outrigger floats in working position

1. Remove locking pin.
2. Pull outrigger float into working position up to the stop on the outrigger cylinder.
ATF 60G-3 193

2019-03_EN
8 Outrigger
3. Insert the locking pin into the hole for the working position and secure it.
ð Outrigger float is shifted into working position and secured.
8.4.4 Supporting the outrigger plates from below
Safety instructions
DANGER
Danger of tipping due to unsuitable ground.
If the ground subsides, the mobile crane may tip. This may lead to per-
sonal injuries and material damage.
1. Select a safe location on a stable ground.
2. Support the outrigger floats from below.
3. Observe the indications in the safety instructions.
DANGER
Danger of tipping due to damaged outrigger floats.
Damaged outrigger plates may break under load. As a result, the mobile
crane may become unstable and overturn. This may lead to personal injur-
ies and material damage.
1. Check the outrigger floats for damages and deformation.
2. Before crane operation, exchange damaged outrigger floats.
3. Remove foreign objects from the bearing surfaces.
WARNING
Danger of tipping due to slipping on smooth steel plates.
On smooth steel surfaces, the outrigger floats cannot have enough adhe-
sion. The mobile crane can slip from the supporting substructure and over-
turn. This may lead to personal injuries and material damage.
1. Use materials with structured surfaces.
2. Weld struts and rips onto smooth surfaces.
Requirements
▪ The required support surface must be known.
▪ The bearing surface of outrigger floats must lay flat on an even ground.
▪ When required, the outrigger floats are supported from below (see examples in graph).
WFN3RUWW2K2064139
194 ATF 60G-3

2019-03_EN
8 Outrigger
X = incorrect
O = correct
The materials for supporting from below must be sufficiently stable.
Examples:
▪ Square timber of hard wood (no conifer wood). Minimum height 100 mm. Free of knots,
without fractures. Same height in every position. The positions must have an offset of 90°
with respect to each other.
▪ Thick steel plates.
▪ Broad welded double T-beams.
Support positioning
1. Place the supports centrally under the outrigger floats.
2. Align the supports such that after extending the outrigger cylinders the remaining distance
is 10 - 15 mm.
8.4.5 Extending outrigger float
Safety instructions
CAUTION
Risk of accidents if it is not possible to see complete working area.
If all the outrigger floats are extended together, it is not possible to see the
entire working area. This may lead to accidents. This may lead to personal
injuries and material damage.
1. Only extend the outrigger float on operator side.
2. Extend all outrigger floats only to level the mobile crane.
WFN3RUWW2K2064139
Requirements
▪ Outrigger floats are shifted into working position and secured.
▪ Outrigger beams are extended to desired outrigger base and locked.
▪ The Axle suspension locking switch is activated.
ATF 60G-3 195

2019-03_EN
8 Outrigger
▪ Mobile crane is lowered completely.
Supporting and levelling mobile crane

1. On the control panel, select the Retracting/extending outrigger floats menu, refer to Menu
"Retracting/extending outrigger floats".
2. On the control panel, press the Preselect all outrigger floats button.
3. On the control panel, press and hold the Extending outrigger float button until all wheels are
raised off the ground.
Important: All wheels shall have a distance of at least 5 cm to the ground.
4. Press the Preselect levelling button on the control panel.
5. Press and hold the Mobile crane levelling button on the control panel until the Levelling OK
indicator appears.
ð Mobile crane is levelled automatically.
6. Check if all wheels of the mobile crane have a distance of at least 5 cm to the ground.
ð The mobile crane is stabilized and levelled for crane operation.
Final activities
On the "Outrigger" control panel
1. Bring the engine to the idling speed.
3. Close and lock both control panels.
In the carrier cab
1. Switch off Working speed / cruise control switch.
2. Switch off the ignition.
3. Switch off Battery main switch switch.
4. Lock carrier cab.
WFN3RUWW2K2064139
196 ATF 60G-3

2019-03_EN
8 Outrigger
8.5 Retracting the outrigger
8.5.1 Preparations in carrier cab
Overview
3 6
4
5
2
1
1 Battery main switch switch 4 Ignition lock

2 Carrier operation/superstructure operation 5 Working speed / cruise control switch
key switch
3 Axle suspension locking switch 6 Starting/stopping engine pushbutton
Requirements
▪ The mobile crane is parked on the installation location.
WFN3RUWW2K2064139
Procedure
2. Switch on Working speed / cruise control switch.
3. Switch on Axle suspension locking switch.
ATF 60G-3 197

2019-03_EN
8 Outrigger
4. Turn Carrier operation/superstructure operation key switch to switch position 1.

ð The carrier has been prepared for outrigging process.
8.5.2 Retracting the outrigger floats

Requirements
Procedure
1. On the control panel, select the Retracting/extending outrigger floats menu, refer to Menu
"Retracting/extending outrigger floats".
2. Press the Preselect all outrigger floats button.
3. Press and hold Retract outrigger float(s) button until all outrigger floats have been fully re-
tracted.
ð Mobile crane is standing on wheels.
8.5.3 Shifting of outrigger floats in transport position
Overview
A Working position 1 Holder

B Transport position 2 Hole for transport position
3 Locking pin
4 Hole for working position
WFN3RUWW2K2064139
5 Guide frame
Shifting of outrigger floats in transport position

1. Remove locking pin.
2. Push the outrigger float with the guide frame up to the stop onto the holder.
198 ATF 60G-3

2019-03_EN
8 Outrigger
3. Insert the locking pin into the hole for the transport position and secure it.
ð Outrigger float is shifted into transport position and secured.
8.5.4 Retracting outrigger beam

Requirements
Overview
1 2.4 m (both outrigger beams retracted) 3 5.4 m

2 4.4 m 4 6.4 m
WFN3RUWW2K2064139
ATF 60G-3 199

2019-03_EN
8 Outrigger
Lock positions and unlocking positions
A B
A Outrigger beam locked 1 Lock pin

B Outrigger beam unlocked
Retracting outrigger beam

1. Unlock both outrigger beams.
2. On the control panel, select the Retracting/extending outrigger beams menu, refer to Menu
"Retracting/extending outrigger beams" [} page 172].
3. Press the Outrigger beam pre-selection button.
4. Press and hold Retract outrigger beam(s) button until both outrigger beams have been fully
retracted.
5. Lock outrigger beam.
6. Retract and lock outrigger beams of opposite side.
ð Outrigger beams have been fully retracted and locked.
Final activities
On the "Outrigger" control panel
1. Bring the engine to the idling speed.
3. Close and lock both control panels.
In the carrier cab
WFN3RUWW2K2064139
1. Switch off Working speed / cruise control switch.

2. Switch off the ignition.
200 ATF 60G-3

2019-03_EN
9 Driving mode
9 Driving mode
9.1 General principles

The following section describes the preparation of the mobile crane for driving on public roads in
the Federal Republic of Germany.
National regulations for the area of application which differ from the above regulations must be
observed.
The traffic regulations and the total allowable weight must be observed.
The allowable axle loads must be observed. For exact specifications, refer to Technical data
[} page 395].
9.2 Before driving
9.2.1 Set down the hook block in the holder
Set down the hook block in the hook block holder on the carrier
Introduction
A 6 t hook block can be set down in the hook block holder on the carrier.
WFN3RUWW2K2064139
ATF 60G-3 201

2019-03_EN
9 Driving mode
Overview
1 Holder 2 6 t hook block
Weight of the hook block

Weight of the 6 t hook block: approx. 175 kg.
Requirements
▪ The mobile crane is correctly supported by the outriggers.
▪ Slings of a sufficient size are available.
Setting down the hook block

1. Attach the hook block to the mobile crane.
2. Set down the hook block in the hook block holder on the carrier.
3. Detach and stow the slings.
4. Set down the telescopic boom.
ð The hook block has been set down in the hook block holder on the carrier.
9.2.2 Attaching the hook block for road travel

WFN3RUWW2K2064139
Requirements
▪ The mobile crane is correctly supported.
▪ Superstructure engine is running.
▪ The superstructure is slewed to the front.
▪ Slewing brake is engaged.
▪ The telescopic boom is retracted.
202 ATF 60G-3

2019-03_EN
9 Driving mode
Hanging the hook block in the sliding coupling
1 Wire rope 3 Rope loop

2 Hook block 4 Sliding coupling
1. Position the hook block at the level of the carrier cab by either raising or lowering the tele-
scopic boom.
2. Mount the rope loop in the sliding coupling.
3. Slowly lower the hook block until the hook of the hook block can be attached to the rope
loop.
4. Attach the hook of the hook block into the rope loop.
5. Set down the telescopic boom in the boom rest and at the same time wind in the wire rope
slowly until the slinging rope and the wire rope no longer sag.
ð The hook block has been hung in the sliding coupling.
Final activities
1. Switch off the superstructure engine.
2. Retract the carrier outrigger and change the outrigger floats to the driving position.
WFN3RUWW2K2064139
ATF 60G-3 203

2019-03_EN
9 Driving mode
9.2.3 Checking resources and tyres
Safety instructions
WARNING
Risk of accidents due to operationally unreliable mobile crane.
If the mobile crane is not operationally reliable, this may lead to accidents
while driving.
1. Check mobile crane before driving.
Checking the air pressure in the tyres

1. Check the air pressure in the tyres. Correct if necessary, see Checking and adapting tyre
pressure [} page 365].
Checking the oil level of the engine

1. Check the oil level of the engine. Refill if necessary, see Checking the oil level of the engine
[} page 303].
Checking the oil level of the hydraulic oil tank

1. Check the oil level of the hydraulic oil tank. Refill if necessary, see Checking the hydraulic
oil level [} page 343].
Checking the coolant level

1. Check coolant level of the engine. Refill if necessary, see Checking the coolant level
[} page 310].
Checking fill level of the heating's fuel tank

1. Check the fill level of the fuel tank. Refill if necessary, see Filling up the heating's fuel tank
[} page 292].
Checking the fuel tank fill level

1. Check the fill level of the fuel tank. Refill if necessary, see Filling up fuel or AdBlue
[} page 293].
WFN3RUWW2K2064139
204 ATF 60G-3

2019-03_EN
9 Driving mode
Checking the fill level of the AdBlue tank
WARNING
Risk of accidents due to fault in the aftertreatment of exhaust gases.
If there is a fault in the aftertreatment of exhaust gases, operation will be
restricted after a certain time. This may result in accidents during driving
operation and crane operation.
1. Top up AdBlue® tank in time.
2. In case of freezing temperatures, switch on the heating *) of the Ad-
Blue® tank in time.
3. In the event of an aftertreatment of exhaust gases fault, switch off the
engine as soon as possible.
4. Make sure the engine is not restarted before the fault of the aftertreat-
ment of exhaust gases has been rectified.
1. In case of freezing temperatures, switch on the heating *) of the AdBlue® tank, refer to Su-
perstructure auxiliary heater [} page 244].
2. Check the fill level of the AdBlue® tank. Refill if necessary, see Filling up fuel or AdBlue
[} page 293].
Checking the filling level of the windshield washer system

1. Check the filling level of the windshield washer system. Refill if necessary, see Filling the
windshield washer system [} page 376].
Checking the windshield wipers
WARNING
Faulty windshield wipers impair visibility.
Defective windshield wipers cannot adequately remove the wetness from
the windows. The visibility may be impaired. This may result in accidents.
This may lead to personal injuries and material damage.
1. Check windshield wipers before starting work.
2. Replace defective windshield wipers.
1. Check the condition of the windshield wipers. Replace if necessary, see Replace the wind-
shield wiper blades [} page 375].
WFN3RUWW2K2064139
ATF 60G-3 205

2019-03_EN
9 Driving mode
Cleaning windshields
WARNING
Impaired visibility due to soiled windows.
Soiled windows may impair visibility. This may result in accidents. This
may lead to personal injuries and material damage.
1. Clean all windshields before starting work.
2. If necessary, clean the windows during period of use, too.
3. Check the fluid level in the windshield washer system's tank. If neces-
sary, refill the tank.
1. Check that the windshields are clean. Clean if necessary.
9.2.4 Requirements for driving mode
Safety instructions
WARNING
Risk of accidents due to loose parts.
Loose equipment parts or tools may fall down form the mobile crane while
driving. This could result in death or injury.
1. All loose equipment parts such as socket pins, retaining clips, locking
pins and lock pins must be fixed to the mobile crane so that they can-
not be lost.
2. Stow additional hook blocks in the tool box. Observe the maximum
payload.
3. Stow away the tools safely.
WARNING
Exceeding the maximum payload of tool box and wood storage.
Maximum payload of the tool box: 250 kg.
Maximum payload of the wood storage: 300 kg.
Keep off the loaded unit! There is a danger that the unit may deform or
tear off. This can cause injuries to persons, which could sometime be fatal.
1. Observe the maximum payload of the tool box and the wood storage.
WFN3RUWW2K2064139
206 ATF 60G-3

2019-03_EN
9 Driving mode
Overview
1 Carrier operation/superstructure operation 9 Left handrail

key switch
2 Stepladder 10 Ladder
3 Hook block 11 Outrigger beam
4 Anemometer 12 Outrigger floats
5 Superstructure lock 13 Ignition lock
6 — 14 Superstructure cab door lock
7 Wheel chocks *) 15 Outrigger control panel
8 Engine cover
General requirements
▪ Loose objects have been removed.
▪ Accessories and attachments are secured against slipping or falling off.
Requirements on superstructure
▪ Superstructure is locked.
▪ Slewing brake has been engaged.
▪ The ignition key is at position 0.
▪ Superstructure cab windshield and sliding door are closed.
▪ All the flaps on the superstructure are closed and secured.
WFN3RUWW2K2064139
▪ All the handrails on the superstructure are closed and secured.

▪ Anemometer *) and aircraft warning lamp *) have been dismounted and stowed away.
▪ All counterweights are in the transport position.
Requirements on carrier
▪ Hook block is attached to the front of the bumper crossmember and secured.
ATF 60G-3 207

2019-03_EN
9 Driving mode
▪ Wheel chocks *) are stowed away securely.

▪ Standard storage: in the wheel chock holders at the rear of the mobile crane.
▪ If there is a spare wheel holder *): in the storage box under the carrier cab.
▪ If there is a tool box *) at the rear of the mobile crane: in the wheel chock holders on the
tool box.
▪ Tools and accessories or stowed away such that they cannot get lost or in the tool box.
▪ Cover of the tool box *) is closed and locked.
▪ Safety accessories (warning triangles, First Aid boxes, warning lamps and fire extinguishers)
are stowed in a place easily accessible.
▪ All the outrigger beams are completely retracted and secured.
▪ All the outrigger floats are in the Driving mode position and are secured or have been re-
moved.
▪ All the covers of the Outrigger system control panels are closed.
▪ The Carrier operation/superstructure operation key switch in the carrier cab is set in rotation
position 1.
▪ All the swivelling ladders are deposited in their holders an secured.
▪ Stepladder is fastened in the holders on the carrier cab.
▪ Lounge bed *) is folded up and secured.
▪ All the working floodlights are switched off.
WFN3RUWW2K2064139
208 ATF 60G-3

2019-03_EN
9 Driving mode
9.3 Starting/stopping engine
9.3.1 Starting the engine
Overview
1 2 3
6 7 8 9 10
5
4
11
12
13
1 Parking brake warning lamp 8 Ignition lock

2 Engine temperature gauge 9 Gearbox display
3 Fuel gauge 10 Speed indicator
4 Battery main switch switch 11 On-board computer display
5 Carrier operation/superstructure operation 12 Gear pre-selection switch
key switch
6 Speedometer with trip meter 13 Parking brake
WFN3RUWW2K2064139
7 Starting/stopping engine pushbutton
Requirements
▪ Carrier operation/superstructure operation key switch is in position 1.
▪ Gear pre-selection switch is in position N.
ATF 60G-3 209

2019-03_EN
9 Driving mode
Switching on the ignition
Wait for at least 10 seconds between switching off the ignition and switch-
ing it back on! Non-compliance may result in problems in the vehicle elec-
tronics.
Version with immobilizer
1 Ignition lock 3 Ignition key, rigid

2 Ignition key, folding
1. Insert the ignition key into the ignition lock.

ð The immobilizer is now deactivated.
ð The ignition is switched on.
WFN3RUWW2K2064139
210 ATF 60G-3

2019-03_EN
9 Driving mode
Version without immobilizer *)
1 Ignition lock 2 Ignition key
1. Insert the ignition key into the ignition lock.

2. Rotate the ignition key to the right.
ð The ignition is switched on.
Self-test when ignition is switched on

The following indicator, pilot and warning lamps light up permanently until the engine starts:
▪ Service brake warning lamp (if the supply pressure is too low).
▪ Parking brake warning lamp (when engaged).
▪ CH indicator in Gearbox display.
▪ Fuel gauge shows filling level.
▪ Engine temperature gauge.
Starting the engine
NOTICE
Engine damage due to improper operation.
It is not allowed to start the engine when theMinor engine fault, Engine oil
level, and Coolant level warning lamps light up.
WFN3RUWW2K2064139
ATF 60G-3 211

2019-03_EN
9 Driving mode
NOTICE
Damages if starter is actuated for too long.
The starter can be damaged if actuated for too long.
1. Do not actuate the starter for more than 20 seconds.
2. Wait for at least 60 seconds before re-attempting to start the engine in
order to protect the batteries.
1 Starting/stopping engine pushbutton
1. Press Starting/stopping engine pushbutton.

ð Engine is running.
Indicators when engine is running

The following indicator, pilot and warning lamps are functioning when the engine is running:
▪ N indicator in Gearbox display.
▪ Parking brake warning lamp.
▪ Carrier central warning indicator.
▪ Speed indicator with integrated hour meter.
▪ Engine temperature gauge (depending on load).
▪ Speedometer.
▪ Fuel gauge.
WFN3RUWW2K2064139
212 ATF 60G-3

2019-03_EN
9 Driving mode
9.3.2 Switching off the engine
Do not switch off the engine while it is running at an increased speed.

Do not switch off the engine immediately after a heavy load, but instead let
it continue running at the idling speed for a few minutes to cool it down.
Version with immobilizer

2. Switch the Gear pre-selection switch into the N position.
4. Remove the ignition key from the ignition lock.
ð The engine is switched off, the immobilizer is activated.
Version without immobilizer *)

4. Turn ignition key to the left and pull it out of the ignition lock.
ð Engine is switched off.
Final activities
9.4 Shifting and driving
9.4.1 Starting and stopping
Safety instructions
WARNING
Risk of accidents due to mobile crane rolling away.
If the parking brake is not engaged when parking the mobile crane, it may
roll away out of control. This can cause an accident. This could cause seri-
ous or fatal injuries.
1. Park mobile crane on frim ground.
3. Set the gearbox to neutral position.
WFN3RUWW2K2064139
4. Secure the mobile crane to prevent it from rolling away, especially on

upward or downward gradients. If necessary, secure with wheel
chocks.
ATF 60G-3 213

2019-03_EN
9 Driving mode
WARNING
Risk of accidents due to deactivated accelerator pedal.
Acceleration is no longer possible when the Carrier operation/superstruc-
ture operation key switch is set to rotation position 2 while driving.
1. Switch the Carrier operation/superstructure operation key switch to ro-
tation position 1.
2. Pull out the key prior to driving.
WARNING
Danger due to lack of braking power.
If the Gear pre-selection switch is switched to neutral position while driv-
ing, the braking power of the engine will not be available. This may lead to
accidents.
1. Do not bring the Gear pre-selection switch into neutral position while
driving.
2. Do not switch the Gear pre-selection switch from D to R while driving.
NOTICE
Engine damage due to overspeed.
The mobile crane may accelerate when driving on downward gradients.
The gearbox is not shifted up automatically in the manual driving mode.
In case of overspeed, an emergency shifting up is activated to protect the
engine.
At 2650 rpm, the emergency shifting up / takes place even if the service
brake and the retarder are activated.
At 3500 rpm, the emergency shifting up / takes place if the retarder is ac-
tivated as well as in the pure deceleration mode.
1. Shift the gearbox into a lower gear on time.
2. Decelerate the mobile crane with the service brake.
NOTICE
Gearbox damage due to improper operation.
Improper operation may lead to gearbox damages.
1. Engage the reverse gear only when the mobile crane has stopped.
2. Do not allow the mobile crane to roll in the opposite direction to the
gear engaged.
WFN3RUWW2K2064139
214 ATF 60G-3

2019-03_EN
9 Driving mode
Overview
1 Gearbox display 2 Gearbox shifting lever
Gear selector lever
1 Gear selector lever DM Forward maneuvering

2 Gear pre-selection switch D Forward driving
A Shift up gears N Neutral position
First spring position = shift up one gear
WFN3RUWW2K2064139
Stop spring position = shift up two gears

B Shift down gears R Reverse driving
First spring position = shift down one gear
Stop spring position = shift down two gears
M/A Toggle between manual/automatic driving RM Reverse maneuvering
modes
ATF 60G-3 215

2019-03_EN
9 Driving mode
S —
Starting/Maneuvering
Requirements
▪ Gear pre-selection switch is set in N position.
▪ Working speed / cruise control switch is switched off.
Starting
1. Press the brake pedal.
2. Rotate the Gear pre-selection switch to D or R.
ð The Gearbox display shows D or R.
3. Release the parking brake.
ð The Parking brake warning lamp goes out.
4. Release the brake pedal, press the accelerator pedal carefully.
ð The mobile crane is set in motion.
Forward gear 3 is programmed as the starting gear. A different forward gear can be engaged
manually.
Carry out a test braking after starting on a dry, non-skidding road.
Maneuvering
NOTICE
Clutch damage due to overload.
In the event of a clutch overload, the display shows Gearbox CL. The
clutch may be damaged due to overload.
1. In the event of a clutch overload, switch Gear pre-selection switch into
position D, N or R.
A maneuvering mode is provided for extremely slow driving.

In the maneuvering mode, the accelerator pedal reacts more sensitively.
1. Press the brake pedal.
2. Switch Gear pre-selection switch into position DM or RM.
ð The Gearbox display shows DM or RM.
WFN3RUWW2K2064139
ð Forward gear 1 and 2 and reverse gear 1 and 2 are available for the manoeuvring mode.
3. Release the parking brake.
ð The Parking brake warning lamp goes out.
4. Release the brake pedal and press the accelerator pedal carefully.
ð The mobile crane is set in motion.
216 ATF 60G-3

2019-03_EN
9 Driving mode
Stopping
NOTICE
Incorrect operation when stopping the mobile crane.
When opening the driver's door while the transmission is not in the N posi-
tion, the Gearbox fault warning lamp is flashing and the Gearbox fault
warning buzzer sounds. This does not indicate a malfunction but an incor-
rect operation.
1. Switch Gear pre-selection switch into position N.
1. Stop the mobile crane to standstill with the service brake.

ð Parking brake warning lamp is lit.
ð The Gearbox display shows N.
ð The mobile crane is standing still.
9.4.2 Activating rear steering
Safety instructions
Gearbox shifts up only to forward gear 3.

A special steering program will be activated for as long as the Steering
program switch is switched on.
The pilot lamp in the Steering program switch is lit.
The Steering program switch pilot lamp in the on-board computer display
flashes.
The Upshift lock pilot lamp in the on-board computer display is lit.
In Germany, driving on public roads is only allowed in the on-road

mode. Observe country-specific regulations deviating from this.
Switch on steering program: Maximum driving speed is walking
speed. Warning sound if speed is too high.
Greater tyre wear when driving with an unlocked rear axle.
When the engine of the mobile crane is re-started, the special steer-
ing programs are deactivated. The special steering programs On-
road/off-road mode remain.
WFN3RUWW2K2064139
ATF 60G-3 217

2019-03_EN
9 Driving mode
Overview of axles and wheels
1 Front wheels 2 Rear wheels
Overview of the rear steering
Overview
A On-road mode C Crab steering

B Manual steering of rear wheels
On-road mode
The front wheels are steered mechanically.
WFN3RUWW2K2064139
The rear wheels are not steered.
Manual rear steering

The front wheels are steered mechanically.
The rear wheels are steered manually with the Manual rear steering to the right/left pushbutton,
independently of the front wheels.
218 ATF 60G-3

2019-03_EN
9 Driving mode
The steering possibilities are:

▪ Crab steering.
The mobile crane can be moved in parallel.
▪ Manual steering of rear wheels.
The rear wheels can be steered manually independently of the steering angle of the front
wheels.
Carrier cab - Rear steering operating elements
1 Unlock rear steering switch 2 Manual rear steering to the right/left push-
button
Activating on-road mode
Overview
WFN3RUWW2K2064139
Requirement
▪ Unlock rear steering switch has been activated.
ATF 60G-3 219

2019-03_EN
9 Driving mode
Activating on-road mode

1. Steer rear wheels to the straight-ahead position with the Manual rear steering to the right/
left pushbutton.
2. Switch off Unlock rear steering switch.
ð The pilot lamp in the switch goes out.
ð The Steering program switch pilot lamp in the on-board computer display goes out.
ð The Upshift lock pilot lamp in the on-board computer display goes out.
ð On-road mode steering program is activated.
Levelling mobile crane

After changing to on-road mode, level mobile crane, refer to Bringing mobile crane into driving
level [} page 235].
Activating manual rear steering
Safety instructions
Gearbox shifts up only to forward gear 3.

A special steering program will be activated for as long as the Steering
program switch is switched on.
The pilot lamp in the Steering program switch is lit.
The Steering program switch pilot lamp in the on-board computer display
flashes.
The Upshift lock pilot lamp in the on-board computer display is lit.
Requirement
▪ Unlock rear steering switch has been deactivated.
Activating manual rear steering

1. Unlock and push backward the Unlock rear steering switch.
ð The pilot lamp in the switch is lit.
ð The Steering program switch pilot lamp in the on-board computer display flashes.
ð The Upshift lock pilot lamp in the on-board computer display is lit.
2. Steer rear wheels with the Manual rear steering to the right/left pushbutton.
9.4.3 Engaging and disengaging axle drive and differential locks
Safety instructions
WFN3RUWW2K2064139
NOTICE
Damages on axles due to improper operation of drives.
Axle drives and gear wheels may be damaged. The mobile crane may no
longer be in driving condition.
1. Apply drive of axle 1 only briefly and in difficult terrain.
220 ATF 60G-3

2019-03_EN
9 Driving mode
NOTICE
Damages on axles due to improper operation of differential locks.
Axle drives and gear wheels may be damaged. The mobile crane may be-
come undriveable.
1. Apply differential locks only briefly and in difficult terrain.
2. Do not steer when inter-wheel differential locks are switched on.
Off-road, if required, switch on ABS off-road mode.
Overview
6 2 3
00s
1 4
1 Axle 1 drive pilot lamp 5 Differential locks pilot lamp

2 Inter-axle differential locks Axle 1 to 3 pilot 6 Remaining period of inter-wheel differential
lamp locks indicator
3 Inter-wheel differential locks pilot lamp 7 Axle drive/differential locks pushbutton
4 Axle 1 pilot lamp
Engaging
WFN3RUWW2K2064139
Sequence of engaging
1. Drive of axle 1 and inter-axle differential locks.
2. All inter-wheel differential locks.
ATF 60G-3 221

2019-03_EN
9 Driving mode
Requirements
▪ Mobile crane is standing still and parking brake is engaged.
▪ All wheels are in the straight-ahead position.
Switching on the drive of Axle 1 and the inter-axle differential locks

1. Push Axle drive/differential locks pushbutton downward once.
ð The Drive menu appears in the on-board computer display.
ð Axle 1 drive pilot lamp is lit.
ð Inter-axle lock Axle 1 to 3 pilot lamp is lit.
ð Axle 1 pilot lamp is lit, indicator has yellow background.
ð The Differential locks pilot lamps are lit. A cross appears in the respective circles.
ð Drive of the axle 1 and both inter-axle differential locks are engaged.
Engaging inter-wheel differential locks

1. Push Axle drive/differential locks pushbutton downward a second time.
ð The Inter-wheel differential locks pilot lamp is lit.
ð The Differential locks pilot lamps are lit. A cross appears in the respective circles.
ð Inter-wheel differential locks are engaged for 10 seconds.
The remaining time of engaged locks is displayed in seconds.
Switching off
Requirements
▪ Mobile crane is standing still and parking brake is engaged.
▪ All wheels are in the straight-ahead position.
Switching off drive of the axle 4 and inter-axle differential locks

1. Push Axle drive/differential locks pushbutton upward once.
ð Axle 1 drive pilot lamp goes out.
ð Inter-axle differential lock Axle 1 to 3 pilot lamps go out.
ð Axle 1 pilot lamp is lit, indicator has black background.
ð The Differential locks pilot lamps are lit. The circles are empty.
ð Drive of the axle 1 and both inter-axle differential locks are switched off.
Switching off inter-wheel differential locks

WFN3RUWW2K2064139
NOTICE! The inter-wheel differential locks are deactivated automatically after 10

seconds.
222 ATF 60G-3

2019-03_EN
9 Driving mode
9.4.4 Brakes
Principle
The braking system of the mobile crane consists of the following components:
▪ Service brake as two-circuit braking system with drum brakes according to ECE R13.
▪ Parking brake as spring loaded brake.
▪ Engine brake.
Failure of on brake circuit causes reduced braking power, the braking distance will be longer. In
this situation, the parking brake must be used as auxiliary brake to slow the mobile crane down
to standstill.
For further information, please refer to chapter Technical data, Brakes [} page 403].
Safety instructions
WARNING
Risk of accidents due to lack of braking power.
A lack of braking power may lead to a significantly longer braking distance
and accidents. This could cause serious or fatal injuries to persons.
1. Do not set the mobile crane in motion without sufficient brake pres-
sure. The warning lamps must have gone out.
2. Check the function of the braking system after starting: Carry out a test
braking.
3. While driving, always observe the air pressure gauges as well as the
Service brake and Parking brake warning lamps.
4. If the Service brake or Air pressure gauge warning lamps light up while
driving, stop the mobile crane at a secure place as fast as possible and
suiting the traffic conditions. If necessary, additionally engage the park-
ing brake.
NOTICE
Instructions regarding driving on down gradients.
1. Change into a lower gear early.
2. Activate the retarder.
3. Use the service brake only briefly as auxiliary brake.
WFN3RUWW2K2064139
ATF 60G-3 223

2019-03_EN
9 Driving mode
Overview
3 3
2
1
6
9
7
1 Parking brake warning lamp 6 Eddy-current brake pilot lamp
2 Service brake warning lamp 7 Parking brake
3 Air pressure gauge 8 Brake pedal
4 — 9 Right steering column switch
5 —
WFN3RUWW2K2064139
224 ATF 60G-3

2019-03_EN
9 Driving mode
Service brake
Overview
1 Brake pedal
1. Gently step on the brake pedal.

ð The mobile crane is decelerated.
Parking brake
WARNING
chocks.
WFN3RUWW2K2064139
ATF 60G-3 225

2019-03_EN
9 Driving mode
WARNING
Overheating of wheel brakes when driving with engaged parking
brake.
The braking power of the service brake may be reduced. The mobile crane
may catch fire. This could cause serious or fatal injuries.
1. Before driving, release parking brake.
2. Do not drive away before the Parking brake warning lamp has gone
out.
Overview
1 Parking brake - braking position 3 Parking brake - ring

2 Parking brake - driving position
Engaging the parking brake

1. Pull parking brake lever backward into braking position. The lever must engage.
ð Parking brake is engaged.
ð Parking brake warning lamp is lit.
Releasing the parking brake

1. Pull the lever ring upward.
2. Push the lever forward up to the stop, into Driving position.
ð The parking brake is released.
ð The Parking brake warning lamp goes out when the brake-air pressure is sufficient.
Parking brake as auxiliary brake
WARNING
Risk of accidents due to failure of service brake.
The failure of the service brake may lead to accidents. This could cause
serious or fatal injuries.
1. Slow the mobile crane down to standstill with the service brake suiting
the traffic conditions.
WFN3RUWW2K2064139
2. Before driving again, have the braking system repaired.
226 ATF 60G-3

2019-03_EN
9 Driving mode
Retarder
Safety instructions
WARNING
Reduced braking power due to overheated wheel brakes.
When the service braking system is used over a prolonged period, the
wheel brakes may overheat. In this way, the braking power may be re-
duced. This may cause an accident.
1. Before driving into a slope, shift the gearbox to a lower gear.
2. Use the retarder.
WARNING
Risk of accidents due to locking drive wheels when using the re-
tarder.
The retarder acts on the driving wheels. When switching on the retarder on
slippery road, the driving wheels may lock. This may cause an accident.
1. When switching the retarder manually, carefully switch the switching
stages in succession.
2. Do not activate the retarder on slippery road.
Description of function of the retarder

The retarder consists of the following components:
▪ Engine brake and intarder with Bremsomat.
▪ Engine brake and intarder (5 manually switchable switching stages).
▪ Engine brake and intarder and eddy-current brake *) (5 manually switchable switching
stages).
• The retarder only has power when a gear is engaged.

• The lower the gear the higher the power of the retarder.
• The retarder is briefly interrupted while the ABS control *) is active.
• The retarder remains switched off for as long as the cruise control is
switched on.
• The retarder function is interrupted for as long as the accelerator pedal is
pressed.
• The retarder is briefly interrupted while gears are shifted.
• If the retarder braking power is no longer sufficient to keep the speed
constant on a down gradient, use the service brake.
WFN3RUWW2K2064139
ATF 60G-3 227

2019-03_EN
9 Driving mode
Switching the engine brake and Bremsomat on/off
0 Engine brake/Bremsomat switched off 1 Engine brake/Bremsomat switched on
Switching engine brake and Bremsomat on

1. Pull the steering column switch from position 0 to position 1.
ð Engine brake and Bremsomat are switched on.
ð The current driving speed of the mobile crane is saved and maintained constant on the
downward gradient. The required braking torque is adjusted infinitely and automatically. The
Intarder pilot lamp lights up when the intarder is functioning.
Switching engine brake and Bremsomat off

1. Press the steering column switch from position 1 to position 0.
ð Engine brake and Bremsomat are switched off.
Take further information about the Bremsomat functionality from the operating manual provided
by the gearbox manufacturer, refer to Intarder.
Off-road mode ABS
Safety instructions
WARNING
Risk of accident from activated off-road mode ABS.
If the off-road mode ABS is engaged, the wheels can lock during braking.
This may lead to accidents involving personal injuries or material damage.
1. Do not activate off-road mode ABS on public roads.
NOTICE! "Off-road mode ABS" is deactivated when the engine is started.

WFN3RUWW2K2064139
228 ATF 60G-3

2019-03_EN
9 Driving mode
Overview
2 3
1 Off-road mode ABS pushbutton 3 Trailer ABS pilot lamp

2 Mobile crane ABS pilot lamp
In the case of the ABS off-road mode, the ABS system is switched to a higher brake slippage.
This enables the stopping distance off-road (e.g. in case of soft or extremely undulating sub-
stratum as well as on downward gradients) to be reduced.
Activating off-road mode ABS

1. Press lower part of Off-road mode ABS pushbutton.
ð Mobile crane ABS pilot lamp is flashing. If a trailer is connected, the Trailer ABS pilot
lamp is flashing additionally.
ð Off-road mode ABS is activated.
Deactivating off-road mode ABS

1. Press upper part of Off-road mode ABS pushbutton.
ð The Mobile crane ABS pilot lamp goes out. If a trailer is connected, the Trailer ABS pilot
lamp goes out additionally.
WFN3RUWW2K2064139
ð Off-road mode ABS is deactivated.
ATF 60G-3 229

2019-03_EN
9 Driving mode
9.4.5 Cruise control
Safety instructions
WARNING
Risk of accidents when cruise control is switched on.
If the driver does not react on time when the cruise control is switched on,
the mobile crane may start to skid or not be braked on time. This may lead
to accidents. Do not use cruise control:
1. In case of uncertain traffic conditions.
2. In case of wintry road conditions.
3. In case of slippery road.
Introduction
The cruise control allows the adjustment of a constant speed.
It is possible that the set speed cannot be maintained in the following situations:
▪ On upward gradients.
▪ On downward gradients.
Requirement
▪ The mobile crane is driving faster than 20 km/h.
Switching cruise control on
Overview
2
WFN3RUWW2K2064139
1 Steering column switch on the right 3 Cruise control pilot lamp

230 ATF 60G-3

2019-03_EN
9 Driving mode
Procedure
1. Press lower part of Working speed / cruise control switch.
2. Tap the steering column switch on the right briefly in position 1.
ð The current speed is saved.
ð Cruise control is switched on, the Cruise control pilot lamp is lit green.
Changing adjusted speed
Overview
1 Increasing the speed 2 Reducing speed
Increasing the speed

1. Tap the steering column switch briefly in position 1.
ð The adjusted speed is increased and saved in accordance with the duration of the tapping.
1. Push steering column switch into position 1 and hold it there.
ð The adjusted speed is increased and saved steadily.
Reducing speed
1. Tap the steering column switch briefly in position 2.
ð The adjusted speed is reduced and saved in accordance with the duration of the tapping.
WFN3RUWW2K2064139
1. Push steering column switch into position 2 and hold it there.

ð The adjusted speed is reduced and saved steadily.
Interrupting cruise control

The cruise control is only briefly interrupted in the following situations:
▪ Gear change.
ATF 60G-3 231

2019-03_EN
9 Driving mode
▪ Accelerating the mobile crane with the accelerator pedal.

▪ The mobile crane is decelerated; at the same time the steering column switch is in posi-
tion 1, refer to Switching the engine brake and Bremsomat on/off [} page 228].
Deactivating the cruise control
Functions
The cruise control is automatically switched off and the adjusted speed is deleted under the fol-
lowing conditions:
▪ The crane driver brakes the mobile crane.
▪ The speed drops below 20 km/h.
▪ The Working speed / cruise control control switch is switched off (upper part pressed).
If the ignition has been switched off, the upper part and then the lower part of the "Work-
ing speed / cruise control control switch" must be pressed to switch on the cruise control
again.
Overview
Procedure
1. Press upper part of Working speed / cruise control switch.
ð The cruise control is switched off and deleted.
WFN3RUWW2K2064139
232 ATF 60G-3

2019-03_EN
9 Driving mode
9.4.6 Tilt adjustment / driving level
Safety instructions
WARNING
Risk of accidents when driving not levelled mobile crane.
The mobile crane may become unstable and overturn. This could cause
serious or fatal injuries.
1. Level the mobile crane before driving.
WARNING
Accidents due to errors when levelling / adjusting tilt.
Errors when levelling /adjusting tilt may lead to accidents.
Observe the following points:
1. Bring rear wheels into the straight forward position.
2. No one is allowed to stay below or above the mobile crane.
3. Instruct unauthorized persons to leave the danger zone of the mobile
crane.
4. Lower the suspension completely before starting the levelling.
5. Carry out levelling only when the mobile crane is standing still, never
while driving.
6. After levelling, the mobile crane must be in a levelled position.
7. When adjusting the tilt, incline the mobile crane from the horizontal po-
sition only as much as is absolutely required. Danger of tipping!
NOTICE
Damages on the mobile crane due to errors when levelling / adjusting
tilt.
Errors when levelling /adjusting tilt may lead to damages on the mobile
crane.
Observe the following points:
1. Carry out levelling / tilt adjustment only at engine speeds up to max.
1200 rpm.
2. While levelling, the axle suspension must not be locked.
3. While adjusting the tilt, the axle suspension must be locked.
WFN3RUWW2K2064139
NOTICE
Damage on the suspension cylinders in case of fully lowered mobile
crane.
If the suspension cylinders are mechanically standing on the block, they
may be damaged and the axle oscillation does not function.
1. Do not drive with a fully lowered mobile crane.
ATF 60G-3 233

2019-03_EN
9 Driving mode
Overview
LEVEL
8 9
1 2 3 1-5
1-3 10
7 6 5 4
1 Driving level pushbutton 6 Axle suspension locking switch
2 Front left-hand suspension cylinder push- 7 Change vehicle height pushbutton
button
3 Front right-hand suspension cylinder push- 8 Levelling pilot lamp
button
4 Rear right-hand suspension cylinder push- 9 Axle suspension locking pilot lamp
button
5 Rear left-hand suspension cylinder push- 10 Axles lifted pilot lamp
button
Tilt adjustment
Requirement
▪ Switch Gear pre-selection switch into position N.
▪ All wheels are in the straight forward position.
Switching axle suspension locking on

1. Unlock and push downward the Axle suspension locking switch.
ð Axle suspension locking pilot lamp lights up.
ð The axle suspension is locked.
WFN3RUWW2K2064139
Changing inclination of mobile crane
Raising left-hand front corner of the vehicle

1. Press and hold upper part of Front left-hand suspension cylinder pushbutton.
ð Left-hand front corner of the mobile crane is raised.
234 ATF 60G-3

2019-03_EN
9 Driving mode
Lowering left-hand front corner of the vehicle

1. Press and hold lower part of Front left-hand suspension cylinder pushbutton.
ð Left-hand front corner of the mobile crane is lowered.
Raising right-hand front corner of the vehicle

1. Press and hold upper part of Front right-hand suspension cylinder pushbutton.
ð Right-hand front corner of the mobile crane is raised.
Lowering right-hand front corner of the vehicle

1. Press and hold lower part of Front right-hand suspension cylinder pushbutton.
ð Right-hand front corner of the mobile crane is lowered.
Raising right-hand rear corner of the vehicle

1. Press and hold upper part of Rear right-hand suspension cylinder pushbutton.
ð Right-hand rear corner of the mobile crane is raised.
Lowering right-hand rear corner of the vehicle

1. Press and hold lower part of Rear right-hand suspension cylinder pushbutton.
ð Right-hand rear corner of the mobile crane is lowered.
Raising left-hand rear corner of the vehicle

1. Press and hold upper part of Rear left-hand suspension cylinder pushbutton.
ð Left-hand rear corner of the mobile crane is raised.
Lowering left-hand rear corner of the vehicle

1. Press and hold lower part of Rear left-hand suspension cylinder pushbutton.
ð Left-hand rear corner of the mobile crane is lowered.
Bringing mobile crane into driving level
Requirement
▪ Vehicle stands still on even road.
▪ Mobile crane is lowered completely.
WFN3RUWW2K2064139
▪ The axle suspension is not locked.

▪ All wheels are in the straight forward position.
▪ The Axle suspension locking pilot lamp must not flash.
ATF 60G-3 235

2019-03_EN
9 Driving mode
Changing the height of the mobile crane
Lifting mobile crane

1. Push upwards and hold Front left-hand suspension cylinder pushbutton, Front right-hand
suspension cylinder pushbutton, Rear left-hand suspension cylinder pushbutton, and Rear
right-hand suspension cylinder pushbutton.
ð The mobile crane is lifted.
Hold the pushbutton pressed until reaching the desired tilt/position.
Lowering the mobile crane

1. Press and hold lower part of Change vehicle height pushbutton.
ð The mobile crane is lowered.
Hold the pushbutton pressed until reaching the desired tilt/position.
Bringing mobile crane into driving level

1. Press and hold the Driving level pushbutton until the colour of the Levelling pilot lamp
changes from blue to yellow.
The levelling process will stop automatically.
2. Release Driving level pushbutton.
ð The mobile crane is levelled.
9.4.7 Driving with trailer
Safety instructions
DANGER
Risk of accident when coupling and uncoupling the trailer
Observe the guidelines of the employers' liability insurance association
when coupling and decoupling the trailer.
WARNING
Risk of accidents when mobile crane and trailer move during prepar-
ation for coupling.
Persons preparing the decoupling can be crushed between the mobile
crane and the trailer. This may result in death or injury.
1. Engage parking brakes of mobile crane and trailer during preparation
for coupling.
WFN3RUWW2K2064139
2. At the time of coupling, no person is allowed to stay between the mo-

bile crane and the trailer.
236 ATF 60G-3

2019-03_EN
9 Driving mode
WARNING
Risk of accidents due to detaching trailer.
If the trailer detaches from towing vehicle while driving, this may lead to
accidents. This may result in death or injury.
1. Couple the trailer to the mobile crane correctly and as prescribed.
WARNING
Risk of accidents due to mobile crane with trailer rolling away on
down gradients.
When parking the mobile crane with trailer for a prolonged period, the air
pressure in the braking system of the trailer may drop. In this way, it may
roll away out of control. This can cause an accident. This may result in
death or injury.
1. Before parking the mobile crane with trailer on a downward gradient,
check the holding force of the mobile crane's parking brake system.
2. If the mobile crane rolls away, a location with less down gradient must
be found.
3. Place wheel chocks under the wheels.
Trailer operation
Coupling the trailer

▪ The tractor vehicle and trailer are secured against rolling away.
1. Open the trailer hitch. Observe the operating manual provided by the manufacturer.
2. Adapt the drawbar of the trailer to the height of the trailer hitch jaw.
3. Release parking brake of towing vehicle. Maneuver the towing vehicle backwards toward
the trailer until the trailer is coupled.
4. Engage parking brake of towing vehicle.
5. Establish electric and pneumatic connections.
6. Release parking brake of trailer.
7. Remove possibly existing wheel chocks.
ð Trailer is coupled to towing vehicle, connections are established.
WFN3RUWW2K2064139
ATF 60G-3 237

2019-03_EN
9 Driving mode
Testing holding force of tractor vehicle's spring-loaded accumulator on up/down gradient
1 Brake lever 3 Parking position

2 Ring 4 Test position
1. Engage parking brake of towing vehicle.

2. Push ring downward and pull brake lever backward up to the stop in test position.
ð The tractor vehicle and trailer combination must come to a stop. If this is not the case, a
location with less downward gradient must be found for parking.
3. Return brake lever into braking position.
4. Place wheel chocks under the wheels of towing vehicle and trailer.
ð The holding force of the tractor vehicle's spring-loaded accumulator has been checked.
Uncoupling the trailer

1. Park the combination.
2. Place wheel chocks under the wheels of trailer.
3. Engage parking brake of trailer.
4. Separate electric and pneumatic connections.
5. Open the trailer hitch.
6. Move towing vehicle away.
ð Connections are separated, trailer and towing vehicle are uncoupled.
WFN3RUWW2K2064139
238 ATF 60G-3

2019-03_EN
9 Driving mode
9.4.8 Parking the mobile crane
Safety instructions
WARNING
4. In case of a coupled trailer, check the holding force of the tractor-
trailer.
chocks.
Parking the mobile crane

1. Stop the mobile crane to standstill with the service brake.
4. Switch all electrical devices off.
5. Switch engine off and remove ignition key.
6. Close all the windows of carrier cab.
9. If necessary, place wheel chocks under the wheels, refer to Wheel chocks [} page 50].
10.Lock all the storage boxes.
11.Lock all the control boxes for the outriggers.
12.Lock all the fuel tanks and all the AdBlue tanks (carrier and superstructure).
13.Lock superstructure cab.
ð The mobile crane is parked correctly.
WFN3RUWW2K2064139
ATF 60G-3 239

2019-03_EN
9 Driving mode
WFN3RUWW2K2064139
240 ATF 60G-3

2019-03_EN
10 Driving mode in winter
10.1 General safety instructions
WARNING
Risk of accident due to snow and ice.
Roof loads such as snow and ice can endanger the operator as well as
other persons.
Layers of snow and ice form a dangerous covering on roof surfaces, plat-
forms and ladders of the mobile crane.
1. Remove unsafe roof loads such as snow and loose chunks of ice be-
fore starting work.
2. Remove snow and ice from windshields and mirrors before starting
work.
3. Remove snow and ice from the ladders and platforms before climbing
up.
4. Remove snow and ice from telescopic boom and jibs.
CAUTION
Freezing of uncovered skin.
In case of severe frost, uncovered skin can freeze onto bare metal sur-
faces.
1. Do not touch metal surfaces with uncovered skin.
2. Wear gloves to protect hands.
10.2 Engine
10.2.1 Fuel
NOTICE
Malfunctions due to incorrect fuel.
At low ambient temperatures, the fluidity of the diesel fuel is reduced. This
may lead to malfunctions.
1. Use the corresponding cold-resistant diesel fuels at low ambient tem-
peratures.
2. Follow the enclosed operating manual of the engine manufacturer.
WFN3RUWW2K2064139
ATF 60G-3 241

2019-03_EN
10.2.2 Engine oil
NOTICE
Damage to the engine due to incorrect engine oil.
Engine oil with incorrect viscosity can damage the engine.
1. Choose the SAE class corresponding to the expected ambient temper-
ature during the utilization period. For approved engine oils, please
refer to the fuel specifications of the engine manufacturer.
10.2.3 Coolant and anti-freeze
NOTICE
Damage to the engine due to missing antifreezing agent.
The coolant can freeze and damage the engine.
1. Check the antifreeze property of the coolant in time and increase the
percentage of antifreezing agents if required.
10.2.4 AdBlue in winter operation
Switching on the heating of the AdBlue tank

1. For switching on the heating of the AdBlue tank, refer to Superstructure auxiliary heater
[} page 244].
10.3 Windshield washing system
WARNING
Risk of accidents due to freezing of wiper nozzles or too little glass
cleaning agent.
If the wiper nozzles freeze up, the windshields can no longer be cleaned
using the windshield washer system. The visibility may be limited. This
may lead to accidents. This could cause serious or fatal injuries.
1. Add sufficient anti-freeze.
2. Increase the percentage of the antifreezing agent corresponding to the
ambient temperature.
WFN3RUWW2K2064139
242 ATF 60G-3

2019-03_EN
10.4 Hydraulic system
NOTICE
Damage to the hydraulic pump due to high speed at very low oil tem-
peratures.
Higher engine speeds and cold hydraulic oils can damage the hydraulic
pumps.
There is the risk of failure of hydraulic pumps.
1. Ensure that engine speeds are not high when cold hydraulic oils are
used.
2. Preheat the oil according to heating instructions.
3. Use hydraulic oil which is suitable for lower temperatures.
At low ambient temperatures and with cold hydraulic oil, the Hydraulic oil filter warning lamp
may light up. The Hydraulic oil filter warning lamp goes out when the hydraulic oil has reached
the operating temperature.
If the Hydraulic oil filter warning lamp continues to glow when the hydraulic oil is warm, the hy-
draulic oil filters shall be changed.
Pay attention to the minimum temperature limit of the oil.
The hydraulic oil used may still be used up to 10 °C below its minimum temperature limit.
If the ambient temperature is below this limit, use a suitable oil. Keep the recommended oils in
mind.
10.4.1 Heating instructions for hydraulic oils

The hydraulic oil will soon be brought closer to the operating temperature by lowering (moving
on the block) or by extending or retracting several times.
The maximum permissible operating temperature is approximately 70-80 °C.
10.4.2 Switching to another oil
NOTICE
Hydraulic pump damage due to choosing the wrong oil.
When the hydraulic system is operated with hydraulic oil such as Renolin
Xtreme Temp 46+, damage to the hydraulic pumps can occur at low tem-
peratures.
There is the risk of failure of hydraulic pumps.
1. Change oils and use the hydraulic oils specified for the ambient tem-
peratures.
WFN3RUWW2K2064139
The oil may only be changed at a specialist workshop.
10.5 Gearbox
At temperatures above -20 °C, the gearbox can be operated and all functions are ensured.
ATF 60G-3 243

2019-03_EN
In the temperature range from -20 °C to -30 °C, a minimum 10 minute warm-up period is re-
quired.
1. Switch Gear pre-selection switch into position N.
3. Increase the idling speed to approximately 1500 rpm.
At temperatures below -30 °C, the instructions in the gearbox manufacturer's operating manual
must be observed.
Observe the oil recommendation in the ZF lubricants list.
10.6 Anti-skid chains
WARNING
Risk of accidents when driving with anti-skid chains.
Incorrect or incorrectly mounted anti-skid chains may damage the tyres,
wheels and other parts of the mobile crane.
Incorrect or incorrectly mounted anti-skid chains may break and be hurled
away together with parts of the vehicle.
This may result in accidents. This could cause serious or fatal injuries.
1. Mounting of anti-skid chains only after consultation with and the ap-
proval of the TADANO Customer Service.
2. Observe the specifications by the After Sales Service of TADANO.
3. Observe the instructions of the anti-skid chains manufacturer.
10.7 Superstructure auxiliary heater
Safety instructions
DANGER
Risk of explosion when operating the auxiliary heater.
Operating the auxiliary heater is not permitted at the following locations:
- Petrol pumps and filling stations.
- Places where combustible gases or vapours may form or be present.
- Places where potentially explosive dust may form or be present.
1. Do not operate the auxiliary heater at these locations.
2. In case of doubt, consult the local safety officer.
WFN3RUWW2K2064139
DANGER
Danger of suffocation when operating the auxiliary heater.
When operating the auxiliary heater in enclosed spaces, there is a risk of
asphyxiation due to exhaust gases.
1. Only operate the auxiliary heater outside of enclosed spaces.
244 ATF 60G-3

2019-03_EN
If the auxiliary heater is operated when the engine is not running, the bat-
teries of the mobile crane are discharged.
1. Charge the batteries at shorter intervals.
Overview
1 Auxiliary heater control unit 2 AdBlue® tank heating switch *)
Operating the functions is carried out via the Auxiliary heater control unit.
For exact specifications regarding the operation and maintenance of the heater, please refer to
the operating manual supplied by the heater manufacturer.
Preheating the engine

WFN3RUWW2K2064139
Requirements
▪ AdBlue® tank heating switch *) is switched off.
▪ The pilot lamp in the switch lights up.
ATF 60G-3 245

2019-03_EN
Procedure
1. Set the power-on time of the auxiliary heater with the Auxiliary heater control unit.
NOTE The battery main switch needn't be switched on.
ð The engine is preheated.
Preheating the engine and preheating the cab
Requirements
▪ AdBlue® tank heating switch *) is switched off.
▪ The pilot lamp in the switch lights up.
Procedure
1. Switch on Battery main switch switch.
2. Switch the blower to stage 1.
3. Set the Temperature control switch to warm.
ð The engine is preheated and the cab is preheated.
Heating the AdBlue tank *)
If outside temperatures below -11 °C are expected, the AdBlue® tank heat-
ing *) must be switched on.
1. Switch on AdBlue® tank heating switch *).

ð The pilot lamp in the switch lights up.
NOTE The thawing of the AdBlue® tank may take up to 60 minutes. When the AdBlue®
has thawed, cab and/or engine are preheated.
ð The AdBlue® tank is heated.
WFN3RUWW2K2064139
246 ATF 60G-3

2019-03_EN
11 Special equipment
11.1 Underride protection
CAUTION
Risk of crushing!
It may not be possible for one person alone to fold-up the underride pro-
tection due to its weight. Owing to uncontrolled folding of the underride
protection, the person may get injured.
1. An assistant is required for folding it up.
The underride protection cannot be folded up if it is connected with the

trailer hitch or different special fittings.
NOTICE! Driving the mobile crane on public roads with raised underride protection is not
allowed. Underride protection must be mounted and bolted.
Overview
1 Underride protection 3 Pin

2 Spring clip
The underride protection is mounted on the rear section of the vehicle and can be loosened and
folded up to increase the angle of approach for off-road driving.
Folding up underride protection

1. Secure the underride protection against folding down.
2. Loosen the spring clip and pull the lower pins.
3. Fold the underride protection upwards and hold it until the pins are pushed back into the
holes and secured with the spring clips.
WFN3RUWW2K2064139
4. Place the underride protection on the pins.

ð The underride protection is folded up.
Fold back the underride protection in the reverse order.
ATF 60G-3 247

2019-03_EN
11.2 Spare wheel
CAUTION
Risk of accidents due to overturning spare wheel.
A non secured spare wheel may turn over. This may lead to accidents in-
volving personal injuries or material damage.
1. Secure spare wheel against tilting.
Overview
1 Fixing screws 3 Spare wheel

2 Bracket
Requirement
▪ The mobile crane is parked horizontally on level ground.
▪ The mobile crane is secured against rolling away.
▪ Engine and ignition are switched off.
▪ The mobile crane is correctly supported.
▪ The superstructure is slewed to the back.
▪ The boom is raised.
▪ The telescopes are fully retracted.
▪ Mechanical slewing lock is engaged.
Removing the spare wheel from the spare wheel holder

WFN3RUWW2K2064139
1. Attach the spare wheel to the hook block.

2. Loosen both fixing screws and lay them down.
3. Remove holder.
4. Lift the spare wheel from the spare wheel holder in the direction of the arrow and place it on
the ground.
248 ATF 60G-3

2019-03_EN
5. Loosen spare wheel from the hook block and secure it against tilting.
ð The spare wheel is removed from the spare wheel holder.
WFN3RUWW2K2064139
ATF 60G-3 249

2019-03_EN
WFN3RUWW2K2064139
250 ATF 60G-3

2019-03_EN
12 Troubleshooting
12 Troubleshooting
12.1 General hints

The following table will help you in quickly finding the cause in case of a failure of or a fault in a
specific function of the device and also in rectifying the same.
A troubleshooting table does not replace an expert. If the cause of a fault cannot be identified or
rectified using the table, please contact our TADANO After-sales Service.
12.2 Differential locks, axles and drive

Fault Possible cause Rectification
Differential locks cannot be activ- Pneumatic switch pressure is too Supply pressure of the com-
ated. low. pressed air system (at least 6
bar (87 PSI)).
The "differential locks" switch is Replace the "differential locks"
faulty. switch.
Electrical connections are defect- Check the electrical connections.
ive or loose.
The solenoid valve is defective. Replace the solenoid valve.
Pneumatic lines are ruptured. Have the pneumatic lines re-
paired.
Pneumatic lines are crushed. Have the pneumatic lines
checked.
The switching mechanism in the Have the switching mechanism
axle is faulty. repaired.
The time-delay relay for enga- Have the time-delay relay re-
ging the differential lock is faulty. placed.
The axle drive cannot be activ- Pneumatic switch pressure is too Supply pressure of the com-
ated. low. pressed air system (at least 6
bar (87 PSI)).
The "axle drive" switch is faulty. Have the switch replaced.
Electrical connections are defect- Check the electrical connections.
ive or loose.
The solenoid valve is defective. Replace the solenoid valve.
Pneumatic lines are ruptured. Have the pneumatic lines re-
paired.
Pneumatic lines are crushed. Have the pneumatic lines
checked.
The switching mechanism in the Have the switching mechanism
axle is faulty. repaired.
Drive shafts are emitting a dron- Balance plates missing on the Replace the drive shafts.
WFN3RUWW2K2064139
ing noise. drive shafts.

Drive shafts are worn out. Replace the drive shafts.
The mobile crane cannot be set The change-over valve of the Set the change-over valve of the
in motion. transfer box is in the neutral pos- transfer box to the on-road gear.
ition.
ATF 60G-3 251

2019-03_EN
12 Troubleshooting
12.3 Chassis hydraulic system - general

Hydraulic oil filter contamination Filter cartridges are contamin- Change the filter cartridges.
indicator lights up at operating ated.
temperature.
Excessive noises of hydraulic Hydraulic pump is defective. Repair or replace the hydraulic
system. pump.
Hydraulic valve is defective. Have the hydraulic valve re-
paired or replaced.
The inlet pipe on the hydraulic oil Have the hydraulic oil tank
tank is blocked. cleaned.
Hydraulic pump is sucking air. Stop the hydraulic pump immedi-
ately. Check the leak tightness
and the oil level of the hydraulic
system and top up oil if required.
The hydraulic system functions Air in the hydraulic system. Check the oil level, bleed the hy-
jerkily or has no power. draulic cylinders.
The suction pipe is leaky. Tighten the bolted connections.
Oil in the hydraulic oil tank lath- Check the hydraulic oil level; top
ers. up oil if required.
The oil viscosity is incorrect. Fill in the prescribed oil depend-
ing on the ambient temperature.
Hydraulic oil temperature is too The oil cooler is contaminated. Clean the oil cooler.
high.
12.3.1 Suspension hydraulics

The axle suspension cannot be The rocker switch is defective or Replace the rocker tip switch;
blocked; the symbol does not the electric cable is broken. check the cable connection.
light up. The key-operated switch is at an Set the key-operated switch to
incorrect switch position. switch position 2 (superstructure
operation).
The fuse is defective. Replace the fuse.
The suspension cannot be The suspension block is defect- Have the valve block replaced.
blocked even if the pilot lamp is ive.
lit up.
The front axle lateral leveling The fuse is defective. Replace the fuse.
does not actuate. The locking pin in the superstruc- Check the pin connection.
ture is not fully engaged.
The proximity switch is defective. Have the proximity switch re-
placed.
The solenoid valve on the front- Have the solenoid valve checked
axle lock valve is faulty. and replaced if required.
WFN3RUWW2K2064139
The mobile crane lowers. Suspension system is defective. Have the suspension system
checked.
The mobile crane suspension The axle suspension is locked. Release the axle suspension
does not function / functions lock.
poorly. Insufficient nitrogen accumulator Have the nitrogen accumulator
pressure in the hydraulic accu- pressure adjusted or topped up
mulator. at a specialist workshop.
252 ATF 60G-3

2019-03_EN
12 Troubleshooting
12.3.2 Inclination adjustment and leveling

The inclination of the mobile The rocker tip switch is defective. Have the rocker tip switch re-
crane cannot be adjusted and placed.
the crane cannot be lowered. The axle suspension is not Lock the axle suspension.
locked.
12.3.3 Outrigger hydraulic system

The outrigger cannot be exten- The key switch is in the incorrect Set the key switch in the chassis
ded or retracted. switch position. to position 2.
Locking pins are still inserted. Remove the pins from the beam.
The outrigger electronic system Get the error corrected in a spe-
is defective. cialist workshop.
The fuse is defective. Replace the fuse.
The outrigger float retracts while The solenoid valve is defective. Have the solenoid valve re-
the mobile crane is supported. placed.
The shut-off valve on the outrig- Clean the shut-off valve, check it
ger cylinder is leaking or dirty. and replace if necessary.
The outrigger cylinder seal is Replace the seal; if necessary
faulty. have the outrigger cylinder re-
placed.
The outrigger float sinks down- The shut-off valve on the outrig- Clean the valve, check it and re-
wards when retracted. ger cylinder is leaking or dirty. place it if required.
The outrigger can only be slowly The engine speed is too low. Increase the engine speed.
extended or retracted.
12.4 Steering
12.4.1 Steering - mechanical part

Excessive backlash of the steer- The track rod connection is Check the track-rod connection;
ing wheel. loose. adjust and tighten if necessary.
Ball-and-socket joints of the track Have the ball joints replaced.
or steering rod have a backlash.
Excessive tire wear, wheels Incorrect track. Set the track to ± 0.
wobble. Incorrect air pressure. Check the pressure and correct it
if required.
The rims or tyres exhibit lateral Have them checked at a special-
or radial run-out. ist workshop and replaced if ne-
WFN3RUWW2K2064139
cessary.
The piston rod of the steering Have the steering cylinder or
cylinder or the track rod is bent. track rod replaced.
Wheel nuts are loosened. Check the wheel nuts for firm fit
and tighten them if required.
ATF 60G-3 253

2019-03_EN
12 Troubleshooting
12.4.2 Steering - hydraulic/electrical part

A steering circuit pilot lamp lights A bolted connection in the steer- Check the bolted connections in
up. ing system of the steering hy- the steering system of the steer-
draulics is loose, fluid loss. ing hydraulics for firm seating.
Check the seals. Top up the fluid
if necessary.
Hydraulic pump is sucking air. Check the leak tightness and
screw couplings.
The suction pipe is leaky. Check the screw couplings.
The “emergency pump” pilot Flow indicator or flow limiting Have the flow indicator or flow
lamp lights up. valve faulty. limiting valve checked.
The emergency steering pump is Have the emergency steering
defective. pump replaced.
12.5 Braking system

Supply pressure is not achieved, The compressor delivery output Check the function.
display on the pressure gauge is too low.
below 5.5 bar. The warning lamp The pressure regulator does not Have a function check performed
lights up. switch off (compressed air sys- in a specialist workshop.
tem is leaky).
The pressure regulator blows off Check the switch-off pressure
continuously. adjustment.
The compressed air system is Have it repaired at a specialist
leaky. workshop.
The warning lamp lights up al- The pressure switch in the BBA Replace the switch.
though the pressure gauge (service brake circuit) I or II is
shows more than 5.5 bar. defective.
The brake cylinders (spring- Release the parking brake com-
loaded section) are not aerated pletely.
completely.
Defect in the spring-loaded cylin- Have a check performed in a
der circuit. specialist workshop.
Poor braking effect despite the Brake linings worn out or con- Have it repaired at a specialist
correct supply pressure. taminated (oily). workshop.
Rims and brakes become hot. No or very little air gap between Have it adjusted at a specialist
brake lining and drum. workshop.
The Wheel sensors warning Sensors, seat are not correct; Check and correct if required; re-
lamp (monitored by the ABS cable connections are not place the damaged parts.
symbol) does not go out after proper.
switching on the ignition. The Electric cables are damaged.
driving and braking behavior
changes. The electronics system is defect- Consult a specialist workshop.
WFN3RUWW2K2064139
ive.
The supply pressure for the com- The mobile crane bus system is Restart the engine; if the display
pressed-air system is not shown faulty. is still faulty, call the TADANO
in the CMV display. After-Sales Service.
254 ATF 60G-3

2019-03_EN
12 Troubleshooting
12.6 Electrical system

Batteries are not or inadequately Batteries are defective. Replace the batteries.
charged. Cables are detached or defect- Have the cable tightened or re-
ive. placed.
The generator is defective. (See: Check the generator, have it re-
the "Generator" symbol on the placed if required.
CMV display lights up or flashes
when the engine is running.)
The "Generator" symbol on the The cable between the alternator Isolate or secure the cable
CMV display lights up or flashes and the regulator is loose or between the alternator and regu-
when the engine is running. there is a short-circuit to earth. lator.
The controller is defective. Have the controller replaced.
The generator is defective. Check the generator, have it re-
placed if required.
No current when the ignition is No connection between the bat- ▪ Switch on the battery main
switched on. tery and the mobile crane. switch.
▪ Replace the battery relay.
▪ Tighten the earthing strap.
12.7 Centralized lubrication system

Centralized lubrication system in- Reservoir empty Top up reservoir
dicator is lit continuously
Lines, connections faulty ▪ Consult a specialist work-
shop
Centralized lubrication system in- ▪ Consult a specialist work-
dicator faulty shop
12.8 Auxiliary heater
Possible causes and rectification

Auxiliary heater switches off. Overheating (fault code F10). ▪ Let the heater cool down.
▪ Check the coolant level on
the expansion tank and top
up if necessary.
▪ Press the temperature lim-
WFN3RUWW2K2064139
iter button on the heater.

▪ Bleed the heater.
▪ Restart the heater.
ATF 60G-3 255

2019-03_EN
12 Troubleshooting
WFN3RUWW2K2064139
256 ATF 60G-3

2019-03_EN
13 Self-help
13 Self-help
13.1 Charging batteries
WARNING
Risk of accidents due to short-circuited battery.
A short-circuited battery may generate very high amperages. This may
cause electric shocks and fires. This may lead to accidents involving per-
sonal injuries or material damage.
1. Avoid metallic contact between the battery's positive pole and the mo-
bile crane.
2. Do not bridge the battery's poles.
3. Do not touch a short-circuited battery and leave the mobile crane.
4. If necessary, call for the fire brigade.
WARNING
Risk of chemical burns due to escaping battery acid.
Batteries contain gases and liquids which can cause significant bodily
harm when coming into contact with skin, eyes, and mucous membranes.
1. Wear safety goggles and acid-proof safety gloves.
2. In case of contact with eyes or skin, immediately rinse thoroughly with
clear water.
3. After rinsing, seek medical attention.
WFN3RUWW2K2064139
ATF 60G-3 257

2019-03_EN
13 Self-help
13.1.2 Charging batteries with charger
Overview
WFN3RUWW2K2064139
1 Battery (2 ea.) 3 Negative pole

2 Positive pole
258 ATF 60G-3

2019-03_EN
13 Self-help
Requirements
▪ Battery main switch switch is switched off.
▪ Operating voltage of the battery charger: 24 V direct current.
Charging battery
1. Open the maintenance hatch.
2. Disconnect the battery's negative pole.
3. Disconnect the battery's positive pole.
4. Connect both battery charger cables to the battery.
5. Connect battery charger to the mains supply.
6. Switch the battery charger on.
Observe the instructions in the battery charger manufacturer's operating manual.
ð The battery is charged.
Charging process finished

1. Switch battery charger off when the charging process has finished.
2. Disconnect battery charger from the mains supply.
3. Disconnect both battery charger cables from the battery.
4. Connect the battery's positive pole.
5. Connect the battery's negative pole.
6. Close the maintenance hatch.
13.1.3 Charging batteries through the charging socket *)
Safety instructions
CAUTION
Risk of accidents when using charging socket for jump starting.
When using the charging socket for jump-starting, it may lead to short cir-
cuits due to high amperages. This may lead to accidents involving per-
1. Only use the charging socket to charge the batteries.
WFN3RUWW2K2064139
ATF 60G-3 259

2019-03_EN
13 Self-help
Overview
1 Charging socket 2 Jump start socket
The charging socket is located close to the battery.
Requirements
▪ Battery main switch switch is switched off.
WFN3RUWW2K2064139
▪ Operating voltage of the battery charger: 24 V direct current.
Charging batteries
1. Open the charging socket cover.
2. Connect the battery charger cable to the charging socket.
260 ATF 60G-3

2019-03_EN
13 Self-help
3. Switch the battery charger on.

Observe the instructions in the battery charger manufacturer's operating manual.
ð The battery is charged.
Charging process finished

1. Switch battery charger off when the charging process has finished.
2. Disconnect the battery charger cable from the charging socket.
3. Close the charging socket cover.
13.2 Starting/stopping the engine with the start/stop pushbutton
Safety instructions
WARNING
Risk of injury due to rotating parts.
Body parts may be severed by rotating parts. This could cause serious or
fatal injuries.
1. Carry out maintenance work only when the engine is switched off.
2. Only remove engine cover for maintenance work or in case of emer-
gency.
3. When working in the immediate proximity of the engine, make sure
that you do not touch or get too close to rotating parts.
4. Wear close-fitting clothes, tie up long hair and protect it with a hair net.
WARNING
Risk of burns on hot engine parts.
The engine and pipes will be hot while the engine is running, as well as
some time after switching off the engine. Contact may lead to severe
burns.
1. Do not touch hot parts when operating the emergency start/stop func-
tion of the engine.
WARNING
Risk of accidents when using the emergency start/stop function.
When starting the engine with the emergency start function and driving the
mobile crane in case of a fault, it is possible that the engine cannot be
switched off in time. This may result in an accident.
WFN3RUWW2K2064139
1. The emergency start/stop function may only be used to drive the mo-
bile crane out of a danger zone.
Open the engine cover to gain access and be able to press the emergency
operations.
ATF 60G-3 261

2019-03_EN
13 Self-help
Requirements
▪ The ignition in the carrier has been switched on.
▪ Engine is switched off.
1 Engine start/engine stop pushbutton
Procedure – Starting engine

1. Press Engine start/engine stop pushbutton.
ð Engine starts and runs in idle.
2. Release Engine start/engine stop pushbutton.
3. Close maintenance hatch / panelling.
ð The engine has been started.
Procedure – Switching off engine

➢ Engine is running.
1. Press and release Engine start / engine stop pushbutton.
WFN3RUWW2K2064139
ð Engine is switched off.
Procedure – Starting the engine and increasing the engine speed

1. Press and hold Engine start/engine stop pushbutton.
ð Engine starts and runs in idle. 3 seconds after engine start, the engine speed reaches
the maximum.
262 ATF 60G-3

2019-03_EN
13 Self-help

ð The engine will continue to run at the current engine speed.
Procedure – Turning engine

➢ Ignition is switched on and the engine is not running.
1. Switch off triggering of the injection pump unit with STAR DIAGNOSIS (Daimler AG dia-
gnostic device).
2. Press Engine start/engine stop pushbutton.
ð The engine turns without starting.
ð The engine stops.
4. Switch on triggering of the injection pump unit with STAR DIAGNOSIS (Daimler AG dia-
gnostic device).
ð Engine has been turned.
13.3 Starting the engine with help from external current
13.3.1 Starting the engine with help from jump leads
Connecting the jump leads
Safety instructions
WARNING
Risk of explosion from oxyhydrogen gas.
Risk of injury from escaping acid gases.
1. Wear safety goggles and acid-proof safety gloves.
2. Donor batteries and mobile crane batteries must have the same
voltage (24 V).
3. Avoid a short circuit using reverse polarity (positive to positive, negat-
ive to negative).
4. Comply with the order sequence for connecting the jump leads.
5. Make sure the jump lead's pole terminals are seated firmly.
WFN3RUWW2K2064139
ATF 60G-3 263

2019-03_EN
13 Self-help
NOTICE
Failure of vehicle electronics caused by errors when jump starting.
Errors when jump starting can cause the vehicle electronics to fail.
1. Donor batteries and mobile crane batteries must have the same
voltage (24 V).
2. Avoid a short circuit using reverse polarity (positive to positive, negat-
ive to negative).
3. Comply with the order sequence for connecting the jump leads.
4. Make sure the jump lead's pole clamps are seated firmly.
Overview
WFN3RUWW2K2064139
1 Battery (2 ea.)
264 ATF 60G-3

2019-03_EN
13 Self-help
Requirements
▪ The mobile crane's engine, ignition and battery main switch are switched off.
▪ The engine, ignition and battery main switch are switched off on the vehicle containing the
donor battery.
▪ The batteries are connected to the vehicles' system as specified.
▪ The jump leads have a diameter of at least 16 mm².
▪ Maintenance hatch on the superstructure is open.
Overview
1 Positive pole of the recipient battery 4 Negative pole of the recipient battery
2 Positive pole of the donor battery 5 Donor battery
3 Negative pole of the donor battery 6 Recipient battery
Note the order sequence for connecting the jump leads.

1. Connect the first red pole terminal of the jump lead to the positive pole of the recipient bat-
tery.
2. Connect the second red pole terminal to the positive pole of the donor battery.
3. Connect the black pole terminal of the jump lead to the negative pole of the donor battery.
4. Connect the second black pole terminal of the jump lead to the negative pole of the recipi-
ent battery.
Starting the engine

1. Start the engine of the donor vehicle and let run in idle.
2. Start attempt in the recipient vehicle: Switch on the battery main switch, switch on the igni-
tion, start the engine.
3. After starting the engine of the recipient vehicle, let it run for a few minutes.
WFN3RUWW2K2064139
ATF 60G-3 265

2019-03_EN
13 Self-help
Disconnecting the jump leads
CAUTION
Risk of burns on hot shunt cable.
The terminals and cables of the jump leads may have become hot during
the starting sequence. This may result in burns to the hands.
1. Wear work gloves.
2. Hold the jump leads using the handles.
3. Do not touch the bare parts of the cable terminals without gloves.
Note the order sequence for releasing the jump leads.

1. Disconnect the first black pole terminal of the jump lead from the negative pole of the recipi-
ent battery.
2. Disconnect the second black pole terminal of the jump lead from the negative pole of the
donor battery.
3. Disconnect the first red pole terminal of the jump lead from the positive pole of the recipient
battery.
4. Disconnect the second red pole terminal of the jump lead from the positive pole of the donor
battery.
5. Attach the battery compartment cover.
13.3.2 Starting the engine with help from jump start socket *)
WFN3RUWW2K2064139
266 ATF 60G-3

2019-03_EN
13 Self-help
Overview
1 Charging socket 2 Jump start socket
Requirements
▪ The engine, ignition and battery main switch are switched off on the vehicle containing the
donor battery.
▪ All batteries are connected to the vehicles' system as specified.
▪ Both vehicles are equipped with 24 V systems.
▪ Suitable connecting cable with a cross section of at least 16 mm², and appropriate connect-
ors are provided.
Inserting connecting cable between the jump start sockets

1. Open the cover of the jump start socket of the vehicle receiving the power supply.
2. Open the cover of the jump start socket of the vehicle containing the donor battery.
3. Connect both jump start sockets using the jump leads.
Starting the engine

1. Start the engine of the donor vehicle and let run in idle.
2. Start attempt in the recipient vehicle: Switch on the battery main switch, switch on the igni-
tion, start the engine.
3. After starting the engine of the recipient vehicle, let it run for a few minutes.
Removing connecting cable between the jump start sockets

1. Remove connecting cable from both jump start sockets.
2. Close jump start socket cap on both vehicles.
3. Stow away the jump leads.
13.4 Bleeding the fuel system

WFN3RUWW2K2064139
Introduction
The following measures must be taken if dirt or air has got into the fuel system:
▪ Replace the filter element.
▪ Clean the fuel system.
ATF 60G-3 267

2019-03_EN
13 Self-help
▪ Bleed the fuel system.

The fuel system must be bled with the hand pump after the following events:
▪ The fuel tank was entirely emptied.
▪ The fuel filter has been replaced.
Overview
WFN3RUWW2K2064139
1 Bleed screw 2 Pump plunger
Requirements
▪ The fuel is topped up.
▪ The fuel filter has been replaced if necessary.
▪ A suitable container has been placed under the water separator.
268 ATF 60G-3

2019-03_EN
13 Self-help
Bleeding the fuel system and delivering fuel

1. Open the bleeder screw.
2. Operate the pump plunger until fuel flows out without any bubbles.
3. Catch overflowing fuel in a suitable container and pour back into the fuel tank.
4. Tighten the bleeder screw.
5. Start the engine. In case of starting problems, ask an assistant to actuate the pump plunger
until the engine runs smoothly.
13.5 Filling the tyres
Safety instructions
WARNING
Failure of service brake due to lack of compressed air.
When driving the mobile crane with the tyre inflator hose screwed on, the
compressed air system of the mobile crane will not be supplied with com-
pressed air. The service brake may fail.
1. After having finished, unscrew and store away the tyre inflator hose.
To prevent damages of the compressor, only the tyres installed on the mo-
bile crane may be filled with compressed air.
Description
Through a tyre inflator connector on the pressure regulator it is possible to fill the tyres with air
from the own compressed air system through a tyre inflator hose.
The pressure regulator is installed on the superstructure.
WFN3RUWW2K2064139
ATF 60G-3 269

2019-03_EN
13 Self-help
Overview
1 Tyre inflator connector 2 Valve cap
Requirements
▪ Tyre inflator hose is provided.
Filling the tyres

WFN3RUWW2K2064139
When beginning to fill the tyres with compressed air, the compressed air
system's pressure must be lower than the switch-on pressure of the com-
pressed air system's compressor. If necessary, use compressed air e.g.
operating the brakes several times.
1. Unscrew valve cap from the tyre inflator connector.

2. Screw the tyre inflator hose onto the tyre inflator connector.
270 ATF 60G-3

2019-03_EN
13 Self-help
3. Remove valve cap of the tyre valve.

4. Screw tyre inflator hose onto the tyre valve.
5. Start engine and allow to run at medium speed.
6. Fill tyres up to the specified tyre air pressure.
8. Unscrew tyre inflator hose from tyre valve and tyre inflator connector, and stow it away.
9. Screw on both valve caps.
ð Tyre is filled.
13.6 Measures in case of an overheated engine
Safety instructions
WARNING
Risk of injury!
The cooling system is under excess pressure. Hot coolant may spray out
when the system is opened, causing burns to the skin or eyes.
➢ The coolant tank may be opened only when the coolant temperature
drops below 90 °C.
1. Loosen the cap slowly using safety gloves or a cloth and release the
excess pressure completely before opening.
NOTICE
Cold shock due to excessively cold coolant!
If excessively cold water is filled in the overheated engine too quickly, the
engine may get damaged. Always fill the coolant gradually.
If the coolant is not available, tap water can also be used temporarily. The
tap water must be replaced with a regular coolant and, if required, the
cooling system must be cleaned in the nearest workshop.
WFN3RUWW2K2064139
ATF 60G-3 271

2019-03_EN
13 Self-help
Overview
1 Coolant tank
Procedure – Topping up coolant

1. Remove the cap of the coolant tank. If the coolant level is too low, fill coolant tank approx-
imately up to half with coolant.
2. Check engine for coolant leaks.
3. Place and close sealing cap of the coolant tank.
WFN3RUWW2K2064139
272 ATF 60G-3

2019-03_EN
14 Emergency operation
WARNING
Risk of accidents when operating the mobile crane with malfunc-
tions.
When operating the mobile crane with malfunctions, traffic safety may not
be ensured. This may result in an accident.
1. Operate the mobile crane with utmost caution.
2. Contact the competent TADANO dealer or the TADANO Customer
Service without delay for reparation.
WARNING
Risk of accidents when operating the mobile crane with emergency
controls.
It is not allowed to use emergency controls instead of the regular operating
elements. This may lead to accidents.
1. Repair damages on operating elements without delay.
WARNING
Valve failure due to damaged rubber caps.
Damage to the rubber caps of emergency controls may lead to the valve
failure. This may lead to accidents.
1. Do not operate emergency controls having rubber caps using sharp-
edged or pointed objects.
2. Replace the damaged rubber caps immediately.
WFN3RUWW2K2064139
ATF 60G-3 273

2019-03_EN
14.2 Retracting/extending outriggers in case of failure of operating

elements
Safety instructions
WARNING
Risk of accidents when working area is not completely visible.
In the event of an emergency actuation, the outrigger floats and outrigger
beams on the opposite side of the mobile crane are always retracted or
extended. This working area cannot be seen. This may result in an acci-
dent.
1. Have an assistant to supervise the working area.
For emergency operation of outriggers an assistant is required.
Overview
Valves in the superstructure
1 Oil supply for emergency operation of out- E Oil supply for outriggers pushbutton
riggers solenoid valve
F Increase hydraulic pressure pushbutton
WFN3RUWW2K2064139
274 ATF 60G-3

2019-03_EN
Valves in the carrier
1
1
C
C A
A D
B
D
B
1 Outrigger emergency operation solenoid A Retract outrigger cylinders pushbutton
valves
B Retract outrigger beam pushbutton
C Extend outrigger cylinder pushbutton
D Extend outrigger beam pushbutton
Requirements
▪ Engine is running in idle.
▪ Maintenance hatch of the superstructure is open.
Hydraulic pressure insufficient for resetting.

If the hydraulic pressure is insufficient for resetting, the pressure can be in-
creased. Pressure increase in three stages.
1. Press the three Increase hydraulic pressure pushbuttons in turn.
Retracting the outrigger floats

NOTICE! Retraction of one outrigger float is described. The other outrigger floats are re-
tracted in an identical manner.
1. Have assistant press and hold the Oil supply for outriggers pushbutton.
WFN3RUWW2K2064139
2. Press and hold the Retract outrigger floats pushbutton until the selected outrigger float has
been retracted completely.
3. Release all pushbuttons.
ð The selected outrigger float is retracted.
ATF 60G-3 275

2019-03_EN
Extending outrigger float

NOTICE! Extension of one outrigger float is described. The other outrigger floats are ex-
tended in an identical manner.
2. Press and hold the Extend outrigger float pushbutton until the selected outrigger float has
extended to the desired height.
ð The selected outrigger float is extended.
Retracting outrigger beam

NOTICE! Retraction of one outrigger beam is described. The other outrigger beams are
retracted in an identical manner.
1. Unlock outrigger beam.
3. Press and hold Retract outrigger beam pushbutton until the selected outrigger beam has
been retracted completely.
ð The selected outrigger beam is retracted and locked.
Extending outrigger beam

NOTICE! Extension of one outrigger beam is described. The other outrigger beams are
extended in an identical manner.
1. Have assistant press and hold the Pressure reduction for extending outrigger beams push-
button.
3. Press and hold the Extend outrigger beam pushbutton until the selected outrigger beam has
extended to the desired outrigger base.
ð The selected outrigger beam is extended and locked.
Final activities
1. Close and lock the maintenance hatche.
WFN3RUWW2K2064139
276 ATF 60G-3

2019-03_EN
14.3 Centring rear wheels in case of failure of the rear steering
Safety instructions
WARNING
Risk of accidents due to change in steering behaviour.
The mobile crane's steering behaviour changes when one or more rear
wheels are in the straight forward position and no longer steerable.
The mobile crane is only partially operational because it can only be
steered with the front wheels. This may result in an accident.
1. Adapt steering behaviour and driving behaviour.
2. Have the damage repaired without delay.
WARNING
Danger of crushing due to moving wheels.
When steering the rear wheels, persons may get crushed between the
wheels and parts of the frame. This could cause serious or fatal injuries.
1. Do not wear loose clothes.
2. When pressing the pushbuttons proceed with utmost caution.
3. Maintain safety distance to the wheels.
For centring the rear wheels an assistant is required.
Overview
WFN3RUWW2K2064139
ATF 60G-3 277

2019-03_EN
Requirements
Preparations
1. Switch off Unlock rear steering switch.
2. Start the engine. Let engine run in idle.
Overview of valves
Valves in the superstructure
1 Oil supply for emergency operation of out- E Oil supply for outriggers pushbutton
riggers solenoid valve
F Increase hydraulic pressure pushbutton WFN3RUWW2K2064139
278 ATF 60G-3

2019-03_EN
Valves in the carrier
1
B
A
1 Rear steering emergency operation solen- A Right turn pushbutton

oid valves
B Left turn pushbutton
Requirements
▪ Engine is running in idle.
▪ Maintenance hatch of the superstructure is open.
Positioning axles straight forward

1. At the Emergency operation solenoid valve, press Right turn pushbutton.
ð Axle steers to the right.
1. Press the Left turn pushbutton on the Emergency operation solenoid valve.
ð Axle steers to the left.
WFN3RUWW2K2064139
ATF 60G-3 279

2019-03_EN
14.4 Switching on cooling system ventilator manually
Safety instructions
WARNING
Risk of injury due to rotating parts.
Body parts may be severed by rotating parts. This could cause serious or
fatal injuries.
1. Carry out maintenance work only when the engine is switched off.
2. Only remove engine cover for maintenance work or in case of emer-
gency.
3. When working in the immediate proximity of the engine, make sure
that you do not touch or get too close to rotating parts.
4. Wear close-fitting clothes, tie up long hair and protect it with a hair net.
WARNING
The engine and pipes will be hot while the engine is running, as well as
some time after switching off the engine. Contact may lead to severe
burns.
1. Do not touch any hot parts when pulling out the plug of the solenoid
valve.
Description
The fan speed for cooling the engine coolant is regulated independently of the engine speed
through a thermo valve.
In case of fault, the fan may run at reduced speed. This means the engine will not be cooled.
WFN3RUWW2K2064139
280 ATF 60G-3

2019-03_EN
Opening cooling system sheeting
1 Panelling 2 Support
1. Open the cooling system panelling and secure with a support.
Unplug the plug of the "fan drive" solenoid valve
1 Solenoid valve 2 Connector

WFN3RUWW2K2064139
1. Unlock the plug and pull it off the Fan drive solenoid valve.
2. Close and lock cooling system panelling.
Result
Cooling system emergency operation is activated.
ATF 60G-3 281

2019-03_EN
Resetting to normal operation

1. Open the cooling system panelling and secure with a support.
2. Insert the plug onto the Fan drive solenoid valve and lock it.
3. Close and lock cooling system panelling.
Result
Cooling system emergency operation is deactivated.
WFN3RUWW2K2064139
282 ATF 60G-3

2019-03_EN
15 Service and maintenance
15.1 Description of maintenance chart

The interval plan lists all care and maintenance activities that must be carried out for maximum
service life. The due dates of the intervals are differentiated according to the following criteria:
▪ Operating hours [oh].
▪ Time [daily, weekly, monthly, annually etc.].
▪ Indicator.
▪ Mileage [km]
NOTICE! Maintenance must be carried out at whichever of these is reached first.
Operating hours can be read on the Hour meter indicator in the on-board computer, refer to "En-
gine information" menu [} page 105].
The mileage may be determined through the odometer.
Some vehicle components require a First Maintenance which differs from the regular intervals.
This First Maintenance is listed separately on the interval plan.
The intervals which must be spaced regularly are listed underneath the Operating hours field.
WARNING
Risk of accidents due to mobile crane rolling away out of control.
If the mobile crane is not secured sufficiently against rolling away, it may
start moving on its own. This may lead to serious injuries and material
damages.
1. Park the mobile crane horizontally on level ground.
4. Switch off the engine and the ignition.
5. Place wheel chocks under the wheels.
WARNING
Risk of accidents due to inadequate maintenance activities.
Maintenance activities require vehicle-specific knowledge and, in case of
working incorrectly, may lead to serious injuries and material damages.
1. Only allow specially trained expert personnel to carry out maintenance
activities.
WFN3RUWW2K2064139
2. Only carry out maintenance activities at an appropriate place such as

an authorized specialist workshop.
ATF 60G-3 283

2019-03_EN
WARNING
Risk of accidents due to impermissible commissioning.
If the mobile crane is put into operation during maintenance and inspection
activities, there is the risk of accidents and material damages.
1. Secure the danger zone and keep unauthorized persons away.
2. Mark the maintenance activities clearly using suitable warning signs.
3. Do not commission the mobile crane during maintenance and inspec-
tion activities.
WARNING
Risk of accidents due to lowering of mobile crane.
When the mobile crane is lowered, persons may get crushed underneath
the mobile crane. This could result in death or serious injury.
1. Secure the danger zone.
2. When lowering or raising, do not stay underneath the mobile crane.
WFN3RUWW2K2064139
284 ATF 60G-3

2019-03_EN
15.3 Daily maintenance tasks
Daily
Remark
Checking folding plugs and spring page 298 X
clips
Checking assemblies for leaks and page 301 X With every oil level check and with every
condition oil change
Checking hydraulic system for leaks page 301 X
Checking the oil level of the engine page 303 X
Checking the coolant level page 310 X
Checking the compressed air sys- page 332 X

tem for leaks
Checking the ABS function page 334 X When setting off and during the journey.
Check the function of the pilot lamps
Performing function check of eddy- page 341 X While driving

current brake
Checking the hydraulic oil level page 343 X
Bulbs and lamps page 354 X Check that all lamps are working and
clean. Take to a specialist workshop if
there is any damage.
Checking fuel tank bleeder valve page 359 X With every oil change. Change when ne-
cessary
Checking transfer case breathers page 361 X With every oil change. Change when ne-
cessary
Checking wheels and tyres page 362 X Immediately in the event of damage (acci-
dent)
Checking the wheel nuts page 362 X
Checking and adapting tyre pres- page 365 X

sure
Checking fill level of reservoir page 386 X Refill when necessary

WFN3RUWW2K2064139
ATF 60G-3 285

2019-03_EN
286

15.4 Recurring maintenance tasks
Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Engine and assemblies
Changing engine oil and replacing page 303 X b Every 2 years, Applies only to oil specification 228.5/51.
the oil filter cartridge every 40,000 Contact the manufacturer if different specific-
km ations are required
Checking hoses and hose clamps page 307 X b
Checking V-ribbed belt for wear and page 308 X c
damage
Checking valve clearance page 308 900 [op. hrs.] X c Adjust if necessary
Replacing the AdBlue filter cartridge page 308 X c
Checking the cooling system and page 308 b Annually
heating system
Changing coolant page 311 b Every 3 years
Cleaning the radiator/coolers page 313 b As required
Replacing the air cleaner element page 315 X b Every 2 years
Checking the air cleaner system page 316 X b Annually
Replacing the fuel filter cartridge page 317 X b Every 2 years
Draining water from fuel system page 318 X b Annually Condensate must not reach the bottom edge
of the filter element
Replacing filter element of water sep- page 319 X b Annually If necessary more often, depending on the
arator fuel quality
Bleeding the fuel system page 321 X b Annually
2019-03_EN
ATF 60G-3
Cleaning exhaust pipe page 323 X c Annually

Drive train
WFN3RUWW2K2064139
2019-03_EN WFN3RUWW2K2064139
ATF 60G-3
Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Checking the oil level of the transfer page 323 b Monthly
case
Changing the transfer case oil page 326 100 [op. hrs.] b Annually, every
10,000 km
Checking drive shafts for noises page 326 a During operation
Check that the flange screws and in- page 326 X c After 6 months
termediate shaft bearing screws are maximum.
secure Every 25,000
km.
Axles and brakes
Checking oil levels of axle drives page 327 b Monthly
Changing the axle drive oil page 330 100 [op. hrs.] X b Annually, every
10,000 km
Checking oil levels of wheel drives page 330 b Monthly
Changing the wheel drive oil page 332 100 [op. Hrs.] / X b Annually, every Monthly oil level check via overflow measure-
1,000 km 10,000 km ment
Visual inspection and switching func- page 332 b Monthly With every oil level check and every oil
tion test change

Testing function of air dryer page 332 X b
Checking brake linings and air gap page 334 X a Every 3 Check in accordance with the legal require-
months ments of the country in which the vehicle is
registered
Checking compressed air system page 335 X b Check in accordance with the legal require-
ments of the country in which the vehicle is
registered
Cleaning drain valves page 337 X b Annually
287
288

Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Engine brake and exhaust flaps page 339 X c Observe the engine manufacturer's require-
ments
Inspect the protective caps, bushings page 339 X c Every 3 Visual inspection. Earlier if there is wear.
and seals months
Inspecting the diaphragm cylinder page 339 X c Visual inspection. Check in accordance with
the legal requirements of the country in which
the vehicle is registered.
Checking the ABS system page 339 X c At a specialist workshop
Check steering drive shafts for cir- page 339 X b
cumferential backlash
Checking ball joints in steering and page 339 X b
track rods for backlash
Checking the screws on axles, steer- page 339 100 [op. hrs.] X b Annually
ing levers, push rods for tightness
Cleaning the eddy-current brake page 341 a Every 6 More often if necessary
months
Check clearance between stator and page 341 X c Annually
rotors
Air gap check page 341 X c Annually
Checking drive shaft screws page 341 After 50 [op. X c Every 6
hrs.], then at months
100 [op. hrs.]
Checking eddy-current brake screws page 342 X c Annually
Check shaft sealing rings on axle page 342 X c Annually
2019-03_EN
Checking insulating sheaths, wiring, page 342 X c Annually

ATF 60G-3
connections, and contacts

Hydraulic system
WFN3RUWW2K2064139
2019-03_EN WFN3RUWW2K2064139
ATF 60G-3
Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Checking hydraulic hoses page 345 b Annually
Replacing hydraulic hoses page 346 c Every 6 years For the first change: 6 years after manufac-
ture (year of manufacture).
Checking the hydraulic accumulator page 346 X c Annually During the winter months, earlier if necessary
preloading pressure
Breathers
Checking bleeder valve of axle drives page 358 X a With every oil change. Change when neces-
sary
Checking braking system bleeder page 358 X a Earlier if necessary
valves
Wheels and tyres
Retightening wheel nuts (axle load page 363 50 km a Monthly After 100 km, after 200 km, after 1000 km and
up to 13 t) every 5000 km
Retightening wheel nuts (axle load page 364 50 km a Monthly After 100 km, after 200 km and every
over 13 t) 1000 km
Interchanging wheels in case of tire page 367 b Every 5,000 Depending on the wear pattern
wear km to 10,000
km

Changing wheel module for air pres- page 367 c Have replaced if necessary
sure display *)
Checking wheel tracking page 368 c Specialist workshop
Checking the toe-in page 368 c Specialist workshop
Outrigger system
Checking and maintaining outrigger page 370 X b Monthly
Check and adjust the wear plates of page 370 X c
the outrigger
289
290

Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Check and adjust the outrigger cylin- page 370 X c
der guide
Checking hoses and cables page 370 X c Every 6
months
Carrier cab
Maintaining doors page 371 X a Annually
Maintaining front cover page 373 X a Annually
Oil/lubricate joints, hinges and all page 374 X b After every wash with the high-pressure
moving parts steam cleaner
Replace the windshield wiper blades page 375 b As required
Filling the windshield washer system page 376 b As required
Air conditioning system - winter oper- page 378 a Monthly Allow to run for 10 minutes
ation
Air conditioning system inspection page 378 X c Annually
Lubricate the shaft bearings, lever page 378 X b Every 6
joints and all moving parts months
Check the condition of the heating page 378 b Monthly Tighten the hose clamps if necessary
lines
Check the electric cables and plug page 378 b Monthly
connections
Check the filter for dirt page 379 b Monthly Clean if only slightly dirty
Changing the fuel filter of the auxili- page 379 X b Annually
ary heater
2019-03_EN
Cleaning rear view camera page 379 a As required

ATF 60G-3
Changing battery of ignition key page 379 a As required

Trailer hitch *)
WFN3RUWW2K2064139
2019-03_EN WFN3RUWW2K2064139
ATF 60G-3
Personnel
Minimum
mainten-
interval
Initial
ance
1200
2400
100
300
600
Remark
Maintaining trailer hitch page 381 X b Refer to the engine manufacturer's specifica-
tions for care instructions
Inspecting the compressed air coup- page 382 X c At every inspection of the brake system
ling heads
Oiling and lubricating
Oiling and lubricating page 383 X a Monthly And after each time the vehicle is washed us-
ing a high-pressure steam cleaner.
Lubricating joints, pins, hinges and all page 383 X a Every 2 weeks After every wash with the high-pressure
moving parts steam cleaner
Lubricating the steering knuckles page 383 Annually
Centralized lubrication system
Inspect the lines and screw couplings page 386 X b
for leaks and damage
Sliding coupling
Checking the sliding coupling for page 387 X b
damage
Suspension

Checking the bellows page 388 X b More often if necessary
a - Operating personnel, b - Maintenance personnel, c - Service personnel

291
15.5 Filling up the heating's fuel tank
Safety instructions
WARNING
Risk of fire due to highly flammable fuel.
Fires may lead to serious injuries and material damages.
1. Omit fire, naked light and sparks when handling fuels.
CAUTION
Health hazard due to fuel.
Fuels irritate eyes, mucous membranes and skin.
1. After contact with the eyes, immediately rinse eyes thoroughly with
clear water and consult a physician.
2. After swallowing, immediately rinse mouth thoroughly with clear water
and consult a physician.
3. Do not inhale the fumes.
4. In case of allergic reactions, immediately consult a physician.
5. For further safety instructions, refer to the heating manufacturer's oper-
ating manual.
Damage to the heating due to incorrect fuel.

Only use the fuels approved by the heating manufacturer.
Overview
WFN3RUWW2K2064139
1 Fuel tank
292 ATF 60G-3

2019-03_EN
Requirements
When filling up with fuel, the following requirements must be met:
Filling up
1. Open the tank cap of the fuel tank.
2. Fill up the fuel tank.
3. Close tank cap of the fuel tank.
15.6 Filling up fuel or AdBlue
Safety instructions
WARNING
CAUTION
Health hazard due to fuel and AdBlue.
Fuel and AdBlue irritate eyes, mucous membranes and skin.
1. After contact with the eyes, immediately rinse eyes thoroughly with
clear water and consult a physician.
2. After swallowing, immediately rinse mouth thoroughly with clear water
and consult a physician.
3. Do not inhale the fumes.
4. In case of allergic reactions, immediately consult a physician.
5. For further safety instructions, refer to the engine manufacturer's oper-
ating manual.
Damage to the engine due to incorrect fuel.

Only use the fuel that is permitted by the engine manufacturer.
Destruction of after treatment of exhaust gases.

AdBlue is required for the after treatment of exhaust gases of the engine.
WFN3RUWW2K2064139
The following requirements must be adhered to:

1. Do not fill up the AdBlue tank with cleaning agent or any other operat-
ing fluid or fuel.
2. Do not add any additives.
3. Do not dilute AdBlue.
4. For further safety instructions, refer to the engine manufacturer's oper-
ating manual.
ATF 60G-3 293

2019-03_EN
Contaminated AdBlue.
Faults in the SCR system (aftertreatment of exhaust gases) due to con-
taminated AdBlue.
1. Only fill up pure AdBlue from clean containers.
2. Remove any contamination from the AdBlue tank.
3. Clean filler neck of the AdBlue tank before filling up.
Overview
1 Side maintenance hatch 4 Top maintenance hatch

2 Fuel tank 5 Holder for pump nozzle
3 AdBlue tank
WFN3RUWW2K2064139
294 ATF 60G-3

2019-03_EN
Opening the maintenance hatches
Overview
1 Lock 4 Side maintenance hatch

2 Button 5 Top maintenance hatch
3 Lever
Opening side maintenance hatch

1. Open lock pushing the button and folding out the lever.
2. Rotate the lever to the right.
ð Maintenance hatch is unlocked.
3. Open side maintenance hatch approx. 20°.
4. Return lever into original position and lock.
5. Open the side maintenance hatch completely.
ð The side maintenance hatch is open.
WFN3RUWW2K2064139
ATF 60G-3 295

2019-03_EN
Securing side maintenance hatch
Overview
1 Locking device
Securing side maintenance hatch

1. Fold the locking device to the front.
Requirements
When filling up with fuel or AdBlue, the following requirements must be met:
▪ The superstructure is rotated to the front.
▪ The side maintenance hatch is open and secured with the locking device.
▪ Fuel pump nozzle is hooked in at the pump nozzle holder.
WFN3RUWW2K2064139
296 ATF 60G-3

2019-03_EN
Accessing the carrier
Overview
1 Ladder 3 Grab handle in the superstructure

2 Grab handles on the carrier
Accessing the carrier

1. Hold on to the carrier with both hands at the grab handles.
2. Access the carrier via the ladder.
Filling up
Safety instructions
Wipe up fuel spillages. Wash off any AdBlue spillages with water immedi-
ately – risk of corrosion.
WFN3RUWW2K2064139
Procedure
1. Go to the fuel nozzle.
2. Open the upper maintenance hatch.
3. Open the tank cap on the fuel tank or AdBlue tank.
4. Take the pump nozzle off the holder. Fill up the fuel tank or the AdBlue tank.
Hold on to grab handle in the superstructure while filling up.
ATF 60G-3 297

2019-03_EN
Finishing fuelling
1. Hang the pump nozzle on the holder.
2. Close the tank cap of the fuel tank or AdBlue tank.
3. Close top maintenance hatch.
Leave the superstructure
Safety instructions
DANGER
Risk of falling due to narrow space available.
1. Hold onto the grab handle on the superstructure cab.
Leave the superstructure

1. Go to the ladder.
2. Leave the carrier, using the ladder.
Final activities
1. Remove the pump nozzle from the holder.
2. Fold locking device to the rear, close maintenance hatch on the side.
15.7 Checking the fasteners
15.7.1 Checking folding plugs and spring clips

Folding plugs and spring clips are reusable securing elements which must be checked at regu-
lar intervals.
DANGER
Danger of accidents due to defective securing elements.
Components may break loose from the mobile crane due to defective se-
curing elements. This may lead to personal injuries and material damage.
1. Use all the securing elements.
2. Check all the securing elements for damage.
3. Check the functioning of all the securing elements.
4. Replace defective securing elements.
WFN3RUWW2K2064139
The securing elements must always perform their function.

The crane operator is autonomously responsible for checking all the securing elements. Before
and after operating the mobile crane it must be checked for damage of the securing elements.
Damaged or worn securing elements must be replaced.
NOTICE! The following description shows the inspection of an individual securing ele-
ment. All reusable securing elements must be checked.
298 ATF 60G-3

2019-03_EN
Types of securing elements

The following reusable securing elements are used depending on the application:
▪ Folding plugs.
▪ Spring clips.
Checking the securing elements for damage

The inspection of the securing elements includes the visual check for the following types of
damage:
▪ Deformation.
▪ Rupture.
▪ Attrition.
In case one of these types of damage is true, the securing element must be replaced.
Checking folding plugs
1 Shank 3 Safety notch

2 Spring clamp
1. Pull out the folding plug.

2. Check the safety notch for damage.
Replace any folding plug with a damaged safety notch.
3. Insert the shank into the hole of the component to be fastened.
4. Check whether the shank can be easily inserted.
5. Press the spring clamp into the safety notch.
6. Check the clamping force of the spring clamp.
WFN3RUWW2K2064139
The spring clamp must not move out off the safety notch by itself.
Replace any folding plug with a spring clamp without clamping force.
ð The folding plug has been checked.
ATF 60G-3 299

2019-03_EN
Checking spring clips
A B
A Spring clip (plug type) 1 Shank

B Spring clip (clamp type) 2 Spring clamp
1. Pull out the spring clip.

2. Insert the shank into the hole of the component to be fastened.
3. Check whether the shank can be easily inserted.
4. Check the clamping force of the spring clip.
The spring clip must not move by itself out off the hole of the component to be fastened.
Replace any spring clip without clamping force.
ð The spring clip has been checked.
15.8 Checking carrier for leaks
15.8.1 Introduction
The mobile crane must be checked for leaks before putting it into operation every day. Due to
the high number of different components, the leakage tests must be carried out in different
places. The following components must be checked for leaks.
▪ Hydraulic system.
▪ Transfer case.
▪ Braking system.
▪ Axles.
Definition of "leak free"

A system is considered leak free if no significant fluid losses are detected. Even if seals are only
exuding or humid, this may be an indication of leakage.
WFN3RUWW2K2064139
300 ATF 60G-3

2019-03_EN
Overview of components
1 Hydraulic system 3 Axles

2 Transfer case
15.8.2 Checking assemblies for leaks and condition

Check for leaks regularly. If you detect a liquid loss, e.g. oil spots on the parking surface, have
the cause remedied immediately at a qualified specialist workshop.
The following must be checked:
▪ Transfer case.
▪ Axles.
▪ Axle drives.
15.8.3 Checking hydraulic system for leaks
Requirements
Checking hydraulic system for leaks and condition

Leaks and damages on the hydraulic system must be eliminated without delay in a specialist
workshop.
WFN3RUWW2K2064139
The hydraulic system consists of various subassemblies:

▪ Suspension hydraulics
▪ Steering hydraulics
▪ Outrigger hydraulic system
1. Check valves, sleeves and connections for leaks.
ATF 60G-3 301

2019-03_EN
2. Check threaded connections for leaks.

3. Check fixing of pipes.
4. Check pipes for damage.
5. Check hydraulic hoses for leaks, cracks and damage.
ð Hydraulic system has been checked for leaks and condition.
If a screw-in connection leaks:
1. Loosen union nut on pipe or hose.
2. Tighten threaded connection.
3. Tighten union nut.
15.9 Engine and assemblies
15.9.1 Engine
Safety instructions
WARNING
Touching hot engine parts may lead to serious burns.
1. Do not touch hot objects.
2. Wear protective gloves.
Pollution due to escaping resources.

Leaking seals may lead to unforeseeable escaping of resources.
1. Replace leaking seals.
2. Eliminate spilled resources immediately in an environmentally friendly
manner.
Pollution due to used oil and oil filters.

Used oil and oil filters are harmful to the environment.
1. Collect used oil suitable containers.
2. Dispose of used oil and oil filters in an environmentally friendly man-
ner.
WFN3RUWW2K2064139
302 ATF 60G-3

2019-03_EN
Checking the oil level of the engine
Safety instructions
NOTICE
Engine and catalytic converter damage due to incorrect oil level.
If the oil level is outside of the permitted limits, the engine and the catalytic
converter may be damaged.
1. If the oil level is too high, suck or drain oil.
2. If the oil level is too low, refill oil.
Requirements
1. Wait approx. 5 to 10 minutes if the engine was running previously.
2. Switch on the ignition. When doing this, observe the Engine oil level warning lamp, refer to
Error messages.
ð If the Engine oil level warning lamp is not lit, the engine oil level is correct.
ð Refill quantity when Engine oil level warning lamp is lit: 7 l.
ð Refill quantity when Engine oil level warning lamp is flashing: 14 l.
ð Also refer to “Engine system status” menu.
Changing engine oil and replacing the oil filter cartridge
Safety instructions
WARNING
Risk of scalding due to splashing hot engine oil.
Splashing hot engine oil may scald skin and eyes.
1. Wear safety goggles.
2. Wear protective gloves and protective clothing.
NOTICE
Engine damage due to old or incorrect engine oil.
WFN3RUWW2K2064139
Old or incorrect engine oil may lead to engine damage.

1. Change the engine oil and replace the filter cartridge regularly as per
the manufacturer's instructions.
2. Only use new oil specified for the engine.
3. Select oil according to the temperature conditions (refer to Technical
data [} page 395]).
ATF 60G-3 303

2019-03_EN
Requirements
▪ The mobile crane is supported by the outriggers.
▪ Superstructure has been rotated 90°.
▪ The superstructure is mechanically locked. Slewing brake has been engaged.
▪ Engine oil is at its operating temperature.
▪ Suitable collecting container is provided.
Draining engine oil
Installation site and overview
WFN3RUWW2K2064139
1 Oil drain valve 3 Oil drain hose
304 ATF 60G-3

2019-03_EN
2 Sealing cap
Depending on the model, the drain valve present must be replaced

with the drain valve included in the scope of delivery.
Procedure
1. Clean the surroundings of the oil drain valve.
2. Place provided collecting container underneath the oil drain valve.
3. Unscrew sealing cap of the oil drain valve.
4. Screw oil drain hose onto the oil drain valve.
5. Evacuate draining oil into the collecting container.
6. When the oil has drained completely, unscrew the oil drain hose and screw the sealing cap
onto the oil drain valve.
ð Engine oil has been drained.
Replacing the oil filter cartridge
Safety notice
NOTICE
Engine damage due to foreign objects in the oil circuit.
Foreign objects in the oil circuit may lead to damage of the engine com-
ponents.
1. Do not wipe out filter housing.

▪ The oil filter is located behind the maintenance hatch on the side of the engine.
WFN3RUWW2K2064139
ATF 60G-3 305

2019-03_EN
1 Oil filter
NOTICE! Use the respective chapter of the engine manufacturer's operating manual.
Procedure
1. Clean the surroundings of the oil filter housing.
2. Replace the oil filter cartridge.
ð Oil filter cartridge has been replaced.
Filling in engine oil

▪ The oil filler neck is located behind the maintenance hatch on the side of the engine.
▪ To fill in oil, open the maintenance hatch on the side of the engine.
WFN3RUWW2K2064139
1 Oil filler neck
306 ATF 60G-3

2019-03_EN
Filling in engine oil

2. Clean the surroundings of the oil filler neck.
3. Unscrew cap of oil filler neck.
4. Fill engine oil into the oil filler neck.
Quantity including oil filter: 25,5 l.
5. Screw cap of oil filler neck on.
6. Start the engine without pressing the accelerator pedal, and maintain idling speed.
7. Observe the warning lamps. Then Engine oil pressure and Minor engine fault warning
lamps must go out.
9. Check screw cap of oil filter and drain screw for leaks.
10.Check oil level after approx. 5 minutes, see Checking the oil level of the engine
[} page 303].
11.If necessary, refill engine oil.
12.Close the maintenance hatch.
ð Engine oil has been changed and checked.
Checking hoses and hose clamps
Safety instructions
NOTICE
Damage of charge air hoses due to exceeded tightening torques on
hose clamps.
When exceeding the maximum permitted tightening torque, the hose
clamp no longer has any spring elasticity. The charge air hose may be
damaged.
1. Do not exceed the maximum permitted tightening torque. (Tightening
torque: 10.2 Nm.)
Requirements
WFN3RUWW2K2064139
ATF 60G-3 307

2019-03_EN
1 Air hoses 3 Coolant hoses

2 Charge air hoses
Checking hoses and hose clamps

1. Inspect the following hoses for damage and to make sure they are secure:
∙ Charge air hoses.
∙ Coolant hoses.
∙ Air hoses.
2. Replace damaged hoses, tighten loose hose clamps.
Checking V-ribbed belt for wear and damage

Have this work done at an authorized specialist workshop.
Checking valve clearance

Replacing the AdBlue filter cartridge

Checking the cooling system and heating system

Have these checked regularly at a specialist workshop.
WFN3RUWW2K2064139
308 ATF 60G-3

2019-03_EN
15.9.2 Engine cooling system
Safety instructions
WARNING
Risk of injury due to hot coolant.
Hot coolant under pressure may gush out when opening the cooling sys-
tem and scald skin or eyes.
1. Use protective gloves.
2. Only open the cooling system at coolant temperatures below 50 °C.
WARNING
Risk of injury due to toxic coolant.
Toxic glicol in the coolant may cause injuries of skin and eyes.
1. Do not bring coolant into contact with skin, eyes or clothing.
2. In the event of eye contact, immediately rinse eyes thoroughly with
clear water.
3. In the event of swallowing coolant, immediately consult a physician.
NOTICE
Engine damage due to mixing different coolants.
Mixing different coolants may lead to flocculation and, thus, cause engine
damage.
1. Only use coolant in accordance with Mercedes Benz specification
325.5 (Glysantin G40).
2. Do not mix coolant in accordance with Mercedes Benz specification
325.5 with any other coolants.
3. In the event that the cooling system still contains a coolant that is not
in accordance with Mercedes Benz specification 325.5 (Glysantin
G40), the cooling system shall be flushed with prior to filling in the new
coolant.
Pollution due to coolant.

Coolant is harmful to the environment.
1. Collect coolant in a suitable container.
2. Dispose of coolant in an environmentally friendly manner.
WFN3RUWW2K2064139
ATF 60G-3 309

2019-03_EN
Checking the coolant level
Safety instructions
NOTICE
Engine damage due to lack of or insufficient anti-freeze or corrosion
protection.
In case of lack of or insufficient anti-freeze protection the coolant may
freeze. This may cause engine damages.
1. Before frost season begins, check coolant for sufficient anti-freeze or
corrosion protection. If necessary, refill anti-freeze and anti-corrosive.
2. Follow the operating manual of the engine manufacturer.
Requirements
▪ The coolant temperature is under 50 °C.
WFN3RUWW2K2064139
310 ATF 60G-3

2019-03_EN
Checking coolant level and coolant
Overview
1 Sealing cap - filler neck 3 Expansion tank

2 Pressure valve 4 Cooling system
Checking coolant level and coolant

1. Clean sealing cap and surroundings of the sealing cap.
2. Open sealing cap slowly and release excess pressure. When release pressure has been re-
leased, open sealing cap and lay it aside.
3. Check coolant level:
Coolant must reach lower edge of filler neck.
4. If necessary, refill coolant in the correct mixing ratios. For the coolant specification and the
mixing ratio refer to the engine manufacturer's operating manual.
5. Before frost season begins, check coolant for sufficient anti-freeze protection.
6. Place the sealing cap onto the filler neck and close.
ð Coolant level and coolant have been checked.
NOTICE! In the case of repeated lack of coolant, contact a specialist workshop.
Changing coolant
Requirements
WFN3RUWW2K2064139

▪ Coolant is lukewarm.
▪ Heating is adjusted at maximum heating power.
▪ Coolant preheating *) is switched off.
▪ Auxiliary heater is switched off.
▪ The air conditioning system is turned off.
ATF 60G-3 311

2019-03_EN
The cooling system must be flushed under the following circumstances:

▪ If heavily soiled.
▪ In case of incompatibility of old anti-freeze agent with the new antifreeze agent. For further
information refer to engine manufacturer's operating manual.
▪ In case of uncertainty regarding the old anti-freeze agent's specification.
NOTICE! Before the coolant change, the vehicle hot-water heating system must have
been opened.
1 Drain hose (2 ea.) 2 Hose clamp (2 ea.)
Draining coolant
1. Clean sealing cap and surroundings of the sealing cap.
2. Open sealing cap slowly and release excess pressure. When release pressure has been re-
leased, open sealing cap and lay it aside.
3. Place suitable collecting container underneath.
4. Release two hose clamps.
5. Pull drain hoses off.
6. Drain coolant into the collecting container.
7. Allow the coolant to drain completely.
8. Plug drain hoses on.
WFN3RUWW2K2064139
9. Tighten two hose clamps.

ð Coolant has been drained.
312 ATF 60G-3

2019-03_EN
Flushing cooling system
Requirement
▪ Coolant has been drained.
▪ The cooling system has been closed.
Procedure
Fill cooling system with fresh water.
1. Start engine and allow to run approx. 5 minutes.
3. Drain water completely.
4. Repeat flushing process twice.
5. Close cooling system.
ð Cooling system has been flushed.
Topping up coolant and bleeding

1. Fill coolant with the correct mixing ratio into filler neck of expansion tank, up to the bottom
edge of the filler neck. For the coolant specification refer to Technical data [} page 395].
3. Allow the engine to run approximately two minutes at idling speed.
If necessary, refill coolant up to the bottom edge of the filler neck.
4. Allow the engine to run approximately four minutes at 800 rpm.
5. Allow the engine to run approximately one minute at 1500 rpm.
6. Screw on the sealing cap of the coolant expansion tank.
Note Screw the cap on at a higher speed because otherwise the coolant will spill over the
filler neck.
8. Check coolant level.
CAUTION! The cooling system is pressurised. CAUTION! Do not open the cool-
ing system before the coolant temperature has fallen below 50°C.
ð The cooling system has been bled.
ð Coolant has been changed.
Cleaning the radiator/coolers
Requirements
WFN3RUWW2K2064139

ATF 60G-3 313

2019-03_EN
Overview
1 Fixing screw (4 ea.) 3 Maintenance hatch

2 Grate
WFN3RUWW2K2064139
Procedure
1. Release all screws, remove grate.
3. Blow the cooler out with compressed air, or clean with a brush.
4. Close the maintenance hatch.
314 ATF 60G-3

2019-03_EN
5. Attach grate.
ð The coolers/radiators have been cleaned.
15.9.3 Air cleaner
Replacing the air cleaner element
Safety instructions
NOTICE
Engine damage due to unfiltered intake air.
Unfiltered intake air may cause damages on the engine.
1. Only perform air cleaner maintenance when engine is switched off.
2. Do not start the engine if the air cleaner element has been removed.
3. No dirt must get into the air intake system while working.
Requirements
WFN3RUWW2K2064139
ATF 60G-3 315

2019-03_EN
Overview
1 Clamp clip 4 Air cleaner housing

2 Air cleaner element 5 Filter cover
3 Rain cap
1. Open all the clamp clips.

2. Remove the sealing cap from the air cleaner housing.
3. Pull the air cleaner element fully out of the air cleaner housing by turning it slightly.
4. Check the air cleaner housing for damage and cracks.
5. Clean the internal surface and the sealing surfaces of the air cleaner housing with a lint-free
damp cloth.
6. Introduce the new air cleaner element into the casing with the open side going in first.
7. Place the sealing cap on the air cleaner housing.
8. Close all the clamp clips.
ð The air cleaner element has been replaced.
Checking the air cleaner system
Safety instructions
NOTICE
Engine damage due to unfiltered intake air.
Unfiltered intake air may cause damages on the engine.
1. Only perform air cleaner maintenance when engine is switched off.
WFN3RUWW2K2064139
2. Do not start the engine if the air cleaner element has been removed.
3. No dirt must get into the air intake system while working.
316 ATF 60G-3

2019-03_EN
Checking the air cleaner system

1. Check the air intake hoses for damage and to make sure that they are secure.
2. Check that the hose clamps are secure.
3. Check the air cleaner housing for damage and cleanliness.
15.9.4 Fuel system
Safety instructions
WARNING
Pollution due to used filter elements, seals and fuel residues.

When disposed of incorrectly, the used components of the fuel system will
pollute the environment.
1. Dispose of filters and seals in an environmentally friendly manner.
2. Collect fuel residues in suitable containers.
Replacing the fuel filter cartridge

Refer to the engine manufacturer's operating manual for instructions.
WFN3RUWW2K2064139
ATF 60G-3 317

2019-03_EN
Water separator
Draining water from fuel system
Safety instructions
Pollution due to used filter elements, seals and fuel residues.

When disposed of incorrectly, the used components of the fuel system will
pollute the environment.
1. Dispose of filters and seals in an environmentally friendly manner.
2. Collect fuel residues in suitable containers.
NOTICE
Frost damages on fuel filter due to freezing of condensate.
If there is water in the filter bowl, it may freeze at low temperatures. The fil-
ter bowl may burst. Fuel may enter the environment. The engine may fail.
1. Before and during the frost season drain condensate and repeat as of-
ten as necessary.
WFN3RUWW2K2064139
Requirements
318 ATF 60G-3

2019-03_EN
Overview
1 Drain valve 5 Filter head

2 Filter bowl 6 Bleed screw
3 Sealing ring (2 pcs.) 7 Fuel hand pump
4 Filter cartridge
Draining water from fuel system

1. Open the maintenance hatch, if necessary.
2. Clean water separator.
3. Place collecting container underneath drain valve.
4. Open the drain valve.
5. Maintain drain valve open until pure fuel escapes.
6. Close the drain valve.
7. Remove the collecting container.
8. Close the maintenance hatch, if necessary.
ð The water separator is drained of water.
Replacing filter element of water separator
Safety instructions
NOTICE
WFN3RUWW2K2064139
Engine faults due to dirty filter element.

A dirty filter element can interfere with the engine's fuel supply. This may
result in engine faults or engine failure.
1. Replace the filter element in good time.
ATF 60G-3 319

2019-03_EN
Requirements
Overview

4 Filter cartridge
Replacing filter cartridge

2. Clean water separator.
4. Unscrew filter element from filter head.
5. Unscrew filter bowl from filter element and clean it.
6. Apply a little fuel onto both sealing rings.
7. Screw filter bowl with new sealing ring onto the filter element and tighten by hand.
8. Screw filter element with new sealing ring onto the filter head and tighten by hand.
WFN3RUWW2K2064139
10.Close the maintenance hatch, if necessary.

ð Filter cartridge has been replaced.
Final activities
1. Perform function check: Start the engine.
2. In case engine does not start, bleed fuel system.
320 ATF 60G-3

2019-03_EN
Bleeding the fuel system
Safety instructions
NOTICE
Engine faults due to air in the fuel system.
If there is air in the fuel system, this can interfere with the engine's fuel
supply. This may result in engine faults or engine failure.
1. Bleed the fuel system.
Requirements
Overview

4 Filter cartridge
WFN3RUWW2K2064139
Bleeding the fuel system

3. Open the bleeder screw.
4. Press the fuel hand pump until fuel comes out of the bleed screw without bubbles.
5. Close the bleeder screw.
ATF 60G-3 321

2019-03_EN
6. Wipe spilled fuel away from water separator with a clean lint-free cloth.
8. Close the maintenance hatch, if necessary.
ð Water separator of the fuel system has been bled.
Fuel tank
1 Maintenance hatch on the side 4 Screw plug

2 Fuel tank bleeding 5 Top maintenance hatch
3 Fuel tank
Requirement
Checking the ventilation filter

1. Clean connecting piece of the ventilation filter and check for free throughput.
ð Ventilation filter has been checked.
WFN3RUWW2K2064139
Replacing the ventilation filter

Draining condensate
1. Empty the tank down to the reserve.
2. Unscrew the drain plug.
322 ATF 60G-3

2019-03_EN
3. Allow the condensate to drain into a suitable container.

4. Clean the sealing surfaces.
5. Check seal, clean and replace if necessary.
6. Screw in and tighten the drain plug with seal.
ð Condensate has been drained.
15.9.5 Exhaust system
Cleaning exhaust pipe

15.10 Drive train
CAUTION
Risk of burns due to hot oil and hot components.
Hot oil and touching hot parts may lead to burns.
1. Before performing inspections, allow oil to cool down to below 50°C.
2. Do not touch hot parts.
15.10.2 Transfer case
Checking the oil level of the transfer case
Safety instructions
WARNING
Rotating wheels can cause injury.
Rotating wheels can pull in persons and objects. This could cause serious
or fatal injuries.
1. Maintain a safe distance from rotating wheels.
2. Remove objects from the vicinity of the wheels.
3. Cordon off/secure the working area.
NOTICE
WFN3RUWW2K2064139
Damage due to incorrect oil level.

A too low oil level causes defective lubrication and reduces lifetime. A too
high oil level leads to overheating.
1. Check the oil level periodically.
ATF 60G-3 323

2019-03_EN
NOTICE
Gearbox damages due to contaminated oil.
Contaminated oil introduces foreign particles into the gearbox system and
may lead to significant damages.
1. Store oil only in clean containers and transfer it from these.
2. Do not use any containers or filling devices which are used for anti-
freeze or engine coolant fluids.
Requirements
▪ The mobile crane is supported by the outriggers as prescribed, refer to Outrigger
[} page 163].
▪ All the wheels hang freely.
WFN3RUWW2K2064139
324 ATF 60G-3

2019-03_EN
Overview
1 Oil filler plug/fluid check plug

Preparations
The following procedure is necessary in order to ensure that the oil is correctly distributed in the
system.
2. Engage 9th gear.
3. Allow to run for approx. one minute (engine speed approx. 1000 rpm).
4. Put gearbox into Neutral.
6. The oil temperature of the transfer case must not exceed 50°C.
1. Clean around the oil filler screws.
2. Unscrew the oil filler screw.
ð The oil level must reach the lower edge of the hole.
ð The transfer case oil level has been checked.
Correcting the oil level of the transfer case
1. If necessary, refill oil through the filler hole.
2. Clean the sealing surface on the transfer case.
WFN3RUWW2K2064139
3. Clean the oil filler plug / fluid check plug and screw in with a new seal and tighten.
ð The transfer case oil level has been corrected.
Other work
Inspect the following during every oil check:
1. That the housing and shafts are free of leaks.
ATF 60G-3 325

2019-03_EN
2. Condition of the transmission suspension.
Changing the transfer case oil

15.10.3 Drive shafts
Checking drive shafts for noises
Checking drive shafts for noises

1. While driving listen for noticeable noises.
2. In case of noticeable noises, immediately contact a specialist workshop.
ð Drive shafts have been checked for noises.
Check that the flange screws and intermediate shaft bearing screws are secure
WFN3RUWW2K2064139
326 ATF 60G-3

2019-03_EN
15.11 Axles and brakes
15.11.1 Axle drives
Safety instructions
CAUTION
NOTICE
Checking oil levels of axle drives
Requirements
▪ The parking brake is released.
[} page 163].
WFN3RUWW2K2064139
ATF 60G-3 327

2019-03_EN
Checking oil levels of axle drives
Axle 1
1 Fluid check plug/oil filler plug

WFN3RUWW2K2064139
328 ATF 60G-3

2019-03_EN
Axle 2
Axle 3
1. Clean the surroundings of the oil filler plug.

2. Screw oil filler plug out.
WFN3RUWW2K2064139
3. Check the oil level.

The oil level must reach the lower edge of the hole.
4. If necessary, refill oil through the filler hole.
5. Clean sealing surface on axle casing.
6. Clean oil filler plug and screw in with new seal.
ATF 60G-3 329

2019-03_EN
7. Perform test on all axle drives.

ð Oil levels of axle drives have been checked.
Changing the axle drive oil

15.11.2 Wheel drives
Safety instructions
CAUTION
NOTICE
Checking oil levels of wheel drives
Requirements
▪ The parking brake is released.
[} page 163].
WFN3RUWW2K2064139
330 ATF 60G-3

2019-03_EN
Checking oil levels of wheel drives
1 Oil filler plug 3 Control mark

2 Oil drain plug
WFN3RUWW2K2064139
1. Turn wheel such that the oil drain plug is located at the lowest point.
The control mark on the oil filler plug is positioned horizontally.
2. Clean the surroundings of the oil filler plug.
3. Remove oil filler plug.
4. Check the oil level.
Oil level must reach the lower edge of filler hole.
5. Clean sealing surface on wheel drive.
ATF 60G-3 331

2019-03_EN
6. Clean oil filler plug and screw in with new seal.

7. Test all wheel drives.
ð Oil levels of wheel drives have been checked.
Changing the wheel drive oil

15.11.3 Visual inspection and switching function test
Requirements
Visual inspection
1. Inspect the axles and axle drives for leaks and damage.
Switching function test

1. Test the function of the differential lock switching; to do this, switch differential locks of the
axle on and off, refer to Engaging and disengaging axle drive and differential locks
[} page 220].
15.11.4 Braking system
Checking the compressed air system for leaks

Check the compressed air system daily for leaks before setting off.
Testing function of air dryer
Requirements
▪ Compressed air system is filled up to cut-out pressure.
WFN3RUWW2K2064139
332 ATF 60G-3

2019-03_EN
Overview
1 Compressed air tank 2 Drain valve
Draining condensate
NOTICE! If condensate escapes, the air dryer is defective. Have the air dryer repaired in a
specialist workshop without delay.
1. Take the provided collecting container.
2. Tilt the actuator pin of the drain valve by pressing from the side.
3. If condensate comes out, tilt the actuator pin until no more condensate comes out.
ð Condensate has been drained.
WFN3RUWW2K2064139
ATF 60G-3 333

2019-03_EN
Checking brake linings and air gap
Safety instructions
WARNING
Risk of accidents due to worn brake linings and brake drums.
Worn brake linings and worn brake drums may lead to reduced braking
power or brake failure. This may lead to accidents involving personal injur-
ies or material damage.
1. Check brake discs and brake drums periodically.
NOTICE! With new brake linings, no full braking nor prolonged braking must be per-
formed in the first 50 km if possible.
Overview
Y Air gap (1.5 ± 0.5 mm) X Minimum lining thickness (6 mm)

1. Remove rubber plug from inspection hole.
2. Check wear of the brake linings.
Have the brake linings replaced if the wearing edge is no longer visible or the minimum lin-
ing thickness has been reached.
3. Check air gap between brake drum and brake lining.
NOTICE! The maximum air gap must not exceed 2 mm.
4. Close inspection hole with rubber plug.
ð Brake linings and air gap have been checked.
NOTICE! They may only be changed by a qualified and trained person or in a specialist
workshop.
WFN3RUWW2K2064139
Checking the ABS function

When setting off and during the journey. Check the function of the pilot lamps.
334 ATF 60G-3

2019-03_EN
15.11.5 Checking compressed air system
Removing panelling
Overview
1 Panelling 2 Screws (3 ea.)
Removing panelling
1. Unscrew all screws and remove panelling.
WFN3RUWW2K2064139
ð The panelling has been removed.
ATF 60G-3 335

2019-03_EN
Overview
1 Supply pressure Service brake, circuit 1 5 Control pressure Brake cylinder Axle 3 test
test connection connection
2 Supply pressure Service brake, circuit 2 6 Brake cylinder pressure Spring-loaded ac-
test connection cumulator cylinder Axle 2 and 3 test con-
nection
3 Supply pressure Parking brake test con- 7 Filling connection for spring-loaded accu-
nection mulator
4 Supply pressure Secondary users system 8 —
test connection
Checking compressed air system

Important pressure values
Cut-out pressure of the pressure 10.0±0.3 bar
regulator
Cut-in pressure of the pressure regu- 8.5-9.5 bar
lator
Axle 1 brake pressure 9.8-10.2 bar
Axle 2 brake pressure 7.5 bar
Axle 3 brake pressure 3 bar
Pressure Brake circuit 1 and 2 9.8-10.2 bar

WFN3RUWW2K2064139
336 ATF 60G-3

2019-03_EN
Fitting panelling
Overview
1 Panelling 2 Screws (3 ea.)
Fitting panelling
1. Fit the panelling and secure it with all screws.
ð The panelling has been fitted.
15.11.6 Cleaning drain valves
Requirements
▪ Compressed air system is filled up to cut-out pressure.
WFN3RUWW2K2064139
ATF 60G-3 337

2019-03_EN
Overview
1 Air tank 2 Drain valve
Procedure
NOTICE! If condensate escapes, the air dryer is defective. Have the air dryer repaired in a
specialist workshop without delay.
WFN3RUWW2K2064139
1. Wipe exterior of drain valve with a moist cloth.

2. Take the provided collecting container.
3. Tilt the actuator pin of the drain valve to all four directions by pressing from the side.
4. If condensate comes out, collect it in the collecting container and tilt the actuator pin until no
more condensate comes out.
ð Drain valve has been cleaned.
338 ATF 60G-3

2019-03_EN
15.11.7 Engine brake and exhaust flaps

Check the function and setting.
15.11.8 Inspect the protective caps, bushings and seals

15.11.9 Inspecting the diaphragm cylinder

15.11.10 Checking the ABS system

15.11.11 Steering
Check steering drive shafts for circumferential backlash

Checking ball joints in steering and track rods for backlash

15.11.12 Checking the screws on axles, steering levers, push rods for tightness
WFN3RUWW2K2064139
ATF 60G-3 339

2019-03_EN
15.11.13 Eddy-current brake *)
Overview
1 Rotor 3 Screws (12 ea.)

2 Stator 4 Screws (8 ea.)
WFN3RUWW2K2064139
340 ATF 60G-3

2019-03_EN
Performing function check of eddy-current brake
WARNING
Risk of burns due to hot components of the eddy-current brake.
Touching hot components of the eddy-current brake may lead to serious
burns.
1. Do not touch any hot components.
While braking with the eddy-current brake, the rotors heat up due to their function.
To check the eddy-current brake, drive on a free route close to the inspection site.
1. Bring right steering column switch into position 2 or 3, refer to .
ð Engine brake, intarder, and eddy-current brake are switched on.
2. Accelerate mobile crane several times with the accelerator pedal and release accelerator
pedal again.
ð Mobile crane accelerates while stepping on the accelerator pedal and brakes when re-
leasing the accelerator pedal.
3. Drive up to the inspection site.
6. Carefully check if the rotors of the eddy-current brake are warm.
ð If the rotors are warm, the eddy-current brake is in order.
Cleaning the eddy-current brake
Requirements
Cleaning the eddy-current brake

▪ Only clean when cooled down.
▪ Do not use any cleaning agents or solvents.
▪ Clean with the high-pressure steam cleaner.
▪ Do not direct the steam jet directly at the electrical connections.
Check clearance between stator and rotors

WFN3RUWW2K2064139
Air gap check

Checking drive shaft screws

ATF 60G-3 341

2019-03_EN
Checking eddy-current brake screws

Check shaft sealing rings on axle

Checking insulating sheaths, wiring, connections, and contacts

15.12 Hydraulic system
WARNING
Risk of accidents due to high oil pressures in the hydraulic system.
When the engine is running, the hydraulic system is subjected to high
pressures which may lead to serious accidents during maintenance activit-
ies.
1. Only work on the hydraulic system when the engine is switched off.
2. Depressurise the hydraulic system.
WARNING
Risk of accidents and damages on the hydraulic system due to con-
taminated filter elements.
Dirt in the hydraulic system and the filter elements may lead to malfunc-
tions and damages of the hydraulic system. This may lead to accidents in-
volving personal injuries and material damage.
1. Only fill in new hydraulic oil from a clean container.
2. Have the filter elements replaced only in a specialist workshop.
3. Change the filter elements, do not clean them.
4. Change the filter elements with every hydraulic oil change.
5. Change the filter elements when the Hydraulic oil filter contamination
indicator lights up.
6. Change the filter elements according to the maintenance plan.
WARNING
WFN3RUWW2K2064139
Risk of accidents due to air in the hydraulic system.

If the hydraulic system contains any air, this may lead to malfunctions.
This may lead to accidents involving personal injuries and material dam-
age.
1. Have a specialist workshop bleed the hydraulic system.
342 ATF 60G-3

2019-03_EN
WARNING
Risk of accidents due to incorrect work on hydraulic accumulators.
The hydraulic accumulators are pressurized and may lead to injuries when
handled incorrectly.
1. Have all the activities on the hydraulic accumulators only performed by
the TADANO FAUN Customer Service.
It is recommended to have an analysis performed by the supplier before a

planned hydraulic oil change or at regulars intervals whether a hydraulic oil
change is necessary. The mobile cranes are delivered with hydraulic oils
with a minimum purity according to ISO 4406 class 18/16/13. The opera-
tion of the hydraulic components is guaranteed up to a purity of 20/18/15.
Depending on the contamination degree and the thermal load of the hy-
draulic oil, possibly shorter intervals as those mentioned in the mainten-
ance plan may be required.
Pollution due to used oil and oil filters.

Used oil and oil filters are harmful to the environment.
1. Collect used oil suitable containers.
2. Dispose of used oil and oil filters in an environmentally friendly man-
ner.
15.12.2 Checking the hydraulic oil level
Safety instructions
WARNING
Risk of accidents due to too low hydraulic oil level.
A too low hydraulic oil level may cause damages on the hydraulic system.
The hydraulic system may fail. This may lead to accidents involving per-
1. Check the hydraulic oil level and refill hydraulic oil if required.
Requirements
WFN3RUWW2K2064139
▪ When starting the test, the hydraulic oil temperature should range between 15 °C and 25 °C.
▪ The telescopic boom is retracted completely.
▪ The telescopic boom is laying in the boom rest.
ATF 60G-3 343

2019-03_EN
WFN3RUWW2K2064139
344 ATF 60G-3

2019-03_EN
Overview
1 Inspection glass 3 Hydraulic oil level setpoint value arrow

2 Filter cover
Checking the hydraulic oil level

1. Read off hydraulic oil level on inspection glass.
Correct oil level: within a range of 10 mm above or below the Hydraulic oil level setpoint
value arrow.
Note: For every 10 °C temperature difference, the oil level changes by approx. 7 mm.
2. If necessary, refill hydraulic oil until the correct oil level is reached.
ð Hydraulic oil level has been checked.
Refilling hydraulic oil
The fluid is topped up via the opening in the filter cover.
1. Clean the surroundings of the filter cover.
2. Unscrew filter cover and refill hydraulic oil through the hole until the correct oil level is
reached.
3. Clean the sealing surfaces.
4. Check cover seal, clean and replace if necessary.
5. Screw the filter cover, including the seal, back onto the hydraulic oil tank.
ð Hydraulic oil has been refilled.
WFN3RUWW2K2064139
15.12.3 Checking hydraulic hoses

Check hydraulic hoses / hoses for damage.
ATF 60G-3 345

2019-03_EN
15.12.4 Replacing hydraulic hoses

15.12.5 Checking the hydraulic accumulator preloading pressure

15.13.1 Fuses
WFN3RUWW2K2064139
346 ATF 60G-3

2019-03_EN
Overview
Fuse assignment
Clamp Ampere Function

F0001 10 A 24 V socket,
trailer socket S
F0002 10 A Hazard warning lights
F0003 15 A Front and rear rotary beacons
F0004 10 A Fog lights,
rear fog lights,
headlight flasher
F0005 10 A —
F0006 5A Air conditioning system
F0007 10 A Switching on the ignition
F0008 10 A —
F0009 40 A —
F0010 10 A OBD diagnostics engine
F0011 10 A Door contact switch,
carrier cab interior lights,
carrier cab courtesy light
F0012 15 A Light rotary switch,
High beam light relay
F0013 15 A ABS system control unit
F0014 25 A ABS system trailer
F0015 10 A —
WFN3RUWW2K2064139
F0016 15 A Working floodlight outriggers

F0017 10 A Gearbox
F0018 7.5 A —
F0019 10 A —
F0020 10 A —
F0021 5A Speedometer
ATF 60G-3 347

2019-03_EN

F0022 10 A —
F0023 10 A —
F0024 10 A Actuating rear steering
F0025 10 A Brake lights
F0026 10 A Reversing lights,
reversing signal
F0027 10 A Indicator lamps and switches, instrument panel
F0028 15 A Heating
F0029 5A Outrigger actuation, left-hand and right-hand
F0030 10 A Rear working floodlight
F0031 5A OBD diagnostics engine
F0032 10 A Trailer socket S
F0033 5A Rear area monitoring
F0034 10 A Mirror heater,
mirror adjustment,
seat heater
F0035 5A —
F0036 10 A ABS system control unit
F0037 5A ABS system trailer socket
F0038 3A Rotary switch, light
F0039 10 A Centralized lubrication system
F0040 10 A —
F0041 10 A Actuating window lifter, passenger side
F0042 5A —
F0043 15 A Circuit board for superstructure movability
F0044 5A Electronic tachograph MTCO,
speedometer
F0045 10 A Eddy-current brake
F0046 10 A —
F0047 10 A Working floodlights on external mirrors
F0048 5A Immobilizer
F0049 10 A Gearbox
F0050 7.5 A —
F0051 10 A —
F0052 10 A —
F0053 7.5 A Direction indicator
F0054 10 A Windshield wipers,
windshield washer,
signal horn,
supertone horn
alternator
WFN3RUWW2K2064139
F0055 10 A Actuating window lifter, driver side

F0056 10 A —
F0057 3A Outrigger actuation, left-hand and right-hand
F0058 10 A CAN distributor module I/0,
left-hand front outrigger, front right D613
left-hand rear outrigger, rear right D614
348 ATF 60G-3

2019-03_EN

carrier D018
carrier D019
carrier D020
F0063 15 A —
F0064 10 A Central control system Carrier A020
F0067 5A Sensors for the central control system carrier A020
F0068 5A Switches for the central control system carrier A020,
CAN distributor module I/0
F0069 10 A —
F0070 5A —
F0071 10 A —
F0072 5A —
F0073 10 A —
F0074 5A Central control system Carrier A020
F0075 5A CAN distributor module I/0,
left-hand front outrigger, front right D613
left-hand rear outrigger, rear right D614
carrier D018
carrier D019
carrier D020
F0080 5A —
F0081 20 A Heating,
relay, automatic connection of blower
F0082 5A Heating
F0083 5A Battery main switch relay
F0084 15 A Voltage reduction device 24V/12V
F0085 5A Immobilizer
F0086 5A Electronic tachograph MTCO
F0087 10 A —
F0088 5A Tyre pressure indicator
F0089 5A Door, left-hand and right-hand
F0090 10 A —
WFN3RUWW2K2064139
F0091 10 A —
F0092 7.5 A Side bordering lights, rear lights, side marker lamps, left clear-
ance lamps
F0093 7.5 A Side bordering lights, rear lights, side marker lamps, right clear-
ance lamps
F0094 7.5 A Side bordering lights, side marker lamps, clearance lamps
F0095 10 A —
ATF 60G-3 349

2019-03_EN

F0096 10 A Left-hand low beam light, high beam light
F0097 10 A Right-hand low beam light, high beam light
F0098 10 A —
F0099 10 A —
F0100 10 A —
ACM = control unit for aftertreatment of exhaust gases

CAN = Controller Area Network
CMV = colour display
MCM = control unit for motor management
OBD = On-Board Diagnostics
*) = Option
Replacing fuses
Safety instructions
WARNING
Risk of accidents due to replacing fuses incorrectly.
Replacing fuses incorrectly may trigger electric shocks and fires. This may
lead to accidents involving personal injuries or material damage.
1. Switch off ignition and battery main switch before repairing.
2. Eliminate the cause of the overload before replacing a blown fuse.
Replacing fuse
1. Switch Battery main switch switch off, refer to Battery main switch.
2. Eliminate the cause of the short circuit.
3. Remove blown fuse and replace with fuse which has same ampere rating.
4. Switch Battery main switch switch on, refer to Battery main switch.
5. Test function of affected consumer.
ð Fuse has been replaced.
15.13.2 Relay
Safety instructions
WARNING
WFN3RUWW2K2064139
Risk of accidents due to incorrect changing of relays.

Incorrect changing of relays may trigger electric shocks and fires. This
may lead to accidents involving personal injuries or material damage.
1. Switch off the battery main switch and the ignition.
2. Eliminate the cause of the damage before replacing a blown relay.
350 ATF 60G-3

2019-03_EN
Overview
WFN3RUWW2K2064139
A- Relay installation location

E
ATF 60G-3 351

2019-03_EN
Relay assignment
Installation location A
Function Relay (K)/diode (V)
ABS system deactivation K101
Heating V022
Rear working floodlight *) K069
Heating K048
Working floodlights on external mirrors *) K068
— —
Automatic connection of blower *) K065
Working floodlight V010
— —
"+" supply K036
Carrier ignition on K001
— —
"+" test terminal P009
"-" test terminal P019
— —
— —
*) = Option
Installation location B
"+" supply K035
— —
— —
— —
Carrier central warning K061
— —
— —
Radio K050
— —
Rear left rotary beacon *), K058
Rear right rotary beacon *)
Signal horn K012
Front left rotary beacon, K018
Front right rotary beacon
Switching on the ignition V011
Direction indicators K010
WFN3RUWW2K2064139
Hazard warning light

— —
— —
*) = Option
352 ATF 60G-3

2019-03_EN
Installation location C
Buzzer V003
Brake light K042
High beam light / headlight flasher K007
Service brake K047
Rear fog light K008
— —
Fog light K006
— —
Left-hand turn signal indicator K033
— —
Right-hand turn signal indicator K034
"+" supply V004
Wiping interval K002
"+" supply V017
— —
— —
Installation location D
— —
— —
— —
— —
Hazard warning lights K029
— —
Hazard warning lights K009
Hazard warning lights V006
— —
Right outrigger working floodlights K067
— —
Left outrigger working floodlights K066
— —
Door contact switch K041
— —
— —
Installation location E
WFN3RUWW2K2064139

— —
— —
— —
Reversing signal V306
Eddy-current brake *) K026
Reversing light K312
ATF 60G-3 353

2019-03_EN

Rotary switch, light V007
Driver's door K011
Passenger door K031
Eddy-current brake (speed on and accelerator pedal de- K032
activation)
Air conditioning system *) K037
— —
— —
*) = Option
Changing relay
1. Switch off ignition and Battery main switch switch.
2. Eliminate the cause of the damage.
3. Remove blown relay and replace with relay which has same connected load.
4. Switch on Battery main switch switch and ignition.
5. Test function of affected consumer.
15.13.3 Bulbs and lamps
Safety instructions
WARNING
Risk of accidents due to defective lamps.
Defective may lead to impaired vision. This may lead to accidents in-
volving injuries and material damages.
1. Check lighting equipment periodically.
2. Replace defective lamps without delay.
Description
The following must be observed for trouble-free operation of the mobile crane:
▪ Keep all the display devices, headlights and lamps clean.
▪ When changing lamps, comply with design, operating voltage and power.
WFN3RUWW2K2064139
354 ATF 60G-3

2019-03_EN
Lamps list
Position Function Type Power
1 Rotary beacon H1 70 W
2 Clearance lamp superstructure, rear P25-1 5W
3 Side marker lamp (*) (*)
4 Reverse light P21W 21 W
5 Rear fog light P21W 21 W
6 Rear light R5W 5W
6 Rear light (Canada) *) P25-2 5W
7 License plate light R10W 10 W
8 Reflector - -
9 Brake light P21W 21 W
10 Flashing light, rear P21W 21 W
WFN3RUWW2K2064139
11 Clearance lamp, rear R10W 10 W

12 Clearance lamp, side (*) (*)
13 Clearance lamp, roof of the carrier cab R19/10 10 W
14 Flashing light, side P25-1 21 W
15 —
16 Flashing light, front PY21W 21 W
ATF 60G-3 355

2019-03_EN
Position Function Type Power

16 Flashing light, front (Canada) *) — —
17 Low beam light / daytime running light
18 Fog light
19 High-beam light
20 Clearance lamp, boom W10/5 5W
21 Roof lights (Canada) *) (*) (*)
Ceiling lamp, carrier cab R19/10 10 W
Instrument panel - switch lights
Instrument panel – indicator lamps W5/1.2 1.2 W
Working floodlights on the outrigger H3 70 W
(in acc. with DIN 72601)

Lamps marked with (*) cannot be replaced individually.
15.14 Breathers
15.14.1 Introduction
The following components have a breathing function via a breather or venting holes:
▪ Axles.
▪ Fuel tank.
▪ Braking system
▪ Bleeder valve on the compressed air valves.
▪ Venting holes on the brake cylinders.
▪ Transfer case.
Defective or dirty breathers and venting holes can cause malfunctions or failures:
▪ Assemblies can be leaky.
▪ Brake valves can vent poorly.
▪ Wheel brakes can become hot.
WARNING
Risk of accidents due to defective breather.
Defective breathers can cause components to fail or malfunction. This may
result in accidents. This could cause serious or fatal injuries.
1. Check breathers periodically.
WFN3RUWW2K2064139
2. Replace defective breathers.
356 ATF 60G-3

2019-03_EN
NOTICE
Damages due to painted-over breather.
A painted-over breather might not work. The component with the breather
function may be damaged.
1. Before carrying out painting work, make sure that breathers are well
covered.
2. Remove the cover once work is complete.
3. Check functionality of the breathers; replace if necessary.
Have the breathers cleaned by a specialist workshop in accordance with

the maintenance plan.
Have the breathers replaced only by specialist workshop.
15.14.3 Requirements
15.14.4 Installation location

WFN3RUWW2K2064139
ATF 60G-3 357

2019-03_EN
15.14.5 Checking bleeder valve of axle drives
Overview
1 Bleeder valve axles
Checking breather
1. Remove external dirt from dirty breathers.
NOTICE! Do not use high-pressure cleaners.
2. Check the breather cap:
- It must be possible to turn the breather cap easily.
- The breather cap must not be damaged.
3. Check that the breather is securely in place. Tighten if necessary.
4. Have damaged breathers replaced by a specialist workshop.
ð Breather has been checked.
15.14.6 Checking braking system bleeder valves
Overview
WFN3RUWW2K2064139
1 Breather on the brake valve
358 ATF 60G-3

2019-03_EN
1 Venting hole brake cylinder
Checking breather
Checking venting holes

1. Clean the area around the venting holes.
NOTICE! Do not use a high-pressure cleaner.
2. Check venting holes for dirt.
3. Clean soiled venting holes by blowing them out.
ð Venting holes have been checked.
15.14.7 Checking fuel tank bleeder valve
WFN3RUWW2K2064139
ATF 60G-3 359

2019-03_EN
Overview
1 2
4
5
6
1 Fuel tank 5 Breathers
2 Fill level sensor 6 Electrical connection
3 Filler neck 7 Fuel return
4 Fuel flow
Checking breather
WFN3RUWW2K2064139
360 ATF 60G-3

2019-03_EN
15.14.8 Checking transfer case breathers
Overview
1 Breather on transfer case
Checking breather
15.15 Wheels and tyres
15.15.1 Service life of wheel rims

A service life of the wheel rim of the mobile crane of approx. 80000 – 100000 km can be as-
sumed with normal use.
Large, spasmodic stresses or driving with excessive axle loads, more than the constructional
guidelines, can lead to a reduction in the specified service life. The wheel rims should therefore
WFN3RUWW2K2064139
be inspected regularly, depending on the conditions of use of the vehicle, and checks for cracks
carried out on the critical areas e.g. welding seam between disc and rim.
Cracks which may be present may not be repaired by welding.
The vehicle operator may only use wheel rims which are approved by the
mobile crane manufacturer.
ATF 60G-3 361

2019-03_EN
15.15.2 Checking wheels and tyres
WARNING
Risk of accidents due to damaged wheels and tyres.
Damaged wheels or tyres may become partially or completely detached
from the mobile crane. This may lead to accidents involving personal injur-
ies or material damage.
1. Check wheels and tyres according to the maintenance plan.
2. Shorten the maintenance intervals in case of severe operating condi-
tions.
3. Observe the following notes.
Check wheels and tyres for:

1. Tyre wear and damages.
2. Tyre pressure.
3. Corrosion.
4. Damaged wheel bolts or wheel nuts.
5. Damaged wheel rims.
6. Wheel nuts secure.
15.15.3 Checking the wheel nuts
Safety instructions
WARNING
Risk of accidents due to loosened wheel nuts or ripped off wheel
bolts.
If wheel nuts are loosened or wheel bolts are ripped off, the wheel may be
detached. This may lead to accidents involving personal injuries or mater-
ial damage.
1. Check the wheel nut indicators periodically.
2. Check that the wheel nuts are secure and tighten them in accordance
3. When driving with axle loads in excess of 13 t, retighten the wheel nuts
in accordance with the maintenance plan.
Wheel nut indicators

The wheel nuts are provided with wheel nut indicators. The arrow tips must point to each other
WFN3RUWW2K2064139
(permitted position). If this is not the case (not permitted position), the wheel nuts must be re-
tightened.
362 ATF 60G-3

2019-03_EN
1 Permitted position 2 Not permitted position
Check that the wheel nuts are secure

1. Check the positions of wheel nut indicators.
2. If the wheel nut indicators are in an not permitted position, re-tighten wheel nuts. See
Retightening wheel nuts [} page 363].
3. Replace damaged or lost wheel nut indicators.
ð Tightness of the wheel nuts has been checked.
NOTICE! When driving with axle loads in excess of 13 t (irrespective of the position of the
wheel nut indicators), the wheel nuts must always be re-tightened in accordance with the
maintenance plan.
15.15.4 Retightening wheel nuts (axle load up to 13 t)
Safety instructions
WARNING
bolts.
ial damage.
WFN3RUWW2K2064139
Re-tightening wheel nuts
Always tighten wheel nuts in a crosswise pattern.

Use a torque wrench.
Do not damage the wheel bolt threads.
ATF 60G-3 363

2019-03_EN
1 Wheel nut indicator 2 Wheel nut
1. Pull all the wheel nut indicators off.

2. Re-tighten all wheel nuts with a torque wrench.
Tightening torque: 680 +/- 30 Nm
3. Put wheel all the nut indicators on the wheel nuts so that the 2 arrows point to each other.
ð Wheel nuts have been re-tightened.
15.15.5 Retightening wheel nuts (axle load over 13 t)
Safety instructions
WARNING
bolts.
ial damage.
Re-tightening wheel nuts

WFN3RUWW2K2064139
Always tighten wheel nuts in a crosswise pattern.

Use a torque wrench.
Do not damage the wheel bolt threads.
364 ATF 60G-3

2019-03_EN
1 Wheel nut indicator 2 Wheel nut
1. Pull all the wheel nut indicators off.

2. Re-tighten all wheel nuts with a torque wrench.
Tightening torque: 680 +/- 30 Nm
WARNING! Replace wheel bolt if it is possible to re-tighten it more than 2 times.
3. Put wheel all the nut indicators on the wheel nuts so that the 2 arrows point to each other.
ð Wheel nuts have been re-tightened.
15.15.6 Checking and adapting tyre pressure
Safety instructions
WARNING
Risk of accidents due to burst tyres.
A too low tyre pressure may lead to overheating and to bursting of tyres.
This may lead to accidents involving personal injuries and material dam-
age.
1. Check tyre pressure before starting to drive.
2. Check and change the tyre pressure only on "cold" tyres.
WARNING
Risk of injury due to bursting tyres.
Tyres may burst during while inflating. Pieces of the tyre may come loose
WFN3RUWW2K2064139
and be ejected. This could result in death or serious injury.

1. Place the tyres in a approved cage while inflating.
2. If there is no cage available, keep a safety distance of at least 3 m in
direction of the running surface while inflating.
ATF 60G-3 365

2019-03_EN
When checking the tyre pressure, the temperature of the tyres must be the same as the ambi-
ent temperature. In case of reducing tyre pressure on warm tyres, it would be too low after cool-
ing. The load-bearing capacity of the tyres would no longer be ensured.
NOTICE! For every 10 °C temperature difference the tyre pressure changes approx. 0.5
bar.
Requirements
Checking and adapting tyre pressure

Tyre pressures table
Tyres Tyre pressure [bar]
385/95 R25 170E 10.0
385/95 R25 170F 9.0
445/95 R25 174F 9.0
525/80 R25 176F 7.0
525/80 R25 179E 7.0
Checking and adapting tyre pressure
Overview
A Without tyre pressure monitoring system 1 Refill valve

B With tyre pressure monitoring system 2 Tyre valve
3 Wheel rim
4 Wheel module
WFN3RUWW2K2064139
Correcting the tyre pressure

1. Correct the tyre pressure at the refill valve, refer to Checking and adapting tyre pressure
[} page 365].
366 ATF 60G-3

2019-03_EN
2. Connect the tyre inflator hose with pressure gauge to the tyre inflator connector of the
vehicle's compressed air system, refer to Test the compressed air system, or to a provided
compressor.
3. Remove the valve cap.
4. Connect the tyre inflator hose to the refill valve.
5. Read tyre pressure on pressure gauge.
6. Adapt the tyre pressure:
- If tyre pressure is too low, increase air pressure.
- If tyre pressure is too high, reduce air pressure.
7. Remove tyre inflator hose.
8. Screw the valve cap onto the valve.
ð The tyre pressure of one wheel has been checked and adjusted.
9. Check the tyre pressure of the other wheels as described above, and adjust if necessary.
ð The tyre pressure of all wheels has been checked and adapted.
15.15.7 Interchanging wheels in case of tire wear

To achieve an even wear pattern on all tyres on the mobile crane, it is advisable to interchange
the wheels. The wheels should be interchanged as soon as an uneven wear pattern is noticed.
Overview
Change of wheels
1. Change wheels as shown in the image.
ð The driving comfort and the tyres' mileage are influenced positively.
Wheel modules for air pressure display *)

When changing the wheels, the wheel modules remain on their original wheel hub and are not
changed with the wheels.
WFN3RUWW2K2064139
15.15.8 Changing wheel module for air pressure display *)

The wheel module for measuring the tyre pressure does not require any maintenance.
ATF 60G-3 367

2019-03_EN
Overview
1 Refill valve 3 Wheel rim

2 Tyre valve 4 Wheel module
Changing wheel module with empty battery

The service life of the battery in the wheel module is approx. 5 years. If the battery is empty, the
tyre pressure is no longer detected.
We recommend to replace all wheel modules if the battery of one wheel module is empty.
Fault in data transmission

In the proximity of transmitter masts or other interfering sources, and at
outside temperatures below -20 °C, the transmission of the tyre pressure
may be interrupted. At a greater distance to the interfering source and at a
higher outside temperature, the tyre pressure will be indicated correctly
again.
1. Have the wheel module with an empty battery replaced in an authorised specialist work-
shop.
15.15.9 Checking wheel tracking

15.15.10 Checking the toe-in

WFN3RUWW2K2064139
368 ATF 60G-3

2019-03_EN
15.16 Outrigger system
WARNING
Risk of accidents due to defective outrigger parts.
Damaged outrigger parts may break off or fall off while driving. This may
lead to accidents involving personal injuries or material damage
1. Visual inspection before driving.
2. Replace damaged parts immediately.

WFN3RUWW2K2064139
ATF 60G-3 369

2019-03_EN
15.16.3 Overview
1 Outrigger system
15.16.4 Checking and maintaining outrigger
Checking outrigger for damage

1. Check hoses and cables for damages, kinks or chafing.
2. Check outrigger floats, guide frames and holders for damages and tightness.
3. Check hydraulic cylinders for damages and oil leaks.
4. Check outrigger beams and outrigger casings for cracks and deformation.
5. Check all locking pins and pin holders for cracks and deformation.
6. Replace defective locking pins.
7. In case of damage on the outrigger structural elements, consult specialist workshop.
ð Visual inspection has been performed.
Cleaning and lubricating outrigger

1. Clean the sliding surfaces of the outrigger beams and holders of the outrigger floats in the
outrigger cylinders.
2. Spread multi-purpose grease on the sliding surfaces of the outrigger beams and holders of
the outrigger floats.
ð Outrigger has been cleaned and lubricated.
15.16.5 Check and adjust the wear plates of the outrigger

WFN3RUWW2K2064139
15.16.6 Check and adjust the outrigger cylinder guide

15.16.7 Checking hoses and cables

370 ATF 60G-3

2019-03_EN
15.17 Carrier cab
15.17.1 General information
Requirements
The following chapter lists working instructions for care and maintenance of important assem-
blies. These must be carried out in accordance with the time intervals in the maintenance
schedule.
This applies for the following assemblies:
▪ Doors and flaps of carrier cab [} page 371]
▪ Windshield washer system [} page 375]
▪ Air conditioning system *) [} page 378]
▪ Rear area monitoring *) [} page 379]
15.17.2 Doors and flaps of carrier cab
Maintaining doors
Maintaining door locks

WFN3RUWW2K2064139
ATF 60G-3 371

2019-03_EN
1. Open driver door.

2. Apply a product containing graphite on the door lock before frost season begins.
3. Check door for good movability.
4. Repeat procedure for passenger door.
Treating door seals
WFN3RUWW2K2064139
372 ATF 60G-3

2019-03_EN
1. Treat door seals and rubber parts with acid-free grease or talcum before frost season be-
gins.
2. Close both doors.
Maintaining front cover
Maintaining lock of front cover
1. Open front cover.

2. Apply a product containing graphite on the lock of the front cover before frost season be-
gins.
3. Check lock of front cover for locking function.
WFN3RUWW2K2064139
ATF 60G-3 373

2019-03_EN
Maintaining hinges of front cover
1. Apply a product containing graphite on the hinges of the front cover before frost season be-
gins.
2. Check front cover for good movability.
3. Close front cover.
15.17.3 Oil/lubricate joints, hinges and all moving parts

▪ Care for parts as per the maintenance plan.
WFN3RUWW2K2064139
374 ATF 60G-3

2019-03_EN
15.17.4 Windshield washer system
Replace the windshield wiper blades
Three windshield wiper blades are located on the carrier windshield.

WFN3RUWW2K2064139
ATF 60G-3 375

2019-03_EN
Overview
1 Wiper arm 3 Windshield wiper blade

2 Plastic adapter
Replace the windshield wiper blades

1. Lift the wiper arm off the pane.
2. Press the plastic adapters together and pull out of the guide.
NOTICE! Pay attention to the installation direction for re-installation!
3. Pull windshield wiper blade out off the guide.
4. Introduce new windshield wiper blade into the guide led by the plastic adapter. The plastic
adapter must engage audibly.
5. If necessary, replace further windshield wiper blades.
ð The windshield wiper blade has been replaced.
Filling the windshield washer system
Safety instructions
CAUTION
Risk of injury due to windscreen washer concentrate.
Windscreen washer concentrate is highly flammable and corrosive. This
may lead to accidents involving personal injuries or material damage.
1. No open flame, no naked light, no smoking when handling windscreen
WFN3RUWW2K2064139
washer concentrate.
clear water. If necessary, seek medical attention.
376 ATF 60G-3

2019-03_EN
Overview
WFN3RUWW2K2064139
1 Filler neck, washing water tank
ATF 60G-3 377

2019-03_EN
Filling the windshield washer system

1. Opening the front cover and secure it against dropping down.
2. Open the cap of the filler neck.
3. Put screen wash into the washing water tank, up to the upper edge of the filler neck.
Observe the correct mixing ratio (follow the instructions of the screen wash manufacturer).
WARNING! Use antifreeze in winter. Adjust the mixing ration to suit the outside
temperature. (follow the instructions of the antifreeze manufacturer)
4. Close the cap of the filler neck.
5. Close and lock the front cover.
ð Windshield washer system has been filled.
15.17.5 Air conditioning system *)
Safety instructions
WARNING
Risk of injury due to coolant.
Coolant is toxic. This may lead to accidents involving personal injuries.
clear water. If necessary, seek medical attention.
2. Filling and repair activities on air conditioning systems may only be
carried out by an authorized specialist workshop.
Air conditioning system - winter operation
Even during the winter months, the air conditioning system must run
approximately 10 minutes at least once a month. This prevents seals
and bearings from drying out.
Air conditioning system inspection

Have a regular inspection carried out at a specialist workshop.
15.17.6 Heating
Lubricate the shaft bearings, lever joints and all moving parts
WFN3RUWW2K2064139
Check the condition of the heating lines

Check the electric cables and plug connections

378 ATF 60G-3

2019-03_EN
Check the filter for dirt

Changing the fuel filter of the auxiliary heater

15.17.7 Rear area monitoring *)
Cleaning rear view camera
The rear view camera is located at the rear of the vehicle, on the right in the direction of travel.
Cleaning rear view camera

The video camera is maintenance-free. Dry wiping should be avoided in order to protect the
glass from scratches. The video camera is resistant against cleaning with high-pressure or
steam cleaners.
1. Depending on the dirt, clean video camera sheet with soft damp cloth.
15.17.8 Changing battery of ignition key
Introduction
The battery is only changed in ignition keys with radio communication. Type CR2032 3.0 V lith-
ium coin batteries are used in the ignition key.
WFN3RUWW2K2064139
ATF 60G-3 379

2019-03_EN
Open battery cover
Overview
1 Battery cover
Procedure
1. Unfold ignition key.
2. Pull battery cover up for opening.
ð Battery cover is open.
Removing dead battery
Overview
WFN3RUWW2K2064139
Procedure
1. Introduce thin object into the removal opening.
2. Push dead battery carefully upwards with the thin object and take it out.
380 ATF 60G-3

2019-03_EN
3. Dispose of dead battery as prescribed.

ð Dead battery has been removed.
Inserting new battery and closing battery cover
Overview
1 New battery 2 Battery cover
Explanation
The battery is inserted with the + pole pointing up.
Procedure
1. Insert new battery at the front of the battery box.
2. Press new battery down until it engages in the battery box.
3. Close battery cover.
ð Battery of the ignition key has been changed.
15.18 Trailer hitch *)
15.18.1 Maintaining trailer hitch
WFN3RUWW2K2064139
The trailer hitch is installed centrally on the rear of the vehicle.
ATF 60G-3 381

2019-03_EN
Overview
1 Trailer hitch
Maintaining trailer hitch

For information about the care and maintenance, refer to the manufacturer's documentation.
15.18.2 Inspecting the compressed air coupling heads

WFN3RUWW2K2064139
382 ATF 60G-3

2019-03_EN
15.19 Oiling and lubricating
15.19.1 Oiling and lubricating
Description
Moving components must be maintained periodically in order to preserve their movability. The
following points must be observed regarding care of the carrier cab:
1. Oil joints, pins and hinges.
Measure out lubricating oil such that a sufficient lubricating effect is obtained. Lubricating oil
should not run out on the components.
2. All the exposed piston rods, e.g. outrigger cylinders, must be cleaned regularly and sprayed
with "Lube Protection Spray".
15.19.2 Lubricating joints, pins, hinges and all moving parts

Lubricate joints, pins, hinges and all moving parts.
15.19.3 Lubricating the steering knuckles
In case of the special equipment "Steering knuckles lubrication ex-

tension of centralized lubrication system", all steering knuckles are
lubricated by the centralized lubrication system.
WFN3RUWW2K2064139
ATF 60G-3 383

2019-03_EN
Overview
1 Lubricating point top steering knuckle (2 2 Lubricating point bottom steering knuckle
places per axle) (2 places per axle)
Lubricating the steering knuckles

1. Clean all lubricating nipples of the steering knuckle bearings.
2. Lubricate all lubricating nipples of the steering knuckle bearings periodically in accordance
ð All steering knuckle bearings are lubricated.
WFN3RUWW2K2064139
384 ATF 60G-3

2019-03_EN
15.20.2 Overview of lubrication points
Standard centralized lubrication system

WFN3RUWW2K2064139
1 Centralized lubrication system 3 Bottom suspension cylinder lubrication

point (6 lubrication points)
2 Top suspension cylinder lubrication point
(6 lubrication points)
ATF 60G-3 385

2019-03_EN
Steering knuckles lubrication extension of centralized lubrication system *)
1 Centralized lubrication system 3 Bottom steering knuckle lubrication point

2 Top steering knuckle lubrication point
15.20.3 Checking fill level of reservoir

1. Checking the fill level of the reservoir
For refilling the reservoir, see Centralized lubrication system [} page 485].
ð Fill level has been checked.
15.20.4 Inspect the lines and screw couplings for leaks and damage
1. Inspect the lines and screw couplings for leaks and damage.
WFN3RUWW2K2064139
386 ATF 60G-3

2019-03_EN
15.21 Sliding coupling
15.21.1 Checking the sliding coupling for damage
1 Sliding coupling
1. Check the sliding coupling for damage.

WFN3RUWW2K2064139
ATF 60G-3 387

2019-03_EN
15.22 Suspension
15.22.1 Checking the bellows
Requirements
WFN3RUWW2K2064139
388 ATF 60G-3

2019-03_EN
Overview
1 Suspension cylinder 2 Bellows
Checking the air bellows on the hydraulic suspension cylinders

1. Check that air bellows fit correctly.
2. Check air bellows for damages.
Have damaged air bellows replaced at a specialist workshop.
WFN3RUWW2K2064139
ATF 60G-3 389

2019-03_EN
WFN3RUWW2K2064139
390 ATF 60G-3

2019-03_EN
16 Crane testing instructions
16.1 Periodic tests of cranes

Every TADANO crane is checked before the delivery in accordance with the DIN standards and
DGUV 52 compliant accident prevention regulations prevailing in the Federal Republic of Ger-
many.
Accident prevention regulations applicable in the Federal Republic prescribe periodic annual
tests, whereas the corresponding national regulations are applicable in other countries.
If national regulations do not exist in a particular country, we recommend conducting these peri-
odic tests in accordance with the DGUV 52 accident prevention regulations applicable in Ger-
many.
Periodic annual tests for cranes can be conducted by crane experts and/or specialists. This test
is primarily a visual inspection for assessing the condition of the entire crane and its compon-
ents.
In addition, according to DGUV 52 accident prevention regulations (§ 26), a test must be con-
ducted by an expert every 4 years. After the 13th year of operation, an annual test needs to be
conducted by an expert.
The defects identified must be documented in the crane inspection log; the operating company
is under obligation to rectify these defects. A subsequent test may be required.
During the periodic tests, the entire hydraulic and electrical control and safety devices must be
checked as well.
The expert or the specialist is solely responsible for determining the complete scope of periodic
tests.
A few important points to be considered during periodic tests are listed below.
However, we would like to emphasize that not all points in the scope of test are represented
here.
16.2 Checking the load-bearing steel structures
WARNING
Risk of accidents due to damage on the load-bearing parts of the mo-
bile crane.
Damaged parts may fail under load. It may result in an accident involving
personal injuries or even death.
1. Check the parts subjected to loads regularly. Ask a specialist company
to repair the damaged parts immediately.
All load-bearing steel structures, such as carrier frame, outrigger casings and outrigger beams,
telescopic boom, superstructure frame, shall be checked periodically depending on the operat-
WFN3RUWW2K2064139
ing conditions, but at least once a year. Likewise, welding seams must be checked thoroughly
even if they are subjected to lower loads.
If the crane is subjected to an impermissible load when operating (e.g. a high impact load due to
a load falling on the rope or similar), the load-bearing parts of the mobile crane must be
checked.
ATF 60G-3 391

2019-03_EN
According to DIN 15018 T3, different stress tolerance coefficients are determined for different
high-strength fine-grain construction steels. The mobile cranes from TADANO have been de-
signed as per this standard for the load spectrum "S1 light" as well as a stress tolerance coeffi-
cient of 25,000 load cycles. A suitable service life of a mobile crane is determined based on this
and the operating conditions. The service life does not depend solely on the specified stress tol-
erance coefficient, but depends on the loads exerted on the mobile crane during the operation
period.
The following drawing shows the load-bearing steel structure and given the tester a few indica-
tions regarding the points to be checked. Points marked with arrows are highly stressed zones
and must be checked when testing and depending on the operating conditions.
We would however like to explicitly emphasize that the drawing does not claim to be complete.
If damage (e.g. cracks, deformations) is detected during these tests, please contact an expert.
Consult TADANO after investigating the fault.
The repair method should then be decided on in consultation between TADANO and the expert.
WFN3RUWW2K2064139
392 ATF 60G-3

2019-03_EN
17 Removal from operation
17.1 Maintenance tasks in the event of temporarily decommissioned

mobile crane
Damage due to long standstill periods
The mobile crane should only be temporarily decommissioned in excep-
tional cases. Long standstill periods promote corrosion of sensitive com-
ponents, ageing and contamination of operating materials.
If the mobile crane is decommissioned for a period up to three months, the following measures
are required to prevent any problems when recommissioning it.
A cool, dry, and dust-free place is recommended for the duration of the decommissioning.
To prevent the fuel from silting up, we recommend to empty the fuel tank and fill it up with diesel
fuel without biodiesel proportion, and to allow the engine to run for at least 30 minutes to flush
all fuel-carrying parts.
17.1.1 Preparing mobile crane for temporary decommissioning

1. Fill fuel tank up, refer to Filling up fuel or AdBlue [} page 293].
In case of cold weather, fill up winter diesel.
2. Empty half of the AdBlue® tank.
3. Support the mobile crane.
4. Drain water from fuel system, refer to Draining water from fuel system [} page 318].
5. Check the oil level of the engine, refer to Checking the oil level of the engine [} page 303].
6. Check coolant level, refer to Checking the coolant level [} page 310].
7. Fully charge the batteries, refer to Charging batteries with charger [} page 258].
8. Disconnect batteries.
ð The mobile crane has been prepared for temporary decommissioning.
17.1.2 Monthly maintenance tasks on temporarily decommissioned mobile

crane
1. Connect batteries.
2. Switch on Battery main switch switch, start engine.
3. Switch heating on, refer to Heating, ventilation, air conditioning system *) [} page 152].
4. Switch auxiliary heater on, refer to Superstructure auxiliary heater [} page 244].
5. Switch air conditioning system *) on.
WFN3RUWW2K2064139
6. Allow engine to run at 900 rpm max. for 10 minutes and, while doing so, watch oil pressure,
oil and coolant temperatures.
7. Switch off air conditioning system *), heating, and auxiliary heater.
8. Stop engine, switch off Battery main switch switch.
9. Disconnect batteries.
ð Maintenance has been performed on mobile crane.
ATF 60G-3 393

2019-03_EN
17.1.3 Putting mobile crane into operation after temporary decommissioning

1. Connect batteries.
2. Check the air pressure in the tyres.
3. Fill AdBlue tank up.
4. Switch on Battery main switch switch, start engine.
5. Switch air conditioning system *) on.
6. Switch heating on, refer to Heating, ventilation, air conditioning system *) [} page 152].
7. Switch auxiliary heater on, refer to Superstructure auxiliary heater [} page 244].
8. Allow engine to run at 900 rpm max. for 10 minutes and, while doing so, watch oil pressure,
oil and coolant temperatures.
9. Switch off air conditioning system *), heating, and auxiliary heater.
10.Retract all outriggers.
11.Check service brake repeatedly on empty level road.
12.Stop engine, switch battery main switch off.
ð Mobile crane is ready for operation.
WFN3RUWW2K2064139
394 ATF 60G-3

2019-03_EN
18 Technical data
18 Technical data
18.1 Filling levels

Engine
Quantity 25,5 l
Oil specification See the engine manufacturer's operating manual
First filling SAE 10W-40
Gearbox
Quantity The oil quantity is noted on the model plate.
Oil specification Refer to ZF List of lubricants TE-ML 02 or the gearbox manu-
facturer's operating manual in the Annex
First filling ECOFLUID M75W-80
Angular gear (top)

Filling quantity 7.2 l
Oil specification MIL-L-2105 B
First filling SAE 90-GL5 HYP
Angular gear (bottom)

Filling quantity 3.8 l
Oil specification MIL-L-2105 B
Transfer case
Quantity 11 l
Quantity with supply lines and oil cool- —
ers
Oil specification MIL-L- 2105 B, API-GL 5
Cooling system
Quantity 43 l
Coolant/antifreezing agent Refer to Mercedes-Benz fuel specifications at http://bevo.mer-
cedes-benz.com, specification 325.5, or operating manual of
the engine manufacturer.
First filling Glysantin G40
Fuel tank
WFN3RUWW2K2064139
Quantity 300 l
Fuel type Diesel in accordance with EN 590 (10 ppm sulphur) or
ASTM D975 (15 ppm sulphur)
AdBlue tank
Quantity 40 l
ATF 60G-3 395

2019-03_EN
18 Technical data
AdBlue tank
Specification AdBlue in accordance with ISO 22241 or DIN 70070
Windshield washer water tank

Quantity 8,7 l
Heating of carrier cab

Heating circuit filling quantity 16 l
Fuel tank 19 l
Air conditioning system

Refrigerant oil filling level —
Refrigerant oil specification ND-Oil 8
Coolant filling level 1,15 kg
Coolant specification R134a
Filling volume, Drive Axle casing Wheel side (left Total

axles and right)
Axle 1 6x6 12.5 l 1.6 l 15.7 l
Axle 2 6x6 16.6 l 1.6 l 19.8 l
Axle 3 6x6 16.5 l 1.6 l 19.7 l
Axles oil type

Oil type Hypoid transmission oil
Oil specification MIL-L- 2105 B, …C, …D
API-GL 5
First filling SAE 90
Oil recommenda- Temperature Designation

tion for axles range
Oil recommendation Below -10 °C SAE 75 W-90 or SAE 75 W-85
-10 °C to 30 °C SAE 90 or multigrade oil
Over 30 °C SAE 140 or multigrade oil
WFN3RUWW2K2064139
396 ATF 60G-3

2019-03_EN
18 Technical data
18.2 Dimensions and weight
Vehicle dimensions
A 11.67 m (up to rear edge of counterweight)

12.16 m (up to rear edge of hoisting winch 2)
B 9.74 m (without tool box)
10.26 m (with tool box)
The carrier can be lengthened by between 0.05 m and 1 m, depending on the additional add-on
parts.
C 2.55 m (tyres 385/95 R25 170F)
2.66 m (tyres 445/95 R25 174F)
2.82 m (tyres 525/80 R25 176F)
D 3.62 m (tyres 385/95 R25 170F)
3.68 m (tyres 445/95 R25 174F)
3.68 m (tyres 525/80 R25 176F)
Mass
Axle load Total Counter- Jib Hook blocks

weight weight
3 x 10 t ≤ 30 t 0.0 t — 20 t hook block hooked in
sliding coupling
3 x 12 t ≤ 36 t 4.2 t 7.4 m 40 t hook block hooked in
sliding coupling
6 t hook block in the rack
3 x 12 t ≤ 36 t 5.2 t — 40 t hook block hooked in
sliding coupling
3 x 13 t ≤ 39 t 7.2 t 7.4 m 40 t hook block hooked in
sliding coupling
2 x 15.3 t / 1 x 14.2 t ≤ 45 t 13.0 t 7.4 m 40 t hook block hooked in
sliding coupling
WFN3RUWW2K2064139
The table is based on the following fittings of the mobile crane:

▪ Tyres 445/95 R 25.
▪ Wheel chocks.
▪ Full fuel tanks.
▪ Driver with 80 kg (176 lbs).
ATF 60G-3 397

2019-03_EN
18 Technical data
The specified axle loads are applicable only in the described equipment conditions. Changes of
equipment may, in some circumstances, lead to different axle loads.
In accordance with EU regulations, axle loads of over 12 t are not permitted when driving on
public roads in the countries of the European Union. Deviating from the aforementioned, valid
regulations of individual countries allow axle loads exceeding 12 t. In the case of axle loads ex-
ceeding 12 t, the maximum permissible speed is reduced dependent on the existing axle load,
refer to Tyres capacities as a function of the travel speed [} page 42].
Adaptations to national registration regulations and technical regulations may require a change
of the technical data and the standard scope of delivery.
Turning radius
On-road mode [m] Special steering program

[m]
Inner edge of carrier 4.9 m 2.7 m
Outer edge of carrier 10.7 m 8.1 m
Telescopic boom 11.3 m 8.9 m
Jib 11.8 m 9.3 m
Overview
3 4
9
2
11
1
WFN3RUWW2K2064139
1 Hook block (40 t load rating) 7 -

2 Hook block (6 t load rating) 8 Counterweight 1.2 t
3 Counterweight 2.1 t 9 Counterweight 0.9 t
4 - 10 -
5 - 11 Storage box
6 -
398 ATF 60G-3

2019-03_EN
18 Technical data
▪ 6x6 drive.
▪ Driver.
▪ No hoisting winch 2. Storage box at the rear.
▪
▪ Storage box at the rear is loaded with 200 kg.
▪ Hook in carrier storage location: 6 t.
▪ Hook in carrier storage location: 20 t
▪ Tyres: 445/95 R25.
▪ Boom telescoping cylinder is locked in telescope 6.
Overview
8
4 5
11
1

2 - 8 Counterweight 1.2 t
3 - 9 Counterweight 0.9 t
4 - 10 -
5 Counterweight 2.1 t 11 Storage box
( 0,8 t + 1.3 t )
WFN3RUWW2K2064139
6 Counterweight 0.9 t
Equipment objects not represented must be transported separately.
ATF 60G-3 399

2019-03_EN
18 Technical data
Required crane configuration
Vehicle equipment for axle load 12 t

▪ The jib *) has been removed.
▪ 6x6 drive.
▪ Driver.
▪
▪ Tyres: 445/95 R25.
Overview
3 4 5 8
10
11
1

WFN3RUWW2K2064139

( 0.8 t + 1.3 t)
6 -
400 ATF 60G-3

2019-03_EN
18 Technical data
▪ 6x6 drive.
▪ Driver.
▪
▪ Tyres: 445/95 R25.
Overview
3 4 5 6 7 8
10
11
1

( 0,8 t + 1.3 t )
WFN3RUWW2K2064139
6 Counterweight 0.9 t
▪ 6x6 drive.
▪ Driver.
▪
ATF 60G-3 401

2019-03_EN
18 Technical data

▪ Tyres: 445/95 R25.
Overview
11
1
1 9
7 10 Hook block (6 t load rating)
8 11 Storage box *)
Equipment objects not represented must be transported separately.
Required crane configuration
Vehicle equipment for axle load 10 t

WFN3RUWW2K2064139
▪ The jib *) has been removed.

▪ 6x6 drive.
▪ Driver.
▪
402 ATF 60G-3

2019-03_EN
18 Technical data

▪ Tyres: 385/95 R25.
18.3 Engine
Engine
Manufacturer Daimler AG / MTU GmbH
Engine type OM936LA / 6R 1000
Number of cylinders 6
Displacement 7.700 cm³
Power / Nominal rotation speed 260 kW (354 PS) / 2200 min-1
Measurement standard for engine ECE R 120
power
Torque / Nominal rotation speed 1400 Nm / 1200–1600 min-1
After treatment of exhaust gases SCR system
Certification EUROMOT 4
18.4 Gearbox
Main gear
Type ZF-AS-Tronic mid 12 AS 1625 SO
Gear shift Automated transmission with torque converter clutch and Tip-
Tronic
Brake Engine brake
Number of gears 12 forward, 2 reverse gears
18.5 Brakes
Brake
Principle Dual circuit brake in accordance with ECE R13
Medium Compressed air
Type Drum brake
Brake circuit 1 Axles 2,3
Brake circuit 2 Axles 1
Parking brake (auxiliary brake) Spring loaded brake on axles 2,3
Retarder Engine brake, Intarder, eddy-current brake *)
Important pressure values

Cut-out pressure of the pressure 10.0±0.3 bar
WFN3RUWW2K2064139
regulator
Cut-in pressure of the pressure regu- 8.5-9.5 bar
lator
Axle 1 brake pressure 9.8-10.2 bar
Axle 2 brake pressure 7.5 bar
Axle 3 brake pressure 3 bar
ATF 60G-3 403

2019-03_EN
18 Technical data
18.6 Wheels and tyres

Tyres Tyre pressure [bar]
385/95 R25 170E 10.0
385/95 R25 170F 9.0
445/95 R25 174F 9.0
525/80 R25 176F 7.0
525/80 R25 179E 7.0
18.7 Outrigger
Hydraulic 4-point double telescopic outriggers with unlockable check valves on the outrigger cyl-
inders.
Possibilities of operation on both sides of the carrier, as well as from the superstructure cab.
Outrigger
Outrigger base, longitudinal 7,01 m
Outrigger base, transversal 6,4 m / 5,4 m / 4,4 m / 2,4 m
Stroke of the outrigger cylinders, front 600 mm
Stroke of the outrigger cylinders, read 600 mm
Size of the outrigger floats 542 mm x 542 mm
Weight of the outrigger floats Approx. 25,5 kg

Electrical system
Batteries 2 x 12 V, 110 Ah
Alternator Three-phase alternator, 100 A
On-board voltage Direct current 24 V
18.9 Lubricants
Maintenance point Lubricant
Grease reservoir of the central lubrica- Lithium soap lubricating grease, in accordance with DIN
tion system 51825-KP2K-20
Wheel bearings of the non-driven axles
Sliding surfaces of the outrigger Lubricating paste, containing MoS2, Cu or Al
Outrigger floats Makraflon HSII
Batteries Battery grease
WFN3RUWW2K2064139
Door locks Graphite powder

Exposed piston rods Lube Protection Spray
404 ATF 60G-3

2019-03_EN
19 Annex
19 Annex
19.1 Gearbox
WFN3RUWW2K2064139
ATF 60G-3 405

2019-03_EN
Operating Instructions
Special Vehicles
ZF-AS Tronic, ZF AS-Tronic mid
Rotary Switch + Shift Lever
Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction

or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Preface
Please read these operating instructions carefully before Your vehicle is equipped with an automatic transmission from
driving the vehicle for the first time. the ZF-AS Tronic model range.
The more familiar you are with your ZF-AS Tronic transmission,
Note the special instructions provided in the vehicle the more economically you will be able to drive with it. These
manufacturer’s operating instructions. operating instructions provide you with the information required
so that you can make full use of the technical advantages of
For the operation and maintenance of the ZF-Intarder you the ZF-AS Tronic.
also need the ZF-Intarder’s operating instructions, order
number 6085 758 102. In order to ensure safe and reliable operation, please note the
specifications governing maintenance.
The ZF Customer Service specialists are available to assist you
in maintenance work or to help if any other problems arise. You
can obtain their addresses from ZF in Friedrichshafen.
Motoring pleasure with ZF transmission is brought to you by
ZF Friedrichshafen AG
Special Driveline Technology
D-88038 Friedrichshafen
Phone +49 (0) 7541 77-0
Subject to technical changes. Fax +49 (0) 7541 77-908000
First edition: 2008 Internet: www.zf.com
4232 758 102 - 2012-02 3

Safety Instructions
The following safety instructions are used in the present

operating instructions: THREATS FOR THE ENVIRONMENT!
Lubricants, consumables, and cleaning agents must
not be allowed to enter the soil, ground water, or
NOTE sewage system.
Reference is made to special procedures, methods, • Ask your localenvironmental protection agency for
information, etc. safety information on the relevant
products and adhere to their requirements.
• Collect used oil in a sufficiently largecontainer.
CAUTION • Dispose of used oil, dirty filters, and cleaning agents
This is used when deviating and unprofessional operation in accordance with environmental protection
can damage the product. regulations.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
DANGER!
This is used when a lack of care can lead to personal
injury or material damage.
4
Table of Contents
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.7.1 Gear change in automatic mode . . . . . . . . . . . . . 22

2.7.2 Gear change in manual mode . . . . . . . . . . . . . . . 22
1 Description of the System . . . . . . . . . . . . . . . . . 10
2.8 Change in direction of travel . . . . . . . . . . . . . . . . 23
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.9 Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Speed range selector . . . . . . . . . . . . . . . . . . . . . . 12
2.10 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 ZF display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Switching off engine / Stopping vehicle . . . . . . . . 25
1.4 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . 14
2.12 Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.5 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.6 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.14 Clutch protection . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.7 ZF auxiliary power units . . . . . . . . . . . . . . . . . . . 15
2.15 Engine overspeed protection . . . . . . . . . . . . . . . . 28
2.15.1 Operating mode: Manual . . . . . . . . . . . . . . . . . . . 28
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.15.2 Operating mode: Automatic . . . . . . . . . . . . . . . . . 28
2.1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . 16
2.16 Operation with clutch-dependent PTO . . . . . . . . . 29
2.2 Setting off, forward driving . . . . . . . . . . . . . . . . . 17 2.16.1 Stationary / Mobile operation . . . . . . . . . . . . . . . . 29
2.2.1 Starting gear correction . . . . . . . . . . . . . . . . . . . . 17 2.16.2 Stationary operation . . . . . . . . . . . . . . . . . . . . . . 29
2.2.2 Hill start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17 Roller test bench . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.18 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.19 System failures (error messages) . . . . . . . . . . . . . 38
2.5 Moving off downhill . . . . . . . . . . . . . . . . . . . . . . . 21
2.20 Starting up the vehicle at
2.6 Changing operating mode: Manual / Automatic . . 21 low temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.20.1 Parking the vehicle at low temperatures . . . . . . . . 41
2.7 Gear change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4232 758 002 - 2012-02 5

Table of Contents
3 Maintenance ZF-AS Tronic / ZF-Intarder . . . . . . 42 4 Maintenance ZF-AS Tronic mid . . . . . . . . . . . . . 56

3.1 Visual inspection of wiring . . . . . . . . . . . . . . . . . . 42 4.1 Visual inspection of wiring . . . . . . . . . . . . . . . . . . 56
3.2 Compressed-air system maintenance . . . . . . . . . . 42 4.2 Compressed-air system maintenance . . . . . . . . . . 56
3.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.1 Type plate ZF-AS Tronic . . . . . . . . . . . . . . . . . . . . 43
4.4 Bleeding the transmission . . . . . . . . . . . . . . . . . . 57
3.3.2 Type plate ZF-Intarder (option) . . . . . . . . . . . . . . . 43
4.5 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . 58
3.4 Bleeding the transmission . . . . . . . . . . . . . . . . . . 44
4.6 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.5 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Oil quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.8 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.7 Oil quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.8.1 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.8 Oil change (ZF-AS Tronic without ZF-Intarder) . . . 46
4.9 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.8.1 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.9 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.10 Oil change ZF-AS Tronic with ZF-Intarder* . . . . . 48
3.10.1 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.10.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.11 Oil level check ZF-AS Tronic with ZF-Intarder* . . 53
3.12 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.13 Transmission maintenance for versions with
external heat exchanger . . . . . . . . . . . . . . . . . . . . 55
4232 758 102 - 2012-02 6

ZF-AS Tronic mid / ZF-AS Tronic
026809
Fig. 1 ZF-AS Tronic mid
027529
Fig. 2 ZF-AS Tronic without ZF-Intarder
4232 758 102 - 2012-02 7

Technical Data
Technical Data
ZF-ASTronic
Transmission type Overdrive 12 AS 2530 SO 12 AS 3040 SO 16 AS 1630 SO

12 AS 2531 SO 12 AS 3041 SO 16 AS 2631 SO
12 AS 2535 SO 12 AS 3045 SO 16 AS 2635 SO
12 AS 2536 SO 12 AS 3046 SO 16 AS 2636 SO
Input torque max. Nm 1) 2500 3000 2600
Ratios Forward gears 12.33 - 0.78 12.29 - 0.78 14.12 - 0.83
Reverse gears 11.41 - 8.88 11.38 - 8.88 13.07 - 10.81
Speedometer electronic Solo version z = 8 / Intarder version z = 8.14
Installation with integrated bell housing
Shift system 3 or 4 gear part and reverse gear are constant mesh; R/C and splitter group synchronized
Shifting operation Automatic mode The transmission system takes over the clutch actuation system and the gear selection process
Manual mode The driver is in charge of gear selection, the transmission system takes over the clutch
actuation system
Weight 4) approx. kg 250 262 262

with ZF-Intarder approx. kg 320 332 332
Oil quantity 3) for standard
installation 2) approx. dm3 12 13 13
with ZF-Intarder approx. dm3 21 23 23
Oil grade according to applicable ZF List of Lubricants TE-ML 02
1) Reference value (depends on vehicle type and vehicle data as well as the 3) For transmissions with a ZF-Intarder refer to operating instructions
prevailing operating conditions) 6085 758 102
2) Transmission inclination 0 to 3° 4) without oil fill, PTO, and clutch
4232 758 102 - 2012-02 8
Technical Data
ZF-ASTronic mid
Transmission type Overdrive 12 AS 1210 SO, 12 AS 1215 SO 12 AS 1620 SO, 12 AS 1625 SO

Input torque max. Nm 1) 1200 1600
Ratios Forward gears 10.37 - 0.81
Reverse gears 10.56 - 8.58
Speedometer electronic z=8
Install a t i o n horizontal on the left with integrated bell housing
Shift system 3 gear part and reverse gear are constant mesh
R/C and splitter group synchronized
Shifting operation Automatic mode The transmission system takes over the clutch actuation system and the gear selection process.
Manual mode The driver is in charge of gear selection, the transmission system takes over the clutch
actuation system
Weight 3) approx. kg 193 211
Oil quantity for standard
installation 2) approx. dm3 7.8 9.3
with heat exchanger approx. dm3 7.5 9.0
Oil grade ZF Ecofluid M or according to applicable ZF List of Lubricants TE-ML 02
1) Reference value (depends on vehicle type and vehicle data as well as the prevailing operating conditions)
2) Transmission inclination 0 to 3°
3) Without oil fill, PTO, and clutch
4232 758 102 - 2012-02 9

Description
1 Description of the System
The automatic ZF-AS Tronic transmission is adapted to the A display on the dashboard shows the driver all the system
engine by means of a standard dry clutch. The clutch is information required (e.g., gear step, failure, etc.).
actuated by the ZF-AS Tronic transmission system, which
means that the clutch pedal can be dispensed with. The transmission actuator and clutch actuator are the most
important components for the complete automation of the
The ZF-AS Tronic consists of a basic transmission and an transmission.
integrated splitter and planetary group.
The transmission actuator consists of transmission electronics,
The basic transmission has a constant mesh design; the shift valves, shift cylinders, and sensors.
splitter and planetary groups are synchronized.
The clutch actuator is an electro-pneumatic actuator with travel
The transmission system changes gears automatically. sensors that takes over the entire clutch actuation.
The ZF-Intarder* is a non-wearing, hydrodynamic auxiliary

brake integrated into the transmission.
*Option
4232 758 102 - 2012-02 10

Description
1.1 Overview
1
4
S
Legend M
A
1a 1b
1 ZF speed range selector
1a Rotary switch 6
1b Shift lever
2* ZF display 10
3* Extension module
4 Transmission actuator with
integrated electronic
control unit
3
5 Clutch actuator
6 Transmission
5
7 Accelerator pedal
8 Brake pedal 9b
2
9a* ZF-Intarder
9b* Electronic ZF-Intarder
control unit (only for 8 7
vehicles equipped with ZF
FRIE
DRIC
HSH
AFEN
AG
ZF-Intarder) ®
10* Connection point for PTO*
* optional
9a
029730
4232 758 102 - 2012-02 11
Description
1.2 Speed range selector
The speed range selector consists of a rotary switch and a With the shift lever, you can change gears and activate or
shift lever. deactivate automatic mode.
Rotary switch Shift lever M/A Changeover manual mode to automatic mode (and
vice versa)
N
D R
DM RM + Shift up 2 gears (spring point end stop)
+ Shift up 1 gear (first spring point)
– Shifting down 1 gear (first spring point)
– Shifting down 2 gears (spring point end stop)
029892 023868
S Search function*
The shift lever springs back again after selection of positions

You can select the following areas with the rotary switch: « + », «+», « – », « – », «S»* and «M/A».
DM = Drive maneuvering (forward) You can perform manual upshifts and downshifts of more than
D = Drive (forward, automatic, or manual) 2 gear steps by repeatedly tipping the shift lever.
N = Neutral
R = Reverse
RM = Reverse maneuvering
* If position “S” (search function) is selected during manual operation
and the engine brake is not applied, the transmission selects the
If the rotary switch is in position «N», the shift lever is without ECO gear (low engine speed).
function. If position “S” (search function) is selected and the engine brake is
applied, the transmission selects the POWER gear (high engine
speed).
4232 758 102 - 2012-02 12

Description
1.3 ZF display Manual mode
Only descriptions of the displays for transmission functions are No bars or arrows are shown when manual mode is active.
provided in these operating instructions. Refer to vehicle Exception: Gear change recommended
manufacturer’s operating instructions for other displays.
The display shows the number of the gear selected, neutral, as Example:
well as the operating mode and failures. Manual mode,
4th gear is engaged.
Automatic mode 024374
The display shows 2 arrows and 4 bars when automatic mode Gear change recommended
is active. Upshifts: Arrow pointing up
Downshifts: Arrow pointing down
Example: Number of gears: one gear per bar
Automatic mode, 4th gear is
engaged. Example:
The 8th gear is engaged in
029885
the transmission; the system
recommends shifting down 2
gears.
029886
4232 758 102 - 2012-02 13

Description
1.4 Accelerator pedal 1.5 Automatic mode
The accelerator pedal position does not need to be changed Rotary switch is in position «D». The gearchange system
during the shift process. selects the optimal starting gear.
If you press the accelerator pedal, the clutch closes auto-
During gear shifts, the engine is influenced by the electronic matically and the vehicle starts to move.
transmission control unit. The gearchange system performs upshifts and downshifts
automatically during travel.
The clutch is actuated by the electronic transmission control
unit depending on accelerator pedal actuation. Gear changes which would result in overreving or stalling of
the engine are prevented by the gearchange system when
driving in the automatic mode.
The driver can manually intervene at any time with the

shift lever, for example in difficult driving situations, without
releasing the accelerator. In the process, the driving mode
changes from automatic to manual.
4232 758 102 - 2012-02 14

Description
1.6 Manual mode 1.7 ZF auxiliary power units
Rotary switch is in position «D». If the switch lever is actuated, Depending on the vehicle version, the ZF-AS Tronic
the transmission system changes over to manual mode. The transmission can be fitted with the following auxiliaries:
driver can also use the shift lever to select a starting gear other
than the suggested one. • ZF-Intarder
• ZF PTO (clutch-dependent)
If you press the accelerator pedal, the clutch closes auto- • ZF emergency steering pump
matically and the vehicle starts to move.
The driver uses the shift lever to engage the requested gears. Operating instructions 6085 758 102 are available for servicing
and maintaining the ZF-Intarder.
High-speed driving is not economical and should be avoided
by the driver.
If the accelerator pedal is pressed when in too high a gear, the

engine may stall.
4232 758 102 - 2012-02 15

Operation
2 Operation 2.1 Starting the engine
Depending on the manufacturer and vehicle type, you may • Engage parking brake D
N
R
have controls and operating processes other than those DM RM
described in this manual such as vehicle control from the crane • Turn rotary switch to «N»
cabin. (transmission in neutral)
029892
Therefore, also observe the operating instructions provided by • Switch on ignition
the vehicle manufacturer.
• Gearchange system self check
(display shows «CH»)
DANGER!
• Do not leave the vehicle when the engine is running • Start the engine 024367
and a gear is engaged.

• Gears cannot be selected if the engine is not • Self check is completed.
functioning (e.g., no fuel); the transmission shifts to «N» appears on the display,
“Neutral”. Engine brake and steering assistance will transmission is in neutral
fail during travel. 024369
NOTE
Gears cannot be selected during engine standstill.
4232 758 102 - 2012-02 16

Operation
2.2 Setting off, forward driving 2.2.1 Starting gear correction
• Start engine (see Ch. 2.1). The driver can correct the starting gear suggested by the
N
D R system.
DM RM
• Turn rotary switch from «N» to «D».
Correct the gear:
• Automatic mode is activated.
029893
• Push shift lever in the « – » or « + » direction.
• The display shows the engaged
starting gear. • The display shows the starting gear selected.
(The system selects the starting
gear itself;the clutch remains
separated.)
024376 Shift lever
• Depress the accelerator pedal and at the same time release
the parking brake.
DANGER!
The vehicle may roll away if the accelerator pedal is
not pressed.
029888
• Vehicle sets off (clutch closes automatically).
4232 758 102 - 2012-02 17

Operation
2.2.2 Hill start
Observe information provided by the vehicle manufacturer.
DANGER!
Engage gear, release parking brake only once
accelerator pedal has been depressed; otherwise, the
vehicle will roll backwards.
4232 758 102 - 2012-02 18

Operation
2.3 Reversing
The transmission is equipped with two reverse gears: Engage reverse gear:
• «RL» = Low reverse gear
• Vehicle must be stationary.
• «RH» = High reverse gear
N
D
• Turn rotary switch to «R».

R
DM RM
• «RL» appears on the display

(clutch remains separated).
DANGER!
029894
If the vehicle is rolling, no gear change into reverse • Depress accelerator pedal and at
occurs! the same time release the brake
Immediately bring the vehicle to a standstill. (the clutch closes automatically).
• Vehicle moves backwards. 024444
• Depending on the vehicle

configuration, the transmission
can shift from «RL» to «RH» and
from «RH» to «RL», respectively. 024445
4232 758 102 - 2012-02 19

Operation
2.4 Maneuvering
Maneuvering mode is provided for extremely slow travel. The system recognizes the maneuvering mode from the rotary
switch position. The 1st forward gear and the 1st reverse gear
In the maneuvering mode, the vehicle (accelerator pedal) is are made available for maneuvering.
more sensitive and clutch actuation differs compared with the
ordinary mode. The full accelerator pedal travel can be used for maneuvering
mode. To quit this mode, the rotary switch needs to be turned
Forward and reverse maneuvering in accordance with the to position «D», «N» or «R».
rotary switch position:
• To maneuver forwards, select « DM ».

DM
D
N
R
RM
Time of maneuvering unlimited
• To maneuver backwards, select « RM ».
If the clutch is overloaded, «CL» is
DM
D
N
R
RM
displayed. Clutch wear might appear.
CAUTION
If the driver does not respond to the
«CL» display, the clutch might be
damaged due to overload.
029898
4232 758 102 - 2012-02 20

Operation
2.5 Moving off downhill 2.6 Changing operating mode: Manual / Automatic
Requirement: Engine is running Possible at any time, also during travel.
If the parking brake is released when a gear is selected and the M/A Changing operating mode from manual to
vehicle rolls off, the clutch automatically closes without the automatic
driver having to press the accelerator pedal.
• Press shift lever to the left and select «M/A».
Changing operating mode from automatic to

DANGER!
manual
When the vehicle rolls off without a gear engaged –
rotary switch is on «N» – the engine brake has no • Press shift lever to the left and select «M/A» or
effect! press shift lever in direction « +/+ » or « –/– ».
Do not let the vehicle roll against the direction of
travel of the engaged gear.
If the vehicle rolls forwards – transmission in neutral – once the

brake has been released and the driver changes from «N» to
«D», the system selects a gear appropriate for the driving M/A
speed. The driveline is thus closed.
029889
N
D R
DM RM
Depending on the vehicle, the transmission may return
independently to automatic mode after a certain time.
029893 024376
4232 758 102 - 2012-02 21

Operation
2.7 Gear change
2.7.1 Gear change in automatic mode 2.7.2 Gear change in manual mode
All upshifts and downshifts are carried out automatically. • Press the control lever (tip function) in « +/+ » or « -/– »
direction.
The gear changes depend on: ‒ « +/– » Change by one gear step
‒ Road resistance ‒ « +/– » Change by two gear steps
‒ Vehicle weight
‒ Position of accelerator pedal
‒ Speed
‒ Engine speed
029890
029887
The display shows the number of the gear engaged. The gearchange system exits automatic mode when a manual
gear change is performed.
4232 758 102 - 2012-02 22

Operation
NOTES 2.8 Change in direction of travel

• You can shift from any gear to neutral at any time using the
rotary switch. This gear change takes priority. Requirement: Vehicle at a standstill
• The accelerator pedal position does not need to be
changed during the shift process as the engine is controlled Reverse travel «R» to forwards travel «D» and vice versa.
electronically.
• A shift command is not performed if the gear change would • Turn rotary switch from «R» or «RM» to «D» or «DM».
result in the max. engine speed being exceeded.
DANGER!
N N
D R D R
Shifting to “Neutral” is also possible during travel. If a DM RM DM RM
shift to “Neutral” is made, the driveline is interrupted.

The engine brake then no longer has any effect.
029895
DANGER!
Changes in direction of travel by moving the rotary
switch from «R» or «RM» to «D» or «DM» and vice
versa may only take place when the vehicle is
stationary, otherwise the transmission shifts to
neutral.
The display is definitive for the direction of travel
selected in the transmission.
4232 758 102 - 2012-02 23

Operation
2.9 Engine brake 2.10 Stopping
• With the accelerator pedal untouched, slow down the

DANGER!
vehicle using the service brake until it reaches a standstill.
The engine brake function is interrupted during the
gear change. The vehicle may accelerate when • The clutch opens automatically before the vehicle reaches
traveling downhill. a standstill so that “stalling” the engine is avoided.
• For extended stops, we recommend selecting the
transmission’s neutral position.
Manual mode
The system deactivates the engine brake during gear • Always engage the service or parking brake when the
changes. Once the gear change is complete, the engine brake vehicle is stationary.
is automatically reactivated.
Automatic mode DANGER!

By activating the engine brake, the system shifts into a lower - When the vehicle is stationary with the engine
gear until the maximum braking torque is reached. running and a gear selected, you simply need to
press the accelerator pedal in order to move the
vehicle!
- Before leaving the vehicle with the engine running,
the transmission must be shifted into neutral and
the parking brake must be engaged.
- Activating the parking brake during travel on a
smooth surface may bring the engine to a standstill.
Steering assistance is then NOT available anymore!
4232 758 102 - 2012-02 24

Operation
2.11 Switching off engine / Stopping vehicle 2.13 Towing
NOTE The manufacturer’s towing instructions must also be observed!

If the transmission is not shifted to neutral before the engine is
switched off, this is done automatically when the ignition is The vehicle may be towed with flange-mounted propshafts or
switched off. floating axles. The following conditions must be met for this:
• It must be ensured that the high range change group is

DANGER!
engaged. The following boundary conditions must be met
Parking the vehicle with a gear engaged is not
for this.
possible since the transmission automatically shifts to
1. Secure power and air supply
neutral. The vehicle might roll away if no brake is
2. Switch on ignition (wait for check phase)
engaged. Therefore, apply the parking brake.
3. No error message results. This ensures that the high
range group is engaged.
• Bring the vehicle to a complete standstill
• No gear is engaged in the main transmission.
• Engage parking brake. D
N
R
DM RM
• Max. towing distance 100 km
• Set rotary switch to «N» (neutral)
• The maximum permissible towing speed depends on the
• Switch off engine via ignition key rear-axle ratio and the tire size and can be read off from the
• Place chocks under wheels (e.g., on 029892 diagram in Fig. 2.1. In addition, the maximum allowed
slopes) towing speeds determined by local legislation must also be
observed.
2.12 Tow starting
Tow starting the engine is not possible.
4232 758 102 - 2012-02 25

Operation
NOTES
Towing with flange-mounted propshaft or installed axle shafts [i Axle]
10.0
is prohibited under the following conditions:
1. Only one of the previously listed conditions in not fulfilled. 9.0
Rdyn 0.7m
2. There is an error message (140) or it cannot be ensured that 8.0
the high range change group and the main transmission are Rdyn 0.6m e.g. F24
7.0
set to “Neutral” (e.g., undefined breakdown, failure of Rdyn 0.5m e.g. 275/80 R22
power and/or air supply). 6.0
3. Suspicion of transmission damage. 5.0
4.0
CAUTION Rdyn 0.4m e.g. 245/70 R19.5
3.0
Towing while a low range change group is engaged or with
an engaged gear in the main transmission leads to significant 2.0
10 15 20 25 30 35 40 45 50
transmission or engine damage within a very short period of
v[km/h]
time. Example: iaxle = 6, Rdyn = 0.5 m
Towing speed from diagram:
Vmax. = 25 km/h
029023
Fig. 2.1 Towing speed
The operator is responsible for ensuring that the required

boundary conditions are met for towing with flange-mounted
propshafts or floating axles.
If the vehicle is towed with disconnected floating axles,

environmental damage due to possible oil loss must be
avoided.
4232 758 102 - 2012-02 26

Operation
2.14 Clutch protection
If there is the risk of clutch overload due to several starting • To preserve the mechanical parts of the clutch release
procedures in quick succession or excessively long mechanism, you should shift the transmission to neutral
maneuvering in too high a starting gear, the display message during longer stops (more than approx. 1 to 2 min., e.g.,
«CL» appears. in congestion, at a traffic light, etc.). This closes the clutch
and takes the strain off the clutch release mechanism.
NOTE
Select an operating mode in which there is no clutch overload, Despite the clutch being automated, the driver still has
for example: considerable influence on the clutch’s service life.
• Accelerate the vehicle (to close the clutch) To keep clutch wear levels as low as possible, we recommend
• Stop always selecting the lowest gear possible when starting off.
• Set off or maneuver in a lower gear
DANGER!
If the driver ignores the warning, the clutch will close
when the accelerator pedal is pressed. Further clutch
overload is thus avoided.
This may cause engine stalling and possibly a rolling
backwards of the vehicle on a gradient. The clutch
opens again when you take your foot off the
accelerator.
4232 758 102 - 2012-02 27

Operation
2.15 Engine overspeed protection 2.15.2 Operating mode: Automatic
To protect the entire driveline from excessive speeds, the Observe information provided by the vehicle manufacturer.
ZF-AS Tronic only allows gear changes which are within the
speed range defined by the vehicle manufacturer.
DANGER!
The vehicle may accelerate when driving downhill.
2.15.1 Operating mode: Manual In order to protect the engine from damage in the
overspeed range (red range), the system performs an
• Ensure that the engine does not exceed the permissible upshift.
speed range.
• If the vehicle speeds up when traveling downhill, there is
no automatic shift into a higher gear.
CAUTION
The engine may be damaged if the vehicle speeds up when
traveling downhill and the engine enters the overspeed
range.
4232 758 002 - 2012-02 28

Operation
2.16 Operation with clutch-dependent PTO
Once a PTO has been activated, a « P » also appears on the • The following, for instance, appears on the display:
display.
Example: « PN » means that the PTO is activated and the
transmission is in neutral.
For additional displays and explanations, see Ch. 2.18.
024406
i.e., PTO 1 is activated, starting gear 3 is engaged.

2.16.1 Stationary / Mobile operation
• With a stationary/mobile PTO, only the following starting

2.16.2 Stationary operation
gears and maneuvering mode can be selected:
‒ ZF-AS Tronic Direct drive: Starting gears 1, 3 With stationary operation of the PTO, no gear can be selected.
Overdrive: Starting gears 2, 4 The transmission remains in neutral.
‒ ZF-AS Tronic mid All starting gears
• The following, for instance, appears on the display:
• The gear changes are only carried out when the vehicle is
stationary. A gear change during travel is impossible.
• Engage PTO and select starting gear.
024370_1
i.e., PTO 2 is activated, the transmission is in neutral.
4232 758 102 - 2012-02 29

Operation
2.17 Roller test bench
DANGER!
The vehicle may leave the rollers even if the
accelerator pedal is not depressed.
N
D R
DM RM
Once you have driven onto a roller test bench

(brake test bench), shift the transmission into
“Neutral”.
029892
• When the rollers are running, the system recognizes the

“driving vehicle” function. If you select a gear, the clutch
closes.
• When the rollers are running, reverse gear cannot be
selected.
4232 758 102 - 2012-02 30

Operation
2.18 Display messages
The display provides information on the transmission status.
Operating displays:
Display Description
• System self-check
- Message is displayed when the ignition is switched on.
024367
• Maneuvering, forwards
(Drive maneuvering)
024368
• Transmission in Neutral
- No gear is engaged in the transmission.
024369
• Power take-off (PTO*)

- Arrow pointing upwards means that PTO 1 is activated.
- «PN» means the PTO (P) is activated and the transmission is in neutral (N).
024370
*PTO = Power Take-Off
4232 758 102 - 2012-02 31

Operation
Display Description
• Power take-off (PTO*) and forward maneuvering mode are activated

- Arrow pointing upwards means PTO 1 is activated.
029941
• Power take-off (PTO*) and reverse maneuvering mode are activated

- Arrow pointing upwards means PTO 1 is activated.
029942
• PTO (two PTOs* are activated)

- Arrow pointing upwards and downwards means that PTO 1 and 2 are activated.
- «P1» means that the PTO is activated and the 1st gear in the transmission is engaged.
024371
• Reverse gear “High”

- High reverse gear is engaged.
024445
• Reverse gear “Low”

- Low reverse gear is engaged.
024444
*PTO = Power Take-Off
4232 758 102 - 2012-02 32

Operation
Display Description
• Reverse maneuvering
024373
• Manual driving mode

- «4» means that the 4th gear is engaged.
024374
• Shift recommendation in manual mode

- 2 bars and an arrow pointing downwards mean that it is possible to shift down by up to 2 gears.
- «5» means that the 5th gear is engaged.
024375
• Automatic mode
- Is indicated in the display by 4 bars with 2 arrows.
- «3» means that the 3rd gear is engaged.
024376
4232 758 102 - 2012-02 33

Operation
Warning notices:
Display Description
• «AL» = Air pressure insufficient (airless)

- Alternates with normal display.
- The compressed-air system of the transmission system does not have sufficient pressure.
024377
NOTE
Only set off when sufficient air pressure has been reached. If the clutch does not open when stopping as
a result of insufficient air pressure, the engine is “stalled”.
DANGER!
• If you change gears at too low an air pressure, the transmission may stay in neutral,so the
direct drive and engine braking effect are lost.
• The clutch cannot open if the air pressure is too low!
• «CC» = Clutch Check

- Clutch position cannot be taught in.
024378
• «CL» = Clutch Load

- Clutch overload, alternates with normal display.
- Select lower gear or stop.
024379
4232 758 102 - 2012-02 34

Operation
Display Description
• «CW» = Clutch Wear

- Clutch has reached wear limit.
- Visit specialist workshop soon to have clutch replaced.
024380
• «EE» = Electronic Error

- Is displayed when communication of the display with transmission electronics malfunctions.
- A system failure is involved. Continuation of travel is not possible!
024381
• «EX» = External signal active

- Gear engagement is prevented by an external signal.
- Starting is prevented by an external signal.
027960
• «FP » = Accelerator pedal

- Take foot off accelerator pedal.
- If the display message does not disappear, there is a system failure. Continuation of travel is not
024383
possible!
• «FS» = Speed range selector position

- Speed range selector position not plausible
- Remedy: Actuate speed range selector again
028668
4232 758 102 - 2012-02 35

Operation
Display Description
• «HT» = High Temperature

- Allow transmission system to cool down.
024384
• «NS» = Neutral Shift

- Select neutral «N» with the speed range selector or rotary switch.
NOTE:
024385 Depending on the vehicle type, the transmission may automatically shift to neutral after a specific period
to protect the mechanical components of the clutch release.
• «TC» = Transmission Check

- Transmission positions cannot be taught in.
024386
4232 758 102 - 2012-02 36

Operation
System failures:
Display Description
• «Wrench» = System failure

- Is displayed when only limited vehicle operation is possible.
- Visit specialist workshop as soon as possible.
024387
NOTE
With certain system failures, the automatic mode is deactivated and the transmission system remains in
manual mode.
• «STOP» + «Wrench» = Serious system failure

S
T - Stop the vehicle. Continuation of travel is not permitted. Workshop visit required.
O
P
024388 DANGER!
If possible, do not stop the vehicle in danger zones.
See also Chapter 2.19 (System failures)
4232 758 102 - 2012-02 37

Operation
2.19 System failures (error messages) Shift lever
• If a « wrench symbol » appears on the display, there is a

system failure. Vehicle operation might potentially only be
possible with restrictions.
If « STOP » plus a wrench symbol appear in the display, a
serious system failure is involved. Stop the vehicle.
Continuation of travel is not permitted.
• It is possible to delete the error message and the resulting 029891
error response when the vehicle is stationary by means of

« Ignition OFF »; wait until display message disappears. If Depending on the version, a two or three digit error number
the display message does not disappear after « Ignition will appear on the display. This number corresponds to the
OFF », switch system off by means of battery master currently active error.
switch. Turn ignition on again. If the error message is still
displayed, a service center stop is required. If 4 bars are displayed in addition to the number shown, this
When contacting the service center, please provide means: error no. + 100 (only in the case of two-digit display)
information on the error number(s).
Retrieving active error numbers:

• Switch on ignition (do not start engine)
• Turn rotary switch to « N »
• Hold shift lever in the « + » position 024404 024405
e.g.: error no. 74 error no. 174
4232 758 102 - 2012-02 38

Operation
If 4 bars and 2 arrows are displayed in addition to the number Calling up inactive error numbers from the error memory:
shown, this means: error no. + 200 (only in the case of two-
digit display message) • Switch on ignition (do not start engine)
• Turn rotary switch to «N» and press the foot brake at the
same time
024391
• Hold shift lever in the « + » position
e.g.: error no. 227 All saved errors are displayed one after another on the display.
4232 758 102 - 2012-02 39

Operation
2.20 Starting up the vehicle at low temperatures
Outside temperature Down to –20 °C –20 °C to –30 °C –30 °C to –40 °C

Oil grade according to ZF List of according to ZF List of according to ZF List of
Lubricants TE-ML 02 Lubricants TE-ML 02 Lubricants TE-ML 02
Engine start permitted permitted Transmission must be prehea-
ted before the engine is started
To be noted – Warm-up phase of at least 10 Preheating e.g. with hot air,
for start minutes, with increased idling which, however, must not
speed of approx. 1500 rpm exceed 130 °C on the trans-
Transmission in neutral mission.
position CAUTION
Do not heat on transmission
and clutch actuator.
Limitations None At transmission temperatures At transmission temperatures
above –20 °C the transmission above –20 °C the transmission
is operable and all functions is operable and all functions
are provided. Longer shifting are provided. Longer shifting
times should be expected. times should be expected.
NOTE
Air leakage on the transmission system will significantly increase at temperatures below –20 °C. It is not sure that the clutch can
be opened for the engine to start in this temperature range.
In such a case, the engine-based starter must be able to overcome the drag torque of the transmission in addition to that of the
engine.
4232 758 102 - 2012-02 40

Operation
2.20.1 Parking vehicle at low temperatures
The vehicle may be parked or the transmission stored for long

periods down to an outside temperature of – 40 °C.
4232 758 102 - 2012-02 41

Maintenance ZF-AS Tronic / ZF-Intarder
3 Maintenance ZF-AS Tronic / ZF-Intarder 3.1 Visual inspection of wiring
• Please also pay attention to the details provided by the • Check wiring for damage in the course of a vehicle
vehicle manufacturer. inspection.
• Regular maintenance increases the transmission’s • Check that connectors are seated correctly; connectors
operational reliability. must be fitted with strain relief.
• Visual inspection for oil leaks in the course of a vehicle

inspection.
3.2 Compressed-air system maintenance
• All transmission maintenance work may only be carried
out when the vehicle is standing on level ground and the • The vehicle manufacturer’s maintenance instructions must
engine is switched off. be observed.
• With all drain, fill, or screw plugs make sure that the • The compressed-air tank should be drained of water
sealing ring has been renewed prior to assembly. weekly, in winter every day.
• Do not point pressurized water jet directly at the breather NOTE

valve. (Ingress of water in transmission: risk of corrosion). When draining the compressed-air tank, the compressed-air
cleaner and water separator should also be drained if this is not
• For transmissions with ZF-Intarder, the ZF-Intarder done automatically.
operating instructions 6085 758 102 are also required.
• On vehicles equipped with an air drier, always comply with
the specified interval for replacement of the cartridge.
4232 758 102 - 2012-02 42

ZF-AS Tronic / ZF-Intarder Maintenance
3.3 Type plates
3.3.1 ZF-AS Tronic type plate 3.3.2 ZF-Intarder type plate (option)
The type plate contains the most important data. The type plate contains the most important Intarder data.
The type plate is located on the left of the transmission when The type plate is located on the side of the Intarder housing.
viewed from the output.
The following information must always be given when making
The following information must always be given when making inquiries, placing orders, or carrying out repairs:
inquiries, placing orders, or carrying out repairs: 1 Intarder parts list number
1 Transmission type (model) 2 Intarder serial number
2 Transmission parts list number
3 Transmission serial no.
ZF FRIEDRICHSHAFEN AG ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY MADE IN GERMANY
ZF-AS Tronic 12 AS 2530 SO 1 INTARDER AS Tronic

MODEL PARTS LIST NO. MODEL SERIAL NO.
PARTS LIST NO. SERIAL NO.
2 4231 030 011 00200100 3 1 6085 020 028 XXX XXX 2
CUSTOMER CUSTOMER
x SPEC. NO.
SPEC. NO SPEEDO
TOTAL SPEEDO TOTAL
x x RATIO
RATIO
RATIO RATIO xn
xn P.T.O. N n=
P.T.O. N x n= x ENGINE
ENGINE OIL CAPACIT OIL GRADE SEE
OIL CAPACIT OIL GRADE SEE 02 IN LITERS LUBRIC. LIST TE-ML
IN LITERS
12 LUBRIC. LIST TE-ML
029367
023906
Example: Transmission type plate Example: Type plate ZF-Intarder
4232 758 102 - 2012-02 43

Maintenance ZF-AS Tronic / ZF-Intarder
3.4 Bleeding the transmission 3.5 Oil change intervals
The transmission oil heats up during travel. This results in the

To ensure the transmission’s required level of operational safety
formation of excess pressure which is continuously discharged
and reliability, the oil-change intervals must be observed as
via a bleeder valve (hose breather)
specified in the ZF List of Lubricants TE-ML 02!
Ensure that the breather valve and hose breather function
For the latest List of Lubricants, visit: http://www.zf.com
properly at all times.
As part of the vehicle inspections, check the following points
with regard to hose breathers:
• The hose must not exhibit any signs of damage, kinks, or 3.6 Oil grade
chafing.
For approved lubricants, refer to ZF List of Lubricants
• The hose must always be at an incline without creating a TE-ML 02.
siphon. “We recommend that you use ZF-Ecofluid M.”
• Do not exceed the max. permitted hose temperature
(e.g., near the exhaust pipes or exhaust turbocharger). The ZF List of Lubricants TE-ML 02 can be obtained from all
ZF Service Centers or from the Internet: http://www.zf.com.
• The end of the hose must be in a dry compartment and
should be approx. 150 mm lower.
3.7 Oil quantity
The oil quantity is noted on the type plate.

Correctly filling the oil in the transmission is crucial for ensuring
a precise oil quantity (see Chapter 3.8.1).
4232 758 102 - 2012-02 44

ZF-AS Tronic Maintenance
4 3 2 1
Example: ZF-AS Tronic 12 AS 2530 SO
1 Tighten oil drain plug to 60 Nm 4 Type plate

2 Tighten oil drain plug to 60 Nm 5 Connection for hose breather or breather valve
3 Tighten oil filler plug to 60 Nm
029921
4232 758 102 - 2012-02 45

Maintenance ZF-AS Tronic
3.8 Oil change (ZF-AS Tronic without ZF-Intarder)
Oil changes must always be carried out with the vehicle

standing on level ground and with the engine switched off.
Always change the oil after a long journey while the

transmission oil is still at operating temperature and of low
viscosity.
DANGER!
Touching hot parts and transmission oil may cause
burns. 3 2 1
1 Oil drain plug
2 Oil drain plug
• Remove oil drain and oil filler plugs (1, 2, and 3) from 3 Oil filler plug, oil filling point
transmission and collect transmission oil in a suitable
029921_1
container and dispose of it in accordance with
environmental regulations.
3.8.1 Oil fill
• Clean solenoid at oil drain plug (2).
• Fill in oil through oil filling point (3).
• Replace sealing ring on oil drain and oil filler plugs.
• The oil level is correct when the oil reaches the lower edge
• Screw in oil drain plugs (1 and 2) and tighten to 60 Nm.
of the oil filling point or when oil escapes at the oil filling
point.
• Tighten oil filler plug (3) to 60 Nm.
4232 758 102 - 2012-02 46

3.9 Oil level check
DANGER!
Insufficient oil in the transmission will result in
transmission damage. Risk of accident!
• Check oil level when vehicle is on level ground.

• Do not check the oil level right after traveling (incorrect
measurement). Only check once the transmission oil has
cooled down (<40 °C).
• Remove oil filler plug (3).
• If the oil level is below the oil filling point, you must top up
the oil (see Chapter 3.8.1).
• If the oil level is OK, screw in the oil filler plug (3) with a
new sealing ring.
Tightening torque: 60 Nm
NOTE
Whenever checking the oil level, also inspect the transmission
for possible leaks.
4232 758 102 - 2012-02 47

Maintenance ZF-Intarder
3.10 Oil change ZF-AS Tronic with ZF-Intarder* • Remove screw plugs (1 and 2) on the transmission and the
Intarder and collect the transmission oil in a suitable
CAUTION container. Dispose of the transmission oil in accordance
The ZF-Intarder must NOT be actuated shortly before parking with environmental regulations.
the vehicle to change the oil!
• Clean the solenoid on the screw plugs and replace the sea-
This ensures that the correct oil level is reached in the
ling rings.
transmission.
• Screw in screw plugs (1 and 2) and tighten to 60 Nm.
NOTES
CAUTION
• When changing the oil, collect it in a suitable container and
Observe the specified tightening torque for screw plugs;
dispose of it according to local environmental protection
otherwise transmission damage may occur!
regulations.
• Always change the oil after a longer journey while the • Replace oil filter.
viscosity.
• Only change the oil when vehicle is on level ground.
DANGER!
burns.
• Switch off engine.
*Option
4232 758 102 - 2012-02 48

ZF-Intarder Maintenance
5
9 11
1 10
4 3 2
1 Oil drain location, Intarder 9 Oil filling point after repair

2 Oil drain location, transmission 10 Tighten screw to 23 Nm
3 Oil filling or oil draining point 11 Filter cover
4 Type Plate
5 Transmission bleeding Tighten screw plugs (1, 2, 3, and 9) to 60 Nm.
019368
4232 758 102 - 2012-02 49

3.10.1 Oil filter change
NOTE
Use a new oil filter for each oil change.
11
DANGER!
With hot transmission oil: Risk of burns!
10
• Remove bolt (10) from filter cover (11). 000529
• Remove filter cover (11) with mounted filter. Remove oil filter from filter
cover.
CAUTION
There is residual oil left in the oiI filter housing!
• Check the O-ring (8) on the filter cover (11) for damage, replace and grease,
if necessary.
000552
• Safely secure solenoid (12) to the new filter.
• Grease O-ring (7).
• Fit filter cover (11) onto new filter(6). Insert the complete unit in the filter
housing until it hits the limit stop.
• Tighten screw (10) to 23 Nm.
11 8 7 6 12
4232 758 102 - 2012-02 50

3.10.2 Oil fill 9
CAUTION
With transmissions with a ZF-Intarder, there is a difference
between an oil fill in the case of an oil change and an oil fill
after a transmission repair.
Oil fill in the case of an oil change
NOTE
The oil fill must always be carried out with the vehicle standing
on level ground and with the engine switched off. Oil grade 3
according to TE-ML 02.
019368
• Remove screw plug (3).
• Fill oil into the transmission until it overflows. End of test run: Vehicle stationary.
Do NOT engage Intarder!
• Screw in screw plug (3) with new sealing ring and tighten
to 60 Nm.
Take a test drive of 2 to 5 km
CAUTION
During test drive, press the footbrake to disengage the Intarder.
Check oil level again and if necessary, top up with oil until it
Do NOT engage the Intarder during the test drive.
overflows.
to 60 Nm.
4232 758 102 - 2012-02 51

Oil fill after a transmission repair

9
NOTE
The oil fill must always be carried out with the vehicle standing
on level ground and with the engine switched off. Oil grade
according to TE-ML 02.
• Remove screw plugs (3 and 9).

• Fill with oil at pos. 9 until oil flows over at pos. 3.
• Screw in screw plugs (3 and 9) with a new sealing ring and
tighten to 60 Nm.
3
Take a test drive of 2 to 5 km
During the test drive, press the footbrake to disengage the
019368
Intarder.
Test drive: Activate the Intarder (step 6) QUICKLY ONCE at the
beginning.
CAUTION
Check oil level again and if necessary, top up with oil until it
End of test run: Vehicle stationary. Do NOT actuate the
overflows.
Intarder!
• Tighten screw plug (3) to 60 Nm.

4232 758 102 - 2012-02 52

3.11 Oil level check ZF-AS Tronic with ZF-Intarder* • Pay particular attention to possible leakages on:
- The transmission,
- The Intarder,
DANGER!
- The oil/water heat exchanger,
- Corresponding coolant pipes.
transmission damage.
Risk of accident!
CHECK
• Stop and park the vehicle without actuating the Intarder.
CAUTION
• When checking the oil, remove the screw plug at the filling
For an oil check, the Intarder must no longer be activated
point (3).
immediately prior to parking the vehicle.
This ensures that the correct oil quantity is reached in the • If the oil level has dropped below the edge of the oil filling
transmission. point, the oil must be topped up until it overflows at the
filling point.
NOTES
• In order to obtain a correct measurement result, the oil level
to 60 Nm.
check must occur with
- Vehicle parked on horizontal ground
- Engine turned off
- Transmission oil cooled down (<40 °C).
Visual check
• Check the oil level within the framework of the vehicle
inspection. If the accumulator charge valve is seriously leaking, then
replace the entire accumulator.
*Option
4232 758 102 - 2012-02 53

3.12 Engine coolant Change interval of the engine coolant:

• Max. 2 years
CAUTION with aluminium heat exchanger (fill premixed)
After refilling the engine coolant, please pay strict attention • Max. 4 years
to the instructions given by the vehicle manufacturer! with stainless steel heat exchanger (fill premixed)
Otherwise, damage may occur to the oil/water heat • Deviating information (shorter change intervals) given by
exchanger! the vehicle or engine manufacturer must be observed.
• Engine coolant NOTE

(mixture of fresh water and antifreeze/anti-corrosion fluid) The entire cooling system must always be rinsed with water
- Recommended amount of antifreeze/anti-corrosion fluid: prior to new fills.
40 ‒ 50 vol. %, to be tested with coolant tester. The coolant must also be replaced immediately if sludge forms
or if the coolant’s concentration falls suddenly.
• Antifreeze/anti-corrosion fluid
Base liquid: Ethylene glycol with corrosion protection
inhibitors
• Fresh water
pH-value 6.5 ‒ 8.0; overall hardness <20 °dH
4232 758 102 - 2012-02 54

3.13 Transmission maintenance for versions with • Check:

external heat exchanger - Let engine run at idle speed for approx. 3 minutes.
– Shift transmission to neutral position.
NOTE
The maintenance work is to be done according to standard – Switch off the engine.
transmission design.
– Perform an oil level check; for ZF-AS Tronic see
Chapter 3.9.
Additionally, the following points are to be noted:
• Draining the oil: Diagram: Transmission with heat exchanger

– Unscrew oil drain plug on heat exchanger (if present)
• Oil fill:
– After the oil fill (see Chapter 3.8.1), screw in the oil filler
plug.
– Shift transmission to the neutral position.
– Let the engine run for approx. 2 ‒ 3 minutes at around
1,200 rpm. This is necessary so that the heat exchanger
and the connecting lines can completely fill up with oil.
– Switch off the engine.
000508
– Refill with oil again until it overflows.
4232 758 102 - 2012-02 55

Maintenance ZF-AS Tronic mid
4 Maintenance ZF-AS Tronic mid 4.1 Visual inspection of wiring
• Please also note the details provided by the vehicle • Check wiring for damage in the course of a vehicle
manufacturer. inspection.
• Regular maintenance increases the transmission’s • Check that connectors are seated correctly; connectors must
operational reliability. be fitted with strain relief.
• Visual inspection for oil leakage within the scope of the

vehicle inspection.
4.2 Compressed-air system maintenance
• All transmission maintenance work may only be carried out
with the vehicle standing on level ground and with the • The vehicle manufacturer’s maintenance instructions must
engine switched off. be observed.
• With all drain, fill, or screw plugs make sure that the sealing • The compressed-air tank should be drained of water weekly,
ring has been replaced prior to assembly. in winter every day.
• Do not point pressurized water jet directly at the breather NOTE

valve. (Ingress of water in transmission: risk of corrosion). When draining the compressed-air tank, the compressed-air
cleaner and water separator should also be drained if this is
not done automatically.
• On vehicles equipped with an air drier, always comply with

the specified interval for replacement of the cartridge.
4232 758 102 - 2012-02 56

ZF-AS Tronic mid Maintenance
4.3 Type plate 4.4 Bleeding the transmission
The type plate contains the most important data. The transmission oil heats up during driving. This causes excess
The type plate is located on the right side of the transmission pressure to build up, which needs to be relieved continuously
when viewed from the output. through a breather valve (hose breather).
Ensure that the breather valve or hose breather function
The following information must always be given when making properly at all times.
inquiries, placing orders, or carrying out repairs:
1 Transmission type (model) As part of the vehicle inspections, check the following points
2 Transmission parts list number with regard to hose breathers:
3 Transmission serial no.
• The hose must not exhibit any signs of damage, kinks, or
chafing.
ZF FRIEDRICHSHAFEN AG • The hose must always be at an incline without creating a
MADE IN FRANCE
siphon.
ASTronic mid 12 AS 1620 SO 1
MODEL • Never exceed the max. permitted hose temperature
PARTS LIST NO. SERIAL NO.
2 3 (e.g. near the exhaust pipes, exhaust turbocharger).
4247 037 004 00 247 443
• The end of the hose must be in a dry compartment and
CUSTOMER xxxxxx
SPEC. NO. should be approx. 150 mm lower.
TOTAL 10.37 - 0.81 SPEEDO xxx
RATIO
RATIO
xn
P.T.O. N xxxxx n= xxxxx
ENGINE
OIL CAPACIT 9.3 OIL GRADE SEE 02
IN LITERS LUBRIC. LIST TE-ML
026814
Example: Transmission type plate
4232 758 102 - 2012-02 57

4.5 Oil change intervals 4.7 Oil quantity
To ensure that the transmission achieves the required level of Correctly filling the oil in the transmission is crucial for ensuring
operational safety and reliability, the oil change intervals a precise oil quantity (see Chapter 4.8.1).
indicated in the ZF List of Lubricants TE-ML 02 must be
observed!
4.6 Oil grade
For permissible lubricants, see ZF List of Lubricants

TE-ML 02.“We recommend that you use ZF-Ecofluid M.”
The ZF List of Lubricants TE-ML 02 can be obtained from all

ZF Service Centers or from the Internet: http://www.zf.com.
4232 758 102 - 2012-02 58

1 2 3
Example: ZF-AS Tronic mid
1 Tighten oil drain plug to 60 Nm 4 Type plate

2 Tighten oil drain plug to 60 Nm 5 Connection for hose breather / breather valve
3 Heat exchanger (option)
029919 / 029920
4232 758 102 - 2012-02 59

4.8 Oil change
Oil changes must always be carried out with the vehicle

standing on level ground and with the engine switched off.
Always change the oil after a longer journey while the

viscosity.
DANGER!
burns.
1 Oil drain plug 1 2

• Remove oil drain and oil filler plugs (1 and 2) from 2 Oil filler plug
transmission and collect transmission oil in a suitable 034648_1
container and dispose of it in accordance with
environmental regulations. 4.8.1 Oil fill
• Clean the oil drain plug (1) and replace the sealing ring. • Fill in oil through oil filling point (2).
• Screw in oil drain plug (1) and tighten to 60 Nm. • The oil level is correct when the oil reaches the lower edge
of the oil filling point or when oil escapes at the oil filler
point.
• Tighten oil filler plug (2) to 60 Nm.
4232 758 102 - 2012-02 60

4.9 Oil level check
DANGER!
transmission damage.
Risk of accident!
• Check oil level when vehicle is on level ground.
• Do not check the oil level right after traveling (incorrect

measurement). Only check once the transmission oil has
cooled down (<40 °C).
• Remove oil filler plug (2).
• If the oil level has dropped below the oil filling point, the oil
must be topped up (see Chapter 4.8.1).
• If the oil level is OK, screw in the oil filler plug (2) with a
new sealing ring.
4232 758 102 - 2012-02 61

Notes
4232 758 102 - 2012-02 62

63
ZF Friedrichshafen AG
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-90 8000
www.zf.com
EN 4232 758 102a - 2012-02

Commercial Vehicle Technology
Manual and automated ZF transmissions

for trucks, buses, light commercial vehicles and special
vehicles with "TE-ML 02" label on the type plate List of lubricants TE-ML 02
Table of contents Page
1. Approved lubricant classes ................................................................................................................................................................ 1

1.1 Trucks and special applications ....................................................................................................................................................... 1
1.2 Buses ............................................................................................................................................................................................... 4
1.3 Light commercial vehicles ................................................................................................................................................................ 5
1.4 Product groups/Models/Versions from the past, not individually listed ............................................................................................5
2. Oil and filter change intervals (filter replacement affects only transmission with Intarder or WSK [torque converter clutch])............6
3. Low temperatures limits ..................................................................................................................................................................... 7
4. Explanation of footnotes and comments ............................................................................................................................................ 7
5. Lubricant classes and approved trade products ................................................................................................................................ 8
1. Approved lubricant classes
1.1 Trucks and special applications
Product groups Lubricant classes

trucks
Note: Instead of the “0“ as the last figure, there may also
be a: 2;3;4;5. First fill (5) Service fill (6)
(Example: 12AS1935, 16S2223)
Ecolite ZF-Ecofluid M ZF-Ecofluid M
S5-42, S6-36, S6-36/2, S5-420 02B(1) / 02E 02B(1) / 02E / 02L
ZF-Ecofluid M ZF-Ecofluid M
S5-580
02B(1) / 02E 02B(1) / 02E / 02L
6S500
02B / 02E 02B / 02E
Ecolite / AS Tronic lite ZF-Ecofluid M ZF-Ecofluid M
6S850, 6AS850 02B(1) / 02E 02B(1) / 02E / 02H(1) / 02L
6S1200, 6S1200 02B(1) / 02E / 02H(1) 02B(1) / 02E / 02H(1) / 02L
Ecolite / AS Tronic lite ZF-Ecofluid M ZF-Ecofluid M
6S700, 6AS700, 6S800, 6AS800, 6S1000, 6AS1000 02E 02B(1) / 02E / 02L
AS Tronic lite
02K 02K
Hydraulic actuators
The list of lubricants TE-ML 02, edition 01.04.2018 replaces all ZF Friedrichshafen AG
previous editions. The current list can be requested from any ZF D-88038 Friedrichshafen
after-salesservice center or accessed on the Internet under www.zf.com/contact
www.zf.com/lubricants.
Page 1 of 15
Continued ZF Friedrichshafen AG / List of lubricants TE-ML 02, edition 01.04.2018

trucks (continuation)
(Example: 12AS1935, 16S2223)
Ecomid without Intarder ZF-Ecofluid M ZF-Ecofluid M
9S75, 8S109, 9S109, 16S109 02B / 02E / 02H 02B / 02E / 02H /02L
Ecomid with Intarder ZF-Ecofluid M ZF-Ecofluid M
8S109IT, 9S109IT, 16S109IT 02E / 02H 02E / 02H / 02L
Ecomid without Intarder / Ecotronic mid
8S1110, 9S910, 9S1110, 9S1310, 9S1510,
02B / 02E 02B / 02E / 02L
9AS910, 9AS1110, 9AS1310, 9AS1510
8S1111, 9S1111, 9S1311 02E 02E / 02L
AS Tronic mid ZF-Ecofluid M ZF-Ecofluid M
12AS1010, 12AS1210, 12AS1220, 12AS1420, 12AS1620 02E 02B / 02E / 02L
Ecosplit without Intarder
8S151, 16S151, 8S181, 16S181, 16S221, 16S251
8S1620, 16S1620, 8S1820, 16S1820, 8S1920, 16S1920,
02B / 02E / 02H 02B / 02E / 02H / 02L
16S2020, 8S2220, 16S2220, 16S2520, 16S2720
16S1580, 16S1680, 16S2180, 16S2280
Ecosplit with Intarder
8S151IT, 16S151IT, 8S181IT, 16S181IT, 16S221IT,
16S251IT ZF-Ecofluid M ZF-Ecofluid M
8S1621, 16S1621, 8S1821, 16S1821, 8S1921, 16S1921, 02E / 02H 02E / 02H / 02L
16S2021, 8S2221, 16S2221, 16S2521, 16S2721
16S1581, 16S1681, 16S2181, 16S2281
Ecosplit without Intarder ZF-Ecofluid M ZF-Ecofluid M
16S2320, 16S2330 02E 02B / 02E / 02L
12S2130, 12S2330, 12S2830
02E 02B / 02E / 02L
8S1630, 16S1630, 8S1830, 16S1830, 8S1930, 16S1930, ZF-Ecofluid M ZF-Ecofluid M
16S2030, 8S2230, 16S2230, 16S2530, 16S2733 02E 02B / 02E / 02H / 02L
Ecosplit with Intarder ZF-Ecofluid M ZF-Ecofluid M
16S2321, 16S2331 02E 02E / 02L
12S2131, 12S2331, 12S2831
02E 02E / 02L
16S1631, 8S1831, 16S1831, 8S1931, 16S1931, ZF-Ecofluid M ZF-Ecofluid M
16S2031, 8S2231, 16S2231, 16S2531, 16S2731 02E 02E / 02H / 02L
Classic Line
8S1350, 16S1455TD, 16S1650, 16S1670, 16S1850,
16S1950, 9S1820,
02B / 02E / 02H 02B / 02E / 02H / 02L
16S1650HD
S6-1550, S6-820, S5-680, S6-680, S5-820
AS Tronic without Intarder
12AS1630, 12AS1930, 12AS2130, 12AS2140, 12AS2300,
12AS2301, 12AS2330, 12AS2340, 12AS2501, 12AS2530,
02E / 02V 02B / 02E / 02L / 02V
12AS2540, 12AS2740, 12AS2940, 12AS3001, 12AS3002,
12AS3140, 16AS2230, 16AS2600, 16AS2601, 16AS2630
AS Tronic with Intarder
12AS1631, 12AS1931, 12AS2131, 12AS2141,
12AS2300IT, 12AS2301IT, 12AS2331, 12AS2341, ZF-Ecofluid M ZF-Ecofluid M
12AS2501IT, 12AS2531, 12AS2541, 12AS2741, 02E / 02V 02E / 02L / 02V
12AS2941, 12AS3001IT, 12AS3002IT, 12AS3141,
16AS2231, 16AS2600IT, 16AS2601IT, 16AS2631
Page 2 of 15

trucks (continuation)
(Example: 12AS1935, 16S2223)
TraXon without Intarder
12TX1410, 12TX1610, 12TX1810, 12TX2010, 12TX2210,
12TX2410, 12TX 2610,
12TX2420, 12TX2620, 12TX2820, 12TX3020, 12TX3220,
02E / 02V 02E / 02L / 02V
12TX3420
16TX1640, 16TX1840, 16TX2040, 16TX2240, 16TX2440,
16TX2640, 16XT2840,16TX3040, 16TX3240, 16TX3440
TraXon with Intarder
12TX1411, 12TX1611, 12TX1811, 12TX2011, 12TX2211,
12TX2411, 12TX 2611,
12TX2421, 12TX2621, 12TX2821, 12TX3021, 12TX3221,
02E / 02V 02E / 02L / 02V
12TX3421
16TX1641, 16TX1841, 16TX2041, 16TX2241, 16TX2441,
16TX2641, 16XT2841,16TX3041, 16TX3241, 16TX3441
Transmatic
(Joint oil circuit of basic transmission and converter lock-
02H(2) 02H(2)
up clutches)
16S151WSK, 16S221WSK, 16S251WSK
TC Tronic
(Separate oil circuit of basic transmission and converter
lock-up clutches)
02E 02B / 02E / 02L
Basic transmission:
12TC2540, 12TC2740
Torque converter lock-up clutches: 02H(2) / ATF in accordance with 02H(2) / ATF in accordance with
TC 2 TE-ML 14(7) TE-ML 14(7)
TC Tronic HD (Heavy Duty)
(Separate oil circuit of basic transmission and converter
lock-up clutches)
02E 02E / 02L
Basic transmission:
12AS3040TCIT
Torque converter lock-up clutches: ZF-Ecofluid M ZF-Ecofluid M
TCHD 02E 02E
NMV 1600L1, 2000L1, 2003L1, 1075K1 ZF-Ecofluid M ZF-Ecofluid M
(engine-dependent PTO“ with independent oil circuit) 02E 02E / 02L
Page 3 of 15
1.2 Buses

buses First fill (5) Service fill (6)
S5-42, S6-36, S6-36/2, 5S600BO 02B(1) / 02E 02B(1) / 02E / 02L
6S890, 6S700BO 02B(1) / 02E 02B(1) / 02E / 02H / 02L
Ecolite without Intarder
S6-85, 6S1000BO, 6S1000BD, 6S1200BO, 6S1200BD, ZF-Ecofluid M ZF-Ecofluid M
6S1350BO, 6S1600BD, 6S1650BO, 6S1700BO, 02B(1) / 02E / 02H 02B(1) / 02E / 02H / 02L
6S1900BO
Ecolite with Intarder
6S1351BO, 6S1601BD, 6S1651BO, 6S1901BO,
02E / 02H 02E / 02H / 02L
6S1701BO
Ecolite / AS Tronic lite
6S710BO, 6AS710BO, 6S1010BO, 6AS1010BO,
02E 02B(1) / 02E / 02L
6S1110BO, 6AS1110BO
AS Tronic lite
02K 02K
Hydraulic actuators
Ecomid without Intarder ZF-Ecofluid M ZF-Ecofluid M
8S180, 8S2100BO, 8S2100BD 02B / 02E / 02H 02B / 02E / 02H / 02L
8S180IT, 8S2101BO, 8S2101BD 02E / 02H 02E / 02H / 02L
Classic Line ZF-Ecofluid M ZF-Ecofluid M
S6-1550, S6-820, S5-680, S6-680, S5-820, 6S1380BD 02B / 02E / 02H 02B / 02E / 02H / 02L
AS Tronic without Intarder
10AS2300BO, 10AS2310B, 10AS2700BO,
02E 02B / 02E / 02L
12AS2000BO, 12AS2300BO, 12AS2301, 12AS2700BO
AS Tronic with Intarder
10AS2010BIT, 10AS2301IT, 10AS2310BIT, ZF-Ecofluid M ZF-Ecofluid M
12AS1601BO, 12AS2000BIT, 12AS2001BO, 02E 02E / 02L
12AS2300BIT, 12AS2301IT, 12AS2301BO, 12AS2701BO
TraXon with Intarder
12TX1611BO, 12TX2011BO, 12TX2411BO,
02E 02E / 02L
12TX2811BO
Ecoshift without Intarder
6S1310BD, 6S1310BO,
02E 02E / 02L
6S1610BD, 6S1610BO, 6S1910BO
Ecoshift with Intarder
6S1311BD, 6S1311BO, ZF-Ecofluid M ZF-Ecofluid M
6S1611BD, 6S1611BO, 02E 02E / 02L
6S1911BO, 6S2111BO
Page 4 of 15
1.3 Light commercial vehicles
Product groups Lubricants / Lubricant classes

Light commercial vehicles First fill (5) Service fill (6)
5S200VO, 5S270VO, 6S300VD, 6S320VD, 6S350VD,
6S380VO,
02E 02B / 02E / 02L
6S420VO
eTronic Petronas Gear Oil T.E. LD SAE
ZF-Ecofluid M
6AS300VD, 6AS320VD, 6AS380VO, 75W-80
02B / 02E / 02L
6AS400VO , 6AS420VO Total Tranself LD SAE 75W80
6S650, 6S720, 6S750
02E 02B / 02E / 02L
6S450, 6S480 ZF-Ecofluid M (9) ZF-Ecofluid M
VW Amarok, VW Crafter, MAN TGE VW spare part no. G 055 538 A2 VW spare part no. G 055 538 A2
6S480 ZF-Ecofluid M (9) ZF-Ecofluid M
IVECO Daily 02E 02E
ZF-Ecofluid M
02E
6S450, 6S480 ZF-Ecofluid M Exxon Mobil Gear Oil MB 317
Mercedes-Benz Sprinter 02E Mercedes-Benz MB 235.10 --
Manual Transmission Oil A 001
989 26 03
Fuchs Titan EG MP 80 ZF-Ecofluid M
5S400
Petronas TUTELA OTZ (80W-90) 02B / 02E
1.4 Product groups/Models/Versions from the past, not individually listed
Product groups/Models/Versions Lubricant classes

Torque converter lock-up clutches (WSK)
02H(2) / ATF in accordance with TE-ML 14(7)
with separate oil circuit
Transmissions without ZF-Intarder
AS Tronic 1 (12AS1800, 16AS2200) ZF-Ecofluid M
Constant-mesh and synchronised transmissions for commercial 02B / 02E / 02H / 02L
vehicles
Transmissions with ZF-Intarder
AS Tronic 1 (12AS1800IT, 16AS2200IT) ZF-Ecofluid M
Constant-mesh and synchronised transmissions for commercial 02E / 02H / 02L
vehicles
Page 5 of 15
2. Oil and filter change intervals (filter replacement affects only transmission with Intarder or WSK
[torque converter clutch])
Caution: Please refer to the previous pages, Section 1, tables, for information on the lubricant classes released for the
individual product groups.
ZF-Ecofluid M was specially designed for applications with manual transmissions and automatic transmissions in commercial
vehicles. The combination of a hydrocrack base oil with a specially balanced additive package ensures excellent oxidation stability
and is thus excellently suited for very long oil change intervals. It warrants high-quality transmission component protection, in
particular of the synchronizers and the gearings. As a result of the flat viscosity characteristic curve, the oil is suited for applications
in all climate zones, particularly in hot and cold regions. Moreover, in comparison with mineral transmission fluids, ZF-Ecofluid M
helps to reduce fuel consumption by 0.5 up to 1.0%.
Truck, bus and special applications according to sections 1.1, 1.2 and 1.4
02B, ZF-Ecofluid M 02K

Lubricant class 02L, 02V
02H, ATF 02E
Application Oil and filter change intervals (3)
- Off-road operation e.g. mining application
1.000 h 5.000 h 10.000 h
- Average speed up to 20 km/h
20.000 km 100.000 km 200.000 km ---
- Stationary drives
1 year 1 year 2 years (4)
- NMV
- Hot country use (8)
- Long-distance transport > 44 t
- Short-distance transport 120.000 km 240.000 km 360.000 km
---
- Tough operating conditions 1 year 2 years 3 years (4)
- Scheduled routes (buses)
- Average speed from 20 to 60 km/h
- Long-distance transport (trucks)
180.000 km 360.000 km 540.000 km
- Long-distance coach journeys (buses) ---
1 year 2 years 3 years (4)
- Average speed as of 60 km/h
- Hydraulic actuators no oil change
--- --- ---
needed
Light commercial vehicles according to section 1.3
Lubricants / Lubricant classes Oil change intervals

02B
Fuchs Titan EG MP 80 60.000 km
Petronas TUTELA OTZ (80W-90)
02L
Total Tranself LD 75W-80 240.000 km
Petronas Gear Oil T.E. LD SAE 75W-80
ZF-Ecofluid M / 02E
Exxon Mobil Gear Oil MB 317
no oil change needed
Mercedes-Benz MB 235.10 -- Manual Transmission Oil A 001
989 26 03
Page 6 of 15
3. Low temperatures limits
Initial vehicle start-up at oil sump

Lubricant classes Oil type / SAE viscosity grade
temperatures
ZF-Ecofluid M
75W / 75W-80 / 75W-85 / 75W-90 / ATF - 40°C
02B / 02E / 02K / 02L / ATF
02B / 02H / 02V 80W / 80W-85 / 80W-90 - 20°C
40, 85W-90, 90 0°C
30 - 15°C
02B / 02H 20W (Torque converter lock-up clutches TC 2
- 40°C
only)
20W (Transmatic only) - 40°C - 5°C
4. Explanation of footnotes and comments
Footnotes
(1) In moderate climate zones, shift quality of non-automated transmissions is impaired when using the lubrication classes 02B /
02H.
(2) Lubricants marked (*) on the following pages must not be used.
(3) Oil and filter change required, depending on what occurs first. Only use genuine ZF filter inserts:
- Intarder 2: 6085 298 026
- Intarder 3: 0501 215 163
- WSK: 0501 202 378
(4) These intervals only apply to a hose breather in a dry area. If there is no hose breather in the dry area, the oil change
intervals specified for lubricant class 02L apply. This restriction does not apply to TraXon and bus applications.
In the case of transmissions filled ex-works with lubricant class 02E / 02V, no oil change must be effected during the first two
years as of initial registration. In case of retrofitting or repair in this period, oil refills with lubricant class 02E / 02V are
permitted. Exception: The limits of application in accordance with the TE-ML 02 (operating hours, mileage [km]) are already
met prior to the expiration of the first two years.
(5) First filling: Only the lubricant classes listed are permitted for initial fillings of transmissions. ZF recommends the oil grades
listed in Tables 1.1 -1.4.
(6) Service filling: The lubricant classes listed are compulsory for service oil changes according to the oil-change intervals
mentioned under Section 2. In case of oil changes at transmission mileage of up to 7500 km, only oils for initial fillings must
be used. In the case of transmissions filled ex-works with lubricant class 02E / 02V, due attention must always be paid to
footer 4.
(7) All lubricants of TE-ML 14 may be used. Oil change intervals and temperature limits of TE-ML 02 do apply.
(8) The denomination „hot country use“ is derived from the area where the vehicle is used, rather than from a country in the
sense of a state.
Regarding ZF units, we say "Hot country use" when:
1. the monthly average temperature exceeds 25°C in more than 2 months within a year
2. or if temperatures rise above 40°C on more than 7 days in a year.
(9) No oil changes are required during transmission operation.
Comments
1. Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 110 and 1328 765 101 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.
4. ZF will not assume liability for damage caused by non-observance of our maintenance instructions.
Page 7 of 15
5. Lubricant classes and approved trade products
Lubricant class 02A
Note:
Oils formerly approved according to lubricant class 02A are now found in lubricant class 02B.
Page 8 of 15
Lubricant class 02B
Note:
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are used.
Manufacturer (02B) Trade name (02B) ZF approval number

ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL GETRIEBEÖL GX 80W-90 ML ZF000672
ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL GETRIEBEÖL GH 75 W 90 SL ZF002260
ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL SNA-E 75W-90 ZF000142
ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL EP PLUS 80W-90 ZF000460
ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL EP 80W-90 ZF001715
BAHRAIN PETROLEUM COMPANY, AWALI/BH SPAREX HP 90 GL-4 ZF001694
BASF SE, LUDWIGSHAFEN/DE EMGARD UAF 7105 ZF001876
BAYWA AG MÜNCHEN, MÜNCHEN/DE TECTROL MULTIGEAR PLUS 8090 ZF001160
BP PLC., LONDON/GB BP ENERGEAR HT 80W-90 ZF000200
BP PLC., LONDON/GB BP ENERGEAR SHX-M 75W-90 ZF000208
BP PLC., LONDON/GB BP ENERGEAR EP 80W-90 ZF001216
BUCHER AG LANGENTHAL, LANGENTHAL/CH UNISYNT ZX SAE 75W90 ZF000354
BUCHER AG LANGENTHAL, LANGENTHAL/CH GEAR ZX TP SAE 80W/90 ZF001721
BUCHER AG LANGENTHAL, LANGENTHAL/CH PENTA TL SAE 75W/90 ZF003411
CASTROL LTD, LONDON/GB CASTROL SYNTRAX UNIVERSAL 80W-90 ZF000227
CASTROL LTD, LONDON/GB CASTROL MANUAL EP 80W-90 ZF001096
CASTROL LTD, LONDON/GB SYNTRAX UNIVERSAL PLUS 75W-90 ZF001471
CASTROL LTD, LONDON/GB CASTROL TRANSMAX MANUAL EP 80W-90 ZF002133
CASTROL LTD, LONDON/GB CASTROL TRANSMAX UNIVERSAL LL 80W-90 ZF002143
CASTROL LTD, LONDON/GB CASTROL TRANSMAX UNIVERSAL LL 75W-90 ZF002144
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES CEPSA TRANSMISIONES EP FE+LD 75W-90 ZF000086
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES MAN SUPER AXLE 3343 75W-90 ZF000965
CHEVRON LUBRICANTS, SAN RAMON, CA/US TRANSLUBE LD SAE 80W ZF000800
CHEVRON LUBRICANTS, SAN RAMON, CA/US TRANSLUBE LD SAE 90 ZF000801
CHEVRON LUBRICANTS, SAN RAMON, CA/US MULTIGEAR 80W-90 ZF000812
CHEVRON LUBRICANTS, SAN RAMON, CA/US MULTIGEAR S 75W-90 ZF000815
CHEVRON LUBRICANTS, SAN RAMON, CA/US DELO GEAR TDL 80W-90 ZF002273
CHEVRON LUBRICANTS, SAN RAMON, CA/US DELO SYN-TDL 75W-90 ZF003353
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/FR GEAR TXS 75W90 ZF000829
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/FR GEAR TDM 80W ZF001039
DAF TRUCKS NV, EINDHOVEN/NL DAF SUPER 80W-90 ZF002125
DE OLIEBRON BV, ZWIJNDRECHT/NL TOR UNI GEAR LD 75W90 ZF000964
ENI S.P.A., ROME/IT ENI ROTRA LSX 75W-90 ZF000860
ENI S.P.A., ROME/IT ENI ROTRA MP 75W-90 ZF003364
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBILUBE 1 SHC 75W-90 ZF000041
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBILUBE S 80W-90 ZF000776
FABRIKA MAZIVA FAM AD, KRUŠEVAC/RS MULTIHIPO 75W-90 SINT ZF000653
FABRIKA MAZIVA FAM AD, KRUŠEVAC/RS MULTIHIPO 80W-90 F PLUS ZF001456
FINKE MINERALÖLWERK GMBH, 27374 VISSELHÖVEDE/DE AVIATICON FINKOGEAR PREMIUM 75W-90 ZF002249
FINKE MINERALÖLWERK GMBH, 27374 VISSELHÖVEDE/DE AVIATICON FINKOGEAR SUPER 80W-90 ZF002299
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN SUPERGEAR MC SAE 80W-90 ZF000722
FUCHS PETROLUB SE, MANNHEIM/DE GEARWAY S5 75W-90 ZF001030
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN TITAN GEAR ZF SAE 80 ZF002313
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN CYTRAC TD SAE 75W-90 ZF003341
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-TRUCK GL-4/GL-5 80W-90 ZF000554
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU G-BOX GL-4/GL-5 75W-90 ZF000962
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU GAZPROMNEFT GL-4/GL-5 75W-90 ZF002302
GAZPROMNEFT-LUBRICANTS, MOSCOW/RU KAMAZ G-PROFI SERVICE LINE GL-4/GL-5 75W-90 ZF003388
GEORG OEST MINERALÖLWERK GMBH & CO.KG, FREUDENSTADT/DE OEST SYNTH GETRIEBEÖL SAE 75W-90 ZF000491
GEORG OEST MINERALÖLWERK GMBH & CO.KG, FREUDENSTADT/DE OEST GETRIEBEÖL FE SAE 80W-90 GL4/5 ZF000565
GRUPA LOTOS S.A., GDANSK/PL TITANIS SUPER GL-5 75W/90 ZF000356
GRUPA LOTOS S.A., GDANSK/PL TITANIS SUPER GL-5 80W-90 ZF001098
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR XP DURA MAX 80W-90 ZF000684
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR TDL 80W-90 ZF000780
GULF OIL INTERNATIONAL, MUMBAI/IN GULF SYNGEAR 75W-90 ZF000863
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR MZ 80W ZF000873
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR MZ 90 ZF000874
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR MZ 85W-90 ZF000875
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR MZ 80W-90 ZF001034
GULF OIL INTERNATIONAL, MUMBAI/IN GULF GEAR ZX 80W ZF001849
HUILES BERLIET S.A., SAINT-PRIEST/FR RTO LONGEVIA TCX ECO 75W-90 ZF001566
IGOL FRANCE, AMIENS/FR SYNTHEGEAR 75W-90 ZF001087
INA MAZIVA LTD., ZAGREB/HR INA HIPENOL TDL 80W-90 ZF000432
INA MAZIVA LTD., ZAGREB/HR INA HIPENOL SHD 75W-90 ZF000977
IPIRANGA PRODUTOS DE PETRÓLEO SA, RIO DE JANEIRO/BR IPIRANGA ULTRAGEAR MB 80W ZF001765
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT, ANTWERP/NL Q8 TRANS XGS 75W-90 ZF000179
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT, ANTWERP/NL Q8 GEAR OIL XG SAE 80W-90 ZF002103
LIEBHERR HYDRAULIKBAGGER GMBH, KIRCHDORF/DE LIEBHERR SYNTOGEAR PLUS 75W-90 ZF001972
LIQUI MOLY GMBH, ULM/DE LIQUI MOLY HYPOID GETRIEBEÖL TDL SAE 80W-90 ZF001323
LIQUI MOLY GMBH, ULM/DE LIQUI MOLY VOLLSYN. HYPOID GETR.ÖL TRUCK (75W-90) ZF001347
MEGUIN GMBH & CO. KG, SAARLOUIS/DE MEGOL HYPOID-GETRIEBEOEL TDL 80W-90 ZF001183
MEGUIN GMBH & CO. KG, SAARLOUIS/DE MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 ZF001291
MOL-LUB KFT, ALMASFUZITO/HU MOL HYKOMOL TDL 75W90 ZF003365
MOTUL SA, AUBERVILLIERS/FR MOTUL GEAR SYNTH TDL 75W-90 ZF000825
NIS AD, NOVI SAD/RS NISOTEC HIPO LD ZF SAE 80W-90 ZF001362
NIS AD, NOVI SAD/RS NISOTEC HIPO SINT TDL SAE 75W-90 ZF002038
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION TM-4/5 75W-90 ZF001013
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION TM-4 SAE 80W ZF001431
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION TM-4 80W-90 ZF001524
Page 9 of 15
Manufacturer (02B) Trade name (02B) ZF approval number

OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION UNI 80W-90 ZF001768
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION UNI S 75W-90 ZF001769
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION MN TM-4/5 75W-90 ZF001945
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION UNI 80W-90 ZF002259
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR LL 80W-90 ZF000311
OY TEBOIL AB, HELSINKI/FI TEBOIL HYPOID SAE 75W-90 ZF001969
OY TEBOIL AB, HELSINKI/FI TEBOIL HYPOID SAE 80W-90 ZF001970
PAKELO MOTOR OIL, SAN BONIFACIO (VR)/IT GLOBAL MULTIGEAR TS SAE 75W/90 ZF001224
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90 ZF000423
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90 ZF000462
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM 4 SAE 80W ZF001476
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM 4 SAE 90 ZF001477
PETROGAL S.A., LISBOA/PT GALP TRANSVEX TDL 75W90 ZF000980
PETROL OFISI A.S., ISTANBUL/TR MAXIGEAR D 75W-90 ZF001591
PETROMIN CORPORATION, JEDDAH/SA PETROMIN GEAR BOX Z12 SAE 80W90 ZF001966
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION STARGEAR AX-ED (SAE 75W-90) ZF001017
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION STARGEAR HD (SAE 80W) ZF001028
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION STARGEAR AX-ED (SAE 75W-90) ZF001738
PHI OIL GMBH, ST. GEORGEN/AT UNIGEAR GOLD 75W90 ZF001203
REPSOL LUBRICANTES Y ESPECIALIDADES, S.A, MADRID/ES REPSOL CARTAGO FE LD 75W90 ZF000451
RN-LUBRICANTS, LLC, MOSCOW/RU TNK TRANS 80W-90 ZF001752
SASOL OIL, RANDBURG/ZA SYN GEAR DIFFERENTIAL OIL 75W-90 ZF000702
SHELL INTERNATIONAL PETROLEUM COMP. LTD, LONDON/GB SHELL SPIRAX S3 AM 80W-90 ZF001292
SHELL INTERNATIONAL PETROLEUM COMP. LTD, LONDON/GB SHELL SPIRAX S3 G 80W-90 ZF001298
SHELL INTERNATIONAL PETROLEUM COMP. LTD, LONDON/GB SHELL SPIRAX S3 G 80W ZF001299
SHELL INTERNATIONAL PETROLEUM COMP. LTD, LONDON/GB SHELL SPIRAX S6 ADME 75W- 90 ZF003334
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL MTF C-I 80W ZF001727
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL MTF C-I 80W-90 ZF001933
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL MTF C-I 85W-90 ZF001936
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC MULTIPURPOSE-II GEAR OIL 80W-90 ZF003332
SK LUBRICANTS, SEOUL/KR TATADW G EP 80W-90 ZF002132
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS GETRIEBEFLUID SML 80W-90 ZF000447
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS WIOLIN RSG 80 ZF000452
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS GETRIEBEFLUID SXL 75W-90 ZF001655
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS WIOLIN ML 4 PLUS SAE 80W ZF001914
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS WIOLIN ML 4 PLUS SAE 80W-90 ZF001915
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DE SRS WIOLIN ML 4 PLUS SAE 90 ZF001916
TOTAL LUBRIFIANTS S.A., NANTERRE/FR ELF TRANSELF SYNTHESE FE 75W-90 ZF001555
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL TRANSMISSION DUAL 9 FE 75W-90 ZF001771
VALVOLINE CUMMINS PVT LIMITED, GURGAON/IN VALVOLINE GEAR GARD PLUS 80W90 ZF000985
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE HEAVY DUTY AXLE OIL PRO 80W-90 ZF001869
VEEDOL INTERNATIONAL LIMITED, GLASGOW/GB VEEDOL TRANSMISSION SYNTHETIC LD 75W-90 ZF001629
VIAL OIL LTD., FRYAZINO/RU CONSOL TRANS LUX 80W-90 ZF000587
YACCO SAS, ST PIERRE LES ELBEUF/FR BVX 1000 75W-90 ZF001612
YORK LUBRICANTS - GINOUVES SAS, LA GARDE/FR YORK 896 75W90 ZF000550
YPF S.A., BUENOS AIRES/AR HIPOIDAL SUPER S 75W-90 ZF003384
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/DE ZF-ECOFLUID X SAE 80W-90 ZF001266
Page 10 of 15
Lubricant class 02E
Manufacturer (02E) Trade name (02E) ZF approval number

ARAL AG, BOCHUM/DE ARAL GETRIEBEÖL SNS-M 75W-80 ZF000130
CASTROL LTD, LONDON/GB CASTROL SYNTRANS Z LONG LIFE 75W-80 ZF000609
CASTROL LTD, LONDON/GB CASTROL TRANSMAX MANUAL Z LONG LIFE 75W-80 ZF002157
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES CEPSA TRANSMISIONES Z5 FE+LD 75W80 ZF002240
DAF TRUCKS NV, EINDHOVEN/NL DAF XTREME 75W-80 ZF002124
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN CYTRAC ULTRA SYNTH SAE 75W-80 ZF001457
HUILES BERLIET S.A., SAINT-PRIEST/FR RTO LONGEVIA BZV ECO 75W-80 ZF001260
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION XT-D 540 (SAE 75W-80) ZF000532
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL TRANSMISSION GEAR 9 FE 75W-80 ZF001773
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/DE ZF-ECOFLUID M SAE 75W-80 ZF002155
Page 11 of 15
Lubricant class 02H
Note:
1. In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W or SAE 30 are
used.
2. Product group Transmatic/Torque converter lock-up clutches TC 2: With oil sump 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/Torque converter lock-up clutches TC 2: The lubricants marked thus (*) may not
be used.
Manufacturer (02H) Trade name (02H) ZF approval number

ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL TURBO DIESEL MD 305 SAE 30 ZF000624
ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL TURBO DIESEL MD 405 SAE 40 (*) ZF000625
CHEVRON LUBRICANTS, SAN RAMON, CA/US URSA TRANS SAE 40 (*) ZF000821
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN UNIVERSAL HD SAE 30 ZF ZF000719
GULF OIL INTERNATIONAL, MUMBAI/IN GULF SUPER DUTY LE 30 ZF001147
IPIRANGA PRODUTOS DE PETRÓLEO SA, RIO DE JANEIRO/BR IPIRANGA ULTRAGEAR 40 (*) ZF001340
IPIRANGA PRODUTOS DE PETRÓLEO SA, RIO DE JANEIRO/BR IPIRANGA ULTRAGEAR ZF 40 (*) ZF002264
PANOLIN AG, MADETSWIL/CH PANOLIN EXTRA DIESEL 30 ZF000393
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM 5 HD SAE 30 ZF001174
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM 5 HD SAE 40 (*) ZF001175
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION ZCS 160 (SAE 80W-90) ZF000026
Page 12 of 15
Lubricant class 02K
Manufacturer (02K) Trade name (02K) ZF approval number

FUCHS PETROLUB SE, MANNHEIM/DE PENTOSIN CHF 11S ZF000832
Page 13 of 15
Lubricant class 02L
Manufacturer (02L) Trade name (02L) ZF approval number

ADDINOL LUBE OIL GMBH, LEUNA/DE ADDINOL GETRIEBEÖL GS 75W-80 SL ZF000974
BARDAHL ASIA PACIFIC PTE LTD, SINGAPORE/SG SYNMAXTRAN 4000 SAE 75W-80 ZF003331
BAYWA AG MÜNCHEN, MÜNCHEN/DE TECTROL SYNTOGEAR MA 7580 ZF001935
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX PRISMA TF SAE 75W/80 ZF001660
CASTROL LTD, LONDON/GB CASTROL SYNTRANS Z 75W-80 ZF000219
CASTROL LTD, LONDON/GB CASTROL TRANSMAX MANUAL Z 75W-80 ZF002214
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES CEPSA TRANSMISIONES FE+LD 75W-80 ZF000472
CEPSA COMERCIAL PETRÓLEO S.A.U., MADRID/ES MAN SUPER GEAR 75W-80 ZF000862
CHEVRON LUBRICANTS, SAN RAMON, CA/US MULTIGEAR MTF 75W-80 ZF000813
CHEVRON LUBRICANTS, SAN RAMON, CA/US MULTIGEAR MTF 75W-80 ZF001220
CHEVRON LUBRICANTS, SAN RAMON, CA/US DELO SYN-MTF XZ 75W-80 ZF002275
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/FR GEAR TDS 75W80 ZF001040
DAF TRUCKS NV, EINDHOVEN/NL DAF PREMIUM 75W-80 ZF002123
DE OLIEBRON BV, ZWIJNDRECHT/NL TOR MT/LD GEAR OIL 75W80 ZF000634
DONGFENG COMMERCIAL VEHICLE CO. LTD, HUBEI/CN DFCV-HDT 31 ZF001809
ENI S.P.A., ROME/IT ENI ROTRA MULTIGEAR 75W-80 ZF000861
EUROPART TRADING GMBH, HAGEN/DE EUROPART SYNTHOGEAR INT. 75W80 ZF001875
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBIL DELVAC XHP TRANSMISSION OIL 75W-80 ZF000089
EXXONMOBIL CORPORATION, HOUSTON, TX/US MOBIL DELVAC 1 TRANSMISSION FLUID 75W-80 ZF001683
FINKE MINERALÖLWERK GMBH, 27374 VISSELHÖVEDE/DE AVIATICON GOLD MTF 75W-90 ZF002294
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN CYTRAC MAN SYNTH SAE 75W-80 ZF001140
FUCHS PETROLUB SE, MANNHEIM/DE PENTOSIN TLD 75W-80 ZF001423
FUCHS PETROLUB SE, MANNHEIM/DE GEARWAY S4 LT 75W-80 ZF001708
FUCHS PETROLUB SE, MANNHEIM/DE GEARWAY S4 75W-80 ZF001710
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN CYTRAC MAT SAE 75W-80 ZF003373
FUCHS PETROLUB SE, MANNHEIM/DE FUCHS TITAN CYTRAC MAT SAE 75W-80 ZF003374
GULF OIL INTERNATIONAL, MUMBAI/IN GULF SYNGEAR FE 75W-80 ZF000683
HAFA FRANCE, YVETOT/FR GEARTARDER SAE 75W-80 ZF000384
IGOL FRANCE, AMIENS/FR TRANS GEAR ZF PLUS 75W80 ZF000960
INA MAZIVA LTD., ZAGREB/HR INA TRANSMOL HD SAE 75W-80 ZF003344
KUWAIT PETROLEUM INTERNATIONAL LUBRICANT, ANTWERP/NL Q8 T 60 NTECH SAE 75W-80 ZF000324
LIQUI MOLY GMBH, ULM/DE LIQUI MOLY TRUCK GETRIEBEÖL HC GL4 SAE 75W-80 ZF000693
MEGUIN GMBH & CO. KG, SAARLOUIS/DE MEGOL PREMIUM GETRIEBEOEL HC GL 4 75W80 ZF000394
MOL-LUB KFT, ALMASFUZITO/HU MOL HYKOMOL SYNTRANS 75W80 ZF001064
MOTUL SA, AUBERVILLIERS/FR MOTUL GEAR SYNTH XD 75W-80 ZF001987
OLIPES S.L., CAMPO REAL - MADRID/ES MAXIGEAR TS 7400 - SAE 75W-80 ZF001439
OOO "LLK-INTERNATIONAL", MOSCOW/RU LUKOIL TRANSMISSION LDI 75W-80 ZF001767
OY TEBOIL AB, HELSINKI/FI TEBOIL GEAR MTF-V ZF003339
PAKELO MOTOR OIL, SAN BONIFACIO (VR)/IT GOLDENGEAR LD PLUS SAE 75W/80 ZF000488
PAZ LUBRICANTS & CHEMICALS, HAIFA/IL PAZ TRANS ULTRA 75W-80 ZF003387
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX GOLD XP SAE 75W-80 ZF001337
PETROGAL S.A., LISBOA/PT GALP TRANSVEX TDL ULTRA 75W80 ZF001275
PETROL OFISI A.S., ISTANBUL/TR MAXIGEAR S 75W-80 ZF001590
PETROMIN CORPORATION, JEDDAH/SA PETROMIN GEAR BOX Z2 SAE 75W80 ZF001967
PETRONAS LUBRICANTS INTERNATIONAL SDN BH, KUALA LUMPUR/MY TUTELA TRANSMISSION FE-GEAR (SAE 75W-80) ZF000530
PHI OIL GMBH, ST. GEORGEN/AT GEAR OIL MDV SILVER 75W80 ZF001386
RALOY LUBRICANTES, S.A. DE C.V., SANTIAGO TIANGUISTEN/MX KRÖNEN TRANSMISSION SYNTHETIC OIL 341 ZF000596
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/DE RAVENOL SSG SPEC SYNT LKW GETRIEBEÖL 75W-80 ZF001111
REPSOL LUBRICANTES Y ESPECIALIDADES, S.A, MADRID/ES REPSOL CARTAGO CAJAS FE LD 75W80 ZF001673
S-OIL CORPORATION, SEOUL/KR S-OIL 7 GEAR EP LL ZF001263
SASOL OIL, RANDBURG/ZA SYN GEARBOX OIL 75W-80 ZF001472
SHELL INTERNATIONAL PETROLEUM COMP. LTD, LONDON/GB SHELL SPIRAX S6 GXME 75W- 80 ZF001481
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL MTF 02L 75W-80 ZF002047
SINOPEC LUBRICANT CO., LTD., BEIJING/CN SINOPEC GREATWALL MTF 02L 75W-80 ZF003393
SK LUBRICANTS, SEOUL/KR SK GEAR EP 75W-80 ZF ZF000779
TAMOIL ITALIA SPA, MILANO/IT TAMOIL TAMGEAR PLUS SAE 75W-80 ZF001338
TOTAL LUBRIFIANTS S.A., NANTERRE/FR TOTAL TRANSMISSION GEAR 8 FE 75W-80 ZF001779
UNIL OPAL, SAUMUR/FR GERION LD 75W80 ZF000367
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE HEAVY DUTY GEAR OIL PRO 75W-80 LD ZF001830
VEEDOL INTERNATIONAL LIMITED, GLASGOW/GB VEEDOL GEAR OIL LD 75W-80 ZF002025
YACCO SAS, ST PIERRE LES ELBEUF/FR BVX Z 1000 75W-80 ZF001042
YORK LUBRICANTS - GINOUVES SAS, LA GARDE/FR YORK 994 ZF000735
ZELLER+GMELIN GMBH&CO.KG , EISLINGEN/DE DIVINOL SYNTHOGEAR INT. 75W80 ZF001679
Page 14 of 15
Lubricant class 02V
Note:
The lubricant class 02V has been specially developed for use in demanding situations at high temperatures. If the
reference "OIL GRADE 02V" is stated on the type plate, in principle only this type of oil may be used on the product
concerned. This also applies for servicing (oil changes, refilling after repair, refill).
Manufacturer (02V) Trade name (02V) ZF approval number

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/DE ZF-ECOFLUID HV SAE 80W-90 ZF003444
Page 15 of 15
19 Annex

WFN3RUWW2K2064139
ATF 60G-3 485

2019-03_EN
Integrated electronic controller
Type BEKA-troniX1
Contents: Page Electronic pump EP-1 with integrated controller BEKA-troniX1:

General information:
1. Functional features and installation dimensions 1
2. Function sequence 2
3. Method of operation 3
4. Adjusting the parameters 4
Supplementary functions: 5
5. Excess pressure valve with micro switch 6
6. Grease level controller 7
Summaries:
7. Signal indicators 8
8. Terminal diagram 9
9. Ordering key for pump 10
10. Retrofitting 11
11. Ordering key for integrated controller 12
1. General information:
The BEKA-troniX1 controller generation is a new design of

units in an integrated mould for the EP family of pumps.
The controlling device is fitted with a database, that saves Installation dimensions:
the following values:
The electrical pump EP-1 with integrated controller BEKA-
– Controlling type troniX1 can be equipped with various reservoir versions.
– Controller version For the installation dimensions of the reservoir versions,
– Serial Number see the description EP-1.
– Manufacturing date
– Method of operation (controlling according to
time or revolutions)
– Set values (adjusting ranges)
The following modes can be selected for the controller by

© BEKA 2012 All rights reserved!
means of the diagnostic software BEKA-DiSys:

176
A) Time controlling
B) Revolution controlling
172 140
239
322
Subject to alterations!
MU2175001112EN
1
BEKA-troniX1
2. Function sequence
Whatever program is being used, once the ignition has BEKA-troniX1 integrated electronic controller:
been switched on the green and the red LED or the green
and the red signal lamp (optional) lights up on the control
panel for 1.5 sec. and shows that the controller is
operational (activation control).
Every time the controller is activated for the first time, a

lubrication process begins. The green LED in the control
half shell is lit during the entire lubrication procedure.
The BEKA-troniX1 integrated electronic controlling device

has memory at its disposal. This also serves to keep a Button for
record of time elapsed. Should the ignition be switched off activating
during lubrication or operational pauses occur, then the interim
time is stopped and recorded. Once the ignition is switched lubrication
on again the remaining lubrication or pause time is read
from the memory and the sequence will be resumed where
it was interrupted.
Red LED showing faults
At any time when the ignition is on, an interim lubrication Green LED showing function
occurs when the button on the side of the pump motor
housing or the illuminated button on the control panel is Technical data for the controller:
activated, this serves as a check of functionality. The pump Operating voltage: 10 to 60 V DC
then immediately starts its lubrication cycle, the lubrication Maximum current load: I = 6,0 A
or cycle duration recorded up to that point is reset and starts Fuse (not included in device): F 6,3 A (5x20) medium
from the beginning. slow-blow fuse
Signal lamp outlet: I = 0,4 A
An interim lubrication can also be triggered via an external Temperature range: -35°C to +75°C
button, and the indication of the red and green LEDs can Degree of protection: IP 65
also be displayed by a red and green signal lamp in the
driver´s cab. Before the electrical connection:
Observe the voltage of the pump motor.
An error can be reset by pressing the interim lubrication
button and the pump starts the lubrication process anew.
The lamp on the illuminated button (green) shows the

functionality of the controller and the current lubrication
sequence.
2
BEKA-troniX1
3. Method of operation
A) Time controller:
When the central lubrication processor is time controlled, Diagram of cycle sequence:
the cycle duration and the lubrication time can be adjusted.
Cycle duration means the period from the beginning of one
lubrication process to the beginning of another lubrication
Lubrication time
process.
Cycle duration
B) Revolution controller:
In the case of revolution fluctuations at lower temperatures If no signal is received from the pump motor for longer than
or high torque, the lubrication duration for the BEKA- the adjustable monitoring time (standard 30 sec.) after the
troniX1 integrated electronic controller is determined by the lubricating process has begun, the controller will indicate a
number of pump motor revolutions. fault.
The pump motor is connected to the controller via sliding The red LED in the pump´s lower motor casing or an
contacts. With every engine revolution a signal is sent to the externally attached signal lamp (optional) start to flash.
controller, which counts the incoming signals.
3
BEKA-troniX1
4. Adjusting the parameters
The cycle time or lubrication time and the number of BEKA-troniX1 integrated electronic controller:
revolutions can be adjusted by means of rotary code
switches in the controller´s sight glass.
To adjust the time setting, remove the red frame on the

pump´s motor housing using a flat screwdriver, loosen the
four Phillips screws and remove the transparent protective
cover.
The cycle duration or lubrication time can be adjusted by
using a flat screwdriver.
System analysis
If the cover plate is not replaced properly, water may enter
port
the controller and damage it. In this case, the guarantee is
no longer valid.
The modes and the adjusting ranges can be changed over

by means of the diagnostic software BEKA-DiSys, even on
site if the controller has already been operated before.
Rotary code switch for setting the cycle duration

All adjusting ranges for the lubrication period and all cycle Rotary code switch for setting the lubricating duration
time ranges can be combined at random.
Adjusting the parameters:
Lubrication times: Cycle duration:

1 to 16 min. (16 notches every 1 min.) 0.5 to 8 h (16 notches every 0.5 h)
2 to 32 min. (16 notches every 2 min.) 2 to 32 min. (16 notches every 2 min.)
2 to 32 sec. (16 notches every 2 sec.) 2 to 32 h (16 notches every 2 h)
Revolutions of pump:
1 to 16 revolutions (16 notches every 1 revolution)
10 to 160 revolutions (16 notches every 10 revolutions)
170 to 320 revolutions (16 notches every 10 revolutions)
When changing the activation modes and the adjusting

ranges, the label in the controller window must be
replaced.
To this effect, a label kit consisting of 18 different label

version is available; these can also be ordered individually
afterwards.
Ref.-no. for label kit: 0490000342 German
Ref.-no. for label kit: 0490030343 English
4
BEKA-troniX1
Additional equipment
The integrated electronic controller BEKA-troniX1 can be Excess pressure valve with micro switch on the pump
supplied with two additional functions: element and grease level controller, built into electronic
pump EP-1:
- System excess pressure monitoring
- Grease level monitoring
The additional equipment can be attached to the BEKA-

troniX1 controller with any selected program.
In case of a version with additional functions, besides the

bayonet connector, two additional four-pole plug-and-
socket connectors are located in the lower part of the motor
casing.
These additional functions cannot be enabled

subsequently in case controllers have been supplied
without the as the plug-and-socket connectors at the lower
part of the motor casing are missing.
The additional plug-and-socket connectors and the cables

of the corresponding switches are marked by colors. Plug-and-socket
The plug-and-socket connector with the green ring serves connectors for
to connect the system pressure monitoring system. The additional functions
plug-and-socket connector with the red ring serves to
connect the grease level monitoring system. View of the integrated electronic controller BEKA-troniX1
Plug-and-socket connectors which are not connected must from below:
be closed using a cover.
The additional functions to the controller can be specified in

the order.
Cover to close an unused plug-and-socket connector for green

the supplementary functions of the integrated electronic marking ring
controller BEKA-troniX1:
Order-no.: 1000913004 red marking ring

5
BEKA-troniX1
5. System excess pressure monitoring
With the BEKA-troniX1 integrated electronic controller, the Excess pressure valve with micro switch on the pump
maximum operating pressure of progressive lubrication element, built into electronic pump EP-1:
system can be monitored.
Micro switch
For this puropose a micro switch has been attached to the
excess pressure valve of pump element.
Should a fault occur in the system, e.g. a blockage at the
point of lubrication, a pressure of more than 250 bar builds
up. A micro switch in the excess pressure valve is activated
and sends a signal to the controller. This switches the pump
off and the fault is indicated by the flashing red LED and
permanent illumination of the green LED or the externally
attached signal lamps.
Technical data for the micro switch:
Operating voltage: 10 to 60 V DC
Maximum current load: I = 1,7A
Contact type: 1 changer Connection to the controller:
Temperature range: -25°C to +85°C
Degree of protection: IP 67
Connection: Cable, length 0.5 m, heat-sealed
with 4-pole right-angle plug
Specify in the order whether the micro-switch is to be

delivered connected to the controller.
If the micro-switch is to be connected to another control
unit, e. g. PLC, an additional cable can be ordered in differnt
lengths (see description EP-1). It can be connected to the
cable heat-sealed to the micro-switch.
The pressure monitoring system can be attached to the green
BEKA-troniX1 controller with any selected program. marking
Pressure relief valves with micro switches can be retrofitted ring
and connected to the controller if it has been ordered with
additional features. Connection to the controller is effected via the four-pole

plug-and-socket connector marked with a green ring, to the
Excess pressure valves with micro-switches required for pump motor´s lower casing; to this effect, the contact plug
replacement can be ordered individually: cover must be removed.
Pressure relief valve with microswitch for PE-120: Pressure relief valve with microswitch for PE-120 V:
Order no: 2152 99115 Order no: 2152 99116:
approx. 99,8
approx. 99,8
M14x1,5
approx. 34,7
G1/4”
BEKA-troniX1
6. Grease level controller
The integrated electronic controller BEKA-troniX1 Grease level controller built in to the 2,5 kg reservoir of an
facilitates monitoring of the grease level in the storage tank. EP-1 central greasing pump:
For purpose a capacitive proximity switch has been built in
to the pump´s reservoir.
As long as there is enough grease available in the reservoir,
the proximity switch sends a signal to the controller. If the
grease level sinks below minimum the proximity switch
turns the signal off.
If the signal remain off for more than 10 sec. then the
controller switches the pump off, so that no air is pumped
into the system.
The red LED on the controller display, situated on the
pump´s motor housing or a built-in red signal lamp, if
available, starts to illuminate.
Once the grease has been refilled, the controller restarts
itself.
The grease level controller can be ordered connected to the

controller; in this case, a connecting cable, length 0,6 mm,
with a right-angle plug M12x1 for connection to the plug- Connection to the controller:
and-socket connector and a right-angle plug M12x1 for
Connection cable
connection to the controller is included in the scope of
length 0.6 m
supplies. The grease level monitoring system is activated.
EDP no.:
1000912998
If the grease level control is to be connected to an external
control unit, e. g. PLC, a cable with a socket M12x1 for
connection to the contact plug of the grease level controller
must be ordered separately (see description EP-1).
The grease level monitoring system can be retrofitted. It

can be connected to the control unit if the pump has been
ordered with additional functions. red
The grease level controller can also be retrofitted. In this marking
case, the function must be activated by means of the ring
software BEKA-DiSys. The function must not be activated if
no grease level controller in connected, as this would

produce a permanent error. The grease level controller can be attached to the BEKA-
The cable must also be ordered separately if the grease troniX1 controller with any selected program.
level controller is to be retrofitted (see drawing on the right).
Connection to the controller is effected via the four-pole Technical data for the capacitive proximity switch:
plug-and-socket connector marked with a red ring, to the Operating voltage: 10 to 60 V DC
pump motor´s lower casing; to this effect, the contact plug Switching type: PNP-turnkey
cover must be removed. Maximal current load: 250 mA
Degree of protection: IP 67
Ambient temperature range: -25°C to +70°C
Connection: 4-pole, M12x1 pluggable
7
BEKA-troniX1
7. Summary of Signal Indicators
The pump´s functions are indicated via two control LEDs BEKA-troniX1 integrated electronic controller:
(green/red) in the display on the pump´s motor casing,
where the red LED always indicates an error in the program
sequence.
These control LED functions may be indicated in the

driver´s cap of the vehicle via built-in signal lamps. These
must be ordered additionally. Red LED error indicator
Green LED function indicator
Standby indicator:
Standby: 1.5 sec.
ON
LED red
OFF
a) Standby ON
LED green
OFF
Lubrication sequence:
ON
LED red
OFF
During whole lubrication
b) Lubrication activated
ON
LED green
OFF
Grease level too low:

Until reservoir is filled
ON
LED red
c) Grease level error OFF
ON
LED green
OFF
Excess pressure in main system:

1 sec.
ON
LED red
OFF
d) Excess pressure error 1 sec.
ON
LED green
OFF
Revolution error in pump engine:

1 sec.
ON
LED red
OFF
e) Revolution and engine driver error ON 1 sec.
LED green
OFF
Memory error:
0.5 sec.
ON
LED red
OFF
f) Memory error 0,5 sec.
ON
LED green
OFF
e) Test lubrication (constant lubrication) Test lubrication:
ON
LED red
In order to adjust the time controlling to continual lubrication OFF
1 sec.
for servicing purposes, the lubrication time must be set to a
higher value than the cycle duration. ON
LED green
OFF 1 sec.
8
Subject to alterations! © BEKA 2012 All rights reserved!
Micro switch for

excess pressure controller
Fill level switch for

grease level controller
BEKA-troniX1
8. Terminal diagram of all connections
green (no. 1)
Signal lamp green
red (no. 2)
grün
Signal lamp red
External signal lamps
orange (no. 4)
Push button for
intermediate lubrication
black (no. 3) rot

Ignition, terminal 15
Ground, terminal 31
brown (ye/gr)
(no. ...) = Cable-no. at unicolored cables
9
BEKA-troniX1
9. Ordering key for EP-1 with integrated controller
Construction type 2175 . 3 . 1 .E . 0 . 1 . 2 . 1 . 000

Motor voltage
with bayonet connector
12V 24V
3 4
Outlet Pump element without PE-60 PE-120 PE-120 V PE-170

Pos. 1 without micro switch 0 7 1 2 G
with micro switch 0 A D N H
Pos. 2 without micro switch 0 8 3 4 J
with micro switch 0 B E P K
Pos. 3 without micro switch 0 9 5 6 L
with micro switch 0 C F A M
Special variants ZZZ
Only one micro switch can be connected to the BEKA-troniX1 controller!
Transparent reservoirs Steel reservoirs
Size of reservoir (kg) 1,9 4 2,5 8 16 2 4 8
without grease level monitoring 1 2 4 8 9 6 7 5
with LM min. plug connection M12x1 in reservoir cover B A C
Additional equipment
without connectors for additional equipment 0
Grease level monitoring 1
System excess pressure monitoring 2
Grease level controller and
system excess pressure monitoring 3
without connection to the controller

4
(only connectors, not connected, not activated)
Parameter Cycle duration

Lubrication time 0.5 to 8 h 2 to 32 min. 2 to 32 h
I 1 to 16 min. 1 A J
II 2 to 32 min. 2 B K
III 2 to 32 sec. 3 C L
Pump revolutions
I 1 to 16 7 G O
II 10 to 160 8 H Q
III 170 to 320 9 I R
Special models 000

The operating modes and setting ranges, respectively, can Additional functions can be activated or deactivated at any time
be subsequently set in the PC by means of the diagnostic if the controller was ordered with additional functions, i.e. if the
software BEKA-DiSys. additional plugs are available on the bottom motor housing!
Positions of outlets:
3
1
10
2
BEKA-troniX1
10. Retrofitting
The integrated controller BEKA-troniX1 can be retrofitted to Connection cable, 5 wires, with bayonet connector:
the electric pump EP-1, i. e. to pumps which have been
delivered without controller and to replace existing
controllers.
However, retrofitting to pumps without controller is only
possible after the year of construction 2004.
Controllers delivered for retrofitting or replacement are not

provided with connection cable, as this is normally
available. If the controller is to be installed in a pump which
has not been equipped with a controller so far, or to be Order-no.: FAZ02499-19
replaced by a controller with another connector, the
connecting cable must be ordered separately.
The connecting cables for any supplementary features

available must also be ordered separately.
To connect the micro-switch for pressure monitoring, see
the description EP-1.
To connect the grease level controller, see description EP-
1.
Plug-and-socket connectors which are not used must be

closed by using a cover.
Cover to close an unused plug-and-socket connector for
the supplementary functions of the integrated electronic
controller BEKA-troniX1:
Order-no.: 1000913004
11
BEKA-troniX1
11. Ordering key for integrated controller BEKA-tronix 1
Construction type 2175 . 90 . 10 . 0 . A . 000
Connector version
with bayonet connector 10
additional equipment
without connectors for additional equipment 0
with grease level monitoring 1
with system excess pressure monitoring 2
with grease level monitoring and
3
system excess pressure monitoring
with contact plugs (not activated) 4
Parameter Cycle duration

Lubrication time 0.5 to 8 h 2 to 32 min. 2 to 32 h
I 1 to 16 min. 1 A J
II 2 to 32 min. 2 B K
III 2 to 32 sec. 3 C L
Pump revolutions
I 1 to 16 7 G P
II 10 to 160 8 H Q
III 170 to 320 9 I R
Special models 000
The operating modes and setting ranges, respectively, can be subsequently set in the PC by means of the
diagnostic software BEKA-DiSys!
Additional functions can be activated or deactivated at any time if the controller was ordered with additional
functions, i.e. if the additional plugs are available on the bottom motor housing.
12
19 Annex
19.3 Heating, ventilation, air-conditioning of chassis cab
WFN3RUWW2K2064139
498 ATF 60G-3

2019-03_EN
Technical Information no. page
Safety instructions 912-180-0002 1/8
Content
0 Universal advises

1.1 Mechanical dangers
1.2 Electrical dangers
1.3 Thermal dangers
2 Safety instructions for installation and maintenance- / repair work

2.1 General instructions
2.2 Transport and lifting
2.3 Air suction
2.4 Processing of glue and sealing material
2.5 Installation of compressors
2.6 Laying of electrical lines
3 Safety instructions for work on the refrigeration circuit and exposure to

refrigerant
3.1 Universal advises
3.2 Safety instruction for filling
4 Safety measures for electronic control units in vehicles:
5 Safety instructions for units with PTC-heating systems
6 Safety instructions for starting
AURORA
Konrad G. Schulz GmbH & Co.KG
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
we reserve the right to make modifications
Author: 10.12.03 KH checked: 07.01.04 MM released: 19.12.03 W.Le
date/name date/name date/name

a b c d
10.12.03
The following risks are the result of risk analysis for standard units:
· Thermal dangers, for example danger of burning on the heat exchanger, evaporator and con-
denser, the connections and the resistance.
· Electrical dangers, for example inappropriate cable laying and installation, short circuit and cable
fire because of missing fuse protection and units with high nominal voltage or supply voltage.
· Mechanical dangers, for example danger of cutting at possible and not avoidable sharp and
edges or tapered screws.
· Dangers at incorrectly installation, for example not required torque or no adequate maintenance.
The following advises and the advises contained in the safety instructions in the units tech-
nical information's have to be followed at installation and operation. The Installer and the op-
erator have to read this advises and instructions before installation and starting.
Dangers at non-observance of the safety instructions

At non-observance of the safety instructions dangers for persons and products are possible and the
loss of all claim for damages can be the result.
The following dangers are possible if the safety instructions are non-observed:
- failure of important product functions
- dangers for people because of thermal, electrical and mechanical influences.
0 Universal advises:
The rules for the prevention of accidents as well as other recognises technical and labour medical
security regulations must be observed.
· The products have to used only according to the intended use. The products shall not used in
improper environment. Please pay attention to the Technical supplement to guarantee
· Before using the products ensure that regulations and laws are strictly adhered according to the
countries. Pay also attention to instructions dependant to the countries, for example danger of fire
(soldering, welding).
· If AURORA-products can cause material damages or dangers to people the customer have to be
made additional external safety precautions. This safety precautions have to ensure a defined op-
eration state also in case of failures (examples are protection grilles, isolation tubes).
· AURORA products have only to be installed in vehicles and machines that fulfil the safety re-
quirements for vehicles and machines. Examples are in the vehicle or machine installed fire
drencher, emergency hammer, protection devices against falling objects or fluids
· In emergency situations switch off the unit.
10.12.03

1.1 Mechanical dangers:
· Do not reach into the operating unit and never stick objects into the blowers.
· If air flaps are free approachable, use vehicle side rebuildings (for example protection grilles) as a
protection against intervention into the air flaps.
· There is a danger of bruising at the self calibration of water valves with servo motor and EVKS.
Do not reach into the self calibration.
· Do not use nozzles into the area of the drivers head.
· On the evaporator, the condenser and the heat exchanger are sharp fins.
· Be careful with long wire cables with pointed ends. The rolled wire cables are suspended. Be
careful by taking off the packing.
· Residual pressure may still remain even after the unit has been emptied. This should initially be
released with extreme care by first slowly loosening the connections.
1.2 Electrical dangers:

· Pay attention to necessary vehicle-sided fuses according to circuit diagram or technical informa-
tion of the heater or the air conditioning unit.
· Use only original fuses with required amperage.
· Electrical connections shall only be made in a voltage-free state. The laying of cables have to be
made carefully especially in the area of bowden cable actuations.
· Check the proper state of the electrical connections in regularly periods.
· Maintenance-work only if the blower-motor is stagnant.
· Cut the blower from the current circuit to avoid injuries.
· Before opening the cover of a air conditioning unit disconnect the battery.
· Electrical cables and operation elements of heaters or air conditioning units have to be installed
into the vehicle in such way that a faultless function under normal conditions is guaranteed.
· Pay attention to the safety instructions for PTC radiators in chapter 5.
1.3 Thermal dangers:

· Attention! Danger of burning! Please do not get into contact with the heat exchangers and its
connections. Cooling tubes and cooling hoses can be hot and stand under pressure. Be careful by
touching them. This also applies to the resistance on the blower when working at the opened unit
and the construction part has not completely cooled down.
· Isolate the free approachable connection tubes.
10.12.03
2 Safety instructions for installation and maintenance- / repair work

2.1 General instructions:
Please pay attention to the safety instructions in chapter 0. and 1.
Qualification of personnel: Installation, maintenance work and repairs must only be done by wellin-
formed and authorised specialists.
Works on unit shall only be done in a not-running state. Take off defect parts immediately.
Faults have to be eliminated instantly.
The safety instructions in the Technical information of the units have to be read before installation.
· Wear necessary protecting equipment at installation, maintenance and repairs as protection

against sharp edges and pointed screws.
· Use suitable tools and working clothes (protecting equipment) for repairs, maintenance and in-
stallation.
· Wearing unsuitable working clothes there is a danger of get stuck and permeation.
· Pay attention for the necessary torque at connecting the fittings and screws.
· Fix the hoses with suitable clamps and with torque required from the producer.
· Fix long cable sets with clamps to avoid risk of stumbling.
· Attention at installation of the insertion frame for CBE/CBM and SRE. There is a risk of squeez-
ing.
· Maintenance work have to be done in regularly intervals.
· Check of the fixing, leak control and laying of the hoses and fittings. The hose fixings are to be
tightened if necessary.
· Change water and oil hoses if the material is not in order. In the case of maintenance the hoses
with cooling medium have to changed very carefully.
2.2 Transport and lifting
· Lift and transport the heating and air conditioning units only on the housings.
· Don’t lift or transport the device on the expansion valve or the cable sets. Don’t pull at the cable
sets. Otherwise the plugs can tear off.
· Protect the products against moisture and mechanical damages during transport and storage.
· Use suitable and unobjectionable lifting devices and load lifting members.
· By working on the roof of vehicles take care for the prevention of accidents. Use working plat-
forms or scaffolding.
· Only use suitable hoisting facilities that are free of dirt, snow or ice.
2.3 Air suction

· Air inlets must be positioned, that under normal operating conditions no exhaust fumes from the
engine or another heater unit could be drawn into the cab.
· During the recirculation operation, there must be air intake without any hindrance. The unit
should not be installed that dust could be directly drawn in from the floor by the air intake. The
recommended height above the floor is > 30 mm.
· Ensure a suitable flow of outside air.
2.4 Processing of glue and sealing material

· Pay attention to the producer-details and the safety data sheet.
· Hands/body must be washed immediately with a suitable handwashing paste and water.
· Do not use solvent.
10.12.03
2.5 Installation of compressors

· The instructions issued by the vehicle/engine manufacturer must be observed.
· Switch off the machine/vehicle and protect against starting before works into the engine com-
partment.
· Refrigerant R134a in according to DIN 8960 must be used for all compressors.
· The EC Safety Data Sheet for R134a must be observed.
· All refrigerant must be drained from the system by suction before opening the refrigerant circuit.
· The unit is under no circumstances to be rinsed with compressed air!
· Damaged compressors must not be installed.
· Secure heavy compressor against falling off. Use suitable handling tools.
· When installing compressors, the manufacturer’s instructions on installation position must be
observed.
· The compressor must be positioned correctly on the mounted and secured properly.
· The compressor mount must be attached to the engine block at a suitable point. The mount
points provided by the engine manufacturer must be used.
· Torque must be taken into account when tightening screws and connections.
· The V belt must be tensioned as instructed. It is advisable to use a tensiometer to measure this.
2.6 Laying of electrical lines
· Take care for security at laying the connection cables. The cables have not be stressed, kinked
or damaged.
· Use only cable that is valid for using in vehicles and with adequate width.
· Lay cables in protective covers if possible and connect the cables properly for example with cable
binders.
· Use rubber bushings for laying the cables through sheets.
· Protect connections against moisture.
· Pay attention to the vehicle producers guidelines for connection of the current supply.
· Use only original fuses with required amperage.
10.12.03
3 Safety instructions for work on the refrigeration circuit and exposure to

refrigerant
3.1 Universal advises

· The unit must always be emptied before any work is carried out on the refrigeration circuit. This
may only be done by specialist personnel.
· Please follow the safety data sheet for refrigerant R134a.
· Do not discharge refrigerant to the environment.
· Liquid refrigerant must not come into contact with the skin.
· Safety glasses must be worn when handling refrigerants.
· If there are failures in the refrigerant circuit the unit must be checked and repaired by a special-
ised workshop.
· The resulting condensate shall not used as drinking water.
CAUTION! Risk of explosion!

· Never carry out soldering or welding work directly on parts in the closed refrigeration circuit or
in its vicinity. Due to the strong heating effect the pressure will increase within the unit giving a
risk of explosion.
· Refrigerant bottles must never be thrown around or subjected to lengthy periods of sunshine or
other heat sources when filled. The highest permitted temperature of a filled refrigerant bottle
must not exceed 45°C.
CAUTION! Risk of contamination!
· It is essential that the refrigeration system is kept free from chlorine and substances containing
chlorine, as well as oils and greases. Consequentially it is necessary to invest in separate
evacuation and filling systems which are exclusively used for R134a.
3.2 Safety instruction for filling
· Air conditioning units must only be filled by wellinformed personnel of an authorised specialists
workshop.
· Fill the unit with refrigerant according to the instructions of the maker of the filling station.
10.12.03
4 Safety measures for electronic control units in vehicles
The following listed safety measures must be unconditionally observed, in order to avoid and prevent
damage to components as well as to the cable set:
· No external voltage should be connected to the control outputs.

· If, for testing purposes, the board voltage is directly fed at the motor, the circuit has to be sepa-
rated from the motor beforehand.
· Only start the engine if the batteries are firmly connected.
· Don't disconnect the batteries when the engine is running.
· Don't use a boost charging device to start the engine.
· Only use separate batteries for help in starting.
· Don't start the vehicle with an external charging unit.
· For fast charging the batteries the battery terminals must be removed. Follow the fast charging
device instructions.
· The control unit connections may only be withdrawn or plugged on again with the electrical sys-
tem switched off.
· Incorrect connection of the control unit supply voltage (e.g. wrong battery terminal connections)
can lead to destruction of the control unit.
· Always withdraw the device plug when testing the connected components.
· Always use the test software, if available, provided for testing the outputs.
· Only use appropriate test leads for measurements on the plugged connections.
· Telephones and radio devices, which are not connected to an outside aerial can lead to func-
tional faults on the vehicle electronics and thus endanger the operating safety.
· Fixed radio aerials without sufficient ground surfaces (plastic roof) will cause considerable inter-
ference through mismatching in the vehicle.
· If sufficient ground surfaces cannot be found then window aerials (adhesive aerials) should be
used.
· When carrying out welding work the earth cable from the electrical welding unit must be con-
nected directly onto the vehicle part to be welded.
· When carrying out electrical welding work the battery terminals must be removed and the two
cables (+ and -) firmly fixed to one another.
· When carrying out work, which could lead to electrostatic charging of vehicle parts (e.g. spraying
on the plastic underseal) any electronic components attached to the control electronics in the vi-
cinity (e.g. external sensors) must be unplugged.
Temperature compatibility of electronic components:

· The indicated permitted temperatures of control units must not be exceeded.
· If temperatures over the max. permitted temperature are anticipated control units must be re-
moved.
General:
Not every malfunction will result in the part or complete breakdown of the unit. In order to test the
condition of the relevant unit the following must be carried out:
· Switch off the engine and ignition.
· Withdraw all plugs from the unit and replace them after approx. 10 seconds.
· Wait for the unit to carry out a „self-test“ if present.
· Check the functioning of the installation again.
10.12.03
5 Safety instructions for units with electrical PTC-radiator

Caution! Danger of life
PTC radiator are voltaged parts.
Service only by electro-specialized personnel
Pay attention to VDE-regulations.
· Use PTC radiator only at running blower.
· Switch off the device immediately if the function is not normal.
· Don't change the original version of the device. Aurora Konrad G. Schulz GmbH & Co. KG take
no charge for possible consequences of changes.
· Possible modifications only at your own risk.
· Pay attention to higher inrush current (slow characteristic fuses are necessary).
· All metal parts on the PTC radiator are voltaged. Secure against touching.
· Operating with to little air flow can alloy the function and the lifetime of the device.
· The operation in aggressive environment is not valid.
· The PTC radiator shall only used for heating of moving air.
· Minimal distances must be valid with the national Instructions.
· A evaporator must not be installed. The condensate can cause short circuits.
· At installation pay attention to necessary free space. If the device is covered there is the risk of
fire.
· Protect the connection plug against water or mechanical damages.
· If the PTC radiator is free accessible, a cleaning of the PTC radiator from dust and dirt is neces-
sary to protect against risk of fire.
Repeated inspections of electrical safety:
Electrical equipment underlie regularly safety inspections according to instruction BGV A2 of the em-
ployers liability insurance association. The tester have to be a electro-technical instructed person.
6 Safety instructions for starting
· A defective device / part shall never be set in operation.

· Defects have to be marked and durable eliminated.
· There have to be a inspection of the machine or vehicle before first starting.
· Check all accessories such as compressor brackets and operation elements. The accessories
must not have loose parts, abrasion, cracks, leakage or other damages.
· Pay attention to persons working on or under the machine or vehicle before starting.
Before starting these persons have to be warned.
· Attention at working with hot operating materials. There is a risk of burning or scalding.
10.12.03
No. Page
Technical Information
912-100-0509 1/7
Heater unit, 24V

Part no.: 151-FN2-0002
1 Safety provisions
2 Use
3 Description of the device
4 Function description
5 Installation, setting, commissioning
6 Changing the heater unit over into an air conditioning device (optional)
7 Operation
8 Maintenance
9 Spare parts
10 Optional accessories
11 Error diagnosis
Encl.: Circuit diagram 912-200-0079
AURORA
Südring 4
D-69427 Mudau
Phone: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
Subject to technical modifications
Created: 29.01.08 KH Checked: 20.02.08 EB Approved: 25.02.08 W.Le
Date/Name Date/Name Date/Name

a) 13573 20.02.08 KH b c d
No. Page
912-100-0509 2/7
1 Safety Instructions 2 Use
For your own safety, please comply with The device has been developed as a heater
the following provisions. unit to heat a cabin.
 Make sure that maintenance and repair

The integrated outside / recirculating air flap
work is exclusively performed by specialized
enables operation with outside/recirculating air.
staff.
 Please do not reach in the device and do The retrofit kit "Evaporator" enables the heater
not put any objects in it. unit to be modified into an air conditioning sys-
 Maintenance work may only be performed tem.
when the engine is not running. To avoid in-
jury, disconnect the fan from the power Note:
supply. The heating unit may only be used within its
 Caution ! Risk of burn injuries! Please, do intended field of application and not in an in-
not touch the heat exchanger and its con- admissible environment.
nectors. Refrigerant lines and hoses may be Anybody performing modifications acts at
hot and pressurized. his/her own risk.
Please do not touch the resistor on the fan To this effect, please comply with the Tech-
when work has to be performed on the open nical Amendments regarding Warranty.
device and when the component has not
cooled down completely. 3 Description of the device
 Remove damaged parts immediately and
have any defects eliminated without delay.
The heater unit consist of a steel sheet hous-
 Caution ! Sharp fins are located on the heat ing with cover and a blower box.
exchanger. The heater unit contains:
 Wear the required personal protection  a three-stage double radial fan DRG 1100,
equipment during maintenance and repair 24V with resistor
work (PPE).
 a heat exchanger, designed as circular-tube
heat exchanger
In case of retrofitting the heater unit with an
 an HCC to control the water valve
evaporator, please comply with the safety pro-
 an HCC to control air distribution
visions acc. to the Technical Information 912-
(Information about the HCC - Heating and
100-0508.
Cooling Controller - is available in the Tech-
nical Information 912-100-0305)
Instruction for assembly and maintenance
work:  a motor-actuated outside/recirculating air
Comply with the relevant accident prevention flap
provisions and the other generally acknowl-  an air grid with filter G4
edged rules regarding safety and occupational
medicine. The air blower box accommodates the
 5-pole servomotor to actuate the air
distribution flap, and
 4 fittings Ø80 mm upwards and 2 lat-
eral fittings Ø80 mm and an opening
360x105 mm.
The heater unit is delivered together with a

control element CBE, an insertable rack and a
water valve with servomotor and hose elbows,
as well as hose clamps, as heater unit set.
No. Page
912-100-0509 3/7
Information regarding connection of the

heat exchanger:
4. Function description: For heating, the energy of the warmed-up
coolant of the vehicle's engine is used.
The fan sucks in recirculating air or outside
air/recirculating air via the heat exchanger,  Connect the warm water hoses to the heat
depending on the flap position. exchanger using suitable worm drive
The outside air flap is actuated electrically. clamps which are tightened at the specified
The air is warmed up at the heat exchanger in torque (4.5  0.5 Nm).
accordance with the temperature in the water  The connection to the coolant in the vehicle
supply line. must be established in accordance with the
information of the vehicle manufacturer. As
The fan is designed in three stages. The speed a rule, connectors are provided at the en-
is set by a vehicle-mounted fan switch on the gine. If you cannot find certain individual in-
control element. formation in the vehicle manufacturer's op-
The fan is protected against overload by a mi- erating manual, obtain information from the
cro-thermo fuse installed on the resistor. engine manufacturer directly.
 Integration into the coolant circuit: The
5. Installation, setting, commission- heater unit is integrated in the coolant circuit
ing using Tee pieces which are available from
AURORA as accessories.
 The diameters of the coolant lines must be
The following interfaces must be connected: selected depending on the connector diam-
 Connection of the water valve eter on the heat exchanger of the heater
 Connection of the warm water hoses on the unit. Different connection diameters can be
heat exchanger connector in acc. with the adapted by reducers. Please note that each
marking on the device (red arrow = water additional connector increases the risk of
supply line) leakage.
To this effect, comply with the instructions  It is recommended to use hot water hoses
regarding connection of the heat exchanger. with an EPDM liner when water is used as
 Assembly of the CBE control element coolant for the heater unit.
 the electrical connection in acc. with circuit  The hose lines must be laid so as to protect
diagram 912-200-0078. persons against injury by the hot lines.
 the interfacing to the air supply  Avoid chafing and deformation.
 When tightening the screw couplings, block
Information regarding lifting and transport the movement of the hoses.
of the heater unit:
Lifting and transport are only admissible by
picking up the device housing. The hose lines must be fixed in the vehicle
The device must not be lifted by picking up the using suitable securing clamps in order to
cable kits or the heat exchanger tubes. avoid chafing or inadmissible mechanical load
Never pull cable kits, as otherwise the con- of the connectors.
nectors might break off.
During transport and intermediate storage, the
device must be protected against humidity and
mechanical damage.
Only use suitable and technically correct hoist-
ing equipment and load carrying devices.
No. Page
912-100-0509 4/7
6 Changing the heater unit over into an air conditioning device (optional)
Use the retrofit kit "Evaporator" with the part number 188-FN9-0001.
The retrofit kit consists of a water tank with evaporator, two water outlets and a condenser unit.
Remove the hoses from the heat exchanger and disconnect the water valve with hose clamp and
hose elbows.
The water tank contained in the heater unit can be removed after the 6 hex. bolts have been turned
out. After removing the 2 screws, remove the heat exchanger from the water tank, put it in the retrofit
water tank with evaporator and fasten it. Subsequently, install the water tank with evaporator and heat
exchanger in the heater unit and re-tighten the water valve with clamp and the hose elbows. Then
secure the 2 water outlets in the underside of the tank.
Further interfaces:
 Electrical connector of thermostat (please comply with circuit diagram 912-200-0077)
 Connection of the coolant hoses to the expansion valve
 Connection of the hot water hoses to the heat exchanger
The retrofitted device forms the air conditioner together with the condenser and a compressor to be
provided by the customer (not included in scope of supplies).
Regarding the condenser unit 175-FN2-0001, please comply with the Technical Information 912-100-
0510 (Encl.).
Regarding the retrofitted device, the instructions regarding the heater / air conditioning unit in
the Technical Information 912-100-0508 (Encl.) is applicable. The information regarding in-
stallation, safety, maintenance, repair and spare parts must be complied with.
7 Operation
Operation is effected by a control element on the vehicle.

A control element CBE can be used.
The CBE features a 3-stage switch, rotary control for air distribution, rotary control for the water valve
to adjust the heating output and an AL/UL (outside/recirculating air) switch for the outside/recirculating
air flap. For retrofitting, the A/C switch can be used to switch the system ON and OFF.
Fan Air distribution Water valve ON/OFF Outside/recirculating air
The CBE is installed with an insertable rack, part no. 433-290-0187 (integral part of the kit of the air
conditioning system).
Hole pattern for insertable rack:
No. Page
912-100-0509 5/7
8 Maintenance Condition of heating lines

- Check the hoses and screw couplings for
ATTENTION proper fastening, leakage and correct installa-
tion. Re-tighten the hose clamps, if necessary.
Make sure to comply with the safety provi-
sions during all maintenance work (Chapter
Electrical equipment
1)!
- Check electrical connection cables and plug-
The device may only be serviced by expert and-socket connectors for perfect condition
staff. and tight fit.
Instructions regarding maintenance work: Electrical equipment

Comply with the relevant accident preven- Check electrical connection cables and plug-
tion provisions and the other generally and-socket connectors for perfect condition
acknowledged rules regarding safety and and tight fit.
occupational medicine.
Condition of filter
Check the filter for contamination.
In case of minor contamination, clean filter mat
Heating circulation
by rinsing in warm water
On replenishing coolant, make sure that the
(max. -40°C) using a fat solvent as additive.
water has the correct quality. (Refer to
In case of serious contamination, clean the
AURORA TI 971-190-0003 corrosion-
filter.
protective / anti-freeze agents for coolant cir-
To identify the air flow direction, the filter mat
cuits).
has a white and a blue side.
Failure of an AURORA water valve due to con-
Clean air side = white
tamination of the water circuit rules out all war-
Dirty air side = blue
ranty claims.
In case of retrofitting of an evaporator, the
The following maintenance intervals are rec-
maintenance intervals acc. to the Technical
ommended:
Information 912-100-0508 also apply.
Maintenance intervals
Monthly visual inspections - company
operating the machine:
Every month, the operating company should
perform the following visual inspections:
No. Page
912-100-0509 6/7
9. Spare parts 10. Optional accessories
See spare parts list 051-FN2-0002 Optional accessories available on request

In case of retrofitting of the heater unit to the See also www.aurora-eos.com
air conditioning system, the spare parts list of
the air conditioning system 071-FN2-0002 also
applies.
11. Error diagnosis
Malfunction Cause Remedy

Fan does not work Fuse faulty or loose Check fuse for tight fit; if necessary,
insert it correctly. Replace faulty fuse. If
a new fault occurs within a short time,
this signals a short-circuit or a blockage.
Check fan for blockage or other fault
and eliminate the cause.
Line break Check lines for loose contact or break
Fan motor faulty Replace fan
Fan switch on CBE faulty Check switch
if necessary, replace CBE
Fan cannot be Short-circuit in the cable or in Eliminate short-circuit; if necessary,
switched off the fan switch mount new cable and/or switch.
Fan works at reduced Contacts clogged Clean connector contacts. Proceed
power carefully to avoid short-circuits.
Electrical cables undersized Lay cables with the recommended cross
section
Heat exchanger seriously clog- Clean carefully and avoid damage re-
ged sulting in leakage.
Attention! Comply with safety instruc-
tions
Fan does not run at all Micro-thermo fuse (MTS) has Replace resistor and check fan motor for
stages tripped cause of malfunction
Fan switch faulty Replace switch by original spare part of
manufacturer.
Connector loosened Check plug-and-socket connector for
tight fit and mount correctly.
Check connector on fan switch.
Resistor faulty Mount new resistor.
No. Page
912-100-0509 7/7

No or insufficient heat- Water supply line temperature Wait for vehicle engine to warm up
ing capacity too low
Heat exchanger fins contamina- Check and, if necessary, clean heat
ted exchanger
Water valve closed Open valve
Water lines bent or squeezed Eliminate cause of fault or install hoses
again
Filter clogged Clean or replace the filter
Water pump pressure insuffi- Coolant does not flow through heat ex-
cient changer. Mount additional or more pow-
erful pumps.
Water escapes from Hose connector loosened Check hose lines for tight fit and re-
the device tighten hose clamps.
Water hose damaged Lay and connect new hose
Heat exchanger damaged Install original spare part and connect it
(Attention! Comply with safety instruc-
tions)
Outside air flap can no Flap deformed Check and, if necessary, straighten flap
longer be adjusted
Flap bearing faulty Check and, if necessary, replace flap
bearing
Motor faulty Replace servomotor
Actuator faulty Replace actuator
No. Page
Technical Information 912-100-0510 1/7
Condenser unit, cpl. 24 V, 2-stage
Part no.: 175-FN2-0001
1 Safety Instructions
2 Design of condenser unit

2.1 Condenser
2.2 Condenser fan
2.3 Collector drier
2.4 Pressure switch
3 Installation instructions
4 Maintenance
5 Spare parts
6 Error diagnosis
AURORA
Südring 4
D-69427 Mudau
Phone: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com

a d g j
b e h k
c f i l
No. Page
1 Safety Instructions Maintenance work on the refrigerating cir-

cuit
For your own safety, please comply with the
following provisions.  Prior to any maintenance work on the refrig-
erating circuit, the system must be drained
The following applies in general: previously. This may only be done by speci-
 Make sure that maintenance and repair alist staff.
work is exclusively performed by specialized  Only the refrigerant R134a in acc. with DIN
staff. 8960 or the
 Maintenance work may only be performed EC safety data sheet in acc. with
when the fan motor is not running. To avoid 91/155/EEC for R134a may be used.
injury, disconnect the fan from the power  No fluorescent additives may be mixed to
supply. the refrigerant.
CAUTION !  Refrigerant must not be discharged or set
 Risk of burn injuries! Please do not touch free into the open air.
the condenser and its supply lines. Refrige-  Liquid refrigerant must not get in contact
rant lines and hoses may be hot and pressu- with the skin.
rized.  Protective glasses are required for handling
Please do not touch the resistor on the fan refrigerants.
when the component has not completely  Before filling the system, it must be evacu-
cooled down. ated carefully. When filling the system,
 Repair work on the refrigerating circuit may comply with the Technical Information 912-
only be performed once the air conditioning 100-0148, page 5. (Please request if requi-
system has been drained. red)
 Remove damaged parts immediately and  The system must never be rinsed with com-
have any defects eliminated without delay. pressed air.
 Wear the required personal protection
equipment during maintenance and repair CAUTION ! Risk of explosion !
work.  Do not perform soldering or welding
work directly on the parts within the
Instruction for assembly and maintenance closed refrigerating circuit or in its close en-
work: vironment. The pressure in the plant rises
Comply with the relevant accident prevention due to the considerable heat produced,
provisions and the other generally acknowl- which might result in explosion.
edged rules regarding safety and occupational  Refrigerant cylinders must not be thrown
medicine. and not be exposed to the sun or other
sources of heat when filled. The max. ad-
The condenser unit uses exclusively the refrig- missible temperature of a filled refrigerant
erant R134a. cylinder must not exceed 45°C.
The condenser unit may only be used within its CAUTION ! Impurities!
intended field of application and not in an in-  It is essential to keep the refrigerating sys-
admissible environment. Anybody performing tem free from chlorine, chlorine-containing
modifications acts at his/her own risk. substances, oil, grease and moisture. Evac-
uating and filling systems should be used
exclusively for R134a.
No. Page
2. Design of condenser unit
The condenser unit consists of a steel sheet housing, a circular tube-type condenser, an axial fan, a
cable kit, a resistor and a collector drier with pressure switch.
The collector drier with pressure switch is fastened to the condenser housing by means of an angular
support.
Collector drier
Pressure switch
Filling capscrew
Cable kit
Resistor
Axial fan
No. Page
2.1 Condenser replaced after each intervention in the refrig-

eration circuit, at the latest every 2 years.
The condenser condensates the compressed
refrigerant, i.e. the refrigerant is supplied to the If the system has to be opened several times in
condenser in gaseous form and leaves the the scope of repair, the collector drier is re-
condenser as a liquid. placed only once.
The condenser's capacity is essentially influ-
enced by the air flow and the air temperature. ATTENTION
The direct outside air has the most favourable Never leave the collector drier open, as other-
air temperature. The ribbed circular-tube sys- wise the drier would be saturated already by
tem consists of the aluminium ribs, copper the air humidity.
tubes, and collector and connection tubes
made of copper. The fins are connected firmly 2.4 Pressure switch:
to the tubes to ensure a good heat transmis-
sion. A pressure switch is located in the collector
drier as safety device to protect the condenser.
2.2 Condenser fan When the operating values specified below for
a condenser pressure are exceeded or under-
The ambient air is sucked through the conden- cut, the pressure switch switches the conden-
ser by means of the axial fan. Thus, the air ser OFF via the electromagnetic coupling and
absorbs the heat of the refrigerant. thus protects the air conditioner against conse-
At the same time, the gaseous refrigerant is quential damage.
cooled down. When the refrigerant is cooled
down to a certain pressure-related tempera- The pressure switch has the following operat-
ture, the refrigerant is condensed and liquefied. ing values at atmospheric excess pressure:
A series resistor for the blower is provided on
the fan. ON OFF
The cable kit is of two-stage design. Coup- Low 2.4 bar max 1.2  0.3 bar
ling pres-
sure
2.3 Collector drier High 19  2 bar 25.0  1.5 bar
pres-
The collector drier serves as expansion tank sure
and supply tank for the refrigerant. Fan 18  1.5 bar 14  1 bar
The drier can bond a small quantity of water
chemically, thus removing it from the circula-
tion.
If the inspection glass shows traces of corro-
sion or tarnish, the collector drier must be re-
placed. Important: The collector drier must be
No. Page
Connection to refrigerating circuit:

3 Installation instructions
Connector for supply line: 3/4“-16UNF
Attention: For assembly, comply with the safety (from compressor)
provisions in Chapter 1.
Connector for return line: 5/8“-18UNF
(to air conditioning device)
Fastening the condenser unit:
During installation, remove the plugscrews only
just before assembly, so that no moisture can get
Note: Assembly may only be performed by quali-
into the system. Moisture within the system de-
fied specilized staff.
creases the refrigerating capacity and the con-
4 H brackets are located on the housing. denser may be damaged.
The condenser unit may only be lifted and trans- Note: Block the movement of the connecting
ported when picked up by the housing. It must hoses when tightening them.
never be lifted by picking up the cable kits, as the
connectors might break away. Please note that the condenser is filled with "pro-
Only use suitable and technically correct hoisting tective gas". After removal of the protective caps
equipment and load carrying devices. on the condenser, the protective gas must es-
During transport and intermediate storage, the cape audibly.
device must be protected against humidity and
mechanical damage. Please check the protective gas filling on installa-
tion.
Connection to power supply: Should no protective gas filling be available, the
device must be handled carefully and checked
Please comply with the circuit diagram 912-200- for leakage. There might be a leakage in a com-
0078 (Encl.) ponent.
Note: The electrical connections may only be On principle, the refrigerating circuit must be
mounted in de-energized condition. checked for leakage while the system is checked
with refrigerant.
Connection of control system at the customer's:
Note:
We recommend to provide a label "Attention! Air
conditioning system is pressurized! Refrigerant
R134a“ in a visible location of the vehicle in order
Connection to utilities at the customer's: to ensure safety during maintenance work on the
refrigerating circuit.
No. Page
4 Maintenance Condition of refrigerant lines

Check the hoses and screw couplings for proper
ATTENTION fastening, leakage and correct installation. If
Make sure to comply with the safety provi- necessary, re-tighten the hose clamps.
sions during all maintenance work! Check all screw couplings and lines of the air
conditioner for leakage using a leakage detector
The system may only be serviced by expert
for R134a.
staff.
When working on the opened sys- Electrical equipment
tem, please comply with the acci- Check electrical connection cables for perfect
dent prevention provisions. condition and tight fit.
Residual pressure Condition of the condenser

Even if the system is evacuated, a residual pres- A contaminated condenser has a reduced con-
sure may be present which must be eliminated, densation capacity. To clean, blow it out or use a
proceeding initially with extreme caution when water jet (no high-pressure cleaning unit).
the screw couplings are released. Subsequently,
the screw coupling can be released completely. Condition of collector drier
If the inspection glass shows traces of corrosion
In damp weather or in rain, the refrigerating cir- or tarnish, the collector drier must be replaced.
cuit must not be opened in the open air. Repair
on the refrigerating circuit may only be performed Monthly visual inspections - company operat-
when the system is evacuated. ing the machine:
Every month, the operating company should per-
The following maintenance intervals are rec- form the following visual inspections:
ommended:
Condition of refrigerant lines
every 2 years - specialist workshop: Check the hoses and screw couplings for proper
Every 2 years or simultaneously with each inter- fastening, leakage and correct installation. Re-
vention in the refrigerating circuit, the collector tighten the hose clamps if necessary.
drier must be replaced.
Condition of the condenser:
every 6 months - specialist workshop: Check condenser for contamination due to dust,
The complete system must be checked twice per vermin or plant particles.
year by specialist staff in an authorized specialist A contaminated condenser has a poor conden-
workshop: sation capacity. To clean, blow it out or use a
water jet (no high-pressure cleaning unit).
Refrigerant Fins deformed by external influence can be
Checking the refrigerating circuit for refrigerant straightened.
level (renewal of contaminated refrigerant and
oil). Note:
Diligence and tidiness are extremely important
requirements for intervention in the refrigerating
circuit. Evacuated refrigerant must not be re-
used. The components of the refrigerating circu-
lation must not be stored in exposed condition.
No. Page
5 Spare parts  When installing spare parts, make sure that

all connectors are clean and in correct condi-
As spare parts are available: the condenser, the tion.
axial fan, the resistor, the collector drier, the
pressure switch, a refrigerant hose DN8 and the  Make sure that new seals are always used.
2-stage cable kit.  To avoid damage to the sealing surfaces and
the seals, wet the sealing rings with refrigera-
See spare parts list: 075-FN2-0001 tor oil before assembly.
Installation of spare parts  When tightening the screw couplings, lock

 During installation of spare parts, remove the the movement of the components concerned
plugscrews only just before assembly, so that using a screw-driver, in order not to damage
no moisture can get into the system. Moisture the solder points.
within the system decreases the refrigerating Note: The condenser is filled with protective gas.
capacity and the condenser may be dam- Upon removing the protective caps from the
aged. condenser, the protective gas must escape audi-
bly.
6 Error diagnosis
Finding Possible cause Remedy

Insufficient air supply to Contamination of cooler Clean cooler fins using a water jet.
the condenser fins of condenser Note: Do not use high-pressure cleaning units.
Suction surface conta- Clean suction surface

minated
Low refrigerating capacity Collector drier clogged Replace collector drier.

or saturated
Axial fan does not operate Connector loose Check plug-and-socket connector for tight fit
and mount correctly.
Connection cable dam- Replace cable
aged or torn
Axial fan runs only at the Resistor faulty. Replace resistor
lowest level MTS has tripped
Loss of refrigerant Refrigerant line broken Check all lines for breakage by external influ-
ence or chafing
Leakage in system Evacuate, fill, check for leakage and repair
No. Page
912-100-0508 1/12
Heating and air conditioning device, 24 V

Part no.: 171-FN2-0002
1 Safety provisions
2 Use
3 Description of the device
4 Function description
5 Installation, setting, commissioning
6 Operation
7 Technical data
8 Maintenance
9 Repair
10 Spare parts
11 Optional accessories
12 Error diagnosis
AURORA
Südring 4
D-69427 Mudau
Phone: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com

a b c d
No. Page
912-100-0508 2/12
1 Safety Instructions Maintenance work on the refrigerating cir-

cuit
For your own safety, please comply with
the following provisions.  Prior to any maintenance work on the re-
frigerating circuit, the system must be
 Make sure that maintenance and repair drained previously. This may only be done
work is exclusively performed by specialized by specialist staff.
staff.  Only the refrigerant R134a in acc. with DIN
 Please do not reach in the device and do 8960 or the
not put any objects in it. EC safety data sheet in acc. with
 Maintenance work may only be performed 91/155/EEC for R134a may be used.
when the engine is not running. To avoid in-  No fluorescent additives may be mixed to
jury, disconnect the fan from the power the refrigerant.
supply.  Do not drain refrigerant in theopen air.
 Caution ! Risk of burn injuries! Please, do  Liquid refrigerant must not get on the skin.
not touch the heat exchanger and its con-  Protective glasses are required for han-
nectors. Coolant and refrigerant lines and dling refrigerants.
hoses may be hot and pressurized.  Before filling the system, it must be evacu-
Please do not touch the resistor on the fan ated carefully. When filling the system,
when work has to be performed on the open comply with the Technical Information 912-
device and when the component has not 100-0148, page 5. (Please request if re-
cooled down completely. quired)
 Remove damaged parts immediately and  The system must never be rinsed with
have any defects eliminated without delay. compressed air.
 Caution ! Sharp fins are located on the
evaporator and the heat exchanger. CAUTION ! Risk of explosion !
 Wear the required personal protection  Do not perform soldering or welding
equipment during maintenance and repair work directly on the parts within the closed
work (PPE). refrigerating circuit or in its close environ-
 Remove capscrews of the refrigerant con- ment. The pressure in the plant rises due to
nectors carefully. the considerable heat produced, which
 If necessary, switch air conditioning off. might result in explosion.
 Refrigerant cylinders must not be thrown
CAUTION ! and not be exposed to the sun or other
The condensed water produced must never be sources of heat when filled. The max. ad-
used as drinking water. missible temperature of a filled refrigerant
cylinder must not exceed 45°C.
Instruction for assembly and maintenance
work: CAUTION ! Impurities!
Comply with the relevant accident prevention  It is essential to keep the refrigerating sys-
provisions and the other generally acknowl- tem free from chlorine, chlorine-containing
edged rules regarding safety and occupational substances, oil, grease and moisture.
medicine. Evacuating and filling systems should be
used exclusively for R134a.
No. Page
912-100-0508 3/12
2 Use tures two water outlets, consisting of water

diaphragms and tube elements.
The device was developed as a heating / air
conditioning unit for air conditioning, ventilation The air blower box accommodates the
and heating.  5-pole servomotor to actuate the air
The system is operated using the Refrigerant distribution flap, and
R134a.  4 fittings Ø80 mm upwards and 2 lat-
eral fittings Ø80 mm and an opening
360x105 mm.
The integrated outside / recirculating air flap
enables operation with outside/recirculating air. The air conditioning unit is delivered together
Especially for operation of the air conditioning, with a condenser unit, the control element
recirculating air mode is more appropriate to CBE, an insertable rack and a water valve with
dehumidify the air in the driver's cab. In cold servomotor and hose elbows, as well as hose
areas, the cab interior can be warmed up fast- clamps, as air conditioning unit set.
er in recirculating air mode. Moreover, a higher
end temperature can be reached. 4. Function description:
In any case, a sufficient outside air supply
must be ensured. The fan sucks in recirculating air or outside
air/recirculating air via the heat exchanger and
Note: the evaporator, depending on the flap position.
The air conditioning unit may only be used The outside air flap is actuated electrically.
within its intended field of application and not The air is warmed up at the heat exchanger in
in an inadmissible environment. accordance with the temperature in the water
Anybody performing modifications acts at supply line.
his/her own risk.
To this effect, please comply with the Tech- Air conditioning function: The refrigerant is
nical Amendments regarding Warranty. expanded on the expansion valve and is in-
jected into the evaporator, where it evaporates
finally. The evaporation heat required to this
3 Description of the device effect is taken from the air entering the air
conditioning unit. The humidity contained in the
The heater/air conditioning unit consist of a air is condensed on the evaporator, which re-
steel sheet housing with cover and a blower sults in a reduction of the air humidity.
box.
The heater/air conditioning unit contains: The fan is designed in three stages. The speed
 a three-stage double radial fan DRG 1100, is set by a vehicle-mounted fan switch on the
24V with resistor control element.
 a circular-tube evaporator with expansion The fan is protected against overload by a mi-
valve cro-thermo fuse installed on the resistor.
 a thermostat with fixed setting to protect
against icing The thermostat switches the evaporator's re-
 a heat exchanger, designed as circular-tube frigerant supply off and on again, if required,
heat exchanger thus preventing icing of the evaporator fins due
 an HCC to control the water valve to freezing condensed water.
 an HCC to control air distribution The operating points of the thermostat with
(Information about the HCC - Heating and fixed setting are:
Cooling Controller - is available in the Tech- OFF: -1.0°C0.6°C
nical Information 912-100-0305) ON: +2.2°C0.6°C
 a motor-actuated outside/recirculating air The probe of the thermostat is inserted be-
flap tween the evaporator fins.
 an air grid with filter G4 .
The device bottom features two ports for
drainage of water. The air conditioning kit fea-
No. Page
912-100-0508 4/12
5. Installation, setting, commission-  Integration into the coolant circuit: The

ing heater unit is integrated in the coolant circuit
using Tee pieces which are available from
AURORA as accessories.
The following interfaces must be connected:  The diameters of the coolant lines must be
 Connection of the water valve selected depending on the connector diam-
 Connection of the warm water hoses on the eter on the heat exchanger of the heater
heat exchanger connector in acc. with the unit. Different connection diameters can be
marking on the device (red arrow = water adapted by reducers. Please note that each
supply line) additional connector increases the risk of
To this effect, comply with the instructions leakage.
regarding connection of the heat exchanger.  It is recommended to use hot water hoses
 Assembly of the CBE control element with an EPDM liner when water is used as
 the electrical connection in acc. with circuit coolant for the heater unit.
diagram 912-200-0077.  The hose lines must be laid so as to protect
 Insert 2 water outlets. The groove on the persons against injury by the hot lines.
circumference of the water diaphragms  Avoid chafing and deformation.
must click safely in the borehole of the  When tightening the screw couplings, block
sheet metal housing. the movement of the hoses.
 the interfacing to the air supply
 Connection of refrigerant lines Assembly of the refrigerant hose lines to the
expansion valve:
Information regarding lifting and transport
of the heater/air conditioning unit: Note: The evaporator is filled with a protective
Lifting and transport are only admissible by gas, which must escape audibly once the seal
picking up the device housing. from the expansion valve has been removed.
The device must not be lifted by picking up the - Remove the back-up disc and the seal from
cable kits or the heat exchanger tubes. the expansion valve
Never pull cable kits, as otherwise the con- - Introduce the refrigerant hose fittings into the
nectors might break off. expansion valve
During transport and intermediate storage, the - Position and mount the flange plate with
device must be protected against humidity and screws M6 x 16.
mechanical damage.
Only use suitable and technically correct hoist-
ing equipment and load carrying devices. Please check the protective gas filling on in-
stallation.
Information regarding connection of the Should no protective gas filling be available,
heat exchanger: the device must be handled carefully and
For heating, the energy of the warmed-up checked for leakage. There might be a leakage
coolant of the vehicle's engine is used. in a component.
On principle, the refrigerating circuit must be

 Connect the warm water hoses to the heat
checked for leakage while the system is filled
exchanger using suitable worm drive
with refrigerant.
clamps which are tightened at the specified
torque (4.5  0.5 Nm).
 The connection to the coolant in the vehicle
must be established in accordance with the
information of the vehicle manufacturer. As
a rule, connectors are provided on the en-
gine. If you cannot find certain individual in-
formation in the vehicle manufacturer's op-
erating manual, obtain information from the
engine manufacturer directly.
No. Page
912-100-0508 5/12
Diligence and tidiness are extremely important

requirements for intervention in the refrigerat- Subsequently, the system must be evacuated
ing circuit. Evacuated refrigerant must not be for at least 45 minutes, in order to reduce ex-
reused. The components of the refrigerating ternal gas to less than 1.5 Vol.%. During evac-
circulation must not be stored in exposed con- uation, the pressure measured in the system
dition. should be < 20 mbar.
It must be ensured that there is no risk of con-
Note: tamination of the refrigerating system by oil
We recommend to provide a label "Attention! from the vacuum pump.
Air conditioning system is pressurized! Refrig-
erant R134a“ in a visible location of the vehicle Fill the system as described in the operating
in order to ensure safety during maintenance manual of the manufacturer of the filling sta-
work on the refrigerating circuit. tion.
ATTENTION
The hose lines must be fixed in the vehicle Never fill the system to overflow. Overfilling
using suitable securing clamps in order to reduces the refrigerating capacity and
avoid chafing or inadmissible mechanical load damage may occur on the system.
of the connectors.
Subsequently, check the system for leakage.
Moreover, check the fan for correct functioning
by setting the 3 fan stages.
FILLING AND COMMISSIONING THE

SYSTEM:
ATTENTION
The air conditioning may only be filled by
an authorized workshop where expert staff
are available.
Please comply with the Technical Information
912-100-0148, page 5 (Please request as re-
quired). Only refrigerant R134a may be used.
No fluorescent additives may be mixed to the
refrigerant.
The system must be flushed with dried nitro-

gen and be checked for leakage. Flushing
serves to dehumidify the system.
The system must never be rinsed with com-
pressed air.
No. Page
912-100-0508 6/12
6 Operation
Operation is effected by a control element on the vehicle.
A control element CBE can be used.
The CBE features a 3-stage switch, rotary control for air distribution, rotary control for the water valve
to adjust the heating output and an A/C switch to turn the system ON and OFF, as well as an AL/UL
(outside/recirculating air) switch for the outside/recirculating air flap.
Fan Air distribution Water valve ON/OFF Outside/recirculating air
The CBE is installed with an insertable rack, part no. 433-290-0187 (integral part of the kit of the air
conditioning system).
Hole pattern for insertable rack:
No. Page
912-100-0508 7/12
7 Technical Details
Rated voltage: 24 Volt

Test voltage: 26 Volt
   
V Water = 1200l/h V Air Q 80 LP Q0 *
Fan stage Pel [dB(A)]  0.5
[m3/h] [kW] [W] Intake side Exhaust side [kW]
3 571 10.4 259 66.0 73.0 7.41
Intake Outside air 2 391 8.2 155 58.0 65.5
Exhaust Defrost 1 203 4.9 72 45.5 52.0
3 620 11.1 274 68.0 73.0
Intake Outside air 2 419 8.6 160 60.0 64.0
Exhaust Foot 1 217 5.2 73 47.0 51.0
compartm. man
3 571 10.4 263 71.0 73.0
Intake Ambient air 2 396 8.0 154 63.5 65.0
Exhaust Defrost 1 204 4.9 72 52.0 51.5
3 620 11.0 280 72.5 73.0
Intake Ambient air 2 423 8.4 158 65.0 64.5
Exhaust Foot 1 218 5.2 72 51.0 50.5
compartm. man
* Air inlet condition: tL1 = 30.1°C

 = 61% r.H.
State of coolant: tc = 44.9°C
t0 = 0.2°C
8 Maintenance Residual pressure

Even if the system is evacuated, a residual
ATTENTION pressure may be present which must be elimi-
nated, proceeding initially with extreme caution
Make sure to comply with the safety provi-
when the screw couplings are released. Sub-
sions during all maintenance work (Chapter
sequently, the screw coupling can be released
1)!
completely.
The device may only be serviced by expert
staff. Refrigerating cycle
Repair work may only be performed once  During interventions in the refrigerating
the air conditioning system has been circuit, all openings must be closed airtight,
drained. so as to prevent humidity from penetrating
To fill and commission the system, please the system.
comply with the instructions in Chapter 5.  In damp weather or in rain, the refrigerating
circuit must not be opened in the open air.
Instructions regarding maintenance work:  To fill and commission the system, please
Comply with the relevant accident preven- comply with the instructions in Chapter 5.
tion provisions and the other generally
acknowledged rules regarding safety and
occupational medicine.
No. Page
912-100-0508 8/12
Heating circulation Monthly visual inspections - company

On replenishing coolant, make sure that the operating the machine:
water has the correct quality. (Refer to Every month, the operating company should
AURORA TI 971-190-0003 corrosion- perform the following visual inspections:
protective / anti-freeze agents for coolant cir-
cuits). Condition of refrigerant and heating lines
Failure of a AURORA water valve due to con- - Check the hoses and screw couplings for
tamination of the water circuit rules out all war- proper fastening, leakage and correct installa-
ranty claims. tion. Re-tighten the hose clamps if necessary.
The following maintenance intervals are rec- Electrical equipment
ommended: - Check electrical connection cables and plug-
Maintenance intervals and-socket connectors for perfect condition
every 6 months - specialist workshop: and tight fit.
The complete system must be checked twice
per year by specialist staff in an authorized Condition of evaporator
specialist workshop: Clean contaminated evaporator. To clean,
blow it out or use a water jet (no high-pressure
Check the refrigerant circuit for the refrig- cleaning unit).
erant level Fins deformed by external influence can be
Replace contaminated refrigerant and oil. straightened.
Condition of refrigerant and heating lines Electrical equipment

Check the hoses and screw couplings for Check electrical connection cables and plug-
proper fastening, leakage and correct installa- and-socket connectors for perfect condition
tion. If necessary, re-tighten the hose clamps. and tight fit.
Condition of evaporator Condensed water outlet:

Clean contaminated evaporator. To clean, Check the water diaphragms for tight fit and
blow it out or use a water jet (no high-pressure safe drainage of the condensed water.
cleaning unit).
Check the outlets of the condensed water. Condition of filter
Fins deformed by external influence can be Check the filter for contamination.
straightened. In case of minor contamination, clean filter mat
by rinsing in warm water
Electrical equipment (max. -40°C) using a fat solvent as additive.
Check electrical connection cables and plug- In case of serious contamination, clean the
and-socket connectors for perfect condition filter.
and tight fit. To identify the air flow direction, the filter mat
has a white and a blue side.
Condensed water outlet: Clean air side = white
Check the water diaphragms for tight fit and Dirty air side = blue
safe drainage of the condensed water.
No. Page
912-100-0508 9/12
ATTENTION ! 10. Spare parts

The visual inspections should also be per-
formed when the air conditioning is not See spare parts list 071-FN2-0002
used.
Moreover, switch the air conditioning sys- Installation of spare parts
tem ON once per month for 10 to 15  During installation of spare parts, remove
minutes to prevent the shaft packing in the the plugscrews only just before assembly,
compressor from drying and becoming brit- so that no moisture can get into the sys-
tle. Otherwise, there is a risk of refrigerant tem. Moisture within the system decreases
the refrigerating capacity and the conden-
escaping. Moreover, the compressor com-
ser may be damaged.
ponents are thus greased at regular inter-
vals.  When installing spare parts, make sure that
all connectors are clean and in correct
Diligence and tidiness are extremely important condition.
requirements for intervention in the refrigerat-  Make sure that new seals are always used.
ing circuit. Evacuated refrigerant must not be
reused. The components of the refrigerating  To avoid damage to the sealing surfaces
circulation must not be stored in exposed con- and the seals, wet the sealing rings with re-
dition. frigerator oil before assembly.
 When tightening the screw couplings, lock
9 Repair the movement of the components con-
cerned using a screw-driver, in order not to
ATTENTION damage the solder points.
Make sure to comply with the safety provi-  When replacing the evaporator or the
sions during all repair work! expansion valve after assembly of the re-
Repair work on the refrigerating circuit may frigerant hose, isolate the expansion valve
only be performed once the air conditioning using isolating tape 889-000-0006!
system has been drained.
REPAIR WORK MAY ONLY BE
PERFORMED BY TRAINED AND ATTENTION
AUTHORIZED EXPERT STAFF. Closed spare parts may be filled with a protec-
tive fluid. Remove plugscrews carefully.
Checklist Repair:
Please check the protective gas filling on in-
Residual pressure
stallation.
Even if the system is evacuated, a residual
Should no protective gas filling be available,
pressure may be present, which must be elimi-
the device must be handled carefully and
nated, proceeding initially with extreme caution
checked for leakage. There might be a leakage
when the screw couplings are released. Sub-
in a component.
sequently, the screw coupling can be released
completely.
On principle, the refrigerating circuit must be
Refrigerating cycle
checked for leakage while the system is filled
 During interventions in the refrigerating
with refrigerant.
circuit, all openings must be closed airtight,
so as to prevent humidity from penetrating
the system. 11. Optional accessories
 In damp weather or in rain, the refrigerating Optional accessories available on request

circuit must not be opened in the open air. See also www.aurora-eos.com
No. Page
912-100-0508 10/12
12. Error diagnosis

Fan does not work Fuse faulty or loose Check fuse for tight fit; if necessary,
insert it correctly. Replace faulty fuse. If
a new fault occurs within a short time,
this signals a short-circuit or a blockage.
Check fan for blockage or other fault
and eliminate the cause.
Line break Check lines for loose contact or break
Fan switch on CBE faulty Check switch
if necessary, replace CBE
Fan cannot be Short-circuit in the cable or in Eliminate short-circuit; if necessary,
switched off the fan switch mount new cable and/or switch.
Fan works at reduced Contacts clogged Clean connector contacts. Proceed
power carefully to avoid short-circuits.
Electrical cables undersized Lay cables with the recommended cross
section
Heat exchanger seriously clog- Clean carefully and avoid damage re-
ged sulting in leakage.
Attention! Comply with safety instruc-
tions
Fan does not run at all Micro-thermo fuse (MTS) has Replace resistor and check fan motor for
stages tripped cause of malfunction
Fan switch faulty Replace switch by original spare part of
manufacturer.
Connector loosened Check plug-and-socket connector for
tight fit and mount correctly.
Check connector on fan switch.
Resistor faulty Mount new resistor.
No. Page
912-100-0508 11/12

No or insufficient heat- Water supply line temperature Wait for vehicle engine to warm up
ing capacity too low
Heat exchanger fins contamina- Check and, if necessary, clean heat
ted exchanger
Water valve closed Open valve
Water lines bent or squeezed Eliminate cause of fault or install hoses
again
Filter clogged Clean or replace the filter
Water pump pressure insuffi- Coolant does not flow through heat ex-
cient changer. Mount additional or more pow-
erful pumps.
Water escapes from Hose connector loosened Check hose lines for tight fit and re-
the device tighten hose clamps.
Water hose damaged Lay and connect new hose
Heat exchanger damaged Install original spare part and connect it
(Attention! Comply with safety instruc-
tions)
Outside air flap can no Flap deformed Check and, if necessary, straighten flap
longer be adjusted
Flap bearing faulty Check and, if necessary, replace flap
bearing
Motor faulty Replace servomotor
Actuator faulty Replace actuator
No. Page
912-100-0508 12/12
Refrigerating capacity:

Compressor does not Break in solenoid of compressor Check current supply to coupling
operate
Vee belt loosened or torn Adjust Vee belt tension, replace Vee
belt
Vee belt pulley does not turn Check, if necessary, renew compressor
although magnetic coupling is
engaged
Compressor coupling slips Replace coupling or renew compressor
Control system faulty Check and, if necessary, replace control

system
Evaporator flooded Expansion valve stuck or Replace expansion valve
blocked in open position
Evaporator iced Thermostat sensor in wrong Reposition sensor
position
Expansion valve or thermostat Replace expansion valve or thermostat
faulty
Evaporator clogged Cooler fins contaminated Clean evaporator
Loss of refrigerant Refrigerant line broken Check all lines for breakage by external
influence or chafing
Leakage in system Evacuate, fill, check for leakage and
repair
Refrigerating capaci- Fan air flow obstructed Check air ducts for obstacles. Eliminate
ty insufficient malfunction
Refrigerant level too low Top up refrigerant (service fitter)
Humidity in system Empty air conditioning system; replace,

evacuate and fill collector drier (service
fitter)
System cooling in- Line broken, ground connection Check, repair or replace lines
termittently faulty or loose contacts in com-
pressor solenoid
System very noisy Vee belt loosened or excessive- Retighten or replace Vee belt
ly worn
Coupling noisy Repair coupling
Support of compressor loos- Repair support, replace compressor
ened or internal compressor
components deformed
Excessive wear of fan motor Replace fan
System overflowing Extract refrigerant until high-pressure
indication is in normal range
System contains insufficient Perform leakage test; replenish system
refrigerant
19 Glossary
Glossary
AdBlue® (ISO 22241/DIN 70070/AUS32)
AdBlue is the brand name for a water-clear,
synthetic 32.5 per cent solution of high-purity
urea in demineralised water that is used for
the final treatment of exhaust gases in a SCR
catalytic converter. AdBlue® is a registered
trademark of the VDA (Verband der Auto-
mobilindustrie = Automobile Industry Associ-
ation) in Germany. Designation in North
America: Diesel Exhaust Fluid (DEF).
WFN3RUWW2K2064139
ATF 60G-3 533

2019-03_EN

Om Atf60g-3 2064139 Uw en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Om Atf60g-3 2064139 Uw en

Uploaded by

Copyright:

Available Formats

Operation Manual

Manufacturer After-Sales Service

2 General safety instructions 15

4 Components and operating elements 55

4.6 Carrier cab - gear selector lever 71

4.9.3 Switching working speed on/off 74

5 Operation of on-board computer 84

6.1 Ladders 133

7 Putting into operation 139

7.1.2 Adjusting seats 144

9 Driving mode 201

9.3.1 Starting the engine 209

9.4.6 Tilt adjustment / driving level 233

10 Driving mode in winter 241

11 Special equipment 247

13.1.3 Charging batteries through the charging socket *) 259

13.5 Filling the tyres 269

14 Emergency operation 273

15 Service and maintenance 283

15.11.10 Checking the ABS system 339

15.12.3 Checking hydraulic hoses 345

15.18.1 Maintaining trailer hitch 381

15.20.1 Installation location 385

16 Crane testing instructions 391

17 Removal from operation 393

18 Technical data 395

1.1 Using the operating manual

Using the operating manual

▪ Further operating manuals depending on the installed special equipments or options.

Definition of the direction specifications

Symbols and safety instructions

Type and source of danger

Tips and recommended actions

Provides information if adherence to specific instructions is important for

1.2 Vehicle identification number, name plate

The following labels should be present on the mobile crane:

1.3 In case of Damage

2 General safety instructions

2.1 Basic Safety Information

2.1.1 Use of the Mobile Crane

2.1.2 Personnel Requirements

4. Replace faulty ladders immediately.

Skilled Repair Technicians

Personal Protective Equipment

2.1.3 Planning Use

When going to the installation location

When carrying out the planned work

Required crane equipment

Permissible Ground Pressure

In case of an unstable support, there is a risk of tipping and thus a risk of

Calculating the support area

Permissible ground pressure (extract from DIN 1054)

Slopes and depressions

ing to the type of ground.

T Depth of depression A Safe distance α Gradient

2.1.4 Ramming or pulling out posts or sheet piles

Aligning the Mobile Crane

outrigger floats, the mobile crane is also evenly aligned.

2.1.6 Service and Maintenance

▪ lack of oil, grease, coolant or de-icing fluid in the various units,

2.1.7 Welding and alignment work

Measures in the event of damage on the steel structure

Measures to protect electronic parts during welding